Fiber Sizing Applicator Filtration and Roll Cleaning for Uniform Coating

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Solution Overview

Problem

Prior art sizing applicators for rapidly moving fibers suffer from issues such as sizing degradation due to radiant heat, contamination by dust and fiber particles, leading to fiber breaks, incomplete sizing, and undesirable product variation, which increase manufacturing costs and reduce productivity.

Innovation Solution

A sizing applicator that filters the sizing liquid and continuously or intermittently cleans the fiber coating element to remove foreign objects and excess sizing, returning the filtered material to a cooler area or fresh sizing supply, eliminating the need for a reservoir and reducing exposure to radiant heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a reservoir is used to maintain sizing liquid in the applicator, then sizing application is continuous, but the sizing degrades due to radiant heat from bushings causing increased viscosity and globule formation

Engineering Contradiction:

Improvesizing application continuityVSAvoidsizing temperature exposure

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent removes the sizing reservoir from the hot forming room environment and places it in a separate, temperature-controlled location. Only a minimal amount of sizing is present in the applicator at any time, eliminating the degradation problem while maintaining continuous application through rapid replenishment from the remote reservoir.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If the applicator is made larger to accommodate more fibers from multiple bushings, then fiber processing capacity increases, but foreign matter collection increases leading to more fiber breaks

Engineering Contradiction:

Improvefiber processing capacityVSAvoidforeign matter contamination

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a doctor blade system that automatically and continuously cleans the applicator roll surface, removing accumulated foreign matter and fiber particles. This self-cleaning mechanism allows the applicator to maintain large size for high productivity without suffering from increased contamination, as the doctor blade constantly removes harmful deposits.

Inventive Principle:

Principle #25Self-service

3Productivity

If the applicator operates at high speed to match fiber movement, then productivity is maintained, but sizing application uniformity decreases due to incomplete coating

Engineering Contradiction:

Improvesizing application speedVSAvoidsizing uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the physical state and application parameters of the sizing liquid by using a doctor blade to create a controlled, thin film on the applicator roll. This ensures complete and uniform coverage of the roll surface, which then transfers consistently to the high-speed moving fibers, maintaining both speed and uniformity.

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If a doctor blade is used to clean the applicator roll, then foreign matter removal is effective, but sizing liquid is also removed requiring continuous replenishment

Engineering Contradiction:

Improveforeign matter removalVSAvoidsizing liquid consumption

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The patent implements a continuous replenishment system where the sizing reservoir rapidly feeds fresh sizing liquid to the applicator roll through capillary action and gravity feed. This continuous supply compensates for the sizing removed by the doctor blade, ensuring the roll remains adequately coated without interruption to the high-speed fiber processing.

Inventive Principle:

Principle #20Continuity of useful action

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 solution reduces fiber breakage, improves product uniformity, decreases manufacturing costs, and enhances productivity by ensuring consistent sizing application and reducing maintenance needs.

Implementation Method 1

a wiper or squeegee 36... to wipe the fiber coating element 32

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

filter 44... to remove foreign objects from the sizing

Methodology Applied

Scientific EffectFilter (physical): Filter (physical)

Implementation Method 3

excess sizing and foreign objects that tend to stay on the working surface 34 are then removed by the doctor blade 26... into a collection basin 40

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentEP1864953B1Fiber sizing applicator and method

Publication Date: 2018.10.03 JOHNS MANVILLE CORP

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Figure 2A~2B

AI summary

Disclosed are sizing applicator apparatus having a member to remove unused sizing and foreign objects from the fiber coating element of the applicator on a continuous or intermittent basis. Also disclosed are sizing applicators having as part of the drive, a servo motor for reduced variation in sizing application. Unused sizing is filtered to remove foreign objects and returned to the applicator right away, or stored in a temperature controlled area until ready to feed back to a sizing applicator. Also disclosed are methods of using the sizing applicator apparatus to produce sized fibers. The apparatus and methods of the invention produce a substantial reduction in the fiber break rate, sizing usage and applicator maintenance.