Coating Composite Pulp Honeycomb Supports with Gravity-Fed Impregnation
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Solution Overview
Problem
Existing methods for coating composite pulp honeycomb support elements with impregnation coatings, particularly those containing cement, face challenges such as high operational costs, low throughput, and inability to maintain mechanical stability and fire/water resistance, due to batch processing and issues with aqueous impregnation agents causing structural softening.
Innovation Solution
A continuous coating method and device where impregnation agents, such as cement-water mixtures, are poured into the passages from above under gravity, with a pouring curtain and conveyance system that prevents excess agent from flowing out, allowing for complete peripheral coating and efficient drainage, utilizing vibration means to aid in the drainage process and incorporating a collecting vessel for excess agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing is used for coating composite pulp honeycomb support elements, then the coating process can be completed, but the throughput is low and operational costs are high
Solution Approach 1:
The honeycomb support elements are pre-positioned in a conveyor system with passages oriented upward before coating begins. This preliminary arrangement allows continuous coating without repositioning, enabling transition from batch to continuous processing and increasing throughput while maintaining manageable device complexity
Solution Approach 2:
The patent implements continuous coating by transporting honeycomb support elements through a coating chamber where impregnation agent is continuously applied. Elements move continuously on a conveyor belt through the coating zone, eliminating batch processing interruptions and significantly increasing productivity
2Ease of manufacture
If aqueous impregnation agents are used to coat passages, then the coating process can proceed, but the paper honeycombs absorb water and lose strength causing structural softening
Solution Approach 1:
The patent changes the physical parameters of the impregnation agent by using non-aqueous solvents or water-based solutions with controlled moisture content. This parameter change prevents excessive water absorption by the pulp honeycomb while still allowing the impregnation coating to be applied effectively, maintaining mechanical stability
Solution Approach 2:
The patent applies impregnation agent in controlled quantities through the upward-oriented passages, ensuring sufficient coating without over-saturation. The continuous flow system allows precise control of agent application, providing partial action that coats the passages adequately without causing structural softening
3Quantity of substance
If impregnation resin is filled from above into passages, then the passages can be coated, but large quantities of excess resin remain adhered to surfaces and run out downwards
Solution Approach 1:
Instead of filling passages from above as in conventional methods, the patent orients passages upward and allows impregnation agent to flow upward against gravity or be applied from below. This inversion prevents excess resin from running downward and adhering to surfaces, reducing material waste while maintaining coating coverage
Solution Approach 2:
The patent uses controlled fluid flow mechanisms to deliver impregnation agent through the passages in a controlled manner. The hydraulic system ensures uniform distribution without over-application, preventing excess resin from accumulating and running out, thus reducing substance loss
4Reliability
If cement-based impregnation coatings are applied to corrugated board composite honeycomb support elements, then fire and water resistance can be increased, but the passages clog up and/or the coating softens the structure
Solution Approach 1:
The patent modifies the rheological parameters of cement-based impregnation coatings by adjusting viscosity, particle size distribution, and suspension properties. These parameter changes allow the thick coating material to flow through the passages without clogging while still providing fire and water resistance when set
Solution Approach 2:
The patent prepares the cement-based impregnation coating in advance with specific flow characteristics and applies it when passages are in the optimal position. Pre-adjusting the coating properties ensures it can penetrate the passages without clogging, while preliminary positioning in the conveyor system allows complete coating before the material sets
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
This approach results in a cost-effective, high-throughput coating process that maintains mechanical stability and enhances fire and water resistance of composite pulp honeycomb support elements, while minimizing energy consumption and preventing structural damage from excessive impregnation.
Implementation Method 1
filling the passages from above, preferably exclusively under the action of gravity
Implementation Method 2
with these the composite pulp honeycomb support elements, whose passages are still filled with impregnation agent, at least in some sections, can be set into vibration so as to aid, in particular to accelerate, the drainage process
Data Source
AI summary
A coating device for coating composite cellulose honeycomb support parts (1) each having a multiplicity of channels (5, 6) extending in an axial direction with an impregnation coating to increase fire, water-resistance and/or mechanical stability of the support parts (1). A conveyor (8) transports the support parts (1) in a conveying direction along a filling station (9) configured to pour impregnation agent (12) from above into the channels (5, 6), and damming agents (16) are configured such that the impregnation agent (12) is prevented or at least delayed from draining downwards out of the channels (5, 6) such that the impregnation agent (12) builds up in the channels (5, 6). An emptying station (19) is arranged downstream of the filling station (9) in the conveying direction, at which emptying station excess impregnation agent (12) drains out of the channels (5, 6) in the composite cellulose honeycomb support parts (1). A corresponding process is also disclosed.