Spunbond Nonwoven Fabric Ejector Slit Width Regulation
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Solution Overview
Problem
Conventional processes for producing spunbonded nonwoven fabrics face challenges in achieving high evenness in basis weight due to fluctuations in fiber ejection rates and air stream variations, leading to unevenness in the final product.
Innovation Solution
A process involving a rectangular ejector with slit width regulation parts and minute-deformation means that dynamically adjusts the slit width based on real-time basis-weight distribution measurements to maintain a CV value of 4.0% or less in the width direction, ensuring consistent evenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production rate of spunbonded nonwoven fabric is increased to achieve high production efficiency, then productivity is improved, but evenness in basis weight deteriorates due to enhanced unevenness
Solution Approach 1:
The patent applies dynamics by making the slit width of the jetting hole adjustable during operation. The slit width regulation member can be deformed by minute-deformation means to change the slit width dynamically, allowing the system to adapt to varying production conditions and maintain evenness while operating at high production rates.
Solution Approach 2:
The patent changes the physical parameter of slit width to control fiber ejection. By adjusting the slit width through deformation of the regulation member, the system optimizes fiber distribution and maintains basis weight evenness across different production rates, resolving the contradiction between productivity and manufacturing precision.
2Device complexity
If conventional production processes are used without dynamic regulation, then device complexity is kept low, but manufacturing precision deteriorates due to fluctuations in fiber ejection amount and air streams
Solution Approach 1:
The patent segments the slit width regulation into multiple adjustable zones along the jetting hole. The slit width regulation member is divided into multiple sections that can be independently deformed by minute-deformation means, allowing localized adjustment of fiber ejection to compensate for variations in basis weight distribution while maintaining overall system simplicity.
Solution Approach 2:
The patent implements feedback control where the basis-weight distribution is measured and used to adjust the slit width dynamically. The minute-deformation means modify the slit width regulation member based on detected variations, creating a closed-loop system that maintains manufacturing precision without excessive complexity.
3Ease of manufacture
If the slit width is fixed without regulation means, then ease of manufacture is improved, but manufacturing precision deteriorates due to inability to adapt to changes in fiber ejection and air flow
Solution Approach 1:
The patent applies self-service by enabling the slit width regulation member to automatically adjust its own geometry through the minute-deformation means. The system self-regulates the slit width in response to detected variations in basis weight, eliminating the need for complex external control mechanisms while maintaining manufacturing precision.
Data Source
Figure 1
AI summary
This method for manufacturing a spunbond nonwoven fabric is a method in which a continuous fiber group discharged from a spinneret is thinned and drawn by a rectangular ejector and gathered into the form of a nonwoven fabric, wherein the method for manufacturing a spunbond nonwoven fabric is characterized in that: an ejection port portion of the rectangular ejector is provided with a pair of slit width restricting parts, which face each other in continuation in the long-side direction of the ejection port; at least one of the slit width restricting parts is a slit width restricting member comprising an integrated item continuous in the long-side direction of the ejection port; a plurality of minute deformation means for causing the slit width restricting member to minutely deform are disposed in the long-side direction of the slit width restricting member; the basis weight distribution in the width direction of the nonwoven fabric gathered in advance is measured; the slit width restricting member is caused by the minute deformation means to partially minutely deform on the basis of the resulting measurement value; and the slit width of the ejection port is partially varied by the minute deformation to adjust the basis weight distribution.