Fine Fiber Sheet Drying Method Preventing Wrinkles

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Solution Overview

Problem

Existing methods for producing sheets containing fine fibers often result in wrinkles, which affect the quality and usability of the final product.

Innovation Solution

A method involving a coating step where a dispersion of fine fibers with diameters of 1000 nm or smaller is applied to a base material, followed by a two-stage drying process, including a non-contact first stage and a restrained second stage, using infrared radiation, to produce a sheet without wrinkles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional drying methods are used for fine fiber sheets, then drying efficiency is improved, but wrinkles are generated on the sheet surface

Engineering Contradiction:
Improvedrying efficiencyVSAvoidsheet surface quality
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The drying process is divided into multiple stages with different drying rates. The first drying stage uses a higher drying rate to remove bulk moisture efficiently, while the second drying stage uses a lower drying rate to prevent wrinkle formation on the sheet surface. This segmentation of the drying process resolves the contradiction between drying efficiency and surface quality.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The drying process employs periodic variation in drying conditions, alternating between high-intensity drying phases and low-intensity drying phases. This periodic action allows the sheet to adapt to drying stress, preventing wrinkle formation while maintaining overall drying efficiency.

Inventive Principle:
Principle #19Periodic action

2Loss of time

If high drying rate is applied to remove moisture quickly, then drying time is reduced, but wrinkles are formed due to rapid moisture loss

Engineering Contradiction:
Improvedrying timeVSAvoidsheet surface smoothness
Core Design Contradiction:
Loss of timeVSManufacturing precision

Solution Approach 1:

The drying time is segmented into multiple stages with different rates. The first stage operates at a high drying rate to quickly remove the majority of moisture, reducing overall drying time. The second stage operates at a lower drying rate to carefully remove remaining moisture without causing surface wrinkles, thus resolving the time-quality contradiction.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The first drying stage performs preliminary moisture removal at high rate before the sheet structure becomes too rigid. This preliminary action prepares the sheet for the second stage where surface quality is prioritized, preventing wrinkles before they can form.

Inventive Principle:
Principle #10Preliminary action

3Device complexity

If single-stage drying is used for simplicity, then process complexity is reduced, but wrinkle prevention is compromised

Engineering Contradiction:
Improvedrying process complexityVSAvoidwrinkle-free sheet production
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The drying process is segmented into two controllable stages with distinct drying rates. The first stage focuses on bulk moisture removal, while the second stage focuses on surface quality maintenance. This segmentation provides a practical balance between process complexity and wrinkle prevention effectiveness.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The drying rate parameter is changed between two distinct levels during the process. The first stage uses a higher drying rate parameter, while the second stage uses a lower drying rate parameter. This parameter change strategy enables wrinkle prevention without requiring overly complex process control.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively prevents wrinkles in the sheet production process, ensuring a high-quality, wrinkle-free sheet with optimal solid content concentration and drying rates.

Implementation Method 1

a drying step of drying the dispersion containing fine fibers coated on the base material to form a sheet containing fine fibers

Methodology Applied
Scientific EffectInfrared radiation: Infrared Radiation

Implementation Method 2

evaporating liquid components in the slurry

Methodology Applied
Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11542659B2Method for producing sheet containing fine fibers
Publication Date: 2023.01.03 OJI HLDG CORP
  • US11542659B2 patent drawing

AI summary

The present invention was accomplished in order to provide a method for producing a sheet containing fine fibers, which enables production of a sheet containing fine fibers without producing wrinkles. The present invention provides a method for producing a sheet containing fine fibers comprising a coating step of coating a dispersion containing fine fibers having a fiber diameter of 1000 nm or smaller on a base material, and a drying step of drying the dispersion containing fine fibers coated on the base material to form a sheet containing fine fibers.