Papermaking Composition for Dust Control
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Solution Overview
Problem
The papermaking process suffers from dusting issues during the creping process and paper handling, leading to runnability and quality problems, as well as potential health risks for workers due to respiratory exposure.
Innovation Solution
A method involving the application of a composition comprising an oil, an emulsifying surfactant, and a formulation aid to a foraminous surface in the papermaking process, which reduces dust generation during the creping and converting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a creping blade is used to scrape the sheet from the dryer cylinder, then the sheet is separated from the cylinder, but dust particles are generated due to mechanical force weakening fiber bonding
Solution Approach 1:
The patent applies a composition to the sheet before the creping process to pre-soften the sheet and reduce dust generation during subsequent mechanical handling. This preliminary treatment modifies the fiber bonding characteristics in advance, allowing the creping blade to separate the sheet with minimal dust particles generated.
Solution Approach 2:
The composition changes the physical parameters of the sheet by softening the fiber structure and modifying inter-fiber bonding. This parameter change reduces the mechanical force required for separation and minimizes dust generation while maintaining effective sheet creping.
2Object-affected harmful factors
If air jets or vacuum systems are used to remove dust, then dust particles are removed from the paper substrate, but energy efficiency is poor and dust from handling is not addressed
Solution Approach 1:
Instead of removing dust after generation, the composition is applied in advance to prevent dust formation during handling operations. This preventive approach eliminates the need for energy-intensive dust removal systems while addressing dust from both the paper substrate and handling processes.
Solution Approach 2:
The patent converts the harmful effect of mechanical force (which causes dust generation) into a benefit by using controlled softening of the sheet. The composition allows mechanical handling to proceed smoothly while preventing dust formation, turning a potentially harmful process into a controlled, dust-free operation.
3Ease of operation
If mechanical force is applied to soften the sheet during creping, then the sheet is separated from the cylinder, but dust particles are generated when fiber bonding is weakened
Solution Approach 1:
The composition modifies the physical parameters of the sheet by chemically softening the fiber structure. This parameter change allows mechanical force to be applied more effectively for separation while reducing the generation of dust particles, as the softened fibers are less prone to breaking and generating dust.
Solution Approach 2:
The composition acts as an intermediary substance between the mechanical creping blade and the sheet fibers. It mediates the interaction by softening the fiber bonding, allowing the blade to separate the sheet with reduced mechanical stress and minimal dust generation.
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 method significantly reduces dust generation during the creping process and subsequent handling, improving the runnability and quality of the paper products while minimizing health risks associated with paper dust exposure.
Implementation Method 1
the composition comprises an oil, an emulsifying surfactant, and a formulation aid
Implementation Method 2
adding an effective amount of a composition to a foraminous surface
Data Source
AI summary
Methods and compositions for improving a papermaking process are provided herein. The compositions include, for example, an oil, an emulsifying surfactant, and a formulation aid. The methods may include adding an effective amount of the composition to a foraminous surface and contacting the foraminous surface with a furnish. Water may be drained through the foraminous surface, thus forming a sheet on the foraminous surface, which may be transferred to a felt, a belt, a fabric, or elsewhere.