Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
  • D21F1/00—Wet end of machines for making continuous webs of paper
  • D21F1/36—Guiding mechanisms
  • D21F1/42—Jets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H20/00—Advancing webs
  • B65H20/14—Advancing webs by direct action on web of moving fluid
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H23/00—Registering, tensioning, smoothing or guiding webs
  • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
  • B65H23/24—Registering, tensioning, smoothing or guiding webs longitudinally by fluid action, e.g. to retard the running web
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
  • D21F5/00—Dryer section of machines for making continuous webs of paper
  • D21F5/18—Drying webs by hot air
  • D21F5/185—Supporting webs in hot air dryers
  • D21F5/187—Supporting webs in hot air dryers by air jets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2406/00—Means using fluid
  • B65H2406/10—Means using fluid made only for exhausting gaseous medium
  • B65H2406/11—Means using fluid made only for exhausting gaseous medium producing fluidised bed
  • B65H2406/112—Means using fluid made only for exhausting gaseous medium producing fluidised bed for handling material along preferably rectilinear path, e.g. nozzle bed for web
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2511/00—Dimensions; Position; Numbers; Identification; Occurrences
  • B65H2511/10—Size; Dimensions
  • B65H2511/13—Thickness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2553/00—Sensing or detecting means
  • B65H2553/40—Sensing or detecting means using optical, e.g. photographic, elements

Definitions

• the present invention relates generally to an air stabilizer device for non-contacting support of a moving flexible continuous web of material.
• the air stabilizer employs two opposite-facing nozzles that direct jets of gas onto the moving web thereby imparting tension in the web.
• An internal baffle is employed to channel air flow within each nozzle. The baffle equalizes the gas pressure across the nozzle and directs air flow towards it.
• a web of paper is formed from an aqueous suspension of fibers (stock) on a traveling mesh papermaking fabric and water drains by gravity and suction through the fabric. The web is then transferred to the pressing section where more water is removed by pressure and vacuum. The web next enters the dryer section where steam heated dryers and hot air completes the drying process.
• the paper machine is, in essence, a water removal system.
• a typical forming section of a papermaking machine includes an endless traveling papermaking fabric or wire, which travels over a series of water removal elements such as table rolls, foils, vacuum foils, and suction boxes.
• the stock is carried on the top surface of the papermaking fabric and is de-watered as the stock travels over the successive de- watering elements to form a sheet of paper. Finally, the wet sheet is transferred to the press section of the papermaking machine where enough water is removed to form a sheet of paper.
• on-line measurements often include basis weight, moisture content, and sheet caliper, i.e., thickness. The measurements can be used for controlling process variables with the goal of maintaining output quality and minimizing the quantity of product that must be rejected due to disturbances in the manufacturing process.
• the on-line sheet property measurements are often accomplished by scanning sensors that periodically traverse the sheet material from edge to edge.
• the reference part is configured so that there is an open space or channel below the reference part.
• suction force is exerted on the web thereby supporting it against the reference surface substantially over the entire measuring area.
• debris and contaminants tend to build on the sensing elements and clog the holes in the reference surface which adversely affect the accuracy of the measuring device.
• stabilization must be accomplished with minimal or no contact to the stabilizing device. This is critical at the high speed at which web material such as paper is manufactured.
• U.S. Patent No. 6,281,679 to King et al. describes a non-contact web thickness measurement system which has dual sensor heads each located on opposite sides of a moving web.
• the system includes a web stabilizer that is based on a vortex of moving air and includes a clamp plate that is mounted near the web, which is to be stabilized, and a circular air channel within the clamp plate that is coincident with its upper surface. When air is introduced into the circular air channel, a field of low pressure is created over the channel and the web is pulled toward this ring of low pressure.
• U.S. Patent No. 6,936,137 to Moeller et al. describes a linear air clamp or stabilizer, for supporting a moving web, which employs a single Coanda nozzle in conjunction with a "backstep" which is a depression downstream from the nozzle.
