Nickel Drum Perforation for Continuous Nonwoven Patterns
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Solution Overview
Problem
Existing machines for producing patterned nonwoven textile products face limitations in creating closed contours without metal bridges, resulting in discontinuous patterns, and struggle with line width restrictions and fiber displacement issues, leading to increased hairiness and poor surface finish.
Innovation Solution
A nickel drum with a low open surface and controlled perforations is used to create patterns with continuous contours and reduced hairiness, allowing for precise water flow management and bonding during the patterning process, enabling patterns with dimensions greater than 2 mm and uniform surface finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solid body relief is welded or glued on a porous canvas, then the relief zone is full and water drainage is not possible, but this causes fibers to be moved around the solid by the flow of water and creates holes in the nonwoven when line width exceeds 2 mm
Solution Approach 1:
The drum surface is made porous with controlled perforations (0.1-1.2 mm diameter at 40-200 per cm²) instead of using solid body relief. This allows water to drain through the drum surface while still providing sufficient support for the nonwoven fabric, preventing fiber displacement and hole formation even at line widths greater than 2 mm.
Solution Approach 2:
The invention changes the physical state of the drum surface from solid to controlled-porosity by precisely controlling perforation dimensions (0.1-1.2 mm) and density (40-200/cm²). This parameter optimization allows the drum to provide mechanical support while enabling water drainage, resolving the contradiction between pattern definition and fiber stability.
2Ease of manufacture
If existing marking technologies use a large open surface drum, then the drum structure is simple, but binding is not allowed and hairiness is increased during marking
Solution Approach 1:
The drum surface is configured with controlled perforations (0.1-1.2 mm diameter, 40-200 per cm²) that provide mechanical support for binding while maintaining manufacturing feasibility. The porous structure allows the drum to hold the nonwoven fabric securely during marking without excessive open surface, thereby reducing fiber displacement and hairiness.
3Ease of operation
If the drum has high open surface area, then water flow management is simple, but patterns cannot be delimited by continuous lines and closed contours cannot be created
Solution Approach 1:
The invention optimizes perforation parameters (0.1-1.2 mm diameter, 40-200 per cm² density) to create a balanced drum surface that enables both continuous pattern lines and adequate water drainage. The controlled porosity provides sufficient structural definition for continuous contours while maintaining water flow management capability through the perforated surface.
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 effectively reduces hairiness and fiber displacement, achieving patterns with continuous contours and improved surface finish, while minimizing fiber loss and hydraulic energy, suitable for various nonwoven materials like cellulosic and polyester blends.
Implementation Method 1
Patterning can only be done effectively by precise management of the flow of water from its emission to its suction through the patterning drum
Implementation Method 2
The drum makes it possible to generate binding (bonding) at the same time as marking (patterning). Thus the ends of free fibers (hairiness) are limited in number because they are integrated into the fibrous mass (fibers bonded together)
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The inventive nickel drum comprises a first part whose lateral surface is provided with perforations at the first level thereof and a second part whose lateral surface is provided with perforations at the second level different from the first level. Said invention can be used for producing nonwovens.