Nonwoven Web Stabilization Plate for Flutter-Free Roller Guidance

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Solution Overview

Problem

The handling of nonwoven webs during manufacture is hindered by air flows that cause fluttering and undesired wrinkling, leading to potential tearing and non-homogeneous properties, which existing solutions like additional rollers and spoiler sheets have failed to adequately address.

Innovation Solution

A method and apparatus involving stabilization plates positioned upstream or downstream of guide or treatment rollers to control air flow, with the nonwoven web physically contacting the plates to minimize air interference, ensuring a stable web path and reducing operational disturbances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If higher web tension is applied to control the nonwoven web and reduce fluttering, then web stability improves, but web strength and width deteriorate

Engineering Contradiction:

Improveweb stabilityVSAvoidweb strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

A stabilization plate is introduced as an intermediary element between the air flow and the nonwoven web. The plate physically blocks and redirects air currents that cause fluttering, while the web remains under normal tension. This mediator approach stabilizes the web without requiring increased tension that would damage web strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention converts the harmful effect of air flow (which causes fluttering) into a beneficial controlled flow pattern. By using the stabilization plate to redirect air flow in a controlled manner, the previously harmful uncontrolled air currents become a manageable element that no longer damages the web.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Stability of the object's composition

If additional rollers or spoiler sheets are added to the conveyance path to counter air flows, then web guidance improves, but device complexity increases

Engineering Contradiction:

Improveweb guidanceVSAvoiddevice complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The stabilization plate is a simple, inexpensive component compared to complex roller assemblies or spoiler sheet systems. It provides effective web stabilization through a straightforward geometric structure that blocks and redirects air flow, eliminating the need for multiple additional rollers or complex guidance mechanisms.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Use of energy by moving object

If air flow is allowed to move freely with the nonwoven web, then energy consumption is reduced, but web quality deteriorates due to fluttering and wrinkling

Engineering Contradiction:

Improveenergy consumptionVSAvoidweb quality

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The stabilization plate extracts or removes the harmful component of air flow (turbulent currents causing fluttering) while allowing the beneficial free flow to continue. The plate selectively blocks only the problematic air currents that contact the web surface, maintaining energy efficiency while improving web quality.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This approach effectively stabilizes the nonwoven web, reducing fluttering and maintaining web integrity, thereby enhancing operational performance without the need for increased web tension, which would otherwise compromise width and strength.

Implementation Method 1

When a nonwoven web is conveyed with a deposition screen belt and/or by guide rollers and/or treatment rollers, a flow of air that moves in the travel direction of the nonwoven web is produced at all times.

Methodology Applied

Scientific EffectAir flow control:

Implementation Method 2

The air entrained by the nonwoven web can also be problematic when the nonwoven web travels around a guide roller and/or a treatment roller.

Methodology Applied

Scientific EffectAir entrainment: Air Entrainment

Implementation Method 3

the nonwoven web is guided in the travel direction past the stabilization plate such that a spacing between a face of the stabilization plate turned toward the nonwoven web and the nonwoven web face is 0 to 20 mm

Methodology Applied

Scientific EffectPhysical contact stabilization:

Implementation Method 4

Attempts to compensate for these disturbances use higher web tension order to control the nonwoven web. This higher web tension results in turn in a smaller width of the nonwoven web on the winder, as well as deteriorated properties of the nonwoven web

Methodology Applied

Scientific EffectTension reduction:

Data Source

PatentUS10094058B2Method and apparatus for guiding a nonwoven web

Publication Date: 2018.10.09 REIFENHAUSER GMBH & CO MASCHFAB

AI summary

A nonwoven web made of plastic fibers and having a web thickness less than 2 mm (preferably less than 1.5 mm) and a grammage less than 30 g/m2 (preferably less than 25 g/m2) and conveyed this web in a travel direction so that it physically contacts a guide or treatment roller. A stabilization plate extending in and transversely to the travel direction of the nonwoven web is provided upstream or downstream of the roller in the travel direction, and the nonwoven web is guided in the travel direction past the stabilization plate such that a spacing between a face of the stabilization plate turned toward the nonwoven web and the nonwoven web face is 0 to 20 mm (preferably 0.1 to 10 mm, and very preferably 0.2 to 5 mm).