Screen Drum Pattern Formation in Nonwoven Production
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Solution Overview
Problem
Existing methods for producing perforated nonwovens cannot introduce patterns such as animal or plant images or geometric figures into the fleece during water needling without compromising the bonding strength, and they often result in ventilation openings distributed over the entire surface, which does not achieve the desired stiffness.
Innovation Solution
The device features a screening drum with areas of elevations arranged to form patterns on the surface, where patterns are created at points with drainage openings instead of elevations, allowing for the introduction of designs like animals, plants, or geometric shapes while ensuring uniform consolidation and strength through targeted perforation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If elevations are distributed over the entire screen drum surface to create perforation, then ventilation is achieved, but the strength and stiffness of the web deteriorates
Solution Approach 1:
The screen drum surface is divided into distinct zones: areas with elevations for uniform consolidation and strength, and elevation-free areas for pattern formation with ventilation. This local differentiation allows different regions to serve different functions, resolving the contradiction between ventilation and strength.
2Shape
If elevations are used to form patterns in the fleece, then pattern introduction is achieved, but the bonding strength deteriorates due to excessive perforation
Solution Approach 1:
The pattern-forming function is extracted from the elevations and assigned to separate elevation-free areas on the screen drum. This separation allows elevations to focus solely on consolidation without compromising bonding strength, while patterns are formed in dedicated zones without perforation.
3Productivity
If drainage openings are distributed over the entire screen drum surface, then liquid removal is efficient, but pattern formation becomes impossible
Solution Approach 1:
The screen drum surface is locally differentiated into areas with elevations for consolidation and elevation-free areas for pattern formation. Both areas contain drainage openings for liquid removal, ensuring that pattern zones do not compromise drainage efficiency while enabling design formation.
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 nonwovens with enhanced strength and stiffness by varying the fleece surface into areas with and without ventilation openings, allowing for diverse patterns without compromising bonding, and allows for the creation of patterns that are not perforated, thus improving the overall quality and variety of the nonwoven fabric.
Implementation Method 1
A device for producing perforated nonwovens by means of hydrodynamic needling is already known from EP 1 001 064 B1
Implementation Method 2
drainage openings for transporting away the liquid sprayed from many outflow openings at high pressure by means of a water beam
Data Source
Figure 1~4
Figure 5A~5C
Figure 5D
AI summary
The invention relates to an apparatus for producing textiles, nonwoven substances, spunbonded fabrics or paper materials (5) with the aid of at least one screen drum (1) having openings (4) for transporting away the fluid (6) which is output from a water bar (7) and having numerous outwardly directed elevations (3) which are situated on the outside of the screen drum (1) for the perforation of the nonwoven (5). The invention is based on the object of providing an apparatus which makes it possible, during the water conversion and at the same time as the perforation, also to make patterns in the nonwoven without influencing the strengthening substantially in the process. The object has been achieved in that one or a plurality of regions (8) on the outer side of the screen drum (1) does/do not have any elevations (3) but only openings (4).