Sheet Manufacturing Apparatus Defibration Capacity Balance
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Solution Overview
Problem
In paper recycling systems, if the shredding capacity exceeds the defibrating capacity, shredded material can accumulate in the defibrating unit and not be properly defibrated, leading to incomplete processing.
Innovation Solution
A sheet manufacturing apparatus is designed with a defibrating unit that has a capacity greater than or equal to the shredding capacity, incorporating a separator to handle remnants and trimmings, ensuring that all material is processed and preventing accumulation by recycling unprocessed material back through the defibrating unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shredding capacity is increased to process more feedstock, then the productivity of the paper recycling system is improved, but the shredded material accumulates in the defibrating unit and cannot be properly defibrated
Solution Approach 1:
The patent applies dynamics by making the defibrating unit's processing capacity adjustable and adaptable to match the variable output of the shredder. The defibrating unit can dynamically adjust its processing rate to handle fluctuations in shredded material input, ensuring complete defibration without accumulation while maintaining high productivity.
Solution Approach 2:
The patent implements feedback control where the system monitors the defibration process and adjusts the defibrating unit's operation based on the actual state of processed material. This feedback mechanism ensures that the defibrating capacity matches the shredding output, preventing accumulation and ensuring complete processing while maintaining high productivity.
2Reliability
If the defibrating capacity is increased to match or exceed shredding capacity, then the defibration completeness is improved, but the device complexity increases due to additional components like separator and conveyance paths
Solution Approach 1:
The patent merges the separator and conveyance path functions into an integrated system that works in conjunction with the defibrating unit. The separator is combined with the defibrating unit, and the conveyance path creates a closed-loop system that efficiently returns remnants without requiring separate complex handling systems, thus reducing overall device complexity while maintaining defibration completeness.
Solution Approach 2:
The conveyance path serves multiple functions: it transports defibrated material from the defibrating unit to the forming unit, and simultaneously returns remnants from the separator back to the defibrating unit. This multi-functionality reduces the need for separate dedicated systems, simplifying the overall device structure while ensuring complete defibration processing.
3Manufacturing precision
If remnants are separated and returned to the defibrating unit through the first conveyance path, then the manufacturing precision of the final sheet is improved, but the processing time increases due to the additional separation and reprocessing cycle
Solution Approach 1:
The patent maintains continuous processing by implementing a closed-loop system where remnants are separated and immediately returned to the defibrating unit through the conveyance path. This continuous circulation allows the system to process material without interruption, maintaining steady production flow while ensuring complete defibration and high sheet quality, thus minimizing time loss.
Solution Approach 2:
The separator performs preliminary separation of remnants before they are returned to the defibrating unit. By pre-separating and preparing the remnants for reprocessing, the system optimizes the subsequent defibration cycle, reducing the time required for complete processing while ensuring high manufacturing precision in the final sheet product.
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 configuration ensures that all shredded material is defibrated, preventing accumulation and ensuring efficient processing, even when remnants and trimmings are mixed with the primary feedstock, thereby maintaining continuous operation and product quality.
Implementation Method 1
a shredder that separates feedstock containing at least fiber into shreds in air
Implementation Method 2
a defibrating unit that defibrates at least the shreds in air
Implementation Method 3
a separator that separates the defibrated material into passed material that passes through multiple apertures, and remnants that do not pass
Data Source
Figure 1
AI summary
An apparatus reduces material left between a shredding unit and a defibrating unit. A sheet manufacturing apparatus including a shredder that separates feedstock containing at least fiber into shreds in air; a defibrating unit that defibrates at least the shreds in air; and a forming unit that forms a sheet using defibrated material defibrated by the defibrating unit; wherein the defibration capacity, which is the amount defibrated per unit time by the defibrating unit, is greater than or equal to the shredding capacity, which is the amount shredded per unit time by the shredder.