PLA Spunbond Nonwoven Processing With Ionization Static Control

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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 existing methods face difficulties in combining spinning, web formation, and bonding efficiently and economically.

Innovation Solution

The system employs ionization bars to control static charges during the production of PLA spunbond nonwoven fabrics, allowing for high-speed processing with minimal waste by exposing the continuous filaments to ions, thereby neutralizing static charges without direct contact, and uses a calender for bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PLA is processed at high speeds to achieve economically attractive production, then productivity increases, but static charge accumulation worsens causing processing difficulties

Engineering Contradiction:

Improveproduction speedVSAvoidstatic charge

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent applies ionization bars that generate ions to neutralize the harmful static charges accumulated during high-speed PLA processing. By converting the harmful electrostatic effect into a controlled ionization process, the system enables high-speed production while eliminating static-related processing difficulties.

Inventive Principle:

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

Solution Approach 2:

The ionization bars serve as an intermediary element between the PLA filaments and the static charge problem. These bars generate ions that act as a mediator to neutralize static charges on the PLA surface without direct contact, allowing high-speed processing to proceed smoothly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If traditional synthetic polymers are used in sheath/core structure, then ease of manufacture improves, but environmental sustainability deteriorates

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material composition parameter by replacing synthetic polymers with PLA in the sheath layer of the sheath/core structure. This parameter change maintains the manufacturability of the bicomponent fiber while improving environmental sustainability, as PLA is biodegradable and renewable.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite sheath/core structure where the sheath is made of PLA and the core is made of a different polymer. This composite structure allows the outer PLA layer to provide environmental benefits while the inner core maintains structural integrity and ease of processing.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If PLA is used to achieve sustainability, then environmental friendliness improves, but processing difficulty increases due to static charge

Engineering Contradiction:

Improveenvironmental impactVSAvoidprocessing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical static control methods (such as grounding or conductive surfaces) with an electrostatic ionization system. The ionization bars generate ions that electrically neutralize static charges, substituting a mechanical approach with an electromagnetic field-based solution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the production of PLA spunbond nonwoven fabrics at commercially viable speeds with reduced static issues, minimizing waste and enhancing fabric properties such as tensile strength and resistance to shrinkage, making the process 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

PatentEP3325703B1System and process for preparing polylactic acid nonwoven fabrics

Publication Date: 2019.07.24 FITESA GERMANY GMBH

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Figure 2A~2C
Figure 3A~3C

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.