Staggered Hole Cusp Die for Melt-Blown Non-Woven Fabric
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Solution Overview
Problem
Conventional cusp dies for producing melt-blown non-woven fabric face limitations in hole diameter and density, leading to inefficient barrier performance against water and air, and are prone to polymer buildup and malfunction.
Innovation Solution
A cusp die design with multiple rows of holes arranged in a staggered configuration, allowing for increased hole density and reduced empty spaces between fibers, enhancing the fabric's barrier properties without modifying existing melt-blown plant structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cusp die hole configurations are used (30-50 holes/inch, 0.15-0.4mm diameter), then the device structure is simple and easy to manufacture, but the barrier performance against water and air is insufficient and empty spaces between fibers are excessive
Solution Approach 1:
The patent transitions from a single-row hole arrangement to a multi-row staggered configuration. The holes are arranged in multiple rows with offset positioning, effectively adding a dimensional aspect to the hole distribution pattern. This multi-dimensional arrangement reduces empty spaces between fibers and improves barrier performance without requiring smaller hole diameters or higher hole densities in a single line.
Solution Approach 2:
The staggered configuration creates an asymmetric pattern where holes in adjacent rows are offset from each other. This asymmetric arrangement optimizes fiber distribution and eliminates gaps that would exist with symmetric aligned hole patterns, thereby enhancing the barrier properties of the non-woven fabric.
2Reliability
If hole diameter is reduced below 0.15mm to improve barrier performance, then filtering power increases, but manufacturing difficulty and cost increase significantly
Solution Approach 1:
Instead of reducing hole diameter to improve barrier performance, the patent increases the dimensional complexity of the hole arrangement by using multiple staggered rows. This approach achieves better fiber distribution and barrier properties while maintaining hole diameters in the manufacturable range of 0.15-0.4mm.
Solution Approach 2:
The patent changes the geometric parameters of the hole configuration from a single-row pattern to a multi-row staggered pattern. By modifying the arrangement parameters (number of rows, staggered positioning, spacing between rows) rather than the hole diameter parameter, the barrier performance is improved while avoiding the manufacturing difficulties associated with sub-0.15mm holes.
3Productivity
If polymer flow rate is increased to improve productivity, then production efficiency increases, but polymer buildup on air blades occurs causing malfunction
Solution Approach 1:
The patent segments the single polymer flow path into multiple flow channels corresponding to the multiple rows of holes. This segmentation distributes the polymer flow more evenly across the die, preventing localized overheating and polymer buildup on the air blades while maintaining high overall productivity through increased total hole density.
Solution Approach 2:
By distributing polymer extrusion across multiple staggered rows of holes, the patent adds a dimensional aspect to the flow distribution. This multi-row configuration spreads the thermal and mechanical loads more uniformly, reducing the risk of polymer degradation and buildup that occurs with concentrated high-flow-rate single-row configurations.
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 new cusp die design significantly reduces empty spaces between fibers, improving the fabric's barrier efficiency and allowing for higher polymer flow rates, resulting in high-quality, high-performance non-woven fabrics.
Implementation Method 1
conducted under pressure towards the holes arranged on the cusp
Implementation Method 2
the polymer material enters the box and starts its path inside it at a temperature of approximately 240-270 °C
Implementation Method 3
The acceleration of the air inside the blade makes it possible to create a flow that, in contact with the polymer, atomises the polymer, creating sprays comprising very fine particles
Implementation Method 4
the polymer material enters the box and starts its path inside it at a temperature of approximately 240-270 °C
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~6
AI summary
A cusp die (1) for producing melt-blown non-woven fabric is provided, defining a sagittal plane (1a), a main extension direction (1b) on the sagittal plane (1a), a first flank (10) and a second flank (11) mutually bounded by the sagittal plane (1a) and comprising an ejection portion (2) extending along the main extension direction (1b) and designed to convey, in use, polymeric fluid towards an external air blade, at least one extrusion pipe (3) configured to convey the polymeric fluid towards the ejection portion (2), a plurality of holes (4) arranged in the ejection portion (2), placed in fluidic through connection with the extrusion pipe (3) and communicating with the outside, wherein the holes (4) are arranged along at least one first row (4a) and a second row (4b) that are distinct and arranged respectively at the first flank (10) and the second flank (11).