Patent Publication Number: US-5626722-A

Title: Headbox of a paper/board machine

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a headbox of a paper/board machine. 
     In the prior art, regulation of the headbox of a paper/board machine is known, wherein it is possible, by means of separate operations, to regulate the consistency of the stock and to regulate its fiber orientation. In the prior art, among other things, so-called dilution headboxes are known, in which the stock consistency is regulated across the web width by means of separate dilution flows. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a new and improved headbox for a paper/board machine. 
     The headbox for a paper machine in accordance with the present invention comprises an inlet header and a turbulence generator directly connected with the inlet header. The stock flow out of the turbulence generator is passed into a slice cone and further from the slice cone onto a forming wire in the paper/board machine. In the headbox construction in accordance with the present invention, in view of the direct connection between the inlet header and the turbulence generator, a tube bank and intermediate chamber are not employed, nor is a stilling chamber connected with the intermediate chamber employed. Instead of such constructions, in the headbox in accordance with the invention, a valve arrangement is utilized by whose means it is possible to regulate both the flow quantity and the flow consistency of the flow departing from the valve which is directed into turbulence tubes of the turbulence generator. 
     In the construction in accordance with the invention, the above flow coming from the valves in the arrangement, whose flow quantity and consistency have been regulated, is passed into the turbulence generator of the headbox so that this flow is passed into substantially all the tubes in the turbulence generator which extend in both a direction across the width of the headbox and vertically at each width location. The quantity of the flow coming from each of the valves can be regulated, and thus, by means of the regulation of these flows, it is possible to regulate the desired slice flow rate profile. The range of regulation of the valve is selected quite broad so that the largest variations in the distribution profile of the inlet header are covered by this range, i.e., by means of the width of the range of regulation of the valve it is possible to regulate the slice flow rate profile coming from the headbox. 
     Besides the slice flow rate profile, by means of the system of valves in accordance with the invention, it is additionally possible to regulate the consistency profile of the flow coming out of the headbox, and by its means, the grammage profile of the paper. According to the invention, to each regulation valve, a stock flow is passed directly from the stock inlet header, and a dilution water flow or equivalent is passed from the dilution-water inlet header or an equivalent tank for dilution water. In the valves, the flows are combined, and the sum or combined flow is passed into a respective one of the turbulence generator of the headbox. A sum or combined flow is distributed into each of the tubes in the turbulence generator, and in the preferred embodiment of the invention a distributor piece, preferably an oblong tube is used, which comprises outlet openings for the sum flow so as to pass the sum flow into the principal stock flow in the turbulence tubes coming from the inlet header. In this manner, the flow coming from the valves can be distributed into all the tubes in the turbulence generator. 
     In accordance with the invention, a headbox of a novel type has been formed, in which it has been possible to omit the conventional tube bank, because the distribution profile of the slice flow can be controlled reliably by means of the regulation valves. From the turbulence tubes, no such precision is required as in the prior art constructions but, by means of the valve regulation, it is possible to correct and to compensate for any faults that may occur in the tubes. 
     The invention will be described in the following with reference to some preferred embodiments of the invention illustrated in the figures in the accompanying drawings. The invention is however, not confined to the illustrated embodiments alone. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The following drawings are illustrative of embodiments of the invention and are not meant to limit the scope of the invention as encompassed by the claims. 
     FIG. 1A shows a valve construction applied in the headbox construction of the present invention. 
     FIG. 1B is a sectional view of the valve taken along the line I--I in FIG. 1A. 
     FIG. 2A is an illustration of principle of a headbox in accordance with the invention. 
     FIG. 2B is a sectional view taken along the line II--II in FIG. 2A. 
     FIG. 2C shows the distribution of dilution fluid as shown in FIG. 2A on an enlarged scale in more detail. 
     FIG. 3A illustrates a construction unit that comprises a number of valves across the width of the headbox, in which unit regulated flows are passed from the valves into the different points of width of the headbox of the paper/board machine. 
     FIG. 3B illustrates a system of coordinates of slice flow rate--headbox width, in which the range of regulation of the regulation valves of the headbox in accordance with the invention is shown, the range of regulation being selected to be broad enough so that it corrects any undesirable disturbance produced by the turbulence generator of the headbox in the flow. 
