Vacuum Chamber Segmentation for Substrate Particle Transfer
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Solution Overview
Problem
Existing methods for transferring particulate material, such as superabsorbent polymer particles, onto a substrate at high speeds are inefficient and inaccurate, often resulting in dust creation and incorrect profile deposition due to insufficient vacuum maintenance during the transfer process.
Innovation Solution
An apparatus with a first moving endless surface and a second moving endless surface, where the ratio of vacuum pressures in adjacent vacuum chambers is optimized to ensure precise deposition, using a higher vacuum pressure in the receiving zone and a lower pressure in the transferring zone to maintain accurate and cost-effective transfer of particulate material onto a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a strong vacuum is applied to ensure accurate deposition of particulate material onto the substrate, then deposition accuracy is improved, but it becomes difficult to maintain sufficient vacuum in a cost-effective manner during transfer to further processing steps, especially at high speeds
Solution Approach 1:
The vacuum system is segmented into two distinct zones: a receiving zone with high vacuum pressure for accurate particle deposition, and a transferring zone with lower vacuum pressure for cost-effective transport. This segmentation allows each zone to have optimized vacuum levels for its specific function, resolving the contradiction between deposition accuracy and cost-effective maintenance
Solution Approach 2:
Different vacuum pressure levels are applied to different spatial locations along the substrate path. The receiving zone receives strong vacuum for precise deposition, while the transferring zone uses reduced vacuum pressure. This local differentiation of vacuum quality enables both high deposition accuracy and cost-effective operation
2Productivity
If the apparatus operates at high speeds (800 ppm or more), then productivity is improved, but accurate transfer of particulate material becomes difficult, resulting in dust creation and incorrect profile deposition
Solution Approach 1:
The vacuum pressure is dynamically adjusted along the substrate path, with higher pressure in the receiving zone and lower pressure in the transferring zone. This dynamic pressure gradient maintains particle adherence at high speeds while enabling efficient transfer, resolving the contradiction between productivity and precision
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 solution enables accurate and cost-effective deposition of particulate material onto a substrate at high speeds, even with fine materials, by utilizing a higher vacuum pressure in the receiving zone and a reduced pressure in the transferring zone, improving the precision and efficiency of the transfer process.
Implementation Method 1
said second moving endless surface moving/being in said receiving zone adjacent a first vacuum chamber (210) and being in gas communication therewith
Implementation Method 2
said second moving endless surface moving/being in said transferring zone adjacent a second vacuum chamber (220), and being in gas communication therewith
Data Source
AI summary
An apparatus for transferring, at high speed and in a very effective and accurate and cost effective manner, particulate material from a first moving endless surface with reservoir(s) to a second moving endless surface carrying a substrate material, such as a nonwoven web material, and transferring said combination of substrate material with particulate material to a further apparatus unit; said second moving endless surface is adjacent and in communication with a first and a second vacuum chamber, with different vacuum pressures and/or different size. Also a process is provided, using the described apparatus.