Pulp Fibre Yarn Extrusion and Dewatering Apparatus
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Solution Overview
Problem
Current methods for producing yarn from natural fibers, such as cotton and rayon, are inefficient, environmentally unfriendly, and require significant chemical treatments, while existing industrial-scale processes for producing fiber yarn from pulp fibers do not exist, limiting the use of sustainable alternatives.
Innovation Solution
A method and apparatus that extrudes a pulp fibre suspension through a nozzle, uses wire sieves to dewater and twist the yarn, and includes adjustable parameters for speed, pressure, and rotating angle to produce cellulose-based yarn continuously, reducing chemical processing and increasing strength and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional paper yarn manufacturing method (slitting paper sheets to strips and twisting) is used, then the process is simple and well-established, but the yarn has limited strength, unsuitable thickness, layered or folded structure, and the manufacturing method is inefficient
Solution Approach 1:
The process is divided into distinct stages: extrusion of fibre suspension through nozzle, dewatering in first wire, twisting in the nip between wires, and drying. This segmentation allows each stage to be optimized independently, improving both strength and efficiency
Solution Approach 2:
The traditional mechanical slitting and twisting of finished paper is replaced by extruding fibre suspension and forming yarn directly in the wet state, then drying. This substitution enables continuous production and eliminates the layered structure problem
2Adaptability or versatility
If cotton is used as raw material for yarn production, then the yarn has good properties and is widely available, but significant water resources are required and it competes with food production in water-scarce regions
Solution Approach 1:
The raw material is changed from cotton (natural fiber requiring irrigation) to cellulose fibers from wood or agricultural residues (can be produced without competing for water). This parameter change maintains yarn production capability while eliminating the water resource conflict
Solution Approach 2:
The invention uses abundant, low-cost cellulose materials (wood fibers, agricultural residues) that can be sustainably harvested, replacing expensive and resource-intensive cotton. These materials are effectively 'disposable' in the sense that they can be continuously sourced without depleting critical resources
3Quantity of substance
If intensive cotton farming is practiced to meet yarn demand, then sufficient raw material is produced, but pollution to waters, wear of soil, and changes in animal population occur
Solution Approach 1:
Agricultural residues and wood fibers, which would otherwise be waste or require intensive farming to replace, are converted into valuable yarn material. This turns potential environmental problems (residue disposal) into benefits (sustainable raw material source)
Solution Approach 2:
Instead of discarding agricultural residues and wood waste, the invention recovers and utilizes these materials for yarn production, eliminating the need for intensive cotton farming and its associated environmental harms
4Adaptability or versatility
If rayon is produced as cotton alternative, then cotton use is reduced, but heavy chemical treatments are still required
Solution Approach 1:
The harmful chemical treatment step is extracted and removed from the production process. The invention achieves cotton substitution through purely mechanical and physical processes (extrusion, dewatering, drying) without requiring the heavy chemical treatments that rayon production demands
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 the production of environmentally friendly, cost-effective cellulose-based yarn that can replace cotton and rayon, utilizing surplus wood and plant materials, with the potential to replace 20% of global cotton demand and open new applications for northern wood fibers.
Implementation Method 1
uses wire sieves to dewater and twist the yarn
Implementation Method 2
at least one vacuum suction box is arranged on opposite side of at least one of the wires in relation of the wire gap
Implementation Method 3
the apparatus is equipped with at least one heating element for drying and treating the yarn to be manufactured
Data Source
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AI summary
A method and apparatus for producing fibre yarn is provided. The novel apparatus includes a first transportation and pressing element (1) and a second transportation and pressing element (5) arranged adjacent to the first transportation and pressing element (1) as well as means for driving the transportation and pressing elements (1, 5). The first and second transportation and pressing elements (1, 5) are arranged to form a nip there between. The apparatus also includes a nozzle (9) for feeding fibre suspension (6), such as pulp fibre suspension, to the nip between the first and second transportation and pressing elements (1, 5).