Method for producing spunbonded fabric
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Solution Overview
Problem
Existing technologies face challenges in adjusting the spinning width and maintaining a constant basis weight distribution of spunbonded nonwovens during operation, especially in cellulosic spunbonded nonwoven production, leading to inefficiencies and product quality issues.
Innovation Solution
The process involves variably adjusting the spinning mass throughput of the nozzle holes along the transverse direction of the spinneret, allowing for precise control of basis weight distribution and enabling the production of nonwovens with varying basis weights across the width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the spinning width is reduced to minimize waste, then the amount of waste material is reduced, but the productivity and output of the production system decreases
Solution Approach 1:
The spinneret is divided into multiple independently controllable nozzle groups arranged along the main axis. Each nozzle group can be selectively activated or deactivated, allowing the spinning width to be dynamically adjusted by switching between different combinations of nozzle groups, thus minimizing waste while maintaining optimal productivity.
Solution Approach 2:
The system transitions from a static spinning width configuration to a dynamic one where the spinning width can be continuously adjusted during operation by controlling different nozzle groups. This dynamic adjustment capability allows the system to optimize between waste reduction and productivity based on real-time production requirements.
2Adaptability or versatility
If modular spinneret designs are used to adjust spinning width, then the adaptability of the system is improved, but the device complexity and thermal decomposition risks increase
Solution Approach 1:
The spinneret is segmented into multiple nozzle groups that can be independently controlled. This segmentation provides adaptability for spinning width adjustment without requiring complete modularization of the entire system, thereby reducing device complexity compared to fully modular designs.
Solution Approach 2:
Multiple nozzle groups are integrated into a single unified spinneret structure with a common melt supply system. This merging approach maintains adaptability while avoiding the complexity of multiple separate modular units, each with their own supply lines and control systems.
3Adaptability or versatility
If modules are switched on or deactivated to change spinning width, then the adaptability is improved, but the melt quality deteriorates due to thermal damage and nozzle clogging
Solution Approach 1:
The spinneret is divided into nozzle groups that can be selectively activated. The key innovation is that the melt supply system is designed to maintain continuous flow to all nozzles, including those currently inactive, preventing thermal damage and clogging while still allowing adaptive spinning width adjustment.
Solution Approach 2:
The melt supply system maintains continuous circulation and flow to all nozzle groups regardless of their active or inactive status. This continuous action prevents the melt from stagnating, undergoing thermal decomposition, or clogging the nozzles, thereby maintaining melt quality while enabling adaptive width adjustment.
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 allows for reliable adjustment of spinning width and basis weight distribution, reducing waste, improving product quality, and enhancing economic efficiency by minimizing the need for complex modular designs and reducing thermal decomposition risks.
Implementation Method 1
a spinning mass is extruded through a plurality of nozzle holes of at least one spinneret to form filaments
Implementation Method 2
the filaments are drawn, in each case, in the extrusion direction
Implementation Method 3
the filaments are deposited on a perforated conveying device to form a spunbonded nonwoven and wherein the nozzle holes of the spinneret are arranged along a main axis oriented in a transverse direction to the conveying direction of the conveying device
Data Source
AI summary
A process for the production of spunbonded nonwoven (1) is shown, wherein a spinning mass (2) is extruded through a plurality of nozzle holes (4) of at least one spinneret (3, 40, 50) to form filaments (5) and the filaments (5) are drawn, in each case, in the extrusion direction, wherein the filaments (5) are deposited on a perforated conveying device (10) to form a spunbonded nonwoven (1) and wherein the nozzle holes (4) of the spinneret (3, 40, 50) are arranged along a main axis (6) oriented in a transverse direction (12) to the conveying direction (11) of the conveying device (10) so that the spunbonded nonwoven (1) formed on the conveying device (10) extends in this transverse direction (12). So as to enable the spinning width and the basis weight distribution of the spunbonded nonwoven to be adjusted reliably and, respectively, to allow the basis weight distribution to be kept constant during operation by means of the process, it is suggested that the spinning mass throughput (31) of the nozzle holes (4) is adjusted variably along the transverse direction (12).