Milling Roller Nonwoven Formation for Fiber Orientation
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Solution Overview
Problem
Conventional aerodynamic nonwoven production methods face challenges in achieving uniform fiber orientation in both machine direction (MD) and cross-direction (CD) due to the chute's orientation perpendicular to the delivery direction, leading to difficulties in aligning fibers and causing duct blockages.
Innovation Solution
A method and device that utilize a moving screening surface with a milling roller in a suction area, defining specific angles (α and β) for nonwoven formation between the screening surface and the milling roller, allowing fibers to be deposited uniformly in both MD and CD orientations, preventing duct clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a chute is used for fiber alignment in aerodynamic nonwoven formation, then fiber orientation perpendicular to delivery direction is improved, but fiber alignment in machine direction deteriorates and duct blockage occurs
Solution Approach 1:
The patent removes the chute component from the aerodynamic nonwoven formation system and replaces it with a milling roller. This extraction eliminates the source of duct blockages while maintaining fiber alignment capability through the milling roller's specific geometric configuration and operational parameters.
Solution Approach 2:
The patent changes the fundamental parameter of fiber alignment from geometric constraint (chute shape) to dynamic control (milling roller rotation speed, diameter, and position relative to screening surface). By adjusting these parameters, the system achieves fiber alignment in both MD and CD directions without causing duct blockages.
2Adaptability or versatility
If conventional aerodynamic method is used for nonwoven formation, then random fiber orientation is achieved, but controlled fiber alignment in both MD and CD deteriorates
Solution Approach 1:
The patent introduces dynamic control through the rotating milling roller, which actively manipulates fiber orientation during the nonwoven formation process. The rotation speed, direction, and position of the milling roller can be adjusted to achieve desired fiber alignment in both machine direction and cross direction, transforming the static random orientation process into a dynamically controllable system.
Solution Approach 2:
The milling roller acts as an intermediary element between the fiber supply and the nonwoven formation area. It mediates the fiber flow by mechanically interacting with the fibers through its rotating surface, thereby controlling their orientation before they are deposited onto the screening surface to form the nonwoven material.
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 enables the production of uniform nonwovens with predetermined MD/CD orientations and prevents duct blockages by forming the nonwoven in the direct operating range of the milling roller, ensuring efficient fiber alignment and production.
Implementation Method 1
sucking fibers or flakes onto a moving screening surface
Implementation Method 2
the fibers or small flakes fly or slide away from this cylinder towards the nonwoven forming point
Data Source
AI summary
An aerodynamic nonwoven formation, in which the nonwoven formation occurs in the operating range of a milling roller. The nonwoven formation takes place using a fiber opening unit, a moving screening surface with suction and a milling roller. The nonwoven-forming fibers are removed from the fiber opening roller and form a nonwoven after a flight or slide route. The nonwoven formation takes place in an area that is limited by an angle a against the direction of movement of the screen and by an angle β with the movement of the screen relative to a section from the center of the milling roller to the screening belt.