PLA Spunbond Nonwoven Processing With Ionization for 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 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, allowing for high-speed production with minimal waste by controlling static through ionization bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If PLA is processed at high speeds to achieve economically attractive production, then productivity is improved, but static charge accumulation occurs causing web wrap and processing difficulties
Solution Approach 1:
The patent applies ionization bars to neutralize the harmful static charge that accumulates during high-speed PLA processing. By introducing ions that counteract the static buildup, the system converts the problematic static electricity into a manageable condition, enabling continuous high-speed production without web wrap or processing interruptions
Solution Approach 2:
The ionization bars serve as an intermediary element between the moving PLA web and the static charge problem. These bars generate ions that act as a mediator to neutralize static accumulation on the fabric surface, allowing the high-speed processing to proceed without direct contact or mechanical intervention
2Object-generated harmful factors
If PLA is processed without synthetic polymer sheath to maintain sustainability, then environmental friendliness is improved, but static control and processing stability deteriorate
Solution Approach 1:
The patent extracts and removes the synthetic polymer sheath from the fiber structure, processing PLA in its pure form without petroleum-based coatings. This extraction maintains the environmental benefits of sustainable material while the ionization system compensates for the loss of static protection that the sheath would have provided
Solution Approach 2:
The ionization bars act as an external intermediary that provides static control functionality without requiring the synthetic polymer sheath. This mediator enables reliable processing of pure PLA fibers while maintaining the environmental sustainability of using only biodegradable materials
3Object-affected harmful factors
If ionization bars are added to control static during PLA processing, then static charge is reduced, but device complexity increases
Solution Approach 1:
The patent employs ionization bars that are relatively simple, inexpensive components compared to complex static control systems. These bars provide effective static neutralization through a straightforward electrical discharge mechanism, adding minimal complexity to the high-speed PLA processing system while solving the static charge problem
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, resulting in fabrics with improved properties suitable for various applications, such as diapers and industrial products, while minimizing environmental impact.
Implementation Method 1
a first ionization source positioned and arranged to expose the PLA continuous filaments to ions
Data Source
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.