Sheet Manufacturing Apparatus with Movable Heating Rollers
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Solution Overview
Problem
The existing sheet manufacturing apparatuses face issues with insufficient heating, where the mat-shaped composition does not get adequately heated during the warming-up process, leading to defects in the final sheet product, and there is a problem of the resin dissolving and sticking to the thermal pressure roller during transport, causing defects.
Innovation Solution
The apparatus employs a heating unit with two rotating bodies that can be positioned to nip and heat the sediment only when necessary, ensuring uniform surface temperatures and preventing overheating or sticking by separating during transport, and using a transmission mechanism to manage the driving force and peripheral speeds for stable sediment transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the thermal pressure roller heats the mat-shaped composition during transport, then the composition is heated, but the resin dissolves and the composition sticks to the roller
Solution Approach 1:
The heating unit is designed with movable heating bodies that can dynamically change position between a heating position (contacting the composition) and a separation position (not contacting the composition). This dynamic adjustment allows the system to heat the composition when needed while preventing sticking by separating during transport, resolving the contradiction between heating effectiveness and sticking prevention.
2Temperature
If the apparatus warms up while transporting the mat-shaped composition, then the thermal pressure roller reaches operating temperature, but the composition is not sufficiently heated
Solution Approach 1:
The heating unit performs preliminary heating of the mat-shaped composition by positioning the heating bodies in contact with the composition before the main pressing operation. This preliminary action ensures the composition reaches the required temperature uniformly throughout the heating process, preventing insufficient heating defects while the roller itself is still warming up to operating temperature.
3Temperature
If the mat-shaped composition remains between the thermal pressure rollers during warming up, then the rollers heat up, but the composition is not adequately heated and defects occur
Solution Approach 1:
The heating unit dynamically adjusts the position of heating bodies based on operational phase: during warming up, heating bodies are positioned to contact and heat the composition; during normal operation, positioning is adjusted to prevent overheating. This dynamic control ensures reliable sheet quality by preventing both insufficient heating during warm-up and overheating during production.
Solution Approach 2:
The system performs preliminary heating of the composition using the movable heating units before the main thermal pressure rolling process begins. This preliminary action ensures the composition is adequately pre-heated, preventing quality defects that would occur if the composition were merely present during roller warm-up without active heating.
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 prevents defects due to insufficient heating, maintains uniform sheet strength, and prevents discoloration and sticking issues, ensuring a stable and high-quality sheet manufacturing process.
Implementation Method 1
a heating body that heats the first rotating body and the second rotating body
Implementation Method 2
when the sediment is nipped and heated by the first rotating body and the second rotating body after heating the first rotating body and the second rotating body
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
Provided a sheet manufacturing apparatus or the like which is capable of reducing defects due to insufficient heating or the like. The sheet manufacturing apparatus includes an accumulation unit that accumulates a material containing a fiber and a resin; a heating unit that includes a first rotating body and a second rotating body and heats a sediment accumulated by the accumulation unit; a displacement mechanism that displaces the heating unit to a first position where the first rotating body and second rotating body nip and heat the sediment and a second position where the first rotating body and the second rotating body are separated from each other; and a controller that displaces the first rotating body and the second rotating body to the first position after heating the first rotating body and the second rotating body in the second position.