Fibrous Web Forming Device with Integrated Dehumidification
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Solution Overview
Problem
Existing devices for producing fibrous webs, such as paper or cardboard, require significant manufacturing effort to produce multiple layers with the same quality, particularly due to complex arrangements of headboxes and dehumidification systems.
Innovation Solution
A device configuration that allows simultaneous sheet formation on two layers of the fibrous web, reducing the number of components by using a Fourdrinier wire former for one-sided dehumidification and a twin-wire former for dual-sided dehumidification, along with a pressing system that enhances surface quality through felt belts and counter-rollers, optimizing production speed and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex arrangement of multiple headboxes and dehumidification systems is used to produce multi-layer fibrous web, then the quality of the fibrous web is improved, but the manufacturing effort and device complexity increase significantly
Solution Approach 1:
The patent combines multiple dehumidification functions into a single integrated dehumidification arrangement that can simultaneously process multiple layers of fibrous material. Instead of using separate dehumidification systems for each layer, the invention merges these functions into one unified system that operates on multiple layers concurrently, thereby reducing device complexity while maintaining quality standards.
Solution Approach 2:
The dehumidification arrangement is designed with multi-functionality to handle different layers of the fibrous web simultaneously. This universal system can process the first layer from the first forming unit and the second layer from the second forming unit through the same dehumidification mechanism, reducing the need for multiple specialized components.
2Reliability
If multiple separate dehumidification arrangements are used for each layer, then the dehumidification effectiveness is improved, but the number of components and manufacturing costs increase
Solution Approach 1:
The patent merges multiple dehumidification functions into a single integrated arrangement that simultaneously processes multiple layers. This unified system maintains effective dehumidification for each layer while reducing the total number of components required, thereby lowering manufacturing effort and costs.
Solution Approach 2:
The integrated dehumidification arrangement is designed to automatically distribute and manage the dehumidification process across multiple layers without requiring separate controlled systems for each layer. The system self-regulates to provide appropriate dehumidification to each layer simultaneously, reducing the need for additional manufacturing complexity.
3Manufacturing precision
If series-connected headboxes and forming units are used, then the layer formation is completed, but the production speed and productivity are reduced
Solution Approach 1:
The patent implements parallel periodic action by simultaneously forming multiple layers through separate forming units that operate concurrently. Instead of completing layer formation sequentially through series-connected units, the system performs periodic formation actions on multiple layers at the same time, significantly increasing production speed while maintaining layer formation quality.
Solution Approach 2:
The invention transitions from a one-dimensional sequential layer formation process to a multi-dimensional parallel process. By arranging forming units and dehumidification arrangements to operate simultaneously on multiple layers, the system adds a temporal dimension to the production process, allowing multiple layers to be formed and processed in parallel rather than in sequence.
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 configuration reduces manufacturing costs and effort while maintaining quality, enabling higher production capacity and improved surface smoothness of the fibrous web.
Implementation Method 1
a Fourdrinier wire former arranged after the second headbox in order to dehumidify the fibrous material applied from the second headbox to the second wire belt
Implementation Method 2
a twin-wire former in the form of a hybrid former arranged after the third headbox in order to dehumidify the fibrous material applied from the third headbox to the second wire belt
Implementation Method 3
the second wire is guided along the first wire over a couch roll in order to couch the second layer onto the first layer of the fibrous web on the couch roll
Data Source
Figure 1
Figure 2
AI summary
Device (1) for producing a fibrous web (FB), having: a first forming unit (10) with an endlessly circulating first fabric belt (12) and a first headbox (17) which is set up to apply suspended fibrous material for forming a first layer (L1) of the fibrous web onto the first fabric belt, and a second forming unit (25) with a second fabric belt (27) which is set up for endless circulation and a second headbox (32) which is set up to apply suspended fibrous material for forming a second layer (L2) of the fibrous web onto the second fabric belt, wherein the second forming unit is arranged above the first forming unit, with the result that the second fabric belt is guided along on the first fabric belt, in order to couch the second layer onto the first layer of the fibrous web at a couching point (30), and the first and the second forming unit are set up for forming the layers in such a way that one of the layers forms at least two plies and the other forms at least one ply of the fibrous web. According to the invention, at least one of the headboxes is configured as a multilayer headbox, with the result that at least two fibrous stock suspension plies which lie on one another can therefore be discharged at the same time for application on the fabric belt side in order to from an at least two-ply layer.