Hydro-entangling Fiber Layer Support Process
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Solution Overview
Problem
Conventional manufacturing processes for hydraulically entangling fiber layers into nonwoven webs often require strong fiber sheets to maintain integrity, limiting processing speed and introducing creases or density variances due to multiple belt transfers.
Innovation Solution
A process where a fiber layer is fully supported from below on a first belt, merged with a second belt, and then transferred to a hydro-entangling fabric, minimizing the need for multiple transfers and allowing for lower basis weight fibers with decreased wet strength characteristics, enabling continuous support and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fiber layer is conveyed unsupported over distance prior to being combined with the nonwoven substrate, then the fiber sheet must have substantial strength to maintain integrity, but this requirement limits processing speed and causes sheet breaks
Solution Approach 1:
The forming fabric acts as an intermediary support medium that carries the fiber layer from the head box to the hydro-entangling station. The fabric provides mechanical support to the weak fiber layer during conveyance, eliminating the need for the fiber sheet to support itself. This allows high-speed processing without sheet breaks while maintaining integrity through the forming fabric's structural support.
2Reliability
If multiple transfer belts are used to support the fiber sheet from forming section to dryer section, then sheet integrity is maintained, but complex machinery is required and creases or density variances are created
Solution Approach 1:
The invention merges the support function with the hydro-entangling process itself. The hydro-entangling fabric serves dual purposes: it supports the fiber layer during conveyance and simultaneously performs the hydro-entangling function. This consolidation eliminates the need for separate transfer belts and intermediate carriers, reducing machinery complexity while maintaining sheet integrity through continuous support.
3Reliability
If multiple transfer belts are used to convey the fiber web, then support is provided, but creases or density variances are created in the sheet
Solution Approach 1:
The forming fabric serves as a stable intermediary that maintains consistent support conditions throughout conveyance. Unlike multiple transfer belts that create variable contact points and potential creases, the single forming fabric provides uniform support across the entire sheet width and length, preventing density variances and crease formation while maintaining sheet integrity.
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
This approach simplifies the transfer process, reduces the significance of fiber layer characteristics, and allows for faster machine processing speeds while maintaining composite material integrity, even with fibers having reduced strength, thereby reducing production losses and minimizing creases or density variances.
Implementation Method 1
The nonwoven web and overlying fiber layer are conveyed under one or more hydraulic entangling manifolds wherein jets of fluid entangle the fibers into and through the nonwoven substrate to form a composite material.
Data Source
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AI summary
A process for hydro-entangling a layer of fibers into a web includes the steps of conveying a web from a supply to lie against a traveling hydro-entangling fabric. A layer of fibers is deposited onto a traveling forming fabric, the forming fabric supporting the fiber layer from below. The forming fabric and the hydro-entangling fabric converge at a combining location where the forming fabric and hydro-entangling fabric orient and travel adjacent each other such that the fiber layer and web are sandwiched between the forming fabric and the hydro-entangling fabric with the fiber layer supported from below by the hydro-entangling fabric and web. The forming fabric is separated from the fiber layer after the web and overlying fiber layer are supported from below by the hydro-entangling fabric and the hydro-entangling fabric is conveyed through a hydro-entangling station to hydro-entangle the fibers into the web.