Dual Tank Additive Supply for Continuous Sheet Manufacturing
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Solution Overview
Problem
Existing sheet manufacturing processes are hindered by the need to stop operations when the binder in the binder vessel is depleted, leading to reduced productivity and potential spills during replenishment.
Innovation Solution
A sheet manufacturing apparatus with two tanks for storing an additive agent, allowing continuous operation by switching to the second tank when the first tank is depleted, and featuring detection units to manage additive agent levels and prevent spills.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single binder vessel is used, then the device complexity is low, but productivity decreases when the binder is depleted requiring apparatus shutdown
Solution Approach 1:
The binder storage system is segmented into a first binder vessel and a second binder vessel that can be independently operated. When one vessel is depleted, the other can continue supplying binder, enabling continuous operation without shutting down the apparatus. This segmentation resolves the contradiction by trading increased system complexity for continuous productivity.
Solution Approach 2:
The second binder vessel is prepared in advance as a backup supply. Before the first vessel is completely depleted, the system can switch to the second vessel, ensuring continuous operation. This preliminary preparation eliminates downtime and maintains productivity despite the added complexity of having multiple vessels.
2Ease of operation
If binder is replenished directly in the binder vessel, then the ease of operation is improved, but harmful factors increase due to potential spills
Solution Approach 1:
A transfer pump is introduced as an intermediary device to move binder from a storage tank to the binder vessel. This intermediary mechanism allows for controlled, spill-free transfer of binder, eliminating the harmful spill risk while maintaining ease of operation through automated or semi-automated replenishment processes.
3Productivity
If the apparatus is shut down to replenish binder, then the binder spill risk is reduced, but productivity decreases
Solution Approach 1:
By segmenting the binder supply into multiple vessels with a switchable configuration, the system can continue operation while one vessel is being replenished. This eliminates the need to shut down the apparatus, maintaining productivity while the transfer pump provides controlled replenishment to minimize spill hazards.
Solution Approach 2:
The transfer pump serves as an intermediary that enables controlled binder transfer during operation or during controlled maintenance periods, eliminating both the need for shutdowns and the risk of spills associated with direct manual replenishment.
Data Source
AI summary
A sheet manufacturing apparatus configured to manufacture a sheet by heating and pressurizing a material containing a fiber and an additive agent includes a supplying unit configured to supply the additive agent in air, a first tank configured to communicate with the supplying unit and store the additive agent, and a second tank configured to communicate with the first tank, store the additive agent, and be able to detach from the sheet manufacturing apparatus.