Vacuum System for Solid Material Transfer
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Solution Overview
Problem
Existing methods for producing absorbent cores with fibers and superabsorbent polymer particles face challenges in achieving complete and accurate transfer of solid material at high speeds, especially when using fine particulate material or when the moving surface lacks reservoirs, due to air flow and vacuum suction issues.
Innovation Solution
An apparatus with a first moving endless surface and gas supply/vacuum systems featuring primary and secondary containers with controlled pressure differences, allowing for precise gas passage through openings to aid in the release and retention of solid material, ensuring consistent and accurate deposition on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum suction is applied through a single container system, then solid material can be retained on the moving surface, but the air flow and vacuum suction become difficult to control and may be impeded, especially at high speeds
Solution Approach 1:
The vacuum system is segmented into a primary vacuum container directly communicating with the moving surface and a secondary vacuum container connected to the primary container. This segmentation allows independent control of vacuum levels in different zones, enabling precise control of air flow and vacuum suction while maintaining reliable solid material retention on the moving surface.
2Productivity
If high process speeds are used to increase productivity, then output increases, but complete and accurate transfer and release of solid material becomes difficult to achieve
Solution Approach 1:
The system dynamically adjusts vacuum levels between the primary and secondary containers to match varying process speeds. At high speeds, the controlled pressure difference between containers maintains optimal vacuum suction and air flow conditions, ensuring complete and accurate solid material transfer and release while sustaining high productivity.
Solution Approach 2:
The vacuum pressure parameters are changed and optimized by introducing a secondary container that can independently adjust its vacuum level. This allows the system to maintain optimal pressure differences across different operating conditions, ensuring accurate material transfer even at high process speeds exceeding 800 or 1000 parts per minute.
3Manufacturing precision
If fine particulate material is used to improve product quality, then the absorbent core formation quality improves, but air flow and vacuum suction are impeded making transfer and release difficult
Solution Approach 1:
The vacuum system provides locally optimized conditions by having the primary vacuum container directly communicate with the moving surface where fine particulate material is handled. The secondary container provides additional vacuum support, creating localized vacuum zones that are optimized for fine particle retention and release while maintaining overall system control.
4Device complexity
If the moving surface comprises substantial zones without reservoirs to simplify structure, then device complexity is reduced, but air flow and vacuum suction are impeded affecting material transfer
Solution Approach 1:
The dual-container vacuum system serves multiple functions: it maintains vacuum suction over large surface zones without reservoirs, controls air flow patterns, and ensures reliable material transfer. The primary and secondary containers work together to provide universal vacuum coverage across the entire moving surface, regardless of whether reservoirs are present.
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 apparatus ensures improved reception and transfer of solid material, enabling more consistent and accurate absorbent core formation, even at high speeds and with fine particulates, by optimizing gas flow and vacuum suction.
Implementation Method 1
The AGM or fibers may be retained on the drum surface, in the reservoirs, by use of vacuum suction under the surface
Implementation Method 2
a gas supply system for applying a gas (e.g. air) to said first moving endless surface and through said openings, for facilitating release of said solid material from said surface
Implementation Method 3
the pressure difference between the pressure in said primary gas container (P1) and the pressure in said secondary gas container (P2) is less than 40%
Data Source
AI summary
An apparatus for making a structure comprising solid material and typically a substrate, said apparatus comprising a first moving endless surface and adjacent thereto one or more stationary primary (vacuum) gas containers (chambers), at least one thereof being connected to a secondary (vacuum) gas container, whereby the pressure difference between primary and secondary containers is minimized; and methods using such an apparatus.