Nonwoven Fabric Fiber Mixing and Deposition
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Solution Overview
Problem
Existing nonwoven fabrics made from continuous filaments and pulp short fibers face challenges in achieving an optimal compromise between liquid absorption capacity and mechanical strength, with issues related to uniform distribution and stability.
Innovation Solution
A method involving the use of at least one meltblow spinneret to produce thermoplastic continuous filaments and a defibrator to create pulp short fibers, where the filament-air and short-fiber/air streams are directed to intersect above a foraminous deposition belt, with aspirated air volume exceeding the combined filament and short-fiber air volumes, ensuring uniform distribution and enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous filaments and pulp short fibers are used to stabilize nonwoven fabric, then mechanical strength is improved, but uniform distribution of fibers is worsened
Solution Approach 1:
The invention divides the fiber supply system into separate streams: a continuous filament stream from a meltblow spinneret and a short fiber stream from a defibrator. Each stream is controlled independently and directed to intersect above the deposition belt, allowing precise control over the distribution pattern of each fiber type to achieve uniform mixing while maintaining mechanical strength.
Solution Approach 2:
The invention introduces a spatial dimension by directing the two fiber streams to intersect above the deposition belt at specific angles. The continuous filament stream and short fiber stream are oriented to cross each other in three-dimensional space, creating a uniform mixture pattern that improves distribution uniformity while maintaining the structural integrity provided by continuous filaments.
2Strength
If continuous filaments are used to stabilize nonwoven fabric, then mechanical strength is improved, but liquid absorption capacity is worsened
Solution Approach 1:
The invention assigns different functional qualities to different fiber types in specific locations: continuous filaments provide mechanical strength and structural stability, while pulp short fibers provide liquid absorption capacity. By controlling the distribution ratio and spatial arrangement of the two fiber types through the intersecting streams, the nonwoven fabric achieves optimal local quality for both strength and absorption.
Solution Approach 2:
The invention creates a composite nonwoven fabric structure combining continuous thermoplastic filaments with pulp short fibers. This composite material leverages the complementary properties of both fiber types: the continuous filaments form a strength-bearing network while the short pulp fibers provide capillary structures for liquid absorption, achieving both mechanical strength and high liquid absorption capacity simultaneously.
3Strength
If larger proportion of continuous filaments is used to stabilize nonwoven fabric, then mechanical strength is improved, but liquid absorption capacity is worsened
Solution Approach 1:
The invention uses a controlled partial proportion of continuous filaments rather than maximizing their amount. By regulating the flow rates of the continuous filament stream and short fiber stream through the intersecting configuration, the system achieves sufficient mechanical strength with a balanced, rather than excessive, amount of continuous filaments, thereby preserving liquid absorption capacity.
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 method results in a nonwoven fabric with high uniformity and an optimal balance between strength and liquid absorption capacity, using a relatively small proportion of continuous filaments, while maintaining economic efficiency.
Implementation Method 1
continuous filaments of thermoplastic material are made by at least one meltblow spinneret
Implementation Method 2
pulp short fibers are made by at least one defibrator
Implementation Method 3
air or process air with a volume flow V4 is aspirated from below through the foraminous deposition belt in the deposition zone
Implementation Method 4
the filament-air stream and the short-fiber/air stream are brought together above the foraminous deposition belt in a contact zone
Implementation Method 5
with a very uniform distribution of continuous filaments and pulp short fibers
Implementation Method 6
deposited in a deposition zone on a foraminous deposition belt to form the nonwoven fabric
Data Source
AI summary
Method for producing a nonwoven fabric from fibres. Continuous filaments are produced from thermoplastic material by at least one meltblown spinneret. Chopped pulp fibres are also produced by at least one pulping device. In the pulping device, at least one chopped-fibre/air stream is produced from the chopped pulp fibres, is passed through and discharged from an outlet channel and flows with an initial volumetric flow V1 and a flow direction S1 in the direction of an air-permeable depositing screen belt. The continuous filaments flow from the at least one meltblown spinneret as a filament/air stream with an initial volumetric flow V2 in the direction of the chopped-fibre/air stream. The filament/air stream and the chopped-fibre/air stream are brought together above the depositing screen belt in a contact zone and deposited as a mixture of continuous filaments and chopped fibres in a depositing region on the depositing screen belt to form the nonwoven fabric or nonwoven web. In the depositing region of the fibres or of the mixture of continuous filaments and chopped fibres, air or process air is sucked through the depositing screen belt from below with a volumetric flow V4. The volumetric flow V4 is greater than the sum of the volumetric flows V1 and V2.