Dry Forming Former Channel System for Uniform Fibre Layer

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Solution Overview

Problem

Existing dry formation processes for fibre layers in paper manufacturing struggle to achieve an even distribution of fibres over the entire forming surface, requiring complex and maintenance-intensive adjustments, and previous solutions lack the ability to adjust during operation, reducing production capacity and efficiency.

Innovation Solution

A dual-drum former apparatus with a channel system above the former and a suction box divided into multiple channels, equipped with regulating elements that allow for independent adjustment of airflow and fibre flow during operation, ensuring a uniform fibre layer formation without stopping the production line.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If complex mixers are used to distribute fibre flow evenly, then fibre layer uniformity is improved, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improvefibre layer uniformityVSAvoidcomplexity of mixers and construction

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The supply conduit is divided into four separate discharge conduits, each serving a specific section of the forming surface. This segmentation allows independent control of fibre flow to different areas, simplifying the distribution system while achieving uniform fibre layer formation without complex mixers

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each discharge conduit is equipped with individual flow adjustment capability, allowing the fibre flow distribution to be optimized for specific local areas of the forming surface. This local control enables uniform fibre layer formation while maintaining simple overall construction

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If adjustment mechanisms are added to improve fibre flow distribution, then fibre layer uniformity is improved, but device complexity and failure risk increase

Engineering Contradiction:

Improvefibre layer uniformityVSAvoidfailure-prone construction

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The discharge conduits are designed with adjustable flow characteristics that can be modified during operation. This dynamic adjustment capability allows optimization of fibre flow distribution without requiring complex mechanical adjustment mechanisms, maintaining reliability while achieving uniform fibre layers

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If fins are added for flow adjustment, then fibre layer uniformity is improved, but adjustment complexity and operational difficulty increase

Engineering Contradiction:

Improvefibre layer uniformityVSAvoiddifficulty of adjustment operation

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The discharge conduits are designed with adjustable parameters such as opening size and flow resistance that can be modified to control fibre flow distribution. These parameter changes enable simple adjustment of fibre layer uniformity without complex operational procedures

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If tight lattices are used for flow control, then fibre layer uniformity is improved, but production interruptions for cleaning increase

Engineering Contradiction:

Improvefibre layer uniformityVSAvoidproduction capacity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The discharge conduits are designed with local flow control capabilities that do not require tight lattices across the entire structure. This allows sufficient fibre flow control while preventing blockage, eliminating the need for production interruptions for cleaning

Inventive Principle:

Principle #3Local quality

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

Enables flexible and effective adjustments for a high-capacity, reliable fibre layer formation, maintaining production efficiency with simplified and reliable construction, allowing for real-time adjustments to achieve a uniform fibre layer on the forming surface.

Implementation Method 1

Below the wire, aligned with the former is a suction box, which produces a suction that draws fibres from the former to the forming surface

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 2

a fibrous raw material, such as wood pulp, is generally defibrillated before the formation of a fibre layer e.g. in a hammer mill to produce separate fibres, which are passed with a conveying air flow via various devices associated with the process into a distributor unit called a former

Methodology Applied

Scientific EffectAir flow: Convection

Data Source

PatentUS7947203B2Procedure and apparatus in dry forming of fibre layer

Publication Date: 2011.05.24 ANPAP

AI summary

The invention relates to a procedure and an apparatus in dry formation of a fibre layer, in which procedure fibre-containing air is passed through a forming wire (7) moving via a former (2) or an equivalent distributor unit and further through a suction box (8) or equivalent placed below the forming wire, and which air is circulated back to the upper part of the same or another former. In the solution of the invention, the air circulated through the suction box (8) is passed to the upper part of the former via channels (17) with an adjustable flow rate.