Multiple Hot Wax Applicators for Rapid Coating Rate Adjustment
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Solution Overview
Problem
Conventional wax coating apparatuses for corrugated paperboard lack the ability to quickly and accurately adjust wax application rates, requiring significant time to change rolls and occupying valuable space in corrugated paperboard plants.
Innovation Solution
A compact paper coating apparatus with multiple independently controllable hot wax applicators, each comprising a press roll and an engraved applicator roll, allows for quick reconfiguration between different wax application rates and fits within constrained plant spaces by using a common hot wax reservoir and a selectively operable positioner to move rolls between active and idle positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single engraved roll applicator is used to control wax application rate, then wax usage is reduced and application is more accurately controlled, but the time required to change rolls when different application rates are desired increases significantly (8-10 hours)
Solution Approach 1:
The single engraved roll applicator is segmented into multiple independently controllable applicators (first hot wax applicator and second hot wax applicator), each with its own engraved roll. This allows different application rates to be selected by activating only the needed applicator(s) rather than changing rolls, resolving the contradiction between precise control and change time.
Solution Approach 2:
The system dynamically switches between different applicators based on the required wax application rate. The selectively operable positioner allows rapid activation or deactivation of specific applicators, enabling the system to adapt to different coating needs without lengthy roll changes while maintaining precise control through the engraved rolls.
2Adaptability or versatility
If multiple wax applicators are installed to provide different application rates, then flexibility and productivity are improved, but the space required in the constrained plant environment increases
Solution Approach 1:
Multiple hot wax applicators are merged into a single integrated coating apparatus with a common frame, drive system, and wax supply system. This consolidation provides multiple application rates and capabilities while occupying minimal plant space, resolving the contradiction between versatility and space requirements.
3Area of stationary object
If a single hot wax applicator is used, then the apparatus is compact and fits in constrained spaces, but the ability to provide different wax application rates is limited
Solution Approach 1:
The coating apparatus is designed with multi-functionality by incorporating multiple independently controllable hot wax applicators that can operate individually or in combination. Each applicator functions as a universal unit capable of providing different application rates, allowing the compact apparatus to deliver versatile coating options without increasing space requirements.
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 precise control over wax application rates, reducing wax usage and operational time, while accommodating different paper components with varying coating needs and fitting within limited plant spaces, enhancing manufacturing flexibility and efficiency.
Implementation Method 1
The first hot wax applicator includes a first press roll, a first engraved applicator roll below and opposite the first press roll so that the continuous paper sheet is therebetween, and with the first engraved applicator roll extending into a hot wax reservoir to pick up hot wax
Implementation Method 2
A doctor blade is adjacent the engraved applicator roll to control a thickness of hot wax
Implementation Method 3
A coating, such as a paraffin wax or tallow wax, may be heated to a liquid state and applied to a continuous paper sheet component
Data Source
AI summary
A paper coater includes a frame, an entry guide roll and an exit guide roll both carried by the frame and along a path of travel of a continuous paper sheet. The paper coater includes independently controllable hot wax applicators carried by the frame between the entry and exit guide rolls. Each independently controllable hot wax applicator includes a press roll, an engraved applicator roll opposite the press roll so that the continuous paper sheet is therebetween, and with the engraved applicator roll extending into a hot wax reservoir to pick up hot wax. Each wax applicator includes a doctor blade adjacent the engraved applicator roll to control a thickness of hot wax. At least one selectively operable positioner relatively moves the press and engraved applicator rolls between active and idle positions. The paper coater provides different wax application rates and can be reconfigured relatively quickly between different application rates.