Foam-based manufacturing system and process
AssigneeKimberly-Clark Worldwide, Inc.
InventorsMarvin E. Swails, Vicky S. Polashock, Michael Payne, Joseph K. Baker, Charles W. Colman
Life of this patent
Estimating the term…
Abstract
A system comprising a pulper configured to (i) accept surfactant, a liquid and fiber stock and (ii) generate a foam that suspends the fiber stock, wherein the foam has a half-life; a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire, wherein a time it takes the foam-suspended fiber stock to move from the pulper to the headbox is less than the half-life; and a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper.
Claims19
A system comprising:
- a pulper configured to (i) accept surfactant, a liquid and fiber stock, and (ii) provide a foam in which the fiber stock is suspended, and (iii) mix the surfactant, liquid, and fiber stock, wherein the pulper comprises one or more agitation blades that mix the surfactant, liquid, and fiber stock to provide the foam;
- a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire;
- a conduit connecting the pulper to the headbox, wherein the conduit is configured to move the foam-suspended fiber stock from the pulper to the headbox in a foam state, further wherein the conduit connecting the pulper to the headbox is configured such that the foam to fiber stock consistency between the pulper and the headbox does not change by more than 25%;
- and
- a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper, the at least some of the foam remaining in a foam state from the forming wire to the pulper, and wherein the foam return device is configured to return at least 60% in mass or volume of the foam to the pulper.
A method comprising:
- providing a foam in a pulper containing a surfactant, water, and a fiber stock mixture, wherein the pulper comprises one or more agitation blades that mix the surfactant, liquid, and fiber stock to provide the foam;
- transporting the foam in which the fiber stock is suspended through a conduit to a headbox in a foam state, wherein the conduit connecting the pulper to the headbox is configured such that the foam to fiber stock consistency between the pulper and the headbox does not change by more than 25%;
- displacing the foam and fiber stock on a forming wire;
- and
- returning at least a portion of the foam from the forming wire to the pulper, wherein at least 60% in mass or volume of the foam is returned to the pulper, and wherein the at least 60% in mass or volume of the foam that is returned to the pulper remains in a foam state from the forming wire to the pulper.
A system comprising:
- a pulper configured to (i) accept surfactant, a liquid and fiber stock, and (ii) provide a foam in which the fiber stock is suspended, and (iii) mix the surfactant, liquid, and fiber stock, wherein the pulper comprises one or more agitation blades that mix the surfactant, liquid, and fiber stock to provide the foam;
- a headbox;
- a conduit connecting the pulper to the headbox, wherein the conduit is configured to move the foam-suspended fiber stock from the pulper to the headbox in a foam state, further wherein the conduit connecting the pulper to the headbox is configured such that the foam to fiber stock consistency between the pulper and the headbox does not change by more than 25%;
- and
- a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper, the at least some of the foam remaining in a foam state from the forming wire to the pulper, and wherein the foam return device is configured to return at least 60% in mass or volume of the foam to the pulper.
Dependencies are inferred from the claim text.