PLA Spunbond Nonwoven Fabric Ionization for High-Speed Processing

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Solution Overview

Problem

The challenge lies in producing polylactic acid (PLA) spunbond nonwoven fabrics at high speeds while minimizing waste and achieving desired fabric properties, as traditional methods face difficulties in combining spinning, web formation, and bonding efficiently.

Innovation Solution

The implementation of a system that includes a PLA source, a spin beam, a collection surface, and an ionization source to expose PLA continuous filaments to ions, along with a calender for bonding, which controls static and enables high-speed production with minimal waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PLA is processed at high speeds to achieve economically viable production, then productivity is improved, but static charge accumulation occurs causing web wraps and processing difficulties

Engineering Contradiction:

Improveproduction speedVSAvoidstatic charge

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces ionization bars that generate ions to neutralize the static charge accumulated during high-speed PLA processing. By converting the harmful static electricity into a controlled electrical phenomenon through ionization, the system eliminates web wraps and processing difficulties while maintaining high production speeds, thus resolving the contradiction between productivity and static charge accumulation

Inventive Principle:

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

2Productivity

If traditional spinning, web formation, and bonding steps are combined at high speeds, then productivity is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveproduction speedVSAvoidfabric properties

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies ionization treatment to the PLA filaments before they complete the spinning and web formation process. By pre-neutralizing static charge that would otherwise interfere with subsequent bonding operations, the system enables high-speed processing while maintaining precise control over fabric properties and structural integrity

Inventive Principle:

Principle #10Preliminary action

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 allows for the production of PLA spunbond nonwoven fabrics at commercially viable speeds with reduced static issues, achieving desired properties and making the production economically attractive.

Implementation Method 1

a first ionization source positioned and arranged to expose the PLA continuous filaments to ions

Methodology Applied

Scientific EffectIonization: Ionisation

Data Source

PatentUS11365497B2System and process for preparing polylactic acid nonwoven fabrics

Publication Date: 2022.06.21 FITESA GERMANY GMBH

AI summary

A system for preparing a polylactic acid (PLA) spunbond nonwoven fabric is provided. In particular, the system includes a first PLA source configured to provide a stream of molten or semi-molten PLA resin; a spin beam in fluid communication with the first PLA source, the spin beam configured to extrude and draw a plurality of PLA continuous filaments; a collection surface disposed below an outlet of the spin beam onto which the PLA continuous filaments are deposited to form the PLA spunbond nonwoven fabric; a first ionization source positioned and arranged to expose the PLA continuous filaments to ions; and a calender positioned downstream of the first ionization source.