Sheet manufacturing device and sheet manufacturing method
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Solution Overview
Problem
The dry paper-making method requires multiple heat roller pairs to apply sufficient heat, making it difficult to construct a compact manufacturing apparatus, and the use of soft rollers for increased contact area and heat transfer leads to material deterioration and frequent maintenance.
Innovation Solution
A sheet manufacturing apparatus with a heat roller that applies heat from its outside surface to the rotating rollers, allowing for efficient thermal transfer and compression with a larger contact area, using rollers with differing hardness and thermal conductivity to prevent material sticking and ensure stable conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple heat roller pairs are used to apply sufficient heat, then heating efficiency is improved, but device complexity and size increase
Solution Approach 1:
The patent combines the heating function and compression function into a single heat roller pair. The heat roller applies both thermal energy and mechanical pressure simultaneously to the material, eliminating the need for separate heating rollers and compression rollers. This merging of functions achieves sufficient heating efficiency while reducing the number of roller pairs from multiple to just one.
Solution Approach 2:
The heat roller is designed to perform multiple functions: heating the material, compressing the material, and conveying the material. By making the roller universal in its capabilities, the system achieves the heating efficiency that would otherwise require multiple specialized rollers, thereby simplifying the overall device structure.
2Temperature
If soft rollers are used to increase contact area and heat transfer, then heating efficiency is improved, but roller durability decreases
Solution Approach 1:
The heat roller is constructed using composite materials that combine the thermal conductivity of metal with the compliance of rubber or elastomer. The metal core provides structural strength and durability, while the rubber or elastomer layer provides the necessary compliance for increased contact area and improved heat transfer to the material. This composite structure resolves the contradiction between durability and heat transfer efficiency.
Solution Approach 2:
The heat roller has different material properties at different locations: the core is made of highly conductive metal for structural integrity and heat distribution, while the outer surface is made of softer rubber or elastomer for enhanced contact with the material. This local differentiation of material quality allows the roller to simultaneously achieve durability through the metal core and heat transfer efficiency through the compliant outer layer.
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 enables efficient heating and compression of materials with reduced heat loss, extended roller life, and stable material conveyance, while maintaining a compact apparatus design.
Implementation Method 1
a heat roller configured to contact the outside surface of at least one of the first rotating roller and the second rotating roller, and heat the outside surface
Data Source
Figure 1~2
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AI summary
A sheet manufacturing apparatus having a compactly configurable heating/compressing unit that heats and compresses material efficiently. A sheet manufacturing apparatus having a heating/compressing unit configured to form a sheet by heating and compressing material including fiber and resin, the heating/compressing unit including a first rotating body that rotates, and a second rotating body that rotates in contact with the first rotating body, and holding, heating, and compressing material by the first rotating body and the second rotating body; and the sheet manufacturing apparatus including a heating unit that heats the outside surface of at least one of the first rotating body and second rotating body.