Modular Forming Head with Revolving Spikes for Fibre Distribution
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Solution Overview
Problem
Existing forming heads for dry forming of fibrous webs face limitations in capacity, even distribution of fibers, and adaptability to different fiber lengths and types, leading to suboptimal product quality and increased costs due to their specificity and mechanical inefficiencies.
Innovation Solution
A modular forming head composed of interconnected distribution units with revolving rollers and adjustable spikes, allowing for customizable assembly and adjustment to meet specific production requirements, ensuring efficient disintegration and even distribution of fibers without compromising capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical scraping or brushing devices are used to remove fibres from the sieve, then the capacity increases, but the fibre distribution becomes uneven and the product quality deteriorates
Solution Approach 1:
The patent replaces mechanical scraping or brushing devices with a suction unit that uses aerodynamic forces to remove fibres from the sieve. The suction unit creates a controlled airflow that draws fibres through the forming wire without the mechanical contact and agitation that causes uneven distribution, thereby maintaining both high capacity and uniform fibre distribution.
Solution Approach 2:
The invention employs a suction unit that utilizes pneumatic principles to remove fibres from the sieve. By creating a pressure differential through suction, the system achieves fibre removal and distribution without mechanical contact, resolving the contradiction between capacity enhancement and distribution uniformity.
2Adaptability or versatility
If the openings in the bottom mesh are made smaller to accommodate shorter fibres, then the adaptability to different fiber lengths improves, but the capacity to process fibers decreases
Solution Approach 1:
The patent removes the bottom mesh or sieve entirely from the forming head, extracting the constraint that limited opening size. This allows fibres of any length to pass through without restriction, maintaining both adaptability to different fibre lengths and high processing capacity, as the suction unit handles fibre removal without needing small mesh openings.
3Manufacturing precision
If a forming head is designed specifically for a given product, then the manufacturing precision improves, but the adaptability to different products decreases
Solution Approach 1:
The patent creates a universal forming head design that can process different types and lengths of fibres effectively. By removing the bottom mesh and using a suction unit with adjustable parameters, the system maintains high manufacturing precision across various fibre types while being adaptable to different products, eliminating the need for product-specific forming head designs.
Solution Approach 2:
The invention introduces dynamic adjustability to the forming head through the suction unit, which can be adjusted to optimize performance for different fibre types and lengths. This dynamic capability allows the system to maintain high manufacturing precision while being versatile across different products, resolving the contradiction between specialization and adaptability.
4Manufacturing precision
If the suction force is increased to improve fiber distribution, then the manufacturing precision improves, but the fiber separation efficiency decreases
Solution Approach 1:
The patent optimizes the suction parameters to achieve the right balance between fibre distribution uniformity and separation efficiency. By carefully controlling the suction force and airflow patterns, the system maintains high manufacturing precision while preserving effective fibre separation, avoiding the trade-off between these two parameters.
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 modular design enhances fiber separation and distribution, enabling the production of uniform webs at higher speeds and improved quality, while allowing for adaptability to various fiber types and lengths, reducing maintenance needs and production costs.
Implementation Method 1
A suction unit is provided underneath the forming wire for drawing the fibres through the bottom and onto the forming wire
Implementation Method 2
The cloud of fibres which is formed inside the forming head of single fibres, which are split up and mixed in the air stream, are transferred down onto the underlying wire
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A forming head for dry forming a fibrous web The invention relates to a forming head (1,25) for dry forming a fibrous web, which forming head is positioned above a forming wire opposite a suction unit. The forming head (1,25) is divided into at least two independent interconnected distribution units (2,3,4,5,26,27,28,29,30,31) each of which comprises at least one revolving roller (11,12,13, 14,15,16,17,18,19,32,33,34,35,36,37,38,39,40,41) provided with protruding spikes (12). By dividing the forming head (1,25) into a plurality of interconnected distribution units (2,3,4,5,26,27,28,29,30,31), a more efficient disintegration of agglomerates, shadows and/or lumps in the fibre material is achieved compared to the known forming heads, thereby ensuring a more homogenous final product.