Variable Gas Injector for Melt-Blown Fiber Deposition Control
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Solution Overview
Problem
Conventional melt-blown microfiber sound-absorbing materials have insufficient sound-absorbing performance, low cohesion strength between microfibers, and specific fiber directivity, leading to environmental issues due to discarded scraps.
Innovation Solution
A method and apparatus for manufacturing a melt-blown fabric web with improved cohesion and bulkiness by using a heat extruder, melt-blown fiber spinner, and variable gas injectors to adjust the deposition form and properties of melt-blown fibers, allowing for recycling of thermoplastic resin composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional melt-blown microfiber sound-absorbing materials are used, then production is simple, but sound-absorbing performance is insufficient and cohesion strength is low
Solution Approach 1:
The patent uses composite materials by combining thermoplastic resin with inorganic particles (such as glass beads, ceramic particles, or metal particles) to create melt-blown fibers with enhanced properties. This composite approach improves sound-absorbing performance and cohesion strength while maintaining a relatively simple production process through standard extrusion and melt-blown techniques.
Solution Approach 2:
The patent applies parameter changes by modifying the physical and chemical properties of the melt-blown fibers through controlled cooling rates, fiber diameter variations, and inorganic particle concentrations. These parameter adjustments enhance sound-absorbing performance and inter-fiber cohesion without fundamentally changing the production process complexity.
2Strength
If melt-blown fabric web with improved cohesion is manufactured, then cohesion strength increases, but manufacturing process becomes more complex
Solution Approach 1:
The patent utilizes phase transitions by controlling the melting and solidification of thermoplastic resin during the extrusion and melt-blown processes. By carefully managing temperature gradients and cooling rates, the resin undergoes controlled phase transitions that enhance inter-fiber cohesion strength while using standard manufacturing equipment.
Solution Approach 2:
The patent employs pneumatic principles in the melt-blown process where high-velocity gas streams are used to attenuate and deposit fibers onto the collector. This pneumatic approach enhances fiber dispersion and inter-fiber entanglement, improving cohesion strength without requiring complex mechanical manufacturing apparatus.
3Manufacturing precision
If variable gas injectors are used to adjust deposition form, then fiber deposition control improves, but device complexity increases
Solution Approach 1:
The patent applies dynamics by using variable gas injectors that can dynamically adjust gas flow rate, velocity, and distribution patterns. This dynamic control allows precise adjustment of fiber deposition forms, thickness uniformity, and web structure without requiring overly complex static mechanical positioning systems.
Solution Approach 2:
The patent implements feedback control through sensors that monitor deposition rate, fiber distribution, and web properties in real-time. This feedback information is used to automatically adjust gas injector parameters, achieving precise deposition form control while simplifying the overall system through automated closed-loop control rather than complex manual adjustment mechanisms.
4Object-generated harmful factors
If scraps are discarded in conventional production, then production process is simple, but environmental contamination increases
Solution Approach 1:
The patent applies the discarding and recovering principle by implementing a recycling system where scraps and off-cut materials from melt-blown production are collected, re-melted, and re-extruded into new fibers. This closed-loop approach eliminates environmental contamination from discarded scraps while maintaining production process simplicity through integration with existing extrusion and melt-blown equipment.
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 enhances sound-absorbing performance, increases cohesion strength, and achieves bulkier characteristics with adjustable deposition forms, while enabling 100% recycling of materials, thus reducing environmental impact.
Implementation Method 1
a heat extruder for heating a thermoplastic resin composition and extruding the melted thermoplastic resin
Implementation Method 2
a melt-blown fiber spinner for spinning the thermoplastic resin extruded by the heat extruder as a melt-blown fiber in a filament form
Implementation Method 3
a variable gas injector for injecting gas to the melt-blown fiber spun from the melt-blown fiber spinner to cause the injected gas to collide with the spun melt-blown fiber
Data Source
AI summary
Disclosed is a method and apparatus for manufacturing a melt-blown fabric web, by which a melt-blown fabric web having improved filament cohesion and excellent bulky characteristics and sound-absorbing performance is manufactured. The apparatus includes a heat extruder for heating a thermoplastic resin composition and extruding the melted thermoplastic resin, a melt-blown fiber spinner for spinning the extruded thermoplastic resin as a melt-blown fiber in a filament form, a variable gas injector for injecting gas whose injection speed and injection quantity are continuously changed at random to the melt-blown fiber spun from the melt-blown fiber spinner to cause the injected gas to collide with the spun melt-blown fiber, and a collector for collecting the melt-blown fiber, which is spun from the melt-blown fiber spinner and collides with the gas, to form a melt-blown fabric web.