     FIG. 4 shows a second arrangement of introduction of the regulated flow coming from the valve, arranged in connection with the turbulence generator of the headbox in accordance with the present invention, in which arrangement, at different points of width of the turbulence generator, there is a mixing chamber, in which the distributor pipe is arranged that is placed at the end of the flow coming from the valve. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the accompanying drawings wherein the same reference numerals refer to the same or similar elements, FIGS. 1A and 1B show a valve construction which is the subject of at least one other patent application assigned to the assignee herein, e.g. U.S. patent application Ser. No. 08/269,348 filed Jun. 30, 1994 and now U.S. Pat. No. 5,490,905, by whose means it is possible to regulate both the quantity and the consistency of a flow independently from one another in a single unit. Since this valve unit is of substantial importance in the headbox in accordance with the present invention, the operation of the valve construction is described briefly with reference to FIGS. 1A and 1B. FIGS. 1A and 1B illustrate a valve in which both the flow quantity is regulated and, independently from the flow quantity regulation, the concentration of the flow is regulated. A dilution-water flow Q b  arrives from a dilution-water header J 2  (FIG. 2) along a duct b into a valve V 1 , and a stock flow Q a  arrives from a stock inlet header J 1  (FIG. 2A) along a duct a into the valve V 1 . The valve V 1  comprises a rotatable spindle F, to which an obstruction part K is connected. When the spindle F is rotated (symbolized by arrow N 1  in FIG. 1A), the obstruction part K moves in relation to the ends of the ducts a and b connected to the valve V 1  and which lead into the space in the valve in which the spindle and obstruction part are situated. In this manner, rotation of the spindle F controls the amount of stock flow through duct a relative to the amount of dilution-water flow through duct b. Thus, for a substantially constant combined flow, the proportion or mixing ratio of dilution water to stock is varied. 
     When the spindle F is displaced along a linear path in the direction of its longitudinal axis (symbolized by arrow N 2  in FIG. 1B), the flow quantity is regulated with a certain mixing ratio, and as described above, when the spindle is rotated, the mixing ratio or consistency of the combined flow Q ab  from the valve V 1  is regulated. The regulation of the mixing ratio is such that when one flow is increased, the other flow is reduced by the equivalent amount, in which case the quantity of the flow Q ab  coming out of the valve via duct ab at that specific mixing ratio remains at an adjusted substantially constant value. The regulation of the flow quantity is achieved by the partial obstruction of the ends of ducts a and b which are obstructed by the obstruction part K by the same degree. 
     FIGS. 2A and 2B show a construction in accordance with the present invention, in which the valve shown in FIGS. 1A and 1B or any other valve construction whatsoever is used that possesses corresponding functions and that performs the regulations stated above: flow quantity regulation and mixing ratio regulation, preferably independent of one another. In FIG. 2A, for the sake of the principle, just one of the valves V 1 ,V 2 , . . . in the system of valves V 100  (FIG. 3A) is shown. There are a number of valves V 1 ,V 2 , . . . placed side by side in a direction transverse to the flow direction of the stock through the headbox (also referred to as the direction of width of the headbox), and by their means the stock flow is regulated across the entire width of the headbox 100 (see FIG. 3A). As shown in FIG. 2A, from the header J 2  for dilution water, a dilution-water flow Q b  is passed to the valve V 1 , and from the stock header J 1  a stock flow Q a  is passed to the valve V 1 . The combined flow Q ab  from the valve, whose flow quantity and consistency are regulated by operation of the valve, is passed via duct (ab) 1  further from the valve V 1  into a turbulence generator G placed after the inlet header J 1  and therefrom into turbulence tubes 10a 1 .1,10a 1 .2, . . . ; 10a 2 .1,10a 2 .2, . . . and from the turbulence tubes into a slice duct H, preferably a slice cone, and further onto the forming wire of the paper/board machine. From the set of valves V 100  which comprises valves V 1 ,V 2 , . . . placed side by side, the parallel flows Q ab  are passed into the turbulence generator G in such a way that the regulated flows Q ab  arriving from the valves V 1 ,V 2 , . . . of the set of valves V 100  are respectively distributed substantially into all the turbulence tubes 10a 1 .1,10a 1 .2, . . . , 10a 1 .n ; 10a 2 .1, 10a 2 .2, . . . , 10a 2 .n ; 10a 3 .1,10a 3 .2, . . . , 10a 3 .n arranged in a respective vertical row at each width location in the turbulence generator G, i.e., flow Q ab  via duct (ab) 1  is passed into turbulence tubes 10a 1 .1, 10a 1 .2, . . . ,10a 1 .n. Thus, by means of the flows arriving from the set of valves V 100 , the entire slice flow rate profile of the headbox is regulated. According to the invention, the range of regulation of each valve and the range of regulation of the whole set of valves V 100  are selected so wide and broad that they can compensate for any faults that may occur in the flow rate through the turbulence generator G of the headbox. The ratio of the amount of the maximal flow ΣQ ab  to the overall flow ΣQ coming from the stock inlet header J 1 , i.e. ΣQ ab  /ΣQ, is in the range from about 0.05 to about 0.15. 
