Plastic Microcreper Retarder Surfaces for High-Speed Sheet Processing
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Solution Overview
Problem
Microcreping of flexible sheet materials is limited by heating and contamination issues, particularly with materials like polyolefin fibers and wood pulp, due to friction-generated heat and wear on machine components, restricting commercial viability and maximum processing speeds.
Innovation Solution
The use of discrete plastic members with specific thermoplastic properties, such as ultra high molecular weight polyethylene, for the stationary pressing and retarding surfaces in microcreping machines, which reduces friction, wear, and distortion, allowing for stable geometry and effective treatment of a wider range of materials without overheating or surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stationary pressing and retarding surfaces are used in microcreping machines, then the microcreping process can be performed, but friction-generated heat and wear on machine components increase, limiting processing speeds and commercial viability
Solution Approach 1:
The patent changes the material parameter of the stationary pressing and retarding surfaces from conventional materials to discrete plastic members with specific thermoplastic properties. This parameter change reduces the coefficient of friction between the stationary surfaces and the traveling flexible sheet material, thereby reducing friction-generated heat and enabling higher processing speeds without overheating or surface damage.
Solution Approach 2:
The patent employs discrete plastic members made from composite or specific thermoplastic materials (such as ultra high molecular weight polyethylene) for the stationary pressing and retarding surfaces. These composite materials combine low friction properties with wear resistance, allowing the microcreping process to operate at higher speeds while minimizing heat generation and component wear.
2Productivity
If conventional stationary pressing and retarding surfaces are used in microcreping machines, then the microcreping process can be performed, but wear on machine components increases, limiting operational lifespan and requiring frequent maintenance
Solution Approach 1:
The patent changes the material parameter of the stationary surfaces to discrete plastic members with enhanced wear-resistant properties. This parameter change significantly reduces wear on machine components during the microcreping process, improving reliability and reducing maintenance requirements while maintaining high operational efficiency.
Solution Approach 2:
The patent employs discrete plastic members that can be easily replaced when worn. These individual pressing and retarding surfaces are designed as replaceable components, allowing quick replacement without replacing entire machine assemblies, thereby maintaining high productivity with minimal downtime for maintenance.
3Device complexity
If conventional stationary pressing surfaces are used in microcreping machines, then the machine structure can be simple, but heating and contamination issues occur with certain materials like polyolefin fibers and wood pulp
Solution Approach 1:
The patent changes the surface material parameter to discrete plastic members with specific thermoplastic properties that are compatible with sensitive materials like polyolefin fibers and wood pulp. This parameter change eliminates heating and contamination issues while maintaining a relatively simple machine structure, as the discrete plastic members are directly integrated into the existing pressing and retarding mechanisms.
4Reliability
If discrete plastic members with specific thermoplastic properties are used for stationary pressing and retarding surfaces, then friction, wear, and distortion are reduced, but the device complexity increases due to the need for discrete components
Solution Approach 1:
The patent segments the stationary pressing and retarding surfaces into discrete plastic members. Each member is independently designed with specific thermoplastic properties, allowing them to be optimized for their specific function while reducing distortion and maintaining geometry stability. The segmented design enables easier replacement and maintenance of individual components.
Solution Approach 2:
The discrete plastic members are designed to be universally applicable across different microcreping machine configurations. The same type of thermoplastic material and component design can be used for both pressing and retarding surfaces, simplifying the overall device complexity through standardization while maintaining geometry stability.
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
This approach enables the microcreping of previously challenging materials like polypropylene and wood pulp at higher speeds with reduced wear and improved product quality, increasing operational efficiency and expanding the range of commercially viable materials and treatments.
Implementation Method 1
a drive force is produced by pressing the sheet material against a drive roll. This positively propels the material through a confined retarding passage
Implementation Method 2
A running length of the sheet material is pressed with considerable force face-wise against this moving surface by a stationary pressing member
Implementation Method 3
at least one stationary retarding member constructed and mounted to cause the retarding member to engage a face of the advancing material in a retarding region to retard the advancing material
Data Source
AI summary
A stationary working surface of a one roll microcreper member is of plastic resin having low wear and friction properties. As a primary pressing member subject to concentrated force it is 0.040 inch thick. One or both opposed retarder members of a bladed microcreper are of the plastic. Thermoplastics meeting wear and friction limits, e.g. ultra high density polyethylene, are employed. Primary extensions, some having openings, slots or holes serve as flexible retarders to engage treated material. By a load-spreading surface, the thermoplastic primary member is restrained without distortion. By this surface being linear it slideably inserts into a mounting. By this surface being parallel to the roll axis the primary member is free for cross-machine thermal expansion. A primary member shown is sheet form, mounted between sheet metal members, one with a restraint surface. Sheet materials of polyolefins, wood pulp, etc. are dry microcreped at improved rates and materials not heretofore capable of being processed can now be processed.