Open-Pore Mesh Pad for Uniform Liquid Film Application
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Solution Overview
Problem
In the paper and cardboard manufacturing process, deposits such as 'stickies' on rolls and fabric covers lead to production downtimes, energy losses, and safety hazards due to the use of aggressive cleaning agents, which also pose risks to personnel health and equipment damage from high-pressure cleaning and corrosion.
Innovation Solution
An apparatus with a metering unit and an open-pore mesh pad applies a liquid active substance uniformly onto moving surfaces, preventing deposits by forming a film that reduces adhesion and contamination, using a composition of various solvents, acids, and other agents, and is designed for efficient operation under extreme conditions without creating aerosols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acidic and alkaline cleaning agents are used to remove deposits, then cleaning effectiveness is improved, but corrosion and damage to rolls and bearings occur
Solution Approach 1:
A polymer compound is introduced as an intermediary substance that modifies the surface properties of rolls and fabric covers. This polymer layer acts as a mediator between the deposits and the roll surface, preventing adhesion of stickies and other contaminants. The polymer compound can be applied in liquid form and forms a protective coating that reduces the need for aggressive cleaning agents, thereby preventing corrosion and damage while maintaining cleaning effectiveness.
Solution Approach 2:
The surface properties of the rolls and fabric covers are modified by changing the chemical parameters through polymer application. This creates a surface with different adhesive properties that prevents deposit formation. By altering the surface chemistry rather than relying on mechanical or chemical cleaning, the system avoids the harmful effects of acidic and alkaline agents while maintaining effective contaminant removal.
2Reliability
If high-pressure cleaning is used to remove deposits, then cleaning effectiveness is improved, but fabric cover damage and reduced service life occur
Solution Approach 1:
The polymer compound is applied in advance to prevent deposit adhesion before contaminants can accumulate. This preliminary protective action creates a barrier that prevents stickies and other deposits from bonding to the fabric cover. By preventing adhesion rather than removing established deposits, the system eliminates the need for high-pressure cleaning that would damage the fabric cover and reduce its service life.
3Reliability
If cleaning personnel use aggressive cleaning agents, then deposit removal is improved, but health hazards and safety risks increase
Solution Approach 1:
The polymer compound enables self-service cleaning by modifying the surface properties to prevent deposit adhesion. The polymer-coated surface naturally resists contaminant accumulation, allowing for gentle cleaning methods that do not require personnel to handle aggressive chemicals. This eliminates health hazards associated with inhalation and skin contact with harsh cleaning agents while maintaining effective deposit removal capabilities.
4Productivity
If deposits accumulate on drying cylinders, then production continues, but heat transfer deteriorates and energy losses increase
Solution Approach 1:
The polymer compound is applied in advance to drying cylinders to prevent deposit formation on the heat transfer surfaces. By creating a protective polymer layer before deposits can accumulate, the system maintains optimal heat transfer efficiency throughout production runs. This preliminary protective action prevents the deterioration of thermal contact between the drying cylinder and the web material, eliminating energy losses while maintaining production continuity.
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 effectively prevents adhesion and contamination on rolls and fabric covers, reducing production losses and ensuring safer, more efficient operation with reduced maintenance needs and improved drying capacity, while eliminating health hazards and equipment damage.
Implementation Method 1
the pad is preferably realized in the form of an open-pore mesh structure and forms a film on the moving surface in dependence on the type and pressure of the active substance metering, the porosity of the pad, the degree of saturation
Data Source
AI summary
An apparatus and a method for applying a liquid active substance onto surfaces moving in a circulating manner, including a metering unit with a pipe system and an application unit. The active substance is conducted to the application unit by the metering unit, and the application unit has a pad with an open-pore mesh structure for receiving and storing the active substance and for applying the active substance onto a moving surface as a film as a function of the degree of saturation and the contact pressure of the pad on the moving surface. Brackets fix the pad in a working position when pushed together and are capable of being pulled apart to exchange the pad. Also, the use of the apparatus for keeping the moving surfaces free from deposits, accumulations or contaminants.