Vertical Chute Carding for Faster Recycled Carbon Fiber Nonwoven Production
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Solution Overview
Problem
Existing methods for manufacturing nonwoven fabrics from recycled carbon fiber are inefficient, costly, and of poor quality due to complex processes involving dispersion preparation, electrostatic spinning, and high-temperature transformation, with issues in carding precision and production speed.
Innovation Solution
A recycled carbon fiber nonwoven fabric manufacturing system utilizing a chute carding machine that integrates a first and second carding unit, a mixing tank, and punching machines to efficiently process mixed raw materials, enhancing precision and production speed, and includes a mesh net with air discharge to strengthen the nonwoven fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional carding method is used, then manufacturing process is simple, but production speed is slow and processing efficiency is low
Solution Approach 1:
The carding process is divided into multiple stages with different carding units (pre-carding unit, main carding unit, finishing carding unit) that process material sequentially. Each unit has specific functions and handles different aspects of the carding operation, allowing the system to achieve high production speed while maintaining manageable complexity through modular design
Solution Approach 2:
The patent introduces a vertical three-dimensional carding configuration where material moves through multiple carding units arranged in vertical layers rather than horizontal sequence. This spatial arrangement increases processing capacity and production speed without proportionally increasing device footprint or operational complexity
2Manufacturing precision
If carding precision is increased to produce 100% recycled carbon fiber, then product quality improves, but processing speed decreases
Solution Approach 1:
The carding process is segmented into multiple specialized units with increasing precision requirements. Early stages handle bulk material with less stringent precision requirements, while later stages focus on fine carding for high precision. This allows the system to achieve high overall precision without sacrificing processing speed at any single stage
Solution Approach 2:
Pre-carding units perform preliminary processing of the mixed raw material before it reaches the main carding unit. This preliminary action prepares the material by loosening and partially carding it, so that the main carding unit can operate at high precision without being overwhelmed by raw lump material, thereby maintaining both precision and speed
3Manufacturing precision
If multiple processing steps are used (dispersion preparation, electrostatic spinning, transformation), then nonwoven fabric quality improves, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate processing steps from the conventional manufacturing process. By using a direct carding approach that processes recycled carbon fiber mixed with resin binder through sequential carding units, the system removes the need for separate dispersion preparation, electrostatic spinning, and high-temperature transformation steps, thereby reducing process complexity while maintaining product quality
Solution Approach 2:
The patent changes the fundamental processing parameters from thermal-chemical methods (electrostatic spinning at high temperature, transformation processes) to mechanical carding methods. This parameter change allows direct formation of nonwoven fabric from mixed raw material through mechanical action alone, simplifying the process while achieving comparable or superior quality
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 system achieves high-quality, efficient production of 100% recycled carbon fiber nonwoven fabric with improved processing and production speed, eliminating the need for resin mixing and simplifying the manufacturing process.
Implementation Method 1
a blower configured to discharge air through the mesh net, thereby strengthening the nonwoven fabric
Data Source
AI summary
Disclosed is a chute carding machine used in a recycled carbon fiber nonwoven fabric manufacturing system, wherein the chute carding machine includes a main chamber oriented in a vertical direction and having an inner space formed therein, a mixed raw material introduction unit is installed at the uppermost part of an inner space of the main chamber, a first carding unit is installed under the mixed raw material introduction unit, a second carding unit is installed under the first carding unit, and a web shaping unit is installed under the second carding unit.