Spunbonding Apparatus Fiber Length Control

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Solution Overview

Problem

Melt blown nonwovens typically exhibit insufficient mechanical strength due to the short length of fibers produced by the process.

Innovation Solution

A spunbonding apparatus that includes a nozzle, a coagulating tank, a deformation region, and a drawing flow pump to extrude and lengthen fibers by providing a drawing flow through a slit passage, enhancing fiber length and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If melt blowing process is used to manufacture nonwovens, then production efficiency is improved, but fiber length becomes short resulting in insufficient mechanical strength

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmechanical strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent changes the physical parameters of the spinning solution by controlling viscosity, molecular weight, and composition ratios to achieve optimal fiber length and mechanical strength while maintaining high production efficiency through the melt blowing process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a dynamic control system that adjusts processing parameters in real-time based on feedback from sensors monitoring fiber properties, allowing optimization of both productivity and mechanical strength during continuous production

Inventive Principle:

Principle #15Dynamics

2Strength

If fiber length is increased to improve mechanical strength, then production complexity increases due to additional processing steps

Engineering Contradiction:

Improvemechanical strengthVSAvoidprocessing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the spin die structure, integrating fiber formation, length control, and initial strengthening mechanisms into a single integrated component, thereby increasing fiber length without adding separate processing steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary strengthening of fibers during the extrusion process itself by controlling the spinning solution properties and extrusion conditions, so that fibers achieve adequate mechanical strength before leaving the spin die, eliminating the need for subsequent strengthening operations

Inventive Principle:

Principle #10Preliminary action

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 apparatus effectively lengthens fibers, thereby improving the mechanical strength of nonwovens produced, addressing the weakness of melt blown fibers.

Implementation Method 1

The coagulating tank contains coagulating liquid to coagulate the spinning solution into at least one fiber

Methodology Applied

Scientific EffectCoagulation: Coagulation

Implementation Method 2

The drawing flow pump provides a drawing flow to the slit passage

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS8303287B2Spunbonding apparatus

Publication Date: 2012.11.06 TAIWAN TEXTILE RESEARCH INSTITUTE

AI summary

A spunbonding apparatus includes at least one nozzle, a coagulating tank, a deformation region, a slit passage, and a drawing flow pump. The nozzle extrudes at least one spinning solution. The coagulating tank contains coagulating liquid to coagulate the spinning solution into at least one fiber. The deformation region is located between the coagulating tank and the nozzle. The slit passage is connected to the coagulating tank and allows the fiber to pass therethrough. The drawing flow pump provides a drawing flow to the slit passage.