Forming Head Agitators and Adjustable Air Inlets for Uniform Fiber Distribution
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Solution Overview
Problem
Current processes for forming nonwoven materials face issues with non-uniform fiber distribution due to air turbulence and the use of screens, which impede fiber flow and reduce productive throughput, especially when processing longer fibers.
Innovation Solution
A device and method that utilize fiber reservoirs with metering systems to deliver fibers independently of air streams, combined with a forming head design featuring agitators and adjustable air inlets to ensure uniform fiber distribution across the forming head, eliminating the need for screens and enhancing cross-directional uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a screen is used to prevent passage of unopened lumps of fiber, then fiber distribution uniformity is improved, but fiber flow is impeded and productive throughput is reduced
Solution Approach 1:
The patent removes the screen component from the forming head system entirely. Instead of using a physical barrier to control fiber passage, the invention uses a combination of air stream control and forming head design features to achieve uniform fiber distribution without any screen barrier, thereby eliminating the throughput penalty associated with screens.
Solution Approach 2:
The patent introduces an intermediary air stream control system that mediates between the fiber supply and the forming head. By carefully controlling the air stream parameters and using adjustable air inlets, the system achieves uniform fiber distribution without requiring a physical screen, thus maintaining high throughput.
2Quantity of substance
If large volumes of air are used to transport fibers to the forming head, then fiber delivery is achieved, but air turbulence is introduced creating uneven and unpredictable fiber distributions
Solution Approach 1:
The patent applies local quality control by using multiple adjustable air inlets positioned at different locations within the forming head. Each air inlet can be independently controlled to create localized air streams that work together to achieve uniform overall fiber distribution, compensating for the turbulence introduced by high-volume air transport.
Solution Approach 2:
The patent makes the air stream control dynamic by allowing adjustment of air inlet openings and air stream parameters during operation. This dynamic control enables the system to adapt to varying fiber delivery conditions and maintain uniform fiber distribution even when large volumes of air are used for transport.
3Quantity of substance
If circular air ducts are used to transport fiber, then fiber transport is achieved, but transition to rectangular ducting is required before the forming head, creating non-uniform fiber distribution
Solution Approach 1:
The patent uses the air stream control system as an intermediary to bridge the gap between circular ducting and the forming head. By carefully managing the air stream transition and using adjustable air inlets, the system compensates for the non-uniform fiber distribution that would otherwise result from the duct transition, maintaining uniform fiber delivery to the forming head.
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 solution achieves improved uniformity in fiber distribution and increased productive throughput by delivering fibers uniformly across the forming head, reducing the impact of air turbulence and fiber length limitations.
Implementation Method 1
The forming head is configured to interface with a vacuum source that is used to draw air into the forming head through the one or more air inlets
Implementation Method 2
a first outlet configured to pass air... a second outlet configured to pass fiber... delivering fibers uniformly across the forming head
Data Source
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AI summary
A method and device for depositing fibers on a forming wire. In one embodiment, a device includes a fiber reservoir having an inlet, a first outlet configured to pass air or gas, and a second outlet configured to pass fiber. The device also includes a fiber meter configured to move fiber out of the reservoir to a forming head via mechanical action and along substantially the entire width of the forming head. The forming head includes one or more air inlets and one or more agitators to blend and open the fiber received from the fiber meter. The forming head interfaces with a vacuum source that draws air into the forming head through the air inlets, which can be adjusted to affect volume and velocity of air drawn into the forming head.