     With reference to FIG. 2A, the line (ab) 1 ,(ab) 2 , . . . ,(ab) n  coming from each valve V 1 , V 2 , . . . (of which only line (ab) 1  coming from valve V 1  is shown) in the set of valves V 100  comprises a distributor piece 11 at its end. The distributor piece 11 comprises a central flow passage 12 and branch passages or openings 13a 1 ,13a 2  opening from the flow passage 12. The flow that arrives from the valve V 1  is distributed, by means of the regulated valve flow Q ab  passing from the valve V 1  into the distributor piece 11, evenly into the stock flow Q flowing in the turbulence tubes and coming directly from the inlet header J 1 . The branch ducts or openings 13a 1 ,13a 2 , . . . in the flow passage 12 in the distributor piece 11 are opened in the flow direction L 1  of the main flow Q coming from the inlet header J 1 . There is a large difference in speed between the flow Q and the regulated flow from the valve, so that the flows coming out of the branch ducts or openings 13a 1 ,13a 2 , . . . are mixed efficiently by the effect of the difference in speed between the flows Q and Q ab . In order that the regulation valves V 1 ,V 2  are also capable of performing the regulation of the flow quantity, the mixing point coming from the valves must be placed in such a way in the turbulence tubes in the turbulence generator that there is a large differential pressure loss between the inlet header and the mixing point. In such a case, the inlet header does not compensate for the flow quantity of the unit to be regulated, and regulation of the quantity by means of the valves V 1 ,V 2  . . . is possible. 
     The connection point between the flow coming from the valve and the main flow is preferably placed in the turbulence generator in the area of the forward side of the turbulence generator in the turbulence tube so that the connecting of the flow Q ab  with the turbulence tube takes place at the point of widening of the turbulence tube. The widening of the flow passage promotes the mixing together of the main flow Q and the regulated flow Q ab . 
     FIG. 2B is a sectional view taken along the line II--II in FIG. 2A. The distributor piece 11 extends centrally into the turbulence tube 10a 1 .1, in which case the stock flow L 1  coming from the inlet header J 1  flows from both sides of the distributor piece 11 from which the combined flow L 2  is released. 
     FIG. 2C shows the distribution of dilution fluid from a distributor piece 11 as shown in FIG. 2A into a plurality of vertically arranged turbulence tubes 10a 1 .1,10a 1 .2 on an enlarged scale and in greater detail. 
     Within the scope of the invention, an embodiment is also possible in which distributor pieces 11 are not employed but the flows Q ab  coming from the valves V 1 ,V 2 , . . . are distributed directly into vertical mixing chambers E 1  which are arranged at different points of width of the headbox of the paper machine. In this embodiment, there would be a mixing chamber for each set of vertically arranged turbulence tubes in the direction of width of the headbox. 
     The feed points of the flow lines coming from the valves V 1 ,V 2 , . . . into the flow coming from the inlet header J 1  are selected so that there is a pressure loss between the feed point and the inlet header J 1 . 
     A respective flow Q ab  coming from a respective one of the valves V 1 ,V 2 , . . . is passed into a respective one of the mixing chambers E 1  in the turbulence generator. Each of the mixing chambers E 1  is connected with a number of turbulence tubes of the turbulence generator at the inlet side and at the outlet side of the mixing chamber. In this manner, one inlet flow Q ab  can be divided into a number of tubes in the turbulence generator. There are several mixing chambers E 1  separated from one another placed side by side across the width of the paper machine. 
     FIG. 3A illustrates the arrangement of distribution in accordance with the invention of the flow coming from the valves V 1 ,V 2  into the turbulence tubes in the turbulence generator G. As shown in FIG. 3A, the set of valves V 100  comprises a number of valves V 1 ,V 2 , . . . ,V n  placed side by side, which valves represent for example the type of valve construction shown in FIGS. 1A and 1B, i.e., a valve by whose means both the flow quantity and the flow consistency can be regulated independently from one another. 
     FIG. 3B illustrates the slice flow rate profile and the range of regulation of the valve in a system of coordinates representing the slice flow and the headbox width. Curve D 1  illustrates the slice flow rate profile produced by the stock header J 1  and the turbulence generator G alone. The desired slice flow rate profile is represented by the straight line D 2 , and the range of regulation of the valve must be larger than the maximal range of variation occurring in the slice flow rate profile D 1 , i.e., in FIG. 3B, the range of regulation of the valve V 1 ,V 2  . . . is the area between the straight lines D 2  and D 3 . Thus, the range of regulation of the valve V 1 ,V 2  . . . must be selected wide enough so that, in the range, it is possible to compensate for a possibly uneven profile of the slice flow rate produced by the inlet header J 1 , by the turbulence generator G and by the slice cone or slice duct H. 
     FIG. 4 shows a second mode of arrangement of the distributor piece 11 in the turbulence generator G. In this arrangement, the distributor piece 11 is arranged in a separate vertical mixing chamber E 1  in the turbulence generator, which mixing chamber E 1  does not comprise partition walls. The flow that is passed out of the distributor piece 11, preferably out of the distributor pipe from the outlets 13a 1 ,13a 2 , . . . in its side face, is mixed with the flow entering into the mixing chamber E 1  from the inlet header J 1 . The mixed flow is passed further in the tubes in the turbulence generator G. In this case, since the stock flow L 1  and the combined flow L 2  are the same for all of the vertically arranged turbulence tubes at that specific location along the width of the headbox, the mixing chamber thus may be open without preventing mixing of the different flows. 
     The examples provided above are not meant to be exclusive. Many other variations of the present invention would be obvious to those skilled in the art, and are contemplated to be within the scope of the appended claims.