• a jet of gas is discharged from the nozzle in a downstream direction that is parallel to the movement of the web.
• a defined area of web material rides on an air bearing as the web passes over the air clamp surface where a thickness measurement device is positioned.
• a non- contacting caliper sensor When employed in a papermaking machine, a non- contacting caliper sensor is particularly suited for measuring the thickness of the finished paper near the take-up reel.
• the heads of the sensor are positioned on a scanner system that generally includes a pair of horizontally extending guide tracks that span the width of the paper.
• the upper head and lower head are each secured to a carriage that moves back-and-forth, on the track, over paper as measurements are made.
• the guide tracks are spaced apart vertically by a distance sufficient to allow clearance for paper to travel between the sensor heads.
• the upper head includes a device that measures the height between the upper head and the upper surface of the web and the lower head includes a device that measures the height between the lower head to the lower surface of the web.
• the lower or upper head includes an air stabilizer to support the moving paper.
• the interrogations spots of the laser triangulation devices are directly above each other. Accurate and precise measurements are attained when the two heads are in alignment but scanner heads will deviate from perfect alignment over time.
• a caliper sensor with misaligned sensor heads will not accurately measure a sheet that is not flat and current air stabilizers do not adequately support the moving sheet to present a sufficiently flat profile for measurement.
• the present invention is based in part on the development of a Coanda air clamp or stabilization system that subjects a moving flexible web, which is traveling in the machine direction, to opposing forces sufficient to create local tension within the web.
• This can be achieved by employing two parallel, opposite-facing elongated Coanda nozzles positioned above or below the moving web with each nozzle exhausting gas at opposite directions.
• Each nozzle includes an elongated slot that is perpendicular to the path of the moving web.
• each Coanda nozzle incorporates an internal baffle that channels or restricts gas flow to a region along the same side as the curved surface of the nozzle, which is referred to as the nozzle's downstream side. The baffle apparently equalizes the internal gas pressure across the nozzle.
• the locations of the two Coanda nozzles serve as separate positions on the machine direction for controlling the height of the moving web.
• the contour of the web can be manipulated to exhibit a planar contour between the two Coanda nozzles to enable accurate thickness and other measurements.
• the air stabilization system's clamping capacity can be improved by optimizing the air pressure of the two exhausting gases so as to establish the requisite pressure region after each nozzle.
• the flag is typically a piece of plastic that is mounted on a mechanism that is employed to calibrate the sensor and to periodically check that the sensor is working properly. In operation, the flag is inserted into the measurement aperture and readings are taking off it.
• Figure IA is a cross sectional view of an embodiment of the air stabilizer system
• Figures IB and 1C are enlarged cross sectional views of Coanda nozzles
• Figures ID and IE are enlarged cross sectional views of baffles
• Figures IF and IG depict the baffles in operation
• Figure 2A depicts the sheet profile as it travels over the two Coanda nozzles and Figure 2B is a schematic depiction of the velocity profiles of the gas jets from the nozzles;
• Figure 3 is a perspective view of the air stabilizer system in dissembled form
• Figure 4 shows the air stabilizer system as part of a sensor head
• Figure 5 is a cross sectional schematic view of a caliper measurement device
• Figure 6A is a cross sectional view of an embodiment of the air stabilizer system with a flush operative surface
• Figures 6B and 6C are enlarged cross sectional views of Coanda nozzles
• Figure 7A is a graph of height of sheet around the mean height vs. scanner displacement
• Figure 7B is a graph of caliper profile vs. scanner displacement
• Figure 8A is a cross sectional view of an embodiment of the air stabilizer system with Coanda nozzles each with a backstep;
• Figures 8B and 8C are enlarged cross sectional views of Coanda nozzles
• Figure 9 is a cross sectional view of an embodiment of the air stabilizer system with a channel in the operative surface
• Figure 10 is a cross sectional view of an embodiment of the air stabilizer with a transparent smooth substrate on the operative surface
• Figure 11 is a cross sectional view of an embodiment of the air stabilizer with recess operative surface.
