Sheet manufacturing apparatus and sheet manufacturing method
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Solution Overview
Problem
Conventional dry paper-making methods require multiple heat roller pairs to apply sufficient heat, leading to increased complexity and reduced reliability due to material deterioration, making it difficult to construct compact sheet manufacturing apparatuses.
Innovation Solution
A sheet manufacturing apparatus with a heating/compressing unit that applies heat from the outside surface of rotating bodies, allowing for efficient heating and compression of material with a smaller heat roller diameter, and a control unit to maintain stable temperatures, reducing material sticking and extending equipment life.
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 increases and reliability decreases
Solution Approach 1:
The patent combines the heating function and compression function into a single heat roller assembly. The heat roller simultaneously applies thermal energy to melt the binder and exerts mechanical pressure to compress the fiber mat, eliminating the need for separate heating rollers and compression rollers used in conventional multi-stage systems.
Solution Approach 2:
The heat roller serves multiple functions: it acts as both a heating element to melt the binder and a compression element to densify the fiber mat. This multi-functional design reduces the total number of rollers needed while maintaining effective heating and compression capabilities.
2Area of stationary object
If soft roller material is used to increase contact area, then heating coverage is improved, but roller durability decreases
Solution Approach 1:
The heat roller employs a composite structure combining a metal core (steel or aluminum) for structural strength and thermal conductivity with an outer layer of heat-resistant elastomer or rubber. This composite design provides both the large contact area needed for effective heating and the durability required for long-term operation at elevated temperatures.
Solution Approach 2:
The patent specifies using heat-resistant materials that can withstand temperatures of 100°C to 200°C, changing the material parameter from conventional roller materials to specialized heat-resistant elastomers or rubbers. This material parameter change enables the roller to maintain both large contact area and high durability under thermal conditions.
3Temperature
If internal heat source is used in roller, then heating capability is improved, but heat loss to environment increases
Solution Approach 1:
The heating element is positioned to pre-heat the heat roller before it contacts the fiber mat. This preliminary heating ensures the roller surface reaches the required temperature (100°C to 200°C) before material processing begins, maximizing heat transfer efficiency to the binder while minimizing prolonged exposure time that would cause energy loss.
Solution Approach 2:
The heat roller operates in continuous contact with the fiber mat during rotation, maintaining constant thermal interaction. This continuous action ensures efficient heat transfer from the roller to the material being processed, maximizing the utilization of applied heat and minimizing energy waste through uninterrupted thermal coupling.
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 achieves efficient thermal transfer and stable temperature control, enabling the production of sheets with reduced heat variation and extended equipment lifespan, while maintaining a compact configuration.
Implementation Method 1
a heating unit that heats the outside surface of at least one of the first rotating body and second rotating body
Data Source
AI summary
A sheet manufacturing apparatus has a heating/compressing unit configured to form a sheet by heating and compressing material including fiber and resin, and the heating/compressing unit includes a first rotating body that rotates, and a second rotating body that rotates in contact with the first rotating body. The sheet manufacturing apparatus holds, heats, and compresses material by the first rotating body and the second rotating body. The sheet manufacturing apparatus includes a heating unit that heats the outside surface of at least one of the first rotating body and second rotating body.