Segmented Feed Roller for Uniform Nonwoven Fiber Distribution
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Solution Overview
Problem
Existing feed devices for fiber tufts lack the flexibility to produce uniform fibrous webs and nonwoven fabrics, as they often result in uneven fiber distribution across the width due to separate feed segments with their own rollers, leading to gaps and reduced uniformity.
Innovation Solution
A feed device with at least two feed segments arranged circumferentially around an opening roller, allowing for independent control of each segment's rollers, which can be aligned or offset to ensure even fiber distribution and mixing ratios, thereby enhancing the uniformity and flexibility of the fibrous web formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate feed rollers are used for each feed segment, then the feed segments can be independently controlled, but gaps between feed rollers reduce manufacturing precision
Solution Approach 1:
Multiple feed segments are merged into a single continuous feed roller structure, eliminating gaps between individual rollers. The feed roller is divided into multiple independently controllable segments along its circumference, allowing each segment to be controlled independently while maintaining continuous contact with the opening roller, thus resolving the contradiction between independent control and uniform fiber distribution.
Solution Approach 2:
The feed roller is segmented into multiple independently controllable sections along its circumference, while remaining a continuous structure. This segmentation allows independent control of fiber feed rates from different sources, while the continuous structure eliminates gaps that would cause non-uniformity in the fiber web.
2Ease of manufacture
If feed rollers are spaced apart for bearing mounting, then bearings can be installed, but this reduces the uniformity of fiber distribution
Solution Approach 1:
The feed roller is designed as a continuous structure where multiple feed segments share a common cylindrical surface. Bearings are mounted on the internal structure supporting the feed roller, not on the feed roller itself, eliminating the need to space apart feed rollers for bearing installation while maintaining continuous fiber distribution across the width.
3Ease of operation
If fiber wick is fed to the center of feed segment, then feeding is simplified, but fiber distribution becomes non-uniform with more fibers in center than edges
Solution Approach 1:
Each feed segment can independently control the distribution characteristics of fibers from its corresponding region of the opening roller. By having multiple feed segments around the circumference, the system creates different local fiber distribution patterns that can be individually adjusted to achieve uniform overall distribution across the width, with each segment compensating for the center-heavy distribution of others.
Data Source
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AI summary
The feeding device (8) for feeding dissolved fibers or fiber flakes onto a transport device (6) comprises at least a first feeding segment (110) and a second feeding segment (210) for feeding a starting material (114, 214), each comprising a feed roller (120, 220); and an opener roller (26) that interacts with the feed rollers (120, 220) of the first and second feeding segments (110, 210) to dissolve the starting material (114, 214). At least the first and second feeding segments (110, 210) are spaced apart from each other in a circumferential direction (U) of the opener roller (26). A nonwoven fabric forming plant (2) comprises a transport device (6) and at least one such feeding device (8) for feeding fibers or fiber flakes onto the transport device (6).