• FIG. IA illustrates an embodiment of the air stabilization system 10 that includes a stainless steel body that is segmented into a central region 12, lateral region 14A and lateral region 14B.
• Central region 12 has an operative surface 32 that is situated between Coanda nozzles 16A and 16B.
• Each nozzle is formed within a dome-shaped structure protruding from the base of the body so that the nozzles are elevated relative to operative surface 32.
• the dome structures preferably exhibit slope curvatures that extend along the length of the nozzles.
• the air stabilization system 10 is employed with a laser- triangulation displacement measuring device (not shown) that is positioned underneath.
• the laser beam incident on moving web 22 and the reflected light both pass through optical channel or orifice 20 that is formed in central region 12.
• the body further includes a lower portion 6 which supports central region 12 and baffle 17.
• Lower aperture 8 permits optical access between the caliper device and optical path channel 20.
• Plate member 17 has cantilever structures 17A and 17B which function as internal baffles as further described herein.
• the air stabilization system 10 is positioned underneath a web of material 22 which is moving from left to right relative to the system; this direction being referred to as the downstream machine direction (MD) and the opposite direction being the upstream machine direction.
• the cross direction (CD) is transverse to the MD.
• Upper lateral surfaces 34A and 34B are preferably coplanar with operative surface 32.
• the contour of web 22 as it travels over operative surface 32 can be controlled with the air stabilization system.
• the profile of web 22 is substantially planar.
• the vertical height between web 22 and operative surface 32 can be regulated by controlling the speed of the gases exhausting through Coanda nozzles 16A and 16B. The higher the speed of the gases, the greater the suction force generated by the nozzles that is applied to the web 22.
• the body of air stabilization system 10 further defines a chamber 18A that serves as an opening for Coanda nozzle 16A and a chamber 18B that serves as an opening for Coanda nozzle 16B.
• Baffle 17A separates chamber 18A from plenum chamber 4OA which in turn is connected to a source of gas 24A via conduit 30A.
• the gas flow rate into plenum 4OA can be regulated by conventional means including pressure controller 28A and flow regulator valve 26A.
• the length of chamber 4OA, as measured along the cross direction, preferably matches that of Coanda nozzle 16A.
• Plenum 4OA essentially serves as a reservoir in which high pressure gas equilibrates before being evenly distributed along the length of Coanda nozzle 16A via chamber 18A.
• baffle 17A serves to equalize the gas pressure in plenum 4OA across the nozzle.
• Conduit 3OA can include a single channel which connects the source of gas 24A to plenum 4OA; alternatively a plurality of holes drilled into the lower surface of the body can be employed. The plurality of holes should be spaced apart along the cross direction of the body in order to distribute gas evenly into plenum 4OA.
• chamber 18B is in gaseous communication with plenum chamber 4OB which is connected to a source of gas 24B via conduit 30B.
• Baffle 17B serves to equalize the gas pressure in plenum 4OB as well.
• Gas flowing into plenum 4OB is regulated by pressure controller 28B and flow regulator valve 26B.
• the configurations of chamber 4OB and conduit 30B are preferably the same as those of chamber 4OA and conduit 30B, respectively. In practice, the pressure is regulated so that the measured flow rates are the same.
• Any suitable gas can be employed in gas sources 24A and 24B including for example, air, helium, argon, carbon dioxide.
• the amount of gas employed is that which is sufficient to discharge the gas through the Coanda nozzles at a velocity of about 20 m/s to about 400 m/s.
• the air stabilization system can be employed to support a variety of flexible web products including paper, plastic, and the like.
• the web can travels at speeds of 200 m/min to 1800 m/min or higher.
• the air stabilization system preferably maintains paper web 22 at a distance ranging from about 100 ⁇ m to about 1000 ⁇ m above Coanda nozzles 16A and 16B.
