Adhesive Dilution System Using Scale Feedback and Static Mixing
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Solution Overview
Problem
Existing methods for mixing adhesives, such as Aquence Lam 5137, in the tissue and paper towel industry are inefficient due to the extensive blending required, necessitating a simpler and more effective method to form a food-grade laminate.
Innovation Solution
A system comprising a dilution tank on a scale with a spray nozzle, mixing assembly including a manifold, static mixer, and eductor, controlled by a system controller to input water and adhesive signals, ensuring precise dilution to a target concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mixing methods are used for adhesives, then the adhesive can be mixed, but the process requires extensive blending time and is inefficient
Solution Approach 1:
The patent employs a hydraulic platform scale to automatically control the mixing process. The scale measures the weight of the dilution tank and provides signals to control the injection of water and adhesive, replacing manual timing and estimation with automated hydraulic measurement and control.
Solution Approach 2:
The system uses feedback from the scale's weight measurements to automatically adjust the mixing process. The scale continuously monitors the weight of the dilution tank and sends signals to the system controller, which adjusts the flow of water and adhesive to maintain the target concentration, creating a closed-loop control system.
2Manufacturing precision
If manual mixing methods are used, then the process is simple in setup, but the mixing precision and concentration control are poor
Solution Approach 1:
The patent replaces manual mechanical mixing with an automated system that uses a hydraulic platform scale and electronic control. The scale's weight measurement signals are processed by a system controller that automatically regulates the mixing process, substituting human operation with automated mechanical and electronic systems.
Solution Approach 2:
The system performs self-regulation through the scale's automatic weight monitoring and control signals. The system controller automatically adjusts the mixing parameters based on real-time weight feedback from the scale, enabling the system to self-correct and maintain precise concentration without continuous human intervention.
3Stability of the object's composition
If extensive blending is performed to ensure proper mixing, then the adhesive concentration can be uniform, but the batch time increases significantly
Solution Approach 1:
The system performs preliminary measurement and control by using the scale to pre-determine the correct amounts of water and adhesive before mixing begins. The scale provides weight signals that allow the system to pre-calculate and automatically deliver the precise quantities needed, ensuring uniform concentration from the start of mixing rather than requiring extended blending to achieve uniformity.
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 enables efficient and accurate mixing of adhesives, improving blending capabilities, reducing batch times, and maintaining a clean environment, while allowing for customization and flexibility in mixing various liquid materials.
Implementation Method 1
a scale, the scale being capable of generating a series of signals related to the weight of the dilution tank when empty and at various levels of fill
Implementation Method 2
a spray nozzle configured to feed water into the dilution tank from a source of water
Implementation Method 3
a static mixer configured to receive from the first outlet and mix the adhesive and the mixture of water and adhesive from the lower portion of the dilution tank
Implementation Method 4
an eductor configured to eject the mixture of the adhesive and the mixture of water and adhesive into the lower portion of the dilution tank
Data Source
AI summary
A system and method are disclosed for diluting an adhesive, the system includes a dilution tank of known capacity, the dilution tank located upon a scale, the scale being capable of generating a series of signals related to the weight of the dilution tank when empty and at various levels of fill; a spray nozzle configured to feed water into the dilution tank from a source of water; a mixing assembly, the mixing assembly including a manifold arrangement having a first inlet configured to receive an adhesive from a source of adhesive and a second inlet configured to receive a mixture of the water and the adhesive received from a lower portion of the dilution tank; a static mixer; and an eductor; and a system controller for generating a target concentration of a diluted adhesive; and controlling the input of water and adhesive into the mixing assembly and dilution tank.