Suction Roller Nozzle Bars Fluid Jet Needling
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Solution Overview
Problem
Inclined wire paper machines, commonly used in the specialty paper industry, lack a separate needling unit for producing fluid-jet needled products, limiting their ability to produce nonwoven webs efficiently.
Innovation Solution
The system modifies an inclined wire paper machine by replacing the front deflection roller with a wire suction roller having a fluid-permeable shell and vacuum zones, and incorporating nozzle bars to deliver fluid jets under overpressure, allowing for energy input suitable for needling fibrous webs, with adjustable vacuum pressures and nozzle configurations for adaptable energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional skew wire paper machine without a separate needling unit is used, then the device complexity is reduced and ease of operation is improved, but the ability to produce fluid-jet needled nonwoven webs is lost
Solution Approach 1:
The suction roller is designed to perform multiple functions: it acts as a deflection roller for the wire belt, a dewatering roller for removing excess suspension, and a needling roller for applying fluid jets to needle the fiber mat. This multi-functionality enables the machine to produce fluid-jet needled nonwoven webs without requiring a separate needling unit, thus resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The invention merges the needling function with the existing suction roller assembly. The nozzle bars are integrated into the suction roller structure, allowing fluid jets to be applied directly at the suction roller location. This combining of functions eliminates the need for a separate needling unit while maintaining the ability to produce fluid-jet needled products.
2Use of energy by moving object
If the front deflection roller is replaced with a suction roller having vacuum zones, then the energy input for needling is improved, but the device complexity increases
Solution Approach 1:
The suction roller incorporates vacuum zones that use pneumatic pressure differentials to control fluid flow and energy input for needling. The vacuum zones create negative pressure to draw fluid through the roller shell and apply it to the fiber mat, enabling precise control of energy input for needling while maintaining a relatively simple mechanical structure.
Solution Approach 2:
The suction roller shell is designed with porous or fluid-permeable structures that allow fluid to pass through while maintaining structural integrity. This porous design enables the roller to function as both a structural component and a fluid delivery mechanism, improving energy input for needling without significantly increasing device complexity.
3Adaptability or versatility
If multiple nozzle bars spaced apart are provided, then the adaptability of energy input to production speed and product portfolio is improved, but the device complexity increases
Solution Approach 1:
The needling system is segmented into multiple independent nozzle bars spaced apart along the suction roller. Each nozzle bar can be independently controlled to adjust energy input for different products and production speeds. This segmentation provides adaptability while keeping each individual nozzle bar relatively simple in structure.
Solution Approach 2:
The system incorporates adjustable vacuum zones that can be dynamically controlled to match different production speeds and product requirements. The vacuum pressure and nozzle bar operation can be adjusted in real-time, providing adaptability without requiring a completely different system for each product type.
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 configuration enables the production of fluid-jet needled fibrous webs by effectively utilizing fluid jets for energy input, suitable for various production speeds and product portfolios, overcoming the limitations of traditional systems.
Implementation Method 1
the deflecting roller at the front of the screen belt in the direction of rotation is designed as a suction roller with a fluid-permeable roller shell and at least one vacuum zone provided within the roller shell
Implementation Method 2
at least one nozzle bar is provided, by means of which fluid jets under overpressure can be discharged towards the screen belt in an area where the screen belt rotates around the suction roller
Data Source
Figure 1
Figure 2
AI summary
Plant and method for producing a fluid jet needled fibrous web (20) from at least one fibrous suspension (11), wherein the fibrous suspension (11) is applied to a screen belt (14) of an inclined screen former (10) forming a fiber web (13), which rotates around a screen suction roller (35) in a rotational direction, the fiber web (13) is acted upon with fluid jets by means of nozzle bars (48, 49) as it rotates around the screen suction roller (35), and fluid is extracted by means of at least one vacuum zone (38, 39) provided within a roller shell (36) of the screen suction roller (35).