• Coanda nozzle 16A has a nozzle opening 70 that is formed on a protruding structure having an upstream upper surface 72 and a downstream upper surface 74.
• Upstream surface 72 is configured as an accurately curved inner surface at nozzle opening 70 whereas downstream surface 74 presents a generally angled planar inner surface at nozzle opening 70.
• Gas emerging from nozzle opening 70 by virtue of the Coanda effect tends to follow a path along the curve of surface portion 72 and to travel upstream from right to left along upper lateral surface 34A. In the process, the surrounding gas is entrained in the air-flow emerging from nozzle opening 70.
• Coanda nozzle 16B with nozzle opening 60 is formed on a protruding structure having a downstream upper surface 62 and an upstream upper surface 64.
• Downstream surface 62 is configured as an accurately curved inner surface at nozzle opening 60 while upstream surface 64 presents a generally angled planar inner surface at nozzle opening 60.
• Gas emerging from nozzle opening 60 follows the curve of surface portion 62 and travels downstream from left to right and along upper lateral surface 34B. Surrounding gas is entrained in the air-flow emerging from nozzle opening 60 to create a suction force.
• FIG. IF depicts baffle 17A laterally extending toward the upstream machine direction side of nozzle 16 A.
• the distal end of baffle 17A is almost flush with the vertical inner wall.
• baffle 17B extends laterally toward the downstream machine direction side of nozzle 16B.
• pressurized gas from plenum chamber 4OA causes the flexible baffle 17A to bend at the edge as the gas is channeled upward along the wall and onto the curved face of Coanda nozzle 16A.
• Figure 1 G illustrates the same effect with respect to baffle 17B as pressurize gas from plenum chamber 4OB causes the flexible baffle 17B to bend at the edge as the gas is channeled upward along the wall and onto the curved face of Coanda nozzle 16B.
• Figure 2A shows a side view of sheet 22 as it passes over Coanda nozzles 16A and 16B, with each nozzle exhausting a jet of gas in opposite directions.
• the nozzles are set apart sufficiently to define a planar surface 32 between them.
• the sheet motion opposes the force imparted by upstream Coanda nozzle 16A, located at the web entry end, while the sheet motion is parallel to the force imparted by downstream Coanda nozzle 16B, located at the web exit end.
• the simultaneous opposing forces apply a tension on the moving sheet that creates the desired sheet profile between the nozzles as the sheet passes over the operative surface. The higher the air velocities from the dual nozzles, the greater the clamping force generated.
• the distance between moving web 22 and surface 32 can be correspondingly decreased or increased.
• the height of downstream Coanda nozzle 16B as measured from the operative surface to the nozzle, is typically the same as that of upstream Coanda nozzle 16A, their heights can be different.
• the sheet profile between the nozzles can be modified.
• the height of each Coanda nozzle ranges from 0.5 to 2.5 mm.
• Figure 2B shows the corresponding velocity profiles of the jets of gas exiting the Coanda nozzles.
• the sheet is moving at a slow speed relative to the speed of the gases exiting the nozzles.
• curve 1 depicts the gas velocity (V) profile along a vertical path or height (H) between Coanda nozzle 16A toward the sheet which is moving in the machine direction.
• the gas velocity decreases gradually and reverses direction at a position near the sheet.
• the gas velocity matches that of the web at the web's surface.
• curve 11 shows a gradual decrease in velocity from the nozzle to the moving web.
• the air stabilizing system can be constructed from five basic units that include a central body member 80, upper body member 46, plate member 17 and side supports 42, 44. They are attached together by conventional means including dowels and screws.
• the generally rectangular- shaped upper body member 46 has outer perimeters, at opposite ends, that define downstream upper surface 74 and upstream surface 64.
• a central region 12 has a measurement orifice 48 that serves as an optical path channel for a laser triangulation caliper device.
