Web Forming Device for Recycled Paper Layer Control
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Solution Overview
Problem
Existing paper recycling apparatuses face challenges in maintaining desired color layers due to moisture infiltration, leading to unwanted color mixing and contamination of additives between layers, resulting in unusable recycled paper products.
Innovation Solution
A web forming device with separate material supply units for different defibrated substances and organic binders, positioned to form distinct layers on a mesh belt, where suction units and drum sections help in accumulating and bonding the layers without intermixing, allowing for precise control of layer thickness and color on both sides of the sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If moisture is used to humidify the defibrated substance during pressurization, then adhesiveness between layers is improved, but color materials and additives infiltrate between layers causing unwanted color mixing
Solution Approach 1:
The patent introduces an organic binder as an intermediary substance that replaces moisture for bonding between layers. The organic binder provides adhesiveness without causing infiltration and color mixing, thus resolving the contradiction between improving layer bonding and preventing contamination.
Solution Approach 2:
The patent changes the chemical parameter of the bonding agent from water-based (moisture) to organic binder-based. This parameter change maintains the bonding function while eliminating the harmful infiltration effect, allowing layers to adhere without color mixing.
2Manufacturing precision
If separate material supply units are used to control color layers, then color accuracy is improved, but device complexity increases
Solution Approach 1:
The patent divides the material supply system into separate units for different colored defibrated substances. Each supply unit can independently control the deposition of specific colors, enabling precise color layer control while managing complexity through modular segmentation.
Solution Approach 2:
The patent applies different colored materials at different locations on the mesh belt, with each location receiving a specific color from its corresponding supply unit. This local quality approach allows precise color control for different regions of the sheet without requiring a completely complex centralized system.
3Adaptability or versatility
If multiple layers are formed with different colors, then product versatility is improved, but the risk of unwanted color mixing increases
Solution Approach 1:
The organic binder acts as a mediator that bonds layers without causing color mixing. This allows multiple colored layers to be formed with different colors (improving versatility) while maintaining reliable separation and preventing unwanted mixing (maintaining reliability).
Solution Approach 2:
By changing from moisture-based bonding to organic binder-based bonding, the patent enables reliable formation of multiple colored layers without color infiltration, thus achieving both versatility in color combinations and reliability in layer separation.
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 solution effectively prevents unwanted color mixing and contamination, enabling the production of recycled paper with precise color control and reduced interlayer peeling, resulting in high-quality sheets with desired color accuracy and strength.
Implementation Method 1
a suction unit that suctions the layer of the first material and the layer of the second material which are accumulated on one surface side of the mesh belt, from another surface side of the mesh belt
Data Source
AI summary
A web forming device includes: a first material supply unit provided with a first release port that releases a first material containing a first defibrated substance and a first organic binder in a gas atmosphere; a second material supply unit provided with a second release port that releases a second material in the gas atmosphere, the second material containing a second defibrated substance and a second organic binder and being different from the first material; and a transporting unit that forms and transports an accumulated substance obtained by accumulating the first material and the second material. The second release port is positioned downstream of the first release port in a transporting direction of the transporting unit, and the accumulated substance is a laminate obtained by laminating a layer of the first material and a layer of the second material.