Melt-Blown Multilayer Material with In-Line Hot Melt Adhesive
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Solution Overview
Problem
Existing methods for producing multilayer materials require multiple process and manufacturing steps to apply an adhesive layer, making the process complex.
Innovation Solution
A method involving a single manufacturing process using two nozzle blocks to successively produce a first layer of melt blown nonwoven fabric and a second layer of hot melt adhesive directly, allowing for optimized adhesion without the need for additional adhesive application steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate adhesive application process is used to create a multilayer material, then the adhesion between layers is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent combines the adhesive application function with the nonwoven fabric production function by integrating a second nozzle block into the melt blowing system. This allows the adhesive layer to be applied simultaneously with the nonwoven fabric formation in a single continuous process, eliminating the need for separate adhesive application equipment and processes while maintaining strong adhesion between layers
2Strength
If multiple process steps are used to apply adhesive layers, then the bonding strength is improved, but the production time increases
Solution Approach 1:
The patent implements continuous production by applying the adhesive layer in real-time during the nonwoven fabric formation process. The second nozzle block continuously deposits adhesive material as the molten polymer is being extruded and formed into the nonwoven fabric, eliminating idle time between production steps and maintaining constant production flow while ensuring adequate bonding strength
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 the production of a multilayer material with optimized adhesion properties, allowing immediate processing without additional adhesive layers, and can be used for applications like acoustic insulation.
Implementation Method 1
a first layer is produced from a melt blown nonwoven fabric by means of a first nozzle block
Implementation Method 2
the second layer is applied directly to the first layer by means of at least one second nozzle block arranged behind the first nozzle block in the transport direction of the conveying device according to the melt blowing process
Implementation Method 3
the second layer is formed from a hot melt adhesive
Data Source
Figure 1
AI summary
The invention relates to a method for producing a multilayer material with at least two layers, each continuously produced successively by means of at least one nozzle block using the melt blowing process. A first layer is produced from a melt blown nonwoven fabric using a first nozzle block and continuously transported away by means of a conveying device. The second layer is applied directly to the first layer using the melt blowing process by means of at least one second nozzle block arranged downstream of the first nozzle block in the conveying direction. The second layer is formed from a hot melt adhesive. The invention further relates to a multilayer material produced according to this method.