Sheet Manufacturing Apparatus with Segmented Cutting for Jam Troubleshooting
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Solution Overview
Problem
Existing sheet manufacturing apparatuses using the wet method require large amounts of water, leading to increased apparatus size and labor for maintenance, as well as high energy consumption in drying processes. Additionally, dry-type apparatuses face difficulties in troubleshooting transportation abnormalities, such as jamming, due to the continuous nature of the sheet until cutting.
Innovation Solution
A sheet manufacturing apparatus comprising a pressing unit, a separate sheet shaping unit, a transportation unit, and a cutting-off unit. The cutting-off unit is strategically placed between the pressing unit and the transportation unit, allowing it to cut off sections of the continuous sheet where transportation abnormalities occur, thereby facilitating easier troubleshooting and reducing apparatus size and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wet method is used for sheet manufacturing, then the sheet can be formed effectively, but the apparatus size increases and requires large amounts of water
Solution Approach 1:
The patent changes the fundamental parameter of the manufacturing method from wet to dry process. The dry-type sheet manufacturing apparatus forms sheets without using water, eliminating the need for large water processing facilities and reducing apparatus size while maintaining effective sheet formation through alternative mechanisms.
2Reliability
If a wet method is used for sheet manufacturing, then the sheet can be formed effectively, but energy consumption in drying process increases
Solution Approach 1:
The patent changes the process parameter from wet to dry manufacturing, eliminating the drying process entirely. The dry-type apparatus forms sheets directly without water, thus eliminating the energy-consuming drying step while maintaining effective sheet formation.
3Productivity
If the workpiece remains as a single continuous sheet until cutting, then the sheet can be formed continuously, but troubleshooting transportation abnormalities becomes difficult
Solution Approach 1:
The patent divides the continuous sheet into separate sheets at regular intervals using a cutting unit. This segmentation allows the sheet to be produced continuously while enabling easy troubleshooting of transportation abnormalities, as each separate sheet can be independently handled and inspected, and abnormal sections can be easily identified and removed.
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 addresses the issues of water usage and energy consumption by employing a dry-type method, and enhances troubleshooting efficiency by allowing for the easy removal of abnormal sections from the continuous sheet, reducing downtime and maintenance costs.
Implementation Method 1
a pressing roller that presses a material containing fibers and a binder, which has a function of bonding the fibers together, to form the material into a shape of a continuous sheet
Data Source
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AI summary
A sheet manufacturing apparatus includes a pressing unit, a separate sheet shaping unit, a transportation unit, and a cutting-off unit. The pressing unit includes a pressing roller that presses a material containing fibers and a binder, which has a function of bonding the fibers together, to form the material into a shape of a continuous sheet. The separate sheet shaping unit cuts the continuous sheet into a shape of a separate sheet. The transportation unit is provided between the pressing roller and the separate sheet shaping unit and transports the continuous sheet formed by the pressing unit to the separate sheet shaping unit. The cutting-off unit is provided between the pressing roller and the transportation unit. When transportation abnormality occurs on the continuous sheet that is being transported, the cutting-off unit cuts off, from the continuous sheet, a part of the continuous sheet where the transportation abnormality occurs.