Sheet Manufacturing Apparatus Roller Adhesion Control
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Solution Overview
Problem
Conventional sheet manufacturing apparatuses using wet slurry processes require large amounts of water, lead to excessive water adhesion on rollers, and energy-intensive drying processes, while dry processes face issues with fiber and resin adhesion to rollers.
Innovation Solution
A sheet manufacturing apparatus incorporating an air-laying unit and a humidifying unit that uses air flow to distribute moisture uniformly throughout the deposited material, reducing surface water and adhesion to rollers, and optimizing air flow velocities and volumes to prevent fiber and resin separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water drops are simply sprayed onto the deposited material accumulated on the mesh belt, then the deposited material can be humidified, but much water sticks to the surface of the deposited material and the deposited fiber then sticks to downstream rollers
Solution Approach 1:
The patent introduces a new dimension for water application by using air flow to carry water vapor or fine droplets through the thickness of the deposited material, rather than spraying water onto the surface. This transforms the water application from a surface-level 2D process to a through-thickness 3D process, enabling uniform humidification without surface water accumulation that causes roller adhesion
Solution Approach 2:
The patent employs air flow as a pneumatic medium to transport water vapor or fine droplets through the deposited material. The air flow acts as a carrier that distributes water uniformly throughout the material thickness, preventing surface water pooling and subsequent roller adhesion while achieving the desired humidification
2Ease of manufacture
If a wet slurry process is used to manufacture sheets, then fibers can be defibrated and rescreened, but a large amount of water is required and the drying process requires much energy
Solution Approach 1:
The patent changes the water content parameter of the deposited material by controlling the amount and distribution of water applied during the air-laying process. By optimizing water distribution throughout the material thickness rather than concentrating it on the surface, the process achieves adequate fiber bonding with reduced total water content, thereby lowering drying energy requirements
Solution Approach 2:
The patent replaces the conventional wet slurry mechanical processing system with an air-laying system that uses pneumatic transport and air flow to deposit and humidify fibers. This substitution eliminates the need for extensive water-based slurry preparation and mechanical screening, significantly reducing overall water consumption and associated drying energy
3Strength
If water is applied to humidify the deposited material, then fiber bonding can be improved, but excessive surface water causes the material to wrap onto rollers
Solution Approach 1:
The patent applies water in the through-thickness dimension of the deposited material using air flow to carry water vapor or fine droplets through the material depth. This dimensional change ensures water reaches the bulk of the material for proper fiber bonding while preventing surface water accumulation that would cause wrapping onto rollers
Solution Approach 2:
The patent introduces air flow as an intermediary medium to deliver water to the deposited material. The air flow acts as a carrier that distributes water uniformly throughout the material thickness, mediating between the need for water (for bonding) and the need to avoid excess surface water (to prevent wrapping)
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 material adhesion to rollers, improves sheet quality, and reduces water usage and energy consumption by uniformly humidifying the material and controlling air flow to enhance bonding between fibers and resin.
Implementation Method 1
a first air flow generator that generates air flow passing through the deposited material in a direction intersecting the support surface supporting the deposited material
Implementation Method 2
supplies droplets or humidified air to the deposited material by the air flow produced by the first air flow generator
Data Source
AI summary
Provided is a sheet manufacturing apparatus that can suppress deposited material from wrapping onto a roller. A sheet manufacturing apparatus according to the invention includes: an air-laying unit that lays material containing fiber and resin; and a humidifying unit that humidifies the deposited material laid by the air-laying unit; the humidifying unit including a first air flow generator that generates air flow passing through the deposited material in a direction intersecting the support surface supporting the deposited material, and supplies droplets or humidified air to the deposited material by the air flow produced by the first air flow generator.