Composite Fiber Sheet Manufacturing Reducing Web Breaks
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Solution Overview
Problem
In continuous paper making, incorporating a high content of functional inorganic substances into sheets leads to weakened paper strength due to hydrogen bond splitting between cellulosic fibers, resulting in web breaks and reduced productivity, especially when producing sheets with high basis weights.
Innovation Solution
A method involving the synthesis of composite fibers by incorporating inorganic particles into a slurry with cellulosic fibers of specific length distributions (16% or more in terms of length-weighted fiber length distribution for 1.2 mm to 2.0 mm fibers and 30% or more for 1.2 mm to 3.2 mm fibers), which are then processed into sheets using a continuous paper machine, enhancing the retention and distribution of inorganic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the amount of inorganic substance mixed with fibers is increased to achieve higher functionality, then the functionality of the sheet is improved, but the paper strength decreases due to hydrogen bond splitting between cellulosic fibers
Solution Approach 1:
The invention uses composite fibers formed by incorporating inorganic particles into cellulosic fibers during the fiber formation process. This creates a composite material where inorganic particles are embedded within the fiber structure, allowing high inorganic content (up to 80% by weight) while maintaining paper strength through the integrated fiber-inorganic composite structure rather than simple mixing
Solution Approach 2:
The inorganic particles are incorporated into the cellulosic fibers during the fiber formation process (pulping stage) before the sheet forming process. This preliminary incorporation ensures that inorganic particles are embedded within the fiber structure in advance, preventing them from acting as separation points for hydrogen bonds during subsequent sheet formation and processing
2Adaptability or versatility
If the amount of inorganic substance is increased to achieve higher functionality, then the functionality is improved, but web break becomes more likely to occur during continuous paper making
Solution Approach 1:
By forming composite fibers where inorganic particles are embedded within cellulosic fibers, the invention creates a unified structure that maintains mechanical integrity. The composite fiber structure prevents inorganic particles from creating weak points that would lead to web breaks, enabling high inorganic content (up to 80% by weight) while maintaining reliable continuous paper making operation
Solution Approach 2:
The invention changes the physical state and distribution parameters of inorganic particles by incorporating them into fiber structures during pulping. This transforms inorganic particles from loose fillers that cause web breaks into integrated components of composite fibers, allowing high concentrations (up to 80% by weight) without compromising web break resistance
3Adaptability or versatility
If small inorganic particles are contained in larger amounts to achieve higher functionality, then the functionality is improved, but the particles tend to leak through meshes of the paper machine
Solution Approach 1:
The invention embeds inorganic particles within the internal structure of cellulosic fibers during the pulping process. This nesting approach ensures that inorganic particles are contained within the fiber matrix and cannot leak through paper machine meshes, enabling high inorganic content (up to 80% by weight) while maintaining effective particle retention
Solution Approach 2:
By creating composite fibers where inorganic particles are integrated into the fiber structure, the invention ensures that particles remain trapped within the fiber matrix throughout the paper making process. This composite structure prevents particle leakage through meshes while maintaining high functionality through elevated inorganic content
4Strength
If the strength of beating pulp is enhanced to increase hydrogen bonds between cellulosic fibers and heighten retention of inorganic substances, then the paper strength is improved, but freeness decreases and dehydration property decreases
Solution Approach 1:
The inorganic particles are incorporated into cellulosic fibers during the pulping stage before sheet formation. This preliminary incorporation ensures that inorganic particles are embedded within the fiber structure in advance, eliminating the need for enhanced beating to improve retention, thereby maintaining good dehydration property while achieving high paper strength
Solution Approach 2:
The composite fiber structure formed by incorporating inorganic particles during pulping provides inherent retention mechanisms that eliminate the need for excessive beating. The integrated composite structure maintains fiber freeness and dehydration property while achieving high paper strength through the composite material architecture rather than mechanical beating
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 reduces web breaks during the production of sheets with high inorganic content, maintains paper strength, and allows for high-speed paper making without web breaks, achieving high yields and ash content retention.
Implementation Method 1
generating composite fibers composed of cellulosic fibers and inorganic particles by synthesizing the inorganic particles in slurry containing the cellulosic fibers
Implementation Method 2
hydrogen bonds between cellulosic fibers are split by the inorganic substance
Data Source
AI summary
The present invention provides a method for reducing web break caused in preparing, by continuous paper making, a fiber sheet containing a high content of functional inorganic substance. The composite fiber sheet manufacturing method includes: generating composite fibers composed of cellulosic fibers and inorganic particles by synthesizing the inorganic particles in slurry containing the cellulosic fibers; and continuously generating a sheet by supplying composite-fiber-containing slurry including the composite fibers to a continuous paper machine. In the composite fiber generating step, at least one of (i) slurry containing cellulosic fibers having a length of 1.2 mm to 2.0 mm in an amount of 16% or more in terms of length-weighted fiber length distribution (%) and (ii) slurry containing cellulosic fibers having a length of 1.2 mm to 3.2 mm in an amount of 30% or more in terms of length-weighted fiber length distribution (%) is used.