• Central body member 80 includes a middle portion 6 and lateral portions 14A and 14B and defines an opening 58 for access to the mounted device within orifice 48.
• the inward facing edge of lateral portion 14A defines upstream upper surface 72 and the inward facing edge of lateral portion 14B defines downstream upper surface 62.
• Plate 17 is preferably constructed of metal such as stainless steel, brass or aluminum that typically ranges from 75 to 125 microns thick with corresponding opening 57.
• the size of the metal sheet is dimensioned to preferably fill the entire space between the gas inlet and exit nozzle on each side of the air clamp (while leaving enough room so that the edges do not catch on the vertical faces below 62 and 72.).
• the air stabilizing system is formed by securing upper body member 46 onto central body member 80, with plate 17 situated between them, so that the upper lateral surfaces 34A and 34B are coplanar with the surface of upper body member 46.
• Side supports 42 and 44 seal the internal plenums and chambers.
• the air stabilization system can be incorporated into on-line dual head scanning sensor systems for papermaking machines which are disclosed in U.S. Patent Nos. 4,879,471 to Dahlquist, 5,094,535 to Dahlquist et al., and 5,166,748 to Dahlquist, all of which are incorporated herein by reference.
• the width of the paper in the papermaking machines generally ranges from 5 to 12 meters and typically is about 9 meters.
• the dual heads which are designed for synchronized movement, consist of an upper head positioned above the sheet and a lower head positioned below the sheet.
• the air stabilization system which is preferably mounted on the lower head, clamps the moving paper to cause it to exhibit an essentially flat sheet profile for measurement as the upper and lower heads travel back and forth in the cross direction over the width of the paper.
• the air clamp can be located in the lower or upper head of a scanning sensor.
• Figure 4 shows an air stabilization system that is incorporated into a recessed compartment within substrate 52 that is part of head 50 of a scanning sensor.
• Measurement orifice 48 is situated between Coanda nozzles 16A and 16B.
• Substrate 52 is positioned so that a web product travels over the air stabilization system in machine direction 54 which is transverse to the lengths of the elongated Coanda nozzles.
• Non-contacting caliper sensors such as those disclosed in U.S. Patent 6,281,679 to King et al., which is incorporated herein by reference, include upper and lower heads equipped with laser triangulation devices. The caliper of a moving sheet that travels between the two heads is determined by identifying the positions of the upper and lower surfaces of the sheet with the laser triangulation devices and subtracting the results from a measure of the separation between the upper and lower heads.
• Figure 5 illustrates a representative non-contacting caliper sensor system that includes first and second scanner heads 13 and 15 respectively, which contain various sensor devices for measuring qualities, characteristics, or features of a moving web of material identified as 3. Heads 13 and 15 lie on opposite sides of web or sheet 3, and, if the measurement is to be performed in a scanning manner across the web in the cross direction, the heads are aligned to travel directly across from each other as they traverse the moving web which is moving in the machine direction.
• a first source/detector 4 is located in first head 13.
• a second source/detector 5 is located in second head 15.
• Source/detectors 4 and 5 comprise closely-spaced first and second sources 4a and 5 a, respectively, and first and second detectors 4b and 5b, respectively, arranged so that measurement energy from first source 4a and interacting with a first surface of web 3 will return, at least in part to first detector 4b, and measurement energy from second source 5a and interacting with the opposite, or second surface, of web 3 will return, at least in part to second detector 5b.
• the source and detector preferably comprise a laser triangulation source and detector, collectively being referred to as an interrogation laser.
• the source/detector arrangement is referred to generally as a distance determining means. From the measured path length from the source to the detector, values for the distance between each distance determining means and a measurement or interrogation spot on one of the web surfaces may be determined.
• the heads 13 and 15 are typically fixed in the position so that the interrogations spots do not move in the machine direction even as the heads are scanned in the cross direction.
• first distance determining means 4 the detected distance value between the distance determining means and a first measurement spot on the web surface (referred to as and for second distance determining means 5, the detected distance value between the distance determining means and a second measurement spot on the opposite web surface (referred to as / 2 ).
