Sheet Manufacturing Apparatus Humidity Control via Segmented Vaporization and Mist

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Solution Overview

Problem

Existing sheet manufacturing apparatuses face challenges in preventing the attachment of fragmented raw materials due to charging, leading to residual issues and inadequate humidity control, which results in condensation and insufficient suppression of material attachment.

Innovation Solution

A sheet manufacturing apparatus incorporating a vaporization-type humidifier to control the space humidity and a mist-type humidifier to humidify the web formed by defibrated substances, along with a separation unit and dust collecting unit, to effectively manage humidity and prevent attachment, while using a control unit to optimize water supply and discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a humidity control unit humidifies fragmented raw materials to suppress remaining and attachment, then the raw materials are humidified, but condensation occurs and remaining and attachment are not sufficiently suppressed

Engineering Contradiction:

Improvesuppression of raw material attachmentVSAvoidcondensation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent divides the humidification function into two separate units: a vaporization-type humidifier for humidifying fragmented raw materials and a mist-type humidifier for humidifying the web. This segmentation allows each unit to be optimized for its specific function, preventing condensation while effectively suppressing raw material attachment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different humidification methods to different locations and stages of the manufacturing process. The vaporization-type humidifier is used in the rough crushing unit and defibration unit where fragmented raw materials are present, while the mist-type humidifier is used in the web former where the web is formed. This local quality approach ensures appropriate humidity control without causing condensation.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If a vaporization-type humidifier humidifies the space where raw material is crushed, then condensation is suppressed, but the web obtained by accumulation of defibrated substances is not sufficiently humidified

Engineering Contradiction:

Improvecondensation suppressionVSAvoidhumidification of web

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent segments the humidification system into two distinct units with different mechanisms. The vaporization-type humidifier handles humidification of fragmented raw materials by vaporization, suppressing condensation. The mist-type humidifier handles humidification of the web by generating fine water droplets that can be effectively absorbed by the accumulated defibrated substances, ensuring sufficient web humidification without causing condensation issues.

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If humidity control is performed using saturated steam, then humidification is achieved, but the web cannot be sufficiently humidified without depending on saturated steam amount

Engineering Contradiction:

Improvesteam amountVSAvoidweb humidification efficiency

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent replaces the traditional saturated steam-based humidification system with a mist-type humidifier that generates fine water droplets through mechanical atomization. This substitution eliminates the dependency on saturated steam amounts and provides more reliable and controllable web humidification, as the mist can be directly applied to the web surface regardless of ambient steam conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 suppresses the attachment of raw materials and ensures appropriate humidity levels, preventing condensation and residual issues, thereby enhancing the manufacturing process by maintaining optimal humidity without relying on saturated steam amounts.

Implementation Method 1

a vaporization-type humidifier that humidifies a space in which the raw material is roughly crushed by the rough crushing unit

Methodology Applied

Scientific EffectVaporization: Evaporation

Implementation Method 2

a mist-type humidifier that humidifies the web that is formed by the web former

Methodology Applied

Scientific EffectMist generation and deposition: Aerosol

Implementation Method 3

a defibration unit that defibrates the raw material roughly crushed by the rough crushing unit, in a gas atmosphere

Methodology Applied

Scientific EffectMechanical defibration: Fracture Mechanics

Data Source

PatentUS11319668B2Sheet manufacturing apparatus

Publication Date: 2022.05.03 SEIKO EPSON CORP

AI summary

The sheet manufacturing apparatus includes: a rough crushing unit that roughly crushes a raw material containing fibers; and a defibration unit that defibrates the roughly crushed raw material in a gas atmosphere. In addition, the sheet manufacturing apparatus includes: first and second web formers that accumulate defibrated substances obtained through a defibrating process and form webs; and a sheet former that forms a sheet of the second web. In addition, the sheet manufacturing apparatus includes: a vaporization-type humidifying unit that humidifies a space in which the raw material is roughly crushed by the rough crushing unit; and a mist-type humidifying unit that humidifies the webs that are formed by the first and second web formers.