Multiply Former Vacuum Box Water Removal
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Solution Overview
Problem
Existing multiply former apparatuses face challenges in increasing production capacity due to slow water removal from formed plies in the production of wallboard and gypsum board, which limits the rate at which multiply webs can be produced.
Innovation Solution
A multiply forming apparatus is designed with a fourdrinier wire, twin wire formers, and vacuum devices to facilitate faster water removal by guiding and urging the intermediate and top plies against the base ply, utilizing curved forming sections and vacuum boxes to enhance centrifugal water discharge and drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multiply former apparatus is used, then the structure is simple and easy to operate, but the water removal rate is slow which limits production capacity
Solution Approach 1:
The forming section is divided into multiple zones: a first forming zone where the intermediate ply is initially formed, a water removal zone with vacuum boxes for efficient water extraction, and a combining zone where the intermediate ply is transferred to the base ply. This segmentation allows each zone to perform its specific function optimally, with the water removal zone specifically designed to increase production capacity through enhanced drainage.
Solution Approach 2:
A vacuum box is introduced as an intermediary device between the first forming section and the combining roll. This vacuum box acts as a mediator that actively removes water from the intermediate ply through suction, enabling faster water removal without requiring complex mechanical pressing systems, thus increasing production capacity while maintaining operational simplicity.
2Productivity
If water removal is accelerated to increase production capacity, then the rate of multiply web formation increases, but the complexity of the vacuum system increases
Solution Approach 1:
The water removal function is extracted from the conventional forming process and implemented as a separate, dedicated vacuum box system. This allows the vacuum system to be optimized independently for water removal efficiency, using simple vacuum boxes positioned to drain water from the intermediate ply without requiring complex integrated mechanisms, thereby increasing production capacity while controlling system complexity.
3Speed
If the intermediate ply is rapidly formed and transferred, then production speed increases, but the quality and uniformity of ply formation may deteriorate
Solution Approach 1:
The intermediate ply is preliminarily formed in a dedicated first forming section with controlled water removal before being transferred to the combining roll. This preliminary formation ensures the ply achieves proper consistency and structure at controlled speed, preventing quality deterioration even as overall production speed increases. The vacuum box performs water removal in advance of the combining operation, ensuring the ply is ready for high-speed transfer.
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
The apparatus significantly increases production capacity by efficiently removing water from the plies, allowing for a higher rate of multiply web formation, thereby addressing the limitations of prior art machines.
Implementation Method 1
A vacuum device 32 is provided for urging the intermediate ply 14 to follow the first wire 22 when the first and second wires 22 and 24 extend away from each other downstream from the first forming section 26
Implementation Method 2
The combining roll 34 urges the intermediate ply 14 against the base ply 12 which is supported by the fourdrinier wire 18
Implementation Method 3
as the top ply 16 guided between the third and fourth wires 38 and 40 moves from the first towards the second extremity 44 and 46 respectively of the second forming section 42, the curved second forming section 42 centrifugally discharges water from the top ply 16 through the fourth wire 40
Data Source
AI summary
A multiply former apparatus is disclosed for forming a base, top and intermediate ply. The apparatus includes a fourdrinier wire for receiving thereon the base ply. A first twin wire former is provided for forming the intermediate ply, the first former cooperating with the fourdrinier wire. A second twin wire former forms the top ply, the second former cooperating with the fourdrinier wire. The second former includes a third looped wire which cooperates with a fourth looped wire for defining therebetween a second forming section for forming the top ply. A vacuum box is disposed upstream relative to a further vacuum device such that the fourth wire is disposed between the vacuum box and the third wire. The vacuum box assists in removing water from the second forming section for increasing a capacity of the apparatus.