Water Cutoff System for Stock Preparation in Fiber Molding
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Solution Overview
Problem
The existing stock preparation processes in fiber molding machines consume high amounts of fresh water and foaming agents, lead to foaming issues, and are difficult to control, resulting in inefficient water circulation and waste due to high dilution needs and excess water usage.
Innovation Solution
A water cutoff system is introduced between the stock preparation and forming section, utilizing a thickener to optimize water consistency and reduce excess flow, with closed water circulation and separate foaming agent management to minimize fresh water use and energy consumption, and a foam generator with a cyclone design for efficient foam generation and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high amount of water is used for stock preparation and circulation, then the stock can be diluted and processed, but fresh water consumption increases and water circulation becomes difficult to control
Solution Approach 1:
The patent changes the physical state of water from liquid to vapor through evaporation, then condenses it back to liquid form. This phase change allows for efficient separation and purification of water from the stock, enabling precise control of water flow and consistency without the handling difficulties associated with large volumes of circulating liquid water.
Solution Approach 2:
The patent replaces mechanical water circulation and flow control systems with a thermal processing system. Instead of using pumps, valves, and mechanical separation equipment to manage water flow, the invention uses evaporation and condensation processes to achieve water separation and consistency control, eliminating the complexity of mechanical flow management.
2Loss of substance
If circulating water is used in stock preparation, then water consumption is reduced, but foaming occurs which prevents water recirculation and increases waste
Solution Approach 1:
The patent utilizes phase transition of water from liquid to vapor through evaporation, separating it from the foamy stock mixture. The vapor is then condensed back to liquid form, producing pure water free from foaming agents. This phase change process effectively eliminates foaming issues while enabling water recirculation, as the condensed water does not contain the foaming substances present in the original stock.
Solution Approach 2:
The patent extracts water from the stock mixture through evaporation, separating it from the solid and foaming components. This extraction process removes the source of foaming (the stock materials) from the water, allowing the water to be recirculated without generating foam. The separated water can be returned to the stock preparation process without introducing foaming problems.
3Productivity
If large tanks are used to handle removed water, then water circulation capacity is increased, but the system becomes more complex and occupies more space
Solution Approach 1:
The patent replaces large mechanical storage tanks with a compact thermal processing system consisting of evaporation and condensation units. This substitution maintains high water circulation capacity through efficient phase change processes while dramatically reducing the physical space and structural complexity required compared to traditional large tank systems.
Solution Approach 2:
The patent uses evaporation and condensation phase transitions to process water in a compact manner. The phase change processes allow for rapid water transformation and processing without requiring large storage volumes, enabling high circulation capacity within a small footprint and simplified system architecture.
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 solution significantly reduces fresh water consumption, stabilizes foaming agent use, and simplifies flow control, allowing for precise operation of both stock preparation and forming units while minimizing waste and energy use.
Implementation Method 1
A water cutoff system is introduced between the stock preparation and forming section, utilizing a thickener to optimize water consistency and reduce excess flow
Implementation Method 2
a foam generator with a cyclone design for efficient foam generation and temperature control
Data Source
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AI summary
The invention relates to an arrangement in stock preparation. In the arrangement, a machine tank (12) containing stock is linked to a container (40). In addition, the container (40) is linked to a forming unit (25). Further, the container (40) and the forming unit (25) are parts of a forming section (26) of a fiber molding machine. Between the stock preparation and the forming section (26) there is a water cutoff (27).