Textile Web Thermal Bonding With Cooling Air to Prevent Drum Sticking
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Solution Overview
Problem
In thermal bonding systems, textile webs tend to stick to the through-flow drum due to negative pressure, high temperature, and moisture loss, leading to reduced operating speed and potential damage, especially with bicomponent thermoplastic fibers.
Innovation Solution
The textile web is guided through a deflection drum, around a through-flow drum, and out via a cooling drum, with cooling air directed onto the web just before detachment to harden and shrink, preventing sticking, using a separate air system that maintains the energy balance by not mixing with heated air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the web is thermally bonded using hot air and negative pressure, then bonding effectiveness is improved, but the web tends to stick to the drum
Solution Approach 1:
Cooling air is introduced through nozzles at specific locations on the drum surface before the web completely detaches, creating a preliminary cooling effect that reduces adhesion and prevents sticking while maintaining bonding effectiveness
Solution Approach 2:
Cooling air is applied locally at specific zones on the drum surface where web detachment occurs, rather than uniformly across the entire drum, allowing localized temperature reduction to prevent sticking without compromising overall bonding quality
2Ease of operation
If cooling air is applied to prevent web sticking, then web detachment is improved, but energy balance of the system is affected
Solution Approach 1:
Cooling air is applied only at specific localized zones on the drum where web detachment occurs, rather than cooling the entire drum surface, thereby minimizing energy consumption while achieving effective web release
Solution Approach 2:
Cooling air is introduced in advance at the detachment zone to create a temperature gradient that facilitates web release, reducing the need for extensive cooling and minimizing energy impact on the overall thermal process
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 method effectively prevents the web from sticking to the through-flow drum, allowing for increased operating speed and reduced damage, while maintaining the system's energy balance and bonding efficiency.
Implementation Method 1
heated fresh air flows through the web and the flow-through drum
Implementation Method 2
The fresh air absorbs moisture from the web and heats it
Implementation Method 3
cooling air is directed from the flow drum onto the web shortly before the point where the web detaches
Implementation Method 4
cooling of the web shortly before the detachment point causes solidification and slight shrinkage of the web
Implementation Method 5
A negative pressure is created within the bonding system, which, in conjunction with the airflow, results in varying pressure and flow conditions
Data Source
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AI summary
The invention relates to a device and a method for consolidating a textile product web, wherein the textile product web (1) is guided over a deflection drum (2) into a consolidation plant, is guided around a through-air drum (5) and out again over a cooling drum (3), wherein heated fresh air flows through the product web (1) and the through-air drum (5) and the waste air is extracted from the consolidation plant. It is provided according to the invention that cooling air (9) is directed onto the product web (1) shortly before the detaching point of the product web (1) from the through-air drum (5).