Profiled Roller Surface for Spunbond Web Fiber Waste Reduction
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Solution Overview
Problem
Existing devices for producing spunbonded nonwoven webs suffer from fiber waste and contamination due to fibers being torn and adhering to the sieve belt during the transfer process, affecting the quality of the final product.
Innovation Solution
A device with a profiled roller surface, featuring macroprofiling in the form of grooves and ridges, and microprofiling for reduced friction, ensures minimal contact between the sieve belt and the roller, preventing fiber waste and contamination by allowing only partial contact with profiling maxima, thereby guiding fibers efficiently to the calender.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the sieve belt is wrapped around the roller with a large angle of wrap to ensure stable fiber deposition, then the fiber deposition stability is improved, but the fiber waste and contamination increase due to increased contact between the sieve belt and roller causing fibers to be pressed into the sieve belt
Solution Approach 1:
The roller surface is equipped with guide edges at specific locations (entry and exit points of the sieve belt) rather than being uniformly structured. These localized guide edges provide the necessary guidance function only where contact is needed, while the rest of the roller surface remains smooth to minimize fiber adhesion and waste.
Solution Approach 2:
The roller surface is segmented into different functional zones: smooth areas for minimal contact and localized guide edges for structural support and guidance. This segmentation allows the roller to perform multiple functions with reduced overall contact area, preventing fiber waste while maintaining deposition stability.
2Manufacturing precision
If the sieve belt contacts the roller surface extensively to ensure proper fiber alignment and deposition, then the fiber alignment is improved, but the contamination of the sieve belt increases due to fibers being pressed into the sieve belt between warp and weft threads
Solution Approach 1:
Guide edges are positioned locally at the entry and exit points of the sieve belt on the roller surface. These localized structures provide sufficient guidance for fiber alignment without creating extensive contact areas that would press fibers into the sieve belt and cause contamination.
Solution Approach 2:
The harmful function of extensive roller-sieve belt contact that causes fiber pressing and contamination is extracted and removed. Only the essential guidance function is retained through minimal guide edges, separating the useful function (alignment) from the harmful effect (contamination).
3Ease of operation
If the roller surface is smooth to minimize friction and allow easy sieve belt movement, then the sieve belt movement efficiency is improved, but the structural support and guidance function is reduced
Solution Approach 1:
The roller surface combines smooth areas for efficient sieve belt movement with localized guide edges for structural support and guidance. The smooth majority of the surface minimizes friction, while the localized raised edges provide the necessary mechanical function without significantly increasing overall friction.
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 solution effectively reduces fiber waste and contamination, enhancing the quality of the spunbonded nonwoven web production by minimizing contact between the sieve belt and the roller, allowing for continuous and efficient fiber conveyance without 'snow flying' issues.
Implementation Method 1
the roller surface of the roller being profiled with the proviso that the sieve belt in each case is only in physical contact with the profiling maxima of the roll surface
Data Source
Figure 1
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Figure 3~4
AI summary
Device for producing a spunbond nonwoven web with a lay-up screen belt onto which fibers can be laid to form the nonwoven web. The lay-up screen belt is guided over at least one roller, and the roller surface is profiled such that the lay-up screen belt is in contact with the profile maxima of the roller surface.