Multi-Layer Web Manufacturing Using Single Carding Apparatus
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Solution Overview
Problem
The production costs of nonwoven web products combining long and short fibers remain high despite advancements in manufacturing techniques, as existing methods do not fully achieve the superior hand feel of all-long-fiber products while reducing costs effectively.
Innovation Solution
A carding cylinder is used to transport long fibers, with multiple combing cylinders forming webs that are layered with short fibers deposited between them, followed by hydroentanglement to bind the layers, allowing for the production of multi-layer web products using a single carding apparatus, reducing equipment needs and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a combination of long and short fibers is used in the furnish, then production costs are reduced, but the hand feel of the web product does not reach the superior quality of all-long-fiber products
Solution Approach 1:
The web product is segmented into multiple layers with different fiber compositions. The top layer contains predominantly long fibers to provide superior hand feel, while the base layer contains the fiber combination for cost efficiency. This segmentation allows each layer to fulfill its specific function optimally.
Solution Approach 2:
Different regions of the web product have different fiber compositions tailored to their specific requirements. The surface layer uses long fibers for tactile quality where consumers directly interact, while the inner layers use mixed fibers for structural support and cost reduction.
2Manufacturing precision
If multiple separate apparatuses are used to produce different fiber layers, then layer quality is controlled precisely, but equipment complexity and investment costs increase
Solution Approach 1:
A single carding apparatus is designed to perform multiple functions: it cards long fibers for the top layer, cards short fibers for the base layer, and controls the deposition of both layers sequentially. This multi-functional design eliminates the need for separate apparatuses while maintaining layer quality control.
Solution Approach 2:
The carding apparatus is equipped with a fiber deposition system that automatically controls the layering process. The system self-regulates the deposition rate and composition of each layer without requiring external intervention or additional specialized equipment.
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 multi-layer web products with improved hand feel and reduced production costs by utilizing a single carding apparatus, extending the life of existing equipment and minimizing investment in new machinery.
Implementation Method 1
A carding cylinder is rotated to transport long fiber
Implementation Method 2
Two combing cylinders comb the long fiber from the carding cylinder to form first and second webs of long fiber
Implementation Method 3
A short fiber deposition unit is disposed adjacent the conveyor carrying the second web and deposits short fiber upon the second web
Implementation Method 4
The layered web may thereafter be subjected to entanglement to better bind the layers together
Data Source
AI summary
An apparatus and method for manufacturing a multi-layer web product. A long fiber stream is directed around a rotating carding cylinder. Two combing cylinders are disposed adjacent the carding cylinder to comb a first web of long fiber and a second web of long fiber, respectively, from the carding cylinder. A first conveyor receives the first web from the first combing cylinder and transports the first web toward a layering point. Similarly, a second conveyor receives the second web from the second combing cylinder and transports the second web toward the layering point. A short fiber deposition unit is disposed adjacent the second conveyor and deposits short fibers onto the second web. At the layering point, the first conveyor deposits the first web onto the second web, with the short fibers sandwiched therebetween, to form a layered web product.