Multi-Layer Fibrous Support Fractionation and Stratification
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Solution Overview
Problem
Current paper manufacturing processes do not effectively separate and control the distribution of different types of fibers and fines in multilayer fibrous supports, leading to suboptimal properties and increased energy consumption.
Innovation Solution
A method involving the fractionation of paper pulp into distinct fiber and fines fractions, followed by hydrocyclone separation based on specific surface area, allowing for tailored treatments and layer formation in multilayer paper or cardboard production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If paper pulp is treated as a mixture under identical conditions, then the manufacturing process is simple, but the properties of the paper are suboptimal and energy consumption is high
Solution Approach 1:
The paper pulp is segmented into distinct fractions based on fiber length and specific surface area. The process divides the pulp into long fibers, short fibers, and fines through fractionation steps, allowing each fraction to receive tailored treatments optimized for its specific properties, thereby improving overall paper quality while managing complexity through systematic division
Solution Approach 2:
Different fractions of the pulp receive different local treatments according to their specific characteristics. Long fibers may receive refining treatments to enhance strength, while fines receive treatments optimized for bonding properties. This localized quality approach ensures each component contributes optimally to the final paper properties
2Use of energy by moving object
If fractionation is implemented to separate fibers and fines, then energy consumption is reduced, but the process complexity increases
Solution Approach 1:
The fractionation process segments the pulp into distinct size-based fractions using a multi-step approach. First, long fibers are separated from short fibers and fines, then short fibers are separated from fines. This systematic segmentation enables energy-efficient targeted treatments while organizing process complexity into manageable stages
Solution Approach 2:
The fractionation process utilizes changes in physical parameters, particularly specific surface area and fiber length, to separate different pulp components. By measuring and sorting based on these parameters, the process achieves efficient separation that reduces overall energy consumption while structuring complexity around clear physical property differences
3Manufacturing precision
If multi-jet headbox is used for layer positioning, then layer distribution is controlled, but mixing at exit reduces stratification advantages
Solution Approach 1:
The fractions are prepared and pre-positioned in the headbox before the forming process begins. Long fiber fractions are positioned in specific zones and short fiber fractions in other zones, creating a predetermined stratification pattern that is then deposited onto the forming fabric, ensuring layer stability is maintained from the outset
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 enhances the mechanical, optical, and surface properties of the final product while reducing energy consumption and treatment costs by optimizing the use of each pulp fraction.
Implementation Method 1
hydrocyclone separation based on specific surface area
Implementation Method 2
hydrocyclone separation based on specific surface area
Data Source
Figure 1a~3b
Figure 3c~3g
Figure 4a~7
AI summary
The invention relates to a method for producing a multi-layer fibrous support, comprising the following steps: a paper pulp comprising fibres and fines is agitated so as to form a fibrous suspension; the fibrous suspension is fractionated into a first main fraction of fibres and a second main fraction of fines; the resulting main fraction of fibres is fractionated by a hydrocyclone in such a way as to form the following two secondary fractions: a fraction of binding fibres; a fraction of coarse fibres; and a multi-layer fibrous support is formed by stratification of the main fraction of fines and the secondary fractions of fibres, or the mixtures thereof.