Yankee Dryer Adhesive Coating Quality Measurement
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Solution Overview
Problem
Conventional creping processes lack real-time measurement capabilities to assess the quality of adhesive coatings on creping cylinders, relying on offline sampling and analysis, which hinders precise control of the creping process and results in suboptimal paper quality.
Innovation Solution
A system and method for determining the quality of adhesive coatings on creping cylinders by measuring properties such as cross-linking, polymer concentration, water content, ash content, and thickness using optical methods, including a coating evaluation system with spectrometers and a creping blade sensing system to adjust process parameters in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional offline sampling and analysis methods are used to assess adhesive coating quality, then the measurement process is simple and does not require complex equipment, but the measurement precision and real-time control capability are insufficient
Solution Approach 1:
The patent replaces mechanical/physical sampling methods with optical measurement systems. Spectrometers and optical sensors detect adhesive coating properties (thickness, composition, cross-linking) through non-contact optical interactions, eliminating the need for physical sample extraction and laboratory analysis while dramatically improving measurement precision and enabling real-time monitoring
Solution Approach 2:
The patent introduces optical intermediaries (light beams, spectrometric analysis) between the adhesive coating and the measurement system. The optical methods act as intermediaries that translate adhesive coating properties into measurable spectral signals, enabling precise indirect measurement of coating quality without direct physical contact or sample destruction
2Measurement precision
If only adhesive coating thickness is measured, then the measurement process is simple and quick, but the measurement precision for comprehensive quality assessment is insufficient
Solution Approach 1:
The patent creates a multi-functional measurement system where a single optical measurement platform performs multiple assessment functions simultaneously. The spectrometric system measures thickness, composition, cross-linking degree, and other adhesive properties through different spectral analyses, enabling comprehensive quality assessment through one integrated system rather than multiple separate measurements
Solution Approach 2:
The patent utilizes changes in optical parameters (absorbance, reflectance, transmittance across different wavelengths) to detect different adhesive coating properties. By analyzing spectral variations at multiple wavelengths, the system distinguishes between thickness, composition, and cross-linking effects, enabling precise differentiation of multiple coating characteristics through parameter transformation
3Productivity
If real-time measurement and control of adhesive coating properties are implemented, then the productivity and quality consistency are improved, but the device complexity and initial investment increase
Solution Approach 1:
The patent implements real-time feedback control where optical measurements of adhesive coating properties are continuously monitored and fed back to the coating application system. This closed-loop feedback enables automatic adjustment of coating parameters (spray rate, adhesive composition, application pressure) to maintain optimal coating quality, improving productivity through reduced defects and rework while the feedback control gradually optimizes system performance
Solution Approach 2:
The patent performs preliminary measurement and adjustment of adhesive coating properties before the coating fully sets or before the paper proceeds to downstream processing. By measuring and controlling coating characteristics in real-time during application, the system prevents quality deviations from occurring, eliminating the need for downstream corrective actions and improving overall process efficiency
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
Enables real-time adjustment of creping process parameters to improve the quality of creped paper by providing comprehensive and precise measurements of adhesive coating properties, enhancing the consistency and quality of tissue products.
Implementation Method 1
determining a quality of the adhesive coating on the creping cylinder may include measuring at least one of a degree of cross-linking of the adhesive polymer, a concentration of the adhesive polymer in the adhesive coating, a water content of the adhesive coating, an ash content of the adhesive coating
Implementation Method 2
determining a thickness of the adhesive coating
Data Source
AI summary
A method for creping paper includes applying an adhesive composition to an outer surface of a creping cylinder (Yankee cylinder) to form an adhesive coating, contacting paper with the adhesive coating, removing the paper and adhesive coating from the creping cylinder, and determining a quality of the adhesive coating. Determining the quality of the adhesive coating may include measuring a degree of cross-linking of the adhesive polymer, a concentration of the adhesive polymer in the adhesive coating, a water content of the adhesive coating, an ash content of the adhesive coating, or combinations thereof. Determining the quality of the adhesive coating may also include determining a thickness of the adhesive coating by measuring light absorbed by the coating and calculating the thickness using Beer's Law. Systems and apparatuses for determining the quality of the adhesive coating and for creping paper are also disclosed.