Suction Device for Spunbond Nonwoven Fabric Compaction
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Solution Overview
Problem
The high operating and maintenance costs, energy consumption, and large volumetric dimensions of calenders in spunbond nonwoven fabric production apparatuses, which complicate the even distribution and compaction of filaments, are significant challenges.
Innovation Solution
A process and apparatus that utilize a suction device with progressively decreasing suction speeds in multiple channels to control the deposition and compaction of filaments on a gas-permeable movable support, eliminating the need for a calender by promoting even distribution and compaction without mechanical treatment, thus reducing energy consumption and maintenance complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a calender is used to compact and distribute filaments in the nonwoven fabric, then the filament distribution evenness and compaction are improved, but the operating costs, maintenance costs, and energy consumption increase significantly
Solution Approach 1:
The patent removes the calender component from the nonwoven fabric production apparatus entirely. Instead of using a calender to compact and distribute filaments, the invention uses a suction device with multiple channels that draws filaments onto a moving support belt, achieving filament distribution and compaction through controlled suction forces rather than mechanical pressing
Solution Approach 2:
The patent replaces the mechanical calender system with a pneumatic suction system. The suction device uses controlled air flow through multiple channels to achieve filament compaction and distribution, substituting mechanical force with controlled pneumatic forces
2Strength
If a calender is used to compact filaments, then the compaction effect is improved, but the energy consumption increases due to heating requirements
Solution Approach 1:
The patent replaces the heated mechanical calender with a cold pneumatic suction system. The suction device achieves filament compaction through controlled air flow forces without requiring thermal energy input, eliminating the heating energy consumption associated with traditional calenders
3Manufacturing precision
If a calender is installed in the apparatus, then the filament compaction and distribution are improved, but the apparatus volume and maintenance complexity increase
Solution Approach 1:
The patent removes the bulky calender component from the apparatus. The suction device with its multiple channels and moving support belt occupies significantly less space than a traditional calender system, reducing the overall apparatus volume while maintaining filament distribution quality
Solution Approach 2:
The patent divides the suction function into multiple separate channels rather than using a single large calender component. This segmentation allows for a more compact arrangement of the suction device components, reducing the overall apparatus volume
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 the economical production of spunbond nonwoven fabrics with even filament distribution and partial compaction, reducing energy consumption and maintenance costs while preventing outside air inflow, which could disrupt the fabric formation.
Implementation Method 1
operating the suction device so as to suction gas below said movable support
Implementation Method 2
a drawing unit in which filaments are drawn by air flows
Data Source
Figure 1~2
AI summary
Process for producing a nonwoven fabric by means of an apparatus for producing a nonwoven fabric comprising a spinneret for extruding filaments, a drawing duct arranged below said spinneret, a movable support permeable to gases and adapted to define a deposition region for said filaments and configured to move said filaments away from the deposition region along a feed direction, a suction device comprising a main suction channel and at least one first group of suction channels downstream of said main suction channel. This process comprises the steps of: (a) extruding a plurality of filaments from the spinneret, said filaments being preferably at least bicomponent filaments; (b) drawing said filaments by means of said drawing duct; (c) depositing the drawn filaments on the movable support to form a nonwoven fabric, and operating said suction device so as to suction gas below said movable support; wherein in said step c) the suction speed between the channels of the first group of channels gradually decreases in the feed direction of the movable support, said suction speed of the channels of the first group of suction channels being less than the suction speed of the main suction channel.