Multi-Layer Meltblown Mat Bonding via Opposed Rollers
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Solution Overview
Problem
Heavy-weight meltblown mats have low tensile properties and exhibit a fibrous surface due to loose fibers, which is not adequately addressed by existing methods that require additional laminating steps to achieve a smooth surface.
Innovation Solution
A method and apparatus for producing multi-layer meltblown mats by depositing fibers onto moving surfaces, using opposed rollers to combine and bond the layers, eliminating the need for pre-manufactured webs to cover fibrous surfaces, and allowing for the creation of bonded sheets with controlled surface finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If heavy-weight meltblown mats are produced using conventional methods, then high absorbency is achieved, but tensile strength is low and surface smoothness is poor due to loose fibers
Solution Approach 1:
The patent combines meltblown fibers with a woven or nonwoven substrate to create a composite material structure. The substrate provides tensile strength and structural integrity, while the meltblown fiber layer maintains high absorbency. This composite approach resolves the contradiction by integrating two materials with complementary properties.
2Quantity of substance
If heavy-weight meltblown mats are produced using conventional methods, then high absorbency is achieved, but surface smoothness deteriorates due to accumulation of loose fibers
Solution Approach 1:
The woven or nonwoven substrate serves as a stable base that prevents fiber accumulation and maintains surface smoothness. The meltblown fiber layer is deposited on this substrate, providing absorbency without the surface defects associated with conventional loose-fiber mats.
3Shape
If pre-manufactured meltblown webs are laminated onto the fibrous surface, then surface smoothness is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The substrate is prepared in advance with a smooth surface structure that inherently prevents fiber accumulation. This preliminary preparation eliminates the need for subsequent lamination steps, as the smooth surface is built into the base material rather than added as a separate layer.
Solution Approach 2:
The patent removes the need for separate lamination operations by integrating the smooth surface function directly into the substrate material. This extraction of the lamination step simplifies the manufacturing process while maintaining surface smoothness.
4Shape
If additional lamination steps are used to cover loose fibers, then surface smoothness is improved, but productivity decreases
Solution Approach 1:
The smooth surface is incorporated into the substrate before the meltblown fibers are deposited. This preliminary structuring of the substrate eliminates the need for post-deposition lamination steps, thereby maintaining high manufacturing efficiency while achieving surface smoothness.
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 solution enhances the tensile properties and surface smoothness of meltblown mats by directly bonding layers during the meltblowing process, eliminating the need for additional lamination steps and enabling customizable surface finishes.
Implementation Method 1
a meltblown head located above the conveyor belt and structured and arranged to deposit meltblown fibers onto the conveyor belt
Implementation Method 2
feeding the first and second layers of meltblown fibers through opposed rollers to form combined meltblown layers
Data Source
AI summary
Systems and methods are disclosed for producing multi-layer meltblown mats. The method includes depositing first meltblown fibers onto a first moving surface such as a conveyor belt to form a first layer of meltblown fibers, and depositing second meltblown fibers onto a second moving surface such as a conveyor belt to form a second layer of meltblown fibers. The first and second layers of meltblown fibers are fed through opposed rollers to form combined meltblown layers comprising the first layer of meltblown fibers and the second layer of meltblown fibers. The combined meltblown layers are bonded together to produce a bonded multi-layer meltblown sheet. The bonded multi-layer meltblown sheet has a first outer exposed surface formed by contact of the first layer of meltblown fibers with the first moving surface, and a second outer exposed surface formed by contact of the second layer of meltblown fibers with the second moving surface.