Non-cutting Impact Mill for Textile Fiber Bundle Splitting
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Solution Overview
Problem
Current methods for splitting fiber bundles into individual fibers are inefficient, causing mechanical damage and fiber shortening, and are not universally applicable, especially for smooth or short fiber bundles, requiring multiple processes and being unsuitable for certain materials.
Innovation Solution
A modified mill with a non-cutting impact mechanism and adjustable design features, including propeller-like striking wings and a dead space volume, allows for gentle longitudinal splitting of fiber bundles into individual fibers without additional subsequent processes, ensuring material protection and increased splitting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional textile openers, tearing systems, rollers or cards are used to split fiber bundles, then fiber bundles can be separated, but mechanical damage and fiber shortening occur, and the equipment cost is high
Solution Approach 1:
The device divides the fiber bundle splitting process into multiple impact zones with progressively smaller striking elements. The first impact zone uses larger elements for initial separation, while subsequent zones use smaller elements for finer splitting, allowing the material to be processed in stages rather than subjected to one aggressive tearing action
Solution Approach 2:
The device changes the parameters of the impact mechanism by using rotating striking elements with varying sizes and speeds. The rotational motion allows for controlled impact frequency and intensity, and the varying element sizes adapt the splitting force to different stages of the separation process, reducing overall mechanical stress on fibers
2Productivity
If multiple processing systems are run in sequence to achieve sufficient fiber bundle splitting, then splitting effect is improved, but processing time and equipment complexity increase
Solution Approach 1:
The device merges multiple impact zones with different striking element sizes into a single integrated processing unit. The first impact zone with larger elements and subsequent zones with smaller elements work in sequence within one device, combining the functionality of multiple separate systems while maintaining a compact structure
Solution Approach 2:
The device adds a rotational dimension to the impact mechanism, transforming linear sequential processing into a rotational multi-zone system. This allows multiple splitting stages to occur in a compact radial arrangement rather than requiring long linear sequences of separate machines
3Adaptability or versatility
If rollers with pins or teeth are used to process fiber bundles, then mechanical splitting can be achieved, but the method is not suitable for smooth fiber bundles and short fiber bundles
Solution Approach 1:
The device creates a universal splitting mechanism that works with both crimped and smooth fiber bundles, as well as various fiber lengths. The impact-based separation method using rotating striking elements provides a consistent splitting action that is effective across different fiber types without requiring material-specific adjustments
Solution Approach 2:
The device replaces the traditional roller-based mechanical system with an impact mechanism using rotating striking elements. This substitution changes the fundamental splitting action from continuous rolling pressure to discrete impact forces, which are more effective at separating smooth and short fiber bundles that do not respond well to roller mechanisms
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 device effectively splits fiber bundles into individual fibers or finer bundles with minimal mechanical damage, suitable for a wide range of materials, including short and crimped fibers, without the need for additional processing steps, ensuring efficient and material-friendly fiberization.
Implementation Method 1
a non-cutting impact mechanism with propeller-like striking wings arranged next to one another on a drive axle
Data Source
Figure 1~2
AI summary
The invention relates to a device for mechanically splitting finite textile fiber bundles, comprising n individual fibers (n = 2) in fiber bundles having less than n individual fibers and/or individual fibers, characterized in that in a milling chamber that is sealed off from the outside and that has one or more dead spaces of at least 10% of the milling chamber volume and in which one or more rotating impact elements operate in a non-cutting manner and so as to reduce load peaks and at a rotational speed that can be adapted to the material but that is at least 200/min, the material is adjustably input in different amounts in batches, treated for an adjustable duration, and then discharged from the milling chamber.