Pneumatic Fiber Feeding for Uniform Random Web Deposition
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Solution Overview
Problem
Existing machines for forming non-woven air-laid webs suffer from non-uniform deposition of fibers on the condenser, leading to additional processing costs and the need for further steps to achieve uniformity.
Innovation Solution
Modifications to the machine design, including the removal or modification of components such as the doffer plate and lower slide plate, addition of a seal with a reverse orientation, and the use of a nose bar extension to control the doffing trajectory, along with air venting passages, to ensure uniform fiber deposition on the condenser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the doffer plate and lower slide plate are present in the conventional machine design, then the machine structure is complete and functional, but the fiber deposition on the condenser becomes non-uniform
Solution Approach 1:
The patent removes the doffer plate and lower slide plate from the machine design to eliminate the problem of non-uniform fiber deposition. By extracting these problematic components, the air supply can flow more freely and uniformly across the condenser surface, resulting in improved fiber deposition uniformity without the interference of solid plates that caused clumping and non-uniform distribution.
2Manufacturing precision
If additional processing steps are added to achieve uniform web deposition, then the deposition uniformity is improved, but the processing cost and time increase
Solution Approach 1:
The patent implements preliminary action by modifying the machine design upfront to prevent non-uniform deposition from occurring in the first place. By removing the doffer plate and lower slide plate before the deposition process begins, and by designing the air supply system to provide uniform airflow, the system achieves uniform web deposition directly during the primary processing step, eliminating the need for costly and time-consuming post-deposition processing steps.
3Quantity of substance
If the air supply is increased to improve fiber entrainment, then more fibers are carried to the condenser, but the deposition becomes less uniform due to turbulence and clumping
Solution Approach 1:
The patent applies local quality by optimizing the air supply distribution across different regions of the condenser. By removing the doffer plate and lower slide plate, the air supply can be distributed more evenly across the entire condenser surface, ensuring that fibers are deposited uniformly throughout. The air supply system is configured to provide appropriate airflow velocity and distribution at each location, preventing both insufficient entrainment and excessive turbulence that would cause non-uniform deposition.
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
The modifications result in a more uniform deposition of fibers on the condenser, reducing processing costs and eliminating the need for additional steps to achieve a uniform web.
Implementation Method 1
The lickerin 12 then doffs the combed fibers therefrom using centrifugal force
Implementation Method 2
The doffed fibers are carried entrained in the air supply AS to a condenser 18
Implementation Method 3
The fibers are deposited on the condenser 18 in a random fashion to form the non-woven fiber web
Data Source
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AI summary
Methods and systems of forming a random fiber web using pneumatic fiber feeding system are disclosed. The method can optionally comprise: providing a plurality of moveable apparatuses including a lickerin and a feeder, the lickerin configured to remove a plurality of fibers from a fibrous mat delivered to adjacent the lickerin by the feeder; doffing the plurality of fibers from the lickerin at a doffing location within the system; communicating an air supply to entrain the plurality of fibers with the air supply after the doffing; and collecting the plurality of fibers from the air supply to form the random fiber web.