Modular Belt Web Transfer for Needling Looms
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Solution Overview
Problem
Existing devices for transferring and introducing sheets of fibers into needling machines are complex, prone to stretching that deteriorates the fibers, and not well-suited for wide or heavy sheets, leading to inconsistencies in the consolidated product and reliability issues with endless belts.
Innovation Solution
A modular belt with a fine pitch is used to position the sheet close to the consolidation zone without stretching, simplifying the transfer device while maintaining or improving the quality of the consolidated sheet, by employing two transfer elements with a gap that decreases in thickness and a downstream end that can be positioned very close to the needling machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transfer devices with large-diameter rollers and water jets are used, then the web can be held in place and compressed, but the device complexity increases and the web must be treated (stretching) which deteriorates its homogeneity
Solution Approach 1:
The invention extracts and eliminates the water jet system from the transfer device, replacing it with a purely mechanical belt-based positioning system. The endless belt alone suffices to position the web close to the needle-punching table without requiring additional water jets for holding and compression, thereby simplifying the device while maintaining web positioning stability.
Solution Approach 2:
The invention introduces an intermediary endless belt that acts as a mediator between the web and the needle-punching machine. This belt can be positioned very close to the needle-punching table inlet, serving as an intermediate transfer surface that eliminates the need for complex water jet systems while maintaining reliable web positioning.
2Manufacturing precision
If additional transfer rollers are positioned close to the needle-punching table, then web stretching is reduced, but the device structure becomes more complex
Solution Approach 1:
The endless belt performs multiple functions simultaneously: it transfers the web, positions it close to the needle-punching table, and eliminates the need for additional transfer rollers. This multi-functional approach reduces web stretching while simplifying the overall device structure compared to systems requiring multiple specialized components.
Solution Approach 2:
The invention changes the positioning parameter by enabling the endless belt to be positioned much closer to the needle-punching table inlet than conventional large-diameter rollers allow. This parameter change (reduced distance) directly reduces web stretching and improves homogeneity without requiring additional complex structural elements.
3Strength
If the endless conveyor bypasses a large-diameter roller, then the web can be supported, but the web cannot be conveyed close to the needle-punching table requiring additional rollers
Solution Approach 1:
The invention changes the geometric parameters of the support system by replacing large-diameter rollers with a fine-pitch modular belt that can operate effectively at much smaller radii. This allows the web to be supported and conveyed in close proximity to the needle-punching table inlet without requiring additional transfer rollers, improving ease of operation.
4Productivity
If conventional transfer devices are used, then web transfer is achieved, but stretching occurs that deteriorates web quality and homogeneity
Solution Approach 1:
The invention changes the critical parameter of transfer distance by positioning the endless belt as close as possible to the needle-punching table inlet. This minimal transfer distance dramatically reduces web stretching during transfer while maintaining full web transfer capability, thereby preserving web homogeneity and quality.
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 allows for high-quality, homogeneous sheet transfer with reduced stretching and a simpler device structure, enhancing the reliability and lifespan of the transfer system by positioning the sheet close to the needling action zone without compromising the sheet's integrity.
Implementation Method 1
By designing a modular conveyor belt with a very fine pitch, the downstream end of the belt can be manufactured with great precision, allowing it to be positioned very close to the consolidation device
Data Source
Figure 1
Figure 2~4
AI summary
Device (9) for transferring and/or introducing a fibre lap, in particular a non-woven lap, into a consolidation installation, in particular a mechanical or hydraulic installation, for example a needling loom, comprising at least one transfer member (11a; 11b) comprising at least one drive roller (12), at least one endless belt (13) extending between an upstream end and a downstream end (15) and at least one sword-shaped or wedge-shaped member, the at least one roller being arranged so as to rotate the endless belt on either side of the downstream end of the at least one sword-shaped or wedge-shaped or spout-shaped member in order to thereby reverse the belt at the apex of the wedge-shaped member, characterised in that the endless belt is a modular belt composed of sections (30) in the form of transverse strips hinged to each other.