• the first and second measurement spots are preferably at the same point in the x-y plane, but on opposite sides of the web, i.e. the measurement spots will be separated by the web thickness. In an ideal static situation, the separation, s, between first and second distance determining means 4 and 5 would be fixed, resulting in a calculated value for web thickness, t, of: t - s - (Zi + / 2 ).
• separation s can vary.
• a dynamic measurement of the spacing between the scanning heads is provided by a z-sensor means, which measures a distance z, between a z-sensor source/detector 6, located in the first head 13, and a z-sensor reference 7, located in the second head 15.
• FIG. 6A illustrates an embodiment of the air stabilization system 110 with a smooth, flush operative surface, supporting moving web 22.
• the stabilizer includes a body that is segmented into a central region 12, lateral region 14A and lateral region 14B.
• Central region 12 has an operative surface 132 that is situated between Coanda nozzles 116A and 116B, which are in gaseous communication with chambers 18A and 18B, respectively.
• Coanda nozzles 116A and 116B exhaust jets of gas in opposite directions.
• the internal gas flows in the nozzles are restricted by baffles 17A and 17B of plate 17, respectively.
• Independently regulated sources of pressurized gas which are described above for the air stabilization system 10 of Figure IA, can be employed and are connected to chamber 18A and 18B.
• Central region 12 defines an optical channel 20 whose upper surface is flush with operative surface 132 and is part of the operative surface 132.
• the body further includes a lower portion 6 which supports central region 12.
• Aperture 8 permits access to optical channel 20.
• Upper lateral surfaces 134A and 134B are preferably coplanar with operative surface 132 to define a smooth flush surface over the body.
• Coanda nozzle 116A has a Coanda slot 170 between upper surface 134A and operative surface 132.
• Coanda slot 170 has a curved convex surface 172 on its downstream side.
• this surface has a radius of curvature (R) ranging from about 1.0 mm to about 10 mm.
• Gas flow from Coanda slot 170 follows the downstream trajectory of curved surface 172, so as to flow in the upstream MD relative to the moving web.
• slot 170 has a width (w) of about 3 mils (76 ⁇ m) to about 5 mils (127 ⁇ m).
• the air clamp's suction force draws the web closer to the stabilizer as the web approaches the stabilizer. However, the web should not be permitted to get too close to the nozzles as this would actually cut off gas flow from the nozzles. This would cause the local pressure to rise and the increase force would push to web away from the stabilizer.
• Coanda nozzle 116B has a Coanda slot 160 between upper surface 134B and operative surface 132.
• Coanda slot 160 has a curved convex surface 162 on its downstream side. Gas flow from the Coanda slot 160 follows the downstream trajectory of curved surface 162 so as to flow in the downstream MD.
• the dimensions of Coanda nozzle 116B can be the same as those of Coanda nozzle 116A.
• a stainless steel air clamp stabilizer having the configuration shown in Figures 6A, 6B and 6C was incorporated into a laser triangulation scanning sensor.
• Each of the two Coanda nozzles had a slot having a width (w) of 0.1 mm and a curvature radius (R) of 1.5 mm.
• the nozzles were approximately 43 mm apart as measured from the center of each nozzle slot.
• the air clamp was employed to support a moving web of paper that was traveling at about 1500 m/min and had a basis weight of 45 grams per square meter (gsm).
• the term "basis weight” refers to the mass or weight per unit area of the paper.
• the distance between the upper surface of the paper and the center of the operative surface of the air stabilizer was measured as the sensor was scanned across the 8.5 m sheet with a laser triangulation sensor as the paper sheet moved horizontally over the surface of the air clamp stabilizer.
• Figure 7A depicts the height of the sheet around the mean distance vs. the scanner displacement or position in the cross direction of the moving sheet. The curve shows that the sheet contour is substantially flat; the 2-sigma variation in the sheet height is 2.7 microns.
