Grooved Foulard Roll Shell for High-Speed Fleece Bindering
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Solution Overview
Problem
Existing nonwoven production systems face challenges in guiding fleece through foulards at high speeds due to the fleece sticking to rollers, which limits operational efficiency.
Innovation Solution
The second roller's shell features a groove-shaped engraving, allowing the fleece to escape and preventing accumulation, enabling higher speed operation by maintaining a significant open surface area and appropriate groove dimensions to prevent sticking, while the first roller's engraving facilitates binder application and drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth roll shell is used on the second roller, then binder application is simple, but the fleece sticks to the roller at high speeds
Solution Approach 1:
The second roller shell is designed with a porous structure containing numerous through-going holes. This porous configuration allows the fleece to pass through without sticking to the roller surface, enabling high-speed operation while maintaining structural simplicity and ease of manufacture.
Solution Approach 2:
The roller shell transitions from a uniform smooth surface to a locally differentiated structure with through-going holes distributed across the surface. This local quality change specifically at the contact region with the fleece prevents sticking while preserving the overall simplicity of the roller design.
2Area of stationary object
If the engraving volume is small, then the roller surface area is large for binder application, but fibers and binder accumulate in the nip
Solution Approach 1:
The through-going holes create a porous structure that provides sufficient volume for fiber and binder escape while maintaining adequate open surface area for binder application. The porous configuration ensures consistent operation by preventing accumulation without sacrificing application surface.
Solution Approach 2:
The solution moves from a two-dimensional surface consideration to a three-dimensional volume consideration by incorporating through-going holes. This dimensional change allows the engraving volume to be sufficiently large for fiber escape while the open surface area remains large enough for effective binder application.
3Volume of stationary object
If the engraving volume is large, then fibers can escape effectively, but the open surface area for binder application decreases
Solution Approach 1:
The porous structure with through-going holes achieves a unique configuration where the volume available for fiber escape is maximized while the open surface area for binder application is preserved. The interconnected pore network allows fibers to penetrate and escape through the roller thickness without significantly reducing the external surface area.
Solution Approach 2:
The through-going holes create a nested structure where the hollow channels are embedded within the roller shell matrix. This nesting allows the engraving volume to be substantial for fiber accommodation while the external open surface area remains largely intact for binder application.
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
Enables high-speed processing of fleece without sticking, ensuring efficient binder distribution and application, and effective drainage of excess binder, resulting in improved operational efficiency and product quality.
Implementation Method 1
the volume of the preferably groove-shaped engraving, which is located in the area of the working width, is greater than the entire volume of the pile, fleece or pre-fleece made of fibers, which runs between the first and second rollers per revolution of the second roller during operation
Implementation Method 2
the fibers of the pile, fleece or preliminary fleece can escape into the preferably groove-shaped engraving in the nip and the fibers of the pile, fleece or preliminary fleece or the binder do not accumulate
Implementation Method 3
the binder can be applied to the fleece by means of the first roll and, on the other hand, superfluous binder can be drained off again through the engraving
Data Source
Figure 1
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Figure 4
AI summary
In a foulard for applying a binder to a gauze, fleece or preliminary fleece, having at least one first roll, which can be rotated about a first roll axis and has an engraved roll sleeve, at least one second roll, which can be rotated about a second roll axis and has a roll sleeve, and wherein the gauze, the fleece or the preliminary fleece runs between the first and second rolls, the roll sleeve of the second roll has a preferably groove-shaped engraving.