Double Wire Press Composite Sheet Forming
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Solution Overview
Problem
Conventional methods for forming composite sheets with fibers and polymers are energy-intensive and costly due to low forming consistency, making it difficult to achieve high basis weight and efficient production.
Innovation Solution
The use of a double wire press for wet web formation, allowing for a higher head-box consistency of 2.0 to 10 weight-%, which enables the creation of composite sheets with a higher basis weight by forming and dewatering the web, and the incorporation of chemically modified fibers and additives to improve compatibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional paper making machines are used for wet web formation, then composite sheets can be formed, but the forming consistency is low (0.15-1.5%) requiring energy-consuming removal of significant amounts of water
Solution Approach 1:
The patent changes the key parameter of forming consistency from the conventional low range (0.15-1.5%) to a higher range (2.0-10 weight-%). This parameter change allows the composite sheet to retain more of its own weight, reducing the amount of water that needs to be removed and thereby reducing energy consumption while maintaining the ability to form sheets of desired basis weight
2Productivity
If conventional methods are used, then composite sheets can be formed, but it is difficult to achieve high basis weight and efficient production
Solution Approach 1:
By changing the forming consistency parameter to a higher range (2.0-10 weight-%), the patent enables the formation of high basis weight composite sheets directly during the wet web formation process. This eliminates the need for subsequent complex consolidation equipment and multiple processing stages, thereby improving production efficiency while reducing device complexity
Solution Approach 2:
The patent makes the wet web formation process multi-functional by enabling it to simultaneously achieve proper sheet formation, adequate water content control, and high basis weight production all in one process step. This universalization of the forming process eliminates the need for separate equipment for each function, reducing overall device complexity and improving productivity
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 method results in a composite product with increased basis weight, stiffness, and caliper, enabling applications like large area modules, while reducing energy requirements and equipment costs, allowing for more efficient and mobile production.
Implementation Method 1
forming and dewatering the web, and the incorporation of chemically modified fibers and additives to improve compatibility and efficiency
Implementation Method 2
forming and dewatering the web in a double wire press
Data Source
Figure 1
AI summary
A composite product comprising a fibrous material (A) and a polymer material (B), wherein the composite product is formed as a sheet, by wet web formation and wherein said web is formed from a suspension of said fibrous material and said polymer material in a double wire press (2a and 2b).