Nonwoven Production Line for Wet-Laid and Carded Web Integration
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Solution Overview
Problem
Existing methods for producing nonwoven fabrics are complex and require precise belt alignment and speed control, limiting flexibility in processing both wet-laid fibers and carded nonwovens.
Innovation Solution
A system comprising a slant wire former, carding machine, hydroentanglement system, and dryer, allowing for flexible production of single- or multi-layer nonwovens by processing either wet-laid or carded fibers independently, with optional combinations, using conveyor belts arranged to avoid belt overlap and speed differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet-laid fibers are deposited on a conveyor belt using parallel belts, then the nonwoven fabric can be produced, but the system becomes very complex requiring absolute belt parallelism and constant tension control
Solution Approach 1:
The patent removes the complex parallel belt guidance system from the process. Instead of using multiple belts that require precise parallel alignment and constant tension control, the invention extracts the wet-laid web directly from the former and processes it vertically through the carding and hydroentanglement systems, eliminating the troublesome belt mechanism entirely.
Solution Approach 2:
The patent inverts the conventional horizontal belt-based processing approach. Instead of moving the web horizontally through parallel belts, the invention processes the web in a vertical direction from the former through the carding machine and hydroentanglement system, completely reversing the problematic belt guidance requirement.
2Adaptability or versatility
If both wet-laid fibers and carded nonwoven are processed in the same system, then production flexibility is improved, but the system complexity increases
Solution Approach 1:
The patent creates a universal processing system where the same vertical processing line (former → carding machine → hydroentanglement → dryer) can handle multiple material types. The system is designed to process wet-laid webs, carded nonwovens, or combinations thereof, all through the same equipment without requiring separate processing lines or complex switching mechanisms.
Solution Approach 2:
The patent segments the production process into independent functional modules: web formation, carding, hydroentanglement, and drying. Each module can process different material types independently, allowing flexible combination of wet-laid and carded materials without interfering with each other, thus achieving versatility without proportional complexity increase.
3Speed
If belts are used to transport fiber webs, then material transport is enabled, but belt misalignment causes uncontrolled distortions in the final product
Solution Approach 1:
The patent extracts and eliminates the belt transport mechanism from the process. Instead of using belts that can misalign and cause web distortion, the invention uses a vertical gravity-assisted process where the web moves directly from the former through the processing stations without intermediate belt handling, completely removing the source of alignment problems.
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 flexible and cost-effective production of nonwovens with varying fiber lengths and basis weights, avoiding distortions due to belt misalignment, and allowing for diverse material combinations.
Implementation Method 1
a hydroentanglement system arranged downstream in the material transport direction with at least one water bar, which is designed to consolidate and/or bond and/or structure a single web of fibers or multiple webs of fibers
Implementation Method 2
a dryer arranged downstream in the material transport direction
Data Source
Figure 1
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AI summary
The invention relates to a system and to a method, comprising: an inclined wire former (1), which is designed to place a web of wet-laid fibrous material (9) on a first circulating belt (10); and having a further belt (13), which is designed to take the web of wet-laid fibrous material (9) from the first circulating belt (10); a carder (15), which is downstream in the material transport direction and is designed to introduce a carded nonwoven (15a) into the system (100); a water jet compacting means, which is arranged downstream in the material transport direction and has at least one water bar (16), which is designed to compact and/or bond and/or structure a single web of fibres or a plurality of webs of fibres; and a dryer (18), which is arranged downstream in the material transport direction; wherein the system is designed to optionally produce a single- or multi-layer nonwoven (19).