Sheet Manufacturing Apparatus Dynamic Parameter Control
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Solution Overview
Problem
Conventional sheet manufacturing apparatuses face difficulties in producing both paper and nonwoven cloth using the same apparatus due to differences in material additives, heat and pressure conditions, and fiber length, making it challenging to manufacture diverse sheets with varying characteristics.
Innovation Solution
A sheet manufacturing apparatus that includes a conveyor unit for varying thickness and density, a mixing unit for adding different additives, a sieve unit with adjustable mesh sizes, and a classifier for fiber length control, allowing for the production of sheets with diverse characteristics using the same materials and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sheet manufacturing apparatus is used to manufacture both paper and nonwoven cloth, then device complexity is reduced, but manufacturing precision deteriorates due to different material additives, heat and pressure conditions, and fiber length requirements
Solution Approach 1:
The patent implements variable control mechanisms that allow dynamic adjustment of manufacturing parameters including conveyor speed, sieve mesh size, classifier configuration, and additive mixing ratios. These dynamic adjustments enable the same apparatus to precisely control sheet characteristics for different product types (paper and nonwoven cloth) while maintaining a single device structure
Solution Approach 2:
The patent changes physical parameters of the manufacturing process including conveyor speed, sieve opening size, classifier settings, and additive composition to produce different sheet characteristics. By varying these parameters, the single apparatus can manufacture both paper and nonwoven cloth with their respective required properties
2Manufacturing precision
If conventional wet process is used for sheet manufacturing, then sheet quality is improved, but water consumption and energy usage increase significantly
Solution Approach 1:
The patent replaces the conventional wet process with a dry process that uses mechanical defibration and air classification instead of water-based processing. This substitution eliminates the need for large amounts of water while maintaining sheet quality through controlled mechanical separation and classification of fibers
Solution Approach 2:
The patent uses air flow and pneumatic classification mechanisms to separate and classify fibers by length and density without using water. The air-based system achieves effective fiber separation and sheet formation while avoiding the water consumption and associated energy requirements of conventional wet processes
3Quantity of substance
If dry process is used for sheet manufacturing, then water consumption is reduced, but sheet quality and fiber separation efficiency deteriorate
Solution Approach 1:
The patent segments the fiber processing into distinct stages: mechanical defibration, air classification by length, and selective separation. This segmentation allows each stage to optimize for its specific function, achieving effective fiber separation and sheet quality comparable to wet processes while maintaining low water consumption
Solution Approach 2:
The patent introduces air as an intermediary medium to facilitate fiber separation and classification in the dry process. The air flow acts as a mediator that enables effective fiber separation by length and density without requiring water, thereby maintaining sheet quality while reducing water consumption
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 sheets with different characteristics by adjusting conveyor speed, additive mixing, sieve mesh size, and classifier usage, effectively manufacturing a range of sheets from various feedstocks with improved strength and density.
Implementation Method 1
a defibrating unit that defibrates the shredded paper
Implementation Method 2
a classifier that classifies the defibrated material
Implementation Method 3
the deposition unit has a conveyor unit that moves while the precipitate is deposited thereon
Data Source
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AI summary
A sheet manufacturing apparatus can process various materials and manufacture a variety of sheets by changing conditions for making the sheets. A sheet manufacturing apparatus 100 according to the invention has a supply unit 10 that supplies feedstock; a defibrating unit 20 that defibrates the feedstock; a classifier 30 that classifies defibrated material that past the defibrating unit 20; a mixing unit 50 that mixes an additive containing resin with the classified material that past the classifier 30; a sieve unit 60 that passes the mixture that past the mixing unit 50 through many openings; a deposition unit 70 that deposits precipitate that past many openings in the sieve unit 60; a forming unit 80 that applies pressure and heat to the web deposited on the deposition unit 70, forming a sheet; and a control unit 90 that changes a condition of at least one of the classifier 30, mixing unit 50, sieve unit 60, deposition unit 70, and forming unit 80.