Single Master Belt Compression of Pulp/SAP Intermixtures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for compressing fluff/SAP mixes face issues such as material loss, increased energy consumption, and mechanical damage to transfer belts due to high SAP content, as well as the need for complex transfer systems when the belt is not used during compression.
Innovation Solution
A method involving a continuous foraminous belt system with suction boxes and bypass guide rolls to separate the pulp/SAP intermix from the belt before and after compression units, allowing for efficient compression without belt damage or material loss, using a carrier web if needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the transfer belt is fed together with the fluff/SAP mix through the compression unit, then the compression process is simplified, but SAP passes through the foraminous belt causing material loss and the belt may be damaged
Solution Approach 1:
The compression process is segmented into two distinct phases: a first low-pressure compression phase where the foraminous belt remains in the nip to maintain web stability, and a second high-pressure compression phase where the belt is separated from the nip to prevent SAP penetration and belt damage. This temporal and functional segmentation allows each phase to optimize for its specific requirements.
Solution Approach 2:
The system dynamically adjusts the position of the foraminous belt relative to the compression nip based on the compression phase. During low-pressure compression, the belt is positioned in the nip for stability; during high-pressure compression, the belt is separated from the nip. This dynamic positioning resolves the contradiction between simplification and material protection.
2Device complexity
If the transfer belt is fed together with the fluff/SAP mix through the compression unit, then the compression process is simplified, but air flow resistance increases and energy consumption increases
Solution Approach 1:
The compression process is segmented into two distinct phases: a first low-pressure compression phase where the foraminous belt remains in the nip to maintain web stability, and a second high-pressure compression phase where the belt is separated from the nip to prevent SAP penetration and belt damage. This temporal and functional segmentation allows each phase to optimize for its specific requirements.
Solution Approach 2:
The system dynamically adjusts the position of the foraminous belt relative to the compression nip based on the compression phase. During low-pressure compression, the belt is positioned in the nip for stability; during high-pressure compression, the belt is separated from the nip. This dynamic positioning resolves the contradiction between simplification and material protection.
3Strength
If support belt is not running through compression, then belt damage is avoided, but multiple transfer systems are required increasing system complexity
Solution Approach 1:
The compression process is segmented into two distinct phases: a first low-pressure compression phase where the foraminous belt remains in the nip to maintain web stability, and a second high-pressure compression phase where the belt is separated from the nip to prevent SAP penetration and belt damage. This temporal and functional segmentation allows each phase to optimize for its specific requirements.
Solution Approach 2:
The system dynamically adjusts the position of the foraminous belt relative to the compression nip based on the compression phase. During low-pressure compression, the belt is positioned in the nip for stability; during high-pressure compression, the belt is separated from the nip. This dynamic positioning resolves the contradiction between simplification and material protection.
4Strength
If support belt is not running through compression, then belt damage is avoided, but mismatched transfer speeds may cause quality issues
Solution Approach 1:
The compression process is segmented into two distinct phases: a first low-pressure compression phase where the foraminous belt remains in the nip to maintain web stability, and a second high-pressure compression phase where the belt is separated from the nip to prevent SAP penetration and belt damage. This temporal and functional segmentation allows each phase to optimize for its specific requirements.
Solution Approach 2:
The system dynamically adjusts the position of the foraminous belt relative to the compression nip based on the compression phase. During low-pressure compression, the belt is positioned in the nip for stability; during high-pressure compression, the belt is separated from the nip. This dynamic positioning resolves the contradiction between simplification and material protection.
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 approach minimizes material loss, reduces energy consumption, and maintains belt integrity while achieving high-quality compression of SAP-containing webs, even with high SAP content, without requiring duplicate drive systems.
Implementation Method 1
a suction system comprising at least a first and a second suction box adapted to suck air through the foraminous belt
Data Source
Figure 1
Figure 2
AI summary
The present invention is a process for compressing intermixtures of fibres, such as cellulosic pulp fibers, with particles, such as superabsorbent particles.