1. Field of the Invention
This invention relates to doctor blade systems, and is concerned in particular with an improved design that facilitates water or debris removal performance while maintaining desired doctor blade holder performance.
2. Description of the Prior Art
Many roll cleaning and sheet shedding applications on paper machines and other web handling applications involve doctor blade support devices commonly referred to as doctor blade holders. Typically, a doctor blade holder is mounted on a doctor-back, which is a heavy-duty beam that spans the paper machine width. The rear portion of a doctor blade is received into the holder, which supports the blade in a pre-determined position relative to a surface to be cleaned. The doctor blade holder works in concert with the doctoring assembly to apply the working edge of the blade, found on the blade's front portion, to an adjacent moving surface.
Certain conventional doctoring apparatus for paper machines are equipped with double doctors; the primary doctor cleans the surface of the roll, while the secondary blade carries away water and debris that may have dislodged from machined features such as holes and/or grooves in the roll surface, typically under affect of centrifugal force, with some additional influence from a reduction in fluid surface tension. This is, however, often not sufficient to adequately dewater the rolls.
U.S. Pat. No. 6,491,791 discloses a method and apparatus to clean roll surfaces or fabrics used in papermaking machines, wherein a doctoring element includes one or two integral doctor blades as well as an integral gas chamber that provides pressurized gas, e.g., compressed air, to the outgoing side of a doctoring apparatus having one doctor blade, and to the inter-blade area of a doctoring apparatus having two doctor blades. The compressed air is provided to enhance the water or dirt removal capabilities. Each of the disclosed apparatus involves doctor blades that are integral with the structure forming the gas chamber within the doctoring element. The apparatus including a two blade doctoring element, for example, provides that the interblade space forms a closely and tightly delineated pocket into which compressed air may be passed ('791 patent, col. 3, lines 18-20). The high pressure compressed air is disclosed to escape under the doctor blades via grooves on the grooved-shell roll being processed ('791 patent, col. 6, lines 59-63).
The use of such integral doctor blades requires that the entire doctoring element be replaced whenever the doctor blades become too worn. The doctoring apparatus are also not disclosed to be position adjustable with respect to the roll, and it is not at all clear how such an integral gas chamber may be incorporated in a doctoring apparatus that provides adjustable position accuracy with respect to a roll as well as flexibility in doctoring a roll along an elongated length of the doctor blade. Further shortcomings of such systems include: 1) The apparatus is not integral with the holder. 2) The apparatus is part of the blade and thus when it is worn or damaged it must be replaced, which is very costly. 3) The apparatus is very rigid and lacks the ability to conform well to the roll surface. 4) The air discharge features and geometry used for the purpose of dewatering can fail to produce adequate dewatering. 5) The apparatus air discharge is always open allowing contaminants to enter from the ambient when the device is not pressurized; the ingress of contaminants may be avoided by applying pressurized air when the machine is under maintenance, but with the disadvantage of the added cost associated with it.
U.S. Pat. No. 6,139,638 discloses a doctor blade holder apparatus that includes a planar upper holding member that is pivotally mounted to a tray such that the position of the upper holding member with respect to the tray may be adjusted by unloading and loading tubes. The upper holding member also includes a plurality of distribution passages that are coupled respectively off of the upper holding member via a plurality of branch conduits to a common header. The pressurized fluid, therefore, must separately travel through the conduits to reach each of the individual areas along the doctor blade holder apparatus, while maintaining sufficiently equalized pressure as the fluid is directed toward the roll along the elongated length of the doctor blade.
There remains a need, therefore, for a cost effective doctor blade holder system that facilitates consistent debris removal without limiting the flexibility of the doctor blade holder system or the effectiveness of the doctoring process, and in particular that improves the dewatering performance of a doctor apparatus operating on various paper machine rolls, while retaining or improving the cleaning performance of the doctor blade, such as, for example in a machine for doctoring a paper machine suction press.
In accordance with an embodiment, the invention provides a doctoring system for cleaning a surface in a papermaking machine, and the doctoring system includes a doctor blade and fluid assist system. The doctor blade is coupled to a doctor blade holder, and the doctor blade holder is coupled to a doctor-back. The fluid assist system is for providing a fluid under positive pressure that is higher than atmospheric pressure. The fluid is directed in a direction generally opposite a direction of movement of the moving surface such that fluid of high momentum is provided to impinge on water resident within the moving surface and adjacent a leading edge of the doctor blade during movement of the moving surface.
In accordance with another embodiment, the system includes a doctor blade and a fluid securing system for providing a fluid within a plenum under positive pressure that is higher than atmospheric pressure, to utilize plenum pressure to position and stabilize the doctor blade into a fixed position against surfaces of the doctor blade holder.
In accordance with another embodiment, the invention provides a method of cleaning a moving surface in a papermaking system. The method includes the steps of coupling a doctor blade to a doctor blade holder and coupling said doctor blade holder to a doctor-back, and providing a fluid within a plenum under positive pressure that is higher than atmospheric pressure, to utilize plenum pressure to position and stabilize the doctor blade into a fixed position against surfaces of the doctor blade holder, while also directing the fluid under positive pressure in a direction generally opposite a direction of movement of the moving surface such that fluid of high momentum is provided to impinge on water resident within the moving surface and adjacent a leading edge of the doctor blade during movement of the moving surface.
The following description may be further understood with reference to the accompanying drawings in which:
The drawings are shown for illustrative purposes only and are not necessarily to scale.
