Natural Fiber Web Production via Ribbon Dispersion and Bonding
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Solution Overview
Problem
Current methods for producing nonwoven sheets of natural flax fibers are complex and expensive, resulting in materials with insufficient mechanical properties, variable thickness, and difficulty in handling, making them unsuitable for composite materials production.
Innovation Solution
A process involving the parallel feeding of separate ribbons of natural long fibers, dispersion through a spike field, tensioning, and bonding to form a continuous web with uniform thickness and high fiber orientation, using a system with upstream and downstream rollers and a binding solution to enhance cohesion without synthetic binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional assembly methods are used to produce nonwoven sheets of natural fibers, then mechanical cohesion is achieved, but the process becomes complex and expensive
Solution Approach 1:
The invention extracts and eliminates the complex assembly steps from the conventional process. Instead of using multiple assembly operations to achieve mechanical cohesion, the patent applies a bonding solution that directly bonds fibers together in a simplified sequence, removing the need for complex assembly equipment and procedures while maintaining adequate mechanical cohesion for handling and composite production
Solution Approach 2:
The invention replaces the mechanical assembly system with a chemical/biological bonding system. Rather than using mechanical forces and complex assembly machinery to achieve fiber cohesion, the patent uses a bonding solution (enzymatic or chemical) that chemically bonds fibers together, substituting a complex mechanical system with a simpler wet-laying and bonding process
2Quantity of substance
If conventional assembly methods are used to produce nonwoven sheets, then fiber assemblies are formed, but the thickness becomes variable and handling becomes difficult
Solution Approach 1:
The invention applies preliminary action by using a bonding solution during the fiber laying process itself, rather than attempting to correct thickness variations afterward. The bonding solution is applied as fibers are being deposited on the screen, allowing for real-time bonding that maintains uniform thickness throughout the nonwoven sheet formation process
Solution Approach 2:
The invention changes the bonding parameter from mechanical assembly to chemical/biological bonding. By using a bonding solution with controlled concentration and application timing, the process achieves more precise and uniform fiber bonding throughout the sheet, resulting in consistent thickness that is easier to handle and process
3Ease of manufacture
If flax tow is used in conventional dry process, then production is simplified, but mechanical properties become insufficient for composite materials
Solution Approach 1:
The invention changes the bonding mechanism parameter from mechanical interlocking (conventional dry process) to chemical/biological bonding. By introducing a bonding solution that creates strong inter-fiber bonds, the mechanical properties of the nonwoven sheet are significantly enhanced while maintaining the production simplicity of the wet-laying process, making it suitable for composite materials production
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 process simplifies the production of a thin, uniform, and cost-effective veil with improved mechanical cohesion, suitable for composite materials, maintaining the environmental benefits of natural fibers while reducing resin usage and manufacturing complexity.
Implementation Method 1
dispersing adjacent ribbons through a field of spikes to form a parallel fiber band
Implementation Method 2
the drive speed of the strip in downstream of the downstream roller being greater than at least twice, advantageously at least six times, the drive speed of the strip by the upstream roller
Implementation Method 3
bonding the fibers of the stretched web to form the veil
Implementation Method 4
drying the strip to form the web
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The inventive method includes the following steps: bringing a plurality of disjointed ribbons (32) of fibers into parallel, at least one ribbon (32) containing long natural fibers; dispersing the adjacent ribbons (32) through a field of tips (60) to form a strip (62) of parallel fibers; tensioning and stretching the strip (62) in the field of tips (60) parallel to an axis of travel (B-B′); binding the fibers of the stretched strip (62) to form the web (60).