Hydro-needling Air Discharge for Nonwoven Compaction
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Solution Overview
Problem
Existing hydrodynamic bonding systems for fleece, woven, or knitted fabrics are sensitive to air entrainment, leading to irregular surfaces and bursting issues at higher speeds or lower surface weights, making reliable production challenging without frequent parameter adjustments.
Innovation Solution
Integration of a deflection device, such as a suction roller or suction box, to actively discharge or deflect entrained air above or below the fiber web, preventing air accumulation and ensuring stable compaction by the compacting plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compacting plate is used to compact the fiber web, then compaction effectiveness is improved, but air entrapment occurs causing the fiber web to burst open at higher speeds or lower basis weights
Solution Approach 1:
The invention extracts and removes the harmful air entrained by the fiber web before compaction using a drainage device with negative pressure. This prevents air from being trapped between the compacting plate and the fiber web, eliminating the bursting problem while maintaining effective compaction.
Solution Approach 2:
The drainage device is positioned upstream of the compacting plate to perform preliminary air removal before the compaction process. By draining air in advance, the system prevents air entrapment during compaction, allowing the compacting plate to function effectively without causing bursts.
2Reliability
If compaction is increased to reduce fiber sensitivity to water jets, then bonding reliability is improved, but air entrapment increases causing surface irregularities
Solution Approach 1:
The drainage device extracts air from between the fiber web and compacting plate, preventing air pockets that would cause surface irregularities. This allows high compaction forces to be applied reliably without creating defects in the finished product.
Solution Approach 2:
The drainage device acts as an intermediary between the fiber web and compacting plate, managing air removal to enable effective compaction without surface defects. It mediates the interaction by maintaining optimal conditions for both compaction and surface quality.
3Productivity
If production speed is increased, then productivity is improved, but air entrapment by the compacting plate increases causing fiber web bursts
Solution Approach 1:
The drainage device performs preliminary air removal before compaction at high speeds. By draining air in advance of the compacting plate, the system prevents air entrapment even during high-speed operation, maintaining productivity without causing fiber web bursts.
Solution Approach 2:
The drainage device actively extracts and removes air from the system before it can be trapped during high-speed compaction. This extraction process enables maintained productivity while eliminating the harmful effect of air entrapment.
4Adaptability or versatility
If basis weight is reduced to produce lighter nonwovens, then product versatility is improved, but air entrapment increases causing compaction failures
Solution Approach 1:
The drainage device extracts air that would otherwise be trapped in lighter, thinner fiber webs during compaction. This enables reliable processing of low basis weight materials that would otherwise be prone to compaction failures due to air entrapment.
Solution Approach 2:
The drainage device serves as an intermediary that protects delicate, low basis weight fiber webs from air entrapment during compaction. It creates optimal conditions for compacting lightweight materials without causing bursts or surface defects.
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
Prevents the fiber web from bursting and maintains a stable, even surface, allowing for consistent production at higher speeds and lower surface weights by effectively managing air flow and ensuring proper compaction.
Implementation Method 1
The drainage device can be designed so that it is actively drawn in with a negative pressure
Implementation Method 2
the air carried along is directed in a streamlined manner so that no air stagnation occurs
Implementation Method 3
The compacting device is designed as a compacting plate that presses the fiber web onto the drum or endless belt
Implementation Method 4
The fibers are then entangled by high-pressure water jets
Data Source
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AI summary
The invention relates to a device for the hydrodynamic consolidation of nonwovens, woven fabrics, or knitted fabrics, comprising a consolidation unit (1) with at least one water bar (4) and a drum (3) or an endless belt (7) between which a fiber web (2) is transported and consolidated, wherein a compacting plate (14) is arranged upstream of the water bar (4) in the direction of travel of the fiber web (2), which compacts the fiber web (2) on the drum (3) or the endless belt (7). The invention is characterized in that at least one discharge device is arranged upstream and/or downstream of the fiber web (2) in the direction of travel of the fiber web (2) upstream of the compacting plate (14), with which the air carried along by the fiber web (2) is discharged.