Cellulose Web Moisture Conditioning for Stable Converting
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Solution Overview
Problem
Natural fiber-based cellulose materials are sensitive to moisture content variations during converting processes, leading to issues like creasing, cutting, and press-forming problems, and excessive energy consumption due to moisture management challenges.
Innovation Solution
A system with a feedback loop using sensors and individually controlled fluid and heat supply nozzles to regulate moisture and heat distribution across the material, optimizing moisture content through data integration and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If moisture content is increased to prevent material damage during converting, then material quality is improved, but energy consumption increases due to excessive drying requirements
Solution Approach 1:
The system performs preliminary moisture conditioning of the material before the converting operation. By adjusting moisture content in advance through controlled fluid supply and environmental conditioning, the material is prepared to prevent damage during converting, thereby avoiding the need for excessive energy-intensive drying operations afterward.
Solution Approach 2:
The system incorporates feedback control mechanisms that monitor material moisture content and converting process conditions in real-time. This feedback enables dynamic adjustment of fluid supply rates and environmental parameters to maintain optimal moisture levels, preventing both over-moistening (which would require excessive drying energy) and under-moistening (which would cause material damage).
2Use of energy by moving object
If moisture content is decreased to reduce energy consumption, then energy efficiency is improved, but material quality deteriorates due to converting problems
Solution Approach 1:
The system applies localized moisture conditioning to different areas of the material based on specific converting requirements. Fluid supply nozzles are positioned to deliver moisture precisely where needed in the supply path, creating local moisture gradients that optimize converting quality in critical areas while minimizing overall moisture content to reduce drying energy requirements.
3Manufacturing precision
If fluid supply is increased to optimize moisture distribution, then manufacturing precision is improved, but device complexity increases due to individual nozzle control requirements
Solution Approach 1:
The fluid supply system is segmented into multiple independently controllable nozzle units distributed along the supply path. Each nozzle or nozzle group can be controlled individually to deliver precise moisture amounts to specific locations, enabling uniform moisture distribution across the material while managing system complexity through modular control architecture.
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
Ensures high-quality conversion products by maintaining consistent moisture levels, reducing energy consumption, and preventing material damage, while allowing for localized moisture adjustments.
Implementation Method 1
an active part is provided that may supply a controlled amount of fluid to desired parts of a blank, prior to converting. Such an active part may be in the form of a system including a plurality of spraying nozzles positioned spread out over the width of the supply path
Implementation Method 2
the feedback loop collects data from the movement of the web or blanks allowing a constant flow per distance even for intermittent movements with varying speed. In addition to the movement of the web/blanks the following parameters and data sets are examples of control input
Implementation Method 3
If too much water is introduced in or with the material and are needed to be dried away in or after the converting process, this leads to excessive need of heat or energy
Data Source
AI summary
This invention relates to Production method for fiber based cellulose material products by means of converting a blank or web, wherein there is provided a production space (1) including a converting production unit (2) intermittently producing a shaped product (5B), a supply station (3) and a supply path (4), comprising the steps of: a. Providing a supply of unconverted blanks or a web (5) at said supply station (3) having a density below 0,5 kg/dm3 and a wet content below 20% weight. b. Feeding an unconverted portion (5A) of said unconverted blanks or a web along said supply path (4), c. Converting said unconverted portion (5A) by means of said converting production unit (2) to a converted product (5B), Wherein also the following further steps are performed:—Providing humidity sensor/s (6) measuring the humidity within said production space (1),—Controllably feeding said unconverted portion (5A) along said supply path (4) to provide a time span (T) during feeding from said supply station (3) to said converting production unit (2), wherein said time span (T) provides for sufficient time of exposure of said unconverted portion (5A) to the environment in said production space (1) to obtain a moisture profile (Δθ) within a preset moisture content (θ1-θ2).