Deckle Board Active Drainage for Paper Machine Uniformity
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Solution Overview
Problem
Standard deckle boards in paper machines create non-uniform moisture, basis weight, and caliper profiles due to their static nature, leading to deckle waves that result in paper rejection and increased production costs.
Innovation Solution
Transforming deckle boards into active drainage elements by incorporating slots, holes, or other shaped openings that allow water to drain through the wire while preventing fiber passage, and optionally attaching them to a vacuum system for enhanced water removal, thereby eliminating deckle waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard static deckle boards are used to prevent stock flow, then stock containment is improved, but basis weight uniformity deteriorates due to deckle wave formation
Solution Approach 1:
The deckle board is transformed from a static structure to a dynamic active drainage element by incorporating openings that enable water removal. The deckle board now actively participates in the drainage process through controlled water flow, converting it from a passive barrier to an active moisture management component that prevents deckle wave formation while maintaining stock containment
Solution Approach 2:
The deckle board is designed with openings (slots, holes, or other shaped openings) that create a porous structure. This porous configuration allows selective passage of water while retaining stock, enabling the deckle board to function as both a containment barrier and an active drainage element simultaneously
2Reliability
If deckle boards act as dams to stop CD flow, then stock overflow is prevented, but moisture uniformity deteriorates due to non-uniform drainage
Solution Approach 1:
The deckle board incorporates localized drainage openings at specific positions and configurations to address moisture accumulation issues. The openings are strategically placed to provide targeted water removal at critical locations, creating non-uniform drainage patterns that compensate for the damming effect and achieve overall moisture uniformity across the stock
3Reliability
If static deckle boards redirect CD flow, then stock confinement is improved, but basis weight profiles deteriorate due to wave-induced non-uniformity
Solution Approach 1:
The deckle board transitions from a static flow redirector to a dynamic drainage-active element. By incorporating water removal capability, the deckle board can actively manage stock flow and moisture content, preventing the formation of basis weight variations while maintaining effective stock confinement through its dual function as barrier and drainage structure
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 more uniform CD profiles for moisture, basis weight, and caliper, reducing operational costs and paper defects by addressing the root cause of non-uniformities at the source without requiring expensive machine rebuilds.
Implementation Method 1
optionally attaching them to a vacuum system for enhanced water removal
Data Source
AI summary
An apparatus for preventing the creation of non-uniform profiles caused by deckle waves though the use of transforming the deckle boards into active drainage elements in the paper forming area of the paper machine, without the need for expensive rebuilds such as dilution control head boxes.