Debonder Surfactant Timing for Fluff Pulp Sheet Integrity
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Solution Overview
Problem
The manufacturing of fluff pulp sheets faces challenges such as sheet breaking, reduced fluff shred quality, poor fiberization energy, and absorption issues, particularly when dealing with mechanically weak sheets during processing.
Innovation Solution
A process involving the application of a debonder surfactant to fluff pulp sheets, either before or after drying, to reduce fiberization energy and improve absorbency, while maintaining high Mullen values and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a debonding agent is applied to the pulp sheet during drying (as in EP 0 132 128 A1), then debonding effect is achieved, but sheet strength is reduced and sheet breaking occurs
Solution Approach 1:
The debonding agent is applied to the pulp sheet after drying is complete, rather than during the drying process. This preliminary action (applying the agent after the sheet has dried and gained strength) allows the sheet to maintain its structural integrity during processing while still achieving the desired debonding effect when the agent is subsequently applied.
2Productivity
If the pulp sheet is dried completely before additive application, then sheet strength is maintained, but processing time is increased
Solution Approach 1:
The drying process is completed as a preliminary step before applying the debonding agent. This allows the sheet to achieve sufficient strength during drying, and then the additive can be applied quickly afterward without compromising sheet integrity, thus maintaining high processing speeds.
3Ease of operation
If mechanical strength is improved during drying, then sheet handling is easier, but fiberization energy is reduced
Solution Approach 1:
The sheet is dried to gain mechanical strength as a preliminary action, making it easier to handle. Then, the debonding agent is applied to reduce fiberization energy requirements during subsequent processing, thus achieving both easy handling and low energy consumption for fiberization.
4Reliability
If debonding agent is applied early in the process, then debonding effect is maximized, but sheet breaking during conveyance increases
Solution Approach 1:
The drying process is completed as a preliminary action to strengthen the sheet before the debonding agent is applied. This timing ensures that the sheet has sufficient mechanical strength to withstand conveyance and handling, preventing sheet breaking while still achieving effective debonding when the agent is applied afterward.
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 process significantly reduces operational risks like sheet breaking, enhances fluff shred quality, and improves absorbency, allowing for high-speed processing without mechanical issues, while maintaining good Mullen values and surfactant retention.
Implementation Method 1
applying at least one debonder surfactant to the web
Implementation Method 2
at least partially drying a fluff pulp mixture comprising fluff pulp fibers and water in a flotation dryer
Data Source
Figure 1
AI summary
A process is provided for making a fluff pulp sheet, comprising forming a web comprising fluff pulp fibers; and applying at least one debonder surfactant to the web, to make the fluff pulp sheet. A fluff pulp sheet is also provided, comprising a web comprising fluff pulp fibers; at least one debonder surfactant; and a fiberization energy of < 145 kJ/kg. Products and uses of the fluff pulp sheet are also provided.