Nonwoven Production Machine Multiple Web Processing Paths
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Solution Overview
Problem
Existing nonwoven production machines can only produce a single grade of nonwoven for a given feed to the spun-bond tower, limiting versatility.
Innovation Solution
A nonwoven production machine with multiple paths for web processing, including water-jet consolidation units and a calender, allowing for different grades of nonwovens to be produced by varying the consolidation and treatment processes, such as calendering, surfactant application, and drying, enabling the creation of diverse web structures and logos.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single consolidation path is used in the nonwoven production machine, then the production process is simple, but only a single grade of nonwoven can be produced for a given feed
Solution Approach 1:
The consolidation process is divided into multiple independent consolidation units (first consolidation unit, second consolidation unit) that can operate independently or in combination. Each unit can be selectively engaged or bypassed to produce different nonwoven grades from the same feed, resolving the contradiction between versatility and complexity.
Solution Approach 2:
The machine incorporates dynamic path selection capabilities where the web can be routed through different consolidation paths based on the desired product grade. The system can dynamically adjust which consolidation units are active and which are bypassed, enabling flexible production of different nonwoven types without reconfiguring the entire machine.
2Manufacturing precision
If water-jet consolidation is applied at high pressure to consolidate the web, then consolidation effectiveness is improved, but the web structure may be damaged or over-consolidated
Solution Approach 1:
The consolidation process is segmented into multiple stages with different consolidation units operating at different pressure levels. The first consolidation unit operates at lower pressure (20-100 bar) to provide gentle initial consolidation, while the second unit operates at higher pressure (50-600 bar) for final consolidation or perforation. This staged approach prevents web damage while achieving the desired consolidation quality.
Solution Approach 2:
The system allows for partial consolidation at each stage rather than full consolidation at once. The first consolidation unit applies partial consolidation, and the second unit provides additional consolidation or selective perforation as needed. This partial action approach prevents over-consolidation and preserves web structural integrity while achieving the required consolidation effectiveness.
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
Enables the production of multiple grades of nonwovens from the same feed, enhancing processing flexibility and allowing for treatments like surfactant application and drying, resulting in improved web properties and structures.
Implementation Method 1
Each consolidation may take place for example using a drum or a conveyor, with projection of water jets.
Implementation Method 2
provided, downstream in the direction of the upper run of the first conveyor, are a calender
Implementation Method 3
a device for creating a vacuum, for example of between 400 and 700 millibar
Data Source
AI summary
A nonwoven production machine includes a spun-bond tower for extruding filaments and associated apparatus for forming the filaments into a web that is consolidated by water jets, a web that is calendered and then softened by water jets, or a web that is only calendered.