The present invention provides an improved doctoring device for dewatering paper machine rolls, such as press rolls, in which machined features in the roll such as grooves and through holes or blind holes carry away unwanted water that needs to be removed. The doctoring device includes several features that comprise the dewatering capability. The flexibility of the doctoring device is retained by (1) making the dewatering features integral with the holder loading features; this is accomplished through use of fiber reinforced pultrusion, or metallic extrusion, and (2) retaining a separate doctor blade component.
The device may include a plurality of mounting structures that are integrally formed as a result of the pultrusion or extrusion process. Further, the conventional doctor blade wear commodity item is retained for cleaning the roll surface, and it remains as a separate low cost consumable component. The holder proper with dewatering features then never requires replacement due to wear. Air would be suitable for most applications, although systems of various embodiments of the invention device are also suitable for use with other fluids such as steam, or even liquids.
In accordance with an embodiment, the invention provides a mechanical and flow device assembly that is used for doctoring paper machine rolls that carry, for example, water.
The doctor blade holder 10 also includes an integral flow plenum 34, and carries the separate doctor blade 24 that doctors the grooved surface 26. The doctor blade holder 10 may be a fiber reinforced pultrusion or metallic extrusion. Air under pressure enters the plenum 34, and then feeds into intermediate plenum 36 through aperture 38. The aperture 38 may comprise either a series of holes or a continuous slot opening. The escaping air under pressure travels between the top of the doctor blade 24 and the underside of the front portion 40 of the doctor blade holder 10, and is directed out an exit 42 toward the grooved surface of the roll as shown at 42. In the absence of pressure, a gap at the exit 42 is closed, preventing contaminants from entering during a machine outage.
During use, the pressure within the intermediate plenum 36 exerts an upward force on forward portion 40 of the holder 10, urging region the portion 40 upward thereby creating the gap at the exit 42. Air flows in the direction of the exit gap 42, which is typically 0.005 inches-0.015 inches if air is used as the fluid. In accordance with other embodiments, other fluids including gasses or even liquids may be used. The portion 40 of the doctor blade holder 10 may be configured with a less stiff fiber lay-up than the remaining portions of the holder 10, ensuring that regions other than region 40 remain relatively undeflected. A properly designed fiber lay-up will deflect a predetermined amount for proper operation and functionality. A communication port 46 at the underside of the doctor blade holder 10 proximate the intermediate plenum 36 ensures that a net downward force will be provided by the blade 24 against region 48 of the doctor blade holder 10. This holds the blade 24 in a stable manner within the holder 10. The blade 24 is also stabilized by having a wedge-shaped geometry as shown at 50.
The holder 60 may be a fiber reinforced pultrusion or metallic extrusion. Air under pressure enters the plenum 64, and then feeds into an intermediate plenum 90 through an aperture 92. The aperture 92 may comprise either a series of holes or a continuous slot opening. A forward region 94 of the holder 60 carries a spring loaded flapper spring 96 (for example, formed of a synthetic or metallic material) that is preloaded against the blade 66. The preloaded flapper spring 96 may be formed of an elongated shape that is received within a complementary elongated shaped recess within the doctor blade holder as shown. In the absence of pressure, a gap at the exit 98 is closed, preventing contaminants from entering during a machine outage. Pressure within intermediate plenum 90 exerts an upward force on the flapper 96, creating a gap at that exit 98. Air flows in the direction of exit 98, and a communication port 100 that is in communication with ambient pressure ensures that a net downward force on the rear portion of blade 66 secures the blade in a stable manner within the holder 60. The blade 66 is also stabilized by providing the wedge-shaped geometry as shown.
Air under pressure enters the plenum 112, and then feeds into an intermediate plenum 126 through an aperture 128 that may be formed as a series of holes or a continuous slot opening. The intermediate plenum 126 is generally formed by geometric features of the holder 110. In accordance with other embodiments, the intermediate plenum may be defined more by geometric features in the blade, as discussed further below with reference to
The blade 116 is also designed to communicate pressure of the intermediate plenum 126 along a clearance path into a region 136 under the blade 116. The clearance path may in an example be provided by grooves 138 that are formed in the back edge of the doctor blade as shown in
In accordance with a further embodiment of the invention shown in
During use, air under pressure enters the plenum 162, and then feeds through an aperture 176 into an intermediate plenum 178 that is partially formed by a recess in the blade as shown at 180. The doctor blade 166 includes lands 182 and lower portions 184 shown in
The doctor blade may be in contact with the roll surface as discussed above, or in certain embodiments, the doctor blade may be installed in a gap-set, non-contact mode as shown in
The doctor blade 200 includes lands and lower portions as discussed above with reference to
In accordance with another embodiment as shown in
The doctor blade 232 includes lands and lower portions as discussed above with reference to
In accordance with another embodiment, and as shown in
Air within plenum 268 flows along a plurality of paths 282 within the blade 262; this flow path is contained entirely within the blade itself, rather than formed by surfaces of both blade and holder as in prior embodiments. The air then discharges from paths 282, and enters a final region 284, which may be provided as a plurality of channels or a continuous slot. The high pressure air then exits the blade at an output end for cleaning a grooved surface of a roll or other moving surface in a papermaking machine.
The pressure-stabilized blades of these embodiments are manufactured with sufficient clearances with respect to the holder, such to facilitate ease of installation of the blade into the holder. Alternatively, the blade could be designed and manufactured with little clearance or slight interference, therefore not needing to rely on pressure to keep the blade stable, but with the penalty of making installation difficult.
Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the invention.
This application claims priority to U.S. Ser. No. 61/146,885 filed Jan. 23, 2009, the disclosure of which is hereby incorporated in its entirety.
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