Random Fiber Web Pneumatic Feeding for Uniform 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 costly processing steps and potential fiber clumping, which results in uneven web quality.
Innovation Solution
Modifications to the machine design include the removal or modification of the doffer plate and lower slide plate, addition of a nose bar and air deflector assembly, and use of an airfoil or damper to control airflow and fiber trajectory, ensuring uniform fiber deposition on the condenser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional machine design with doffer plate and lower slide plate is used, then the machine structure is simple, but the fiber deposition on the condenser is non-uniform causing edge regions to be removed
Solution Approach 1:
The patent removes the doffer plate and lower slide plate from the traditional machine design. This extraction of problematic components eliminates the source of non-uniform fiber deposition while simplifying the overall machine structure. The removal directly addresses the technical contradiction by eliminating the component causing deposition issues without adding complexity.
Solution Approach 2:
The patent introduces a nose bar as an intermediary component between the lickerin and the condenser. This nose bar serves as a mediator to control fiber trajectory and improve deposition uniformity. The nose bar extends into the air stream to guide fibers onto the condenser surface, resolving the deposition uniformity issue without requiring complex additional mechanisms.
2Manufacturing precision
If the doffer plate and lower slide plate are kept in the traditional configuration, then the machine is easier to manufacture, but fibers clump together and roll down to the condenser causing non-uniform deposition
Solution Approach 1:
The patent extracts and removes the doffer plate and lower slide plate that cause fiber clumping. By eliminating these components, fibers no longer clump together and roll down to the condenser, thereby improving deposition uniformity. The removal of these problematic parts actually simplifies manufacturing compared to trying to modify them to prevent clumping.
Solution Approach 2:
The patent replaces the mechanical fiber transfer system (doffer plate and lower slide plate) with a pneumatic system where fibers are carried entrained in an air stream directly from the lickerin to the condenser. This substitution eliminates mechanical contact that causes clumping and simplifies the manufacturing process.
3Manufacturing precision
If additional processing steps are added to correct non-uniform deposition, then web quality improves, but production costs increase and productivity decreases
Solution Approach 1:
The patent implements preliminary action by modifying the machine design upfront to ensure uniform fiber deposition directly at the source. The nose bar and modified air stream configuration are built into the system before production, preventing non-uniform deposition from occurring in the first place. This eliminates the need for subsequent corrective processing steps, thereby maintaining both high web quality and production efficiency.
4Manufacturing precision
If the air stream is not properly controlled, then the machine operation is simpler, but fibers are not uniformly entrained and deposited on the condenser
Solution Approach 1:
The patent introduces the nose bar as an intermediary that simplifies air stream control. The nose bar extends into the air stream and naturally guides both the air and fibers onto the condenser surface. This intermediary component creates proper airflow patterns without requiring complex control systems, maintaining ease of operation while achieving uniform deposition.
Solution Approach 2:
The modified air stream system is designed to self-regulate and naturally entrain fibers uniformly. The air supply and nose bar configuration create a self-organizing flow pattern that automatically ensures uniform fiber deposition without requiring active control or monitoring systems, thereby maintaining operational simplicity.
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 fiber deposition on the condenser, reducing the need for additional processing steps and improving web quality, thereby enhancing production efficiency and reducing costs.
Implementation Method 1
The lickerin 12 then doffs the combed fibers therefrom using centrifugal force and the combed fibers enter an air supply AS flowing past the lickerin 12
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
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.