Dry Sheet Manufacturing Using Composite Binder
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Solution Overview
Problem
Current sheet manufacturing methods, such as pulp molding, require large amounts of water and energy, and struggle with incorporating coloring materials, which can detach due to external forces and result in uneven tone and reduced strength due to thermal fusion bondable powders coagulating inadequately.
Innovation Solution
A dry sheet manufacturing method using a mixing unit to combine fibers with a composite including resin and coloring material, followed by a bonding unit that applies heat and pressure to form a strong, uniform sheet without water, ensuring the coloring material is integrated with the resin for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pulp molding is used to manufacture sheets, then uniform fiber deposition and good dispersion of paper strengthening agents are achieved, but large volumes of water are required and extensive energy is consumed for dewatering and drying
Solution Approach 1:
The invention changes the fundamental parameter of the manufacturing process from wet to dry. Instead of using water as a carrier for fibers and binders, the process uses air to transport and deposit dry fibrous material and thermal fusion bondable powders. This parameter change eliminates the need for dewatering and drying operations, dramatically reducing energy consumption while maintaining uniform deposition through controlled air flow and deposition conditions.
Solution Approach 2:
The invention replaces the hydraulic system of pulp molding with a pneumatic system. Air flow is used to transport fibers and binders through ducts and deposit them on the sheet, substituting the water-based mechanical transport and deposition system. This substitution eliminates the need for water handling infrastructure and energy-intensive dewatering/drying equipment.
2Ease of manufacture
If coloring materials are simply mixed into the sheet, then tone adjustment is achieved, but the pigment detaches due to outside forces such as undulation, impact, and abrasion
Solution Approach 1:
The invention merges the coloring material with the thermal fusion bondable powder into a single composite binder system. The coloring material is incorporated into the powder that also provides bonding functionality. When heated, this composite binder melts and bonds the fibers together while simultaneously anchoring the coloring material within the bonded matrix, preventing detachment from external forces.
Solution Approach 2:
The invention uses a composite material system where the binder is not a single substance but a composite of thermal fusion bondable powder and coloring material. This composite structure allows the binder to perform multiple functions: bonding fibers together and embedding the coloring material for fastness, while maintaining the dry processing advantage.
3Ease of manufacture
If thermal fusion bondable powders are simply mixed, then bonding is achieved, but the powders coagulate and form rough parts that reduce sheet strength
Solution Approach 1:
The invention introduces air as an intermediary medium to transport and distribute the thermal fusion bondable powders. Instead of direct contact mixing that causes coagulation, the powders are suspended and transported in air flow through ducts to the deposition area. This intermediary air medium prevents particle-to-particle contact during transport, maintaining uniform distribution and preventing coagulation.
Solution Approach 2:
The invention uses pneumatic principles to handle the thermal fusion bondable powders. Air flow is used to transport the powders through a duct system and control their deposition location and distribution uniformity. This pneumatic handling system prevents the powders from coagulating during the manufacturing process while ensuring even distribution across the sheet.
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 reduces water and energy consumption, achieves strong and uniformly colored sheets with improved bonding, and eliminates the need for extensive infrastructure, while maintaining high tensile strength and color uniformity.
Implementation Method 1
a bonding unit configured to bond the fibrous material and the composite together to form a sheet
Implementation Method 2
thermal fusion bondable powder with a dry method
Data Source
Figure 1~2
Figure 3~4(d)
AI summary
Provided is a sheet manufacturing apparatus that is able to manufacture a sheet with superior strength or tone by performing mixing of fibers and a powdered resin in a state with little liquid. A sheet manufacturing apparatus according to the invention includes a mixing unit in which fibers and a composite integrally including a resin and a coloring material are mixed, and a bonding unit that bonds the fibers and the composite. Additionally, a sheet manufacturing apparatus according to the invention includes a mixing unit in which fibers and a composite integrally including a resin and a coagulation inhibitor are mixed, and a bonding unit that bonds the fibers and the composite.