• Figure 7B depicts the corresponding laser caliper profile derived from 10 cross direction scans from one side of the paper to the other.
• FIG 8A illustrates an embodiment of the air stabilization system 210 that incorporates opposite-facing nozzles that are configured with backsteps that increase the suction force which is applied to moving web 22.
• the stabilizer includes a body that is segmented into a central region 12, lateral region 14A and lateral region 14B.
• Central region 12 has an operative surface 232 that is situated between Coanda nozzles 216A and 216B, which are in gaseous communication with chambers 18A and 18B, respectively.
• Coanda nozzles 216A and 216B exhaust jets of gas in opposite directions toward surface 234A and 234B, respectively, which are downstream of the backstep features of nozzles.
• baffles 17A and 17B of plate 17 again equalizes the gas pressure in the plenum chambers.
• Independently regulated sources of pressurized gas which are described above for the air stabilization system 10 of Figure IA, can be employed and are connected to chamber 18A and 18B.
• Central region 12 includes an optical channel 20.
• the body further includes a lower portion 6 which supports central region 12.
• Aperture 8 permits access to optical channel 20.
• Coanda nozzle 216A has a Coanda slot 270 between upper surface 274 and operative surface 232 which are preferably coplanar.
• Coanda slot 270 has a curved convex surface 272 on its downstream side.
• this surface has a radius of curvature (R) ranging from about 1.0 mm to about 10 mm, and in one embodiment it is about 1.6 mm.
• Airflow from the Coanda slot 270 follows the trajectory of the curved surface 272.
• the term "backstep" is meant to encompass a depression on the stabilizer surface located a distance downstream from Coanda slot 270 preferably sufficient to create a vortex. The combination of the Coanda slot and backstep generates an amplified suction force and an extensive air bearing.
• backstep 220 allows a Coanda jet to expand and create an additional suction force.
• jet expansion is necessary to create the suction force but vortex formation is not a prerequisite. Indeed, vortex formation does not always occur downstream from the backstep and is not necessary for operation of the air clamp stabilizer.
• the stabilizer's suction force initially draws the web closer to the stabilizer as the web approaches the stabilizer. Subsequently, the air bearing supports and reshapes the web so that the web exhibits a relatively flat profile as it passes over the backstep.
• Coanda slot 270 has a width (b) of about 3 mils (76 ⁇ m) to 5 about mils (127 ⁇ m).
• the backstep location (L) is about 1 mm to about 6 mm and preferably about 2 mm to 3 from Coanda slot 270.
• Coanda nozzle 216B has a Coanda slot 260 between upper surface 264 and operative surface 232.
• Coanda slot 260 has a curved surface 262 on its downstream side.
• the dimensions of structures forming Coanda nozzle 216B, including backstep 230 and lower surface 234B, can be the same as those for Coanda nozzle 216A.
• Figure 9 illustrates an embodiment of air stabilization system 310 wherein the operative surface 332 is located on the lower surface of channel 336 that is formed in the body of the stabilizer.
• operative surface 332 is located farther away from moving web 22 to reduce the likelihood that web 22 comes into contact with operative surface 332.
• the stabilizer includes a body that is segmented into a central region 12, lateral region 14A, with upper surface 334A, and lateral region 14B, with upper surface 334B.
• Plate 17 forms baffles 17A and 17B.
• Central region 12 has an optical operative surface 332 that is situated between opposite facing Coanda nozzles 316A and 316B, which are in gaseous communication with chambers 18A and 18B, respectively.
• Central region 12 defines an optical channel 20.
• the depth of channel 334 within central region 12 can range from 1400 ⁇ m to 2000 ⁇ m or more.
• the remaining structures of the stabilizer can be same as those illustrated in Figure 6A; however, it is understood that a channel can be incorporated into any air stabilization system described above to provide additional clearance between the moving web and operative surface.
• Figure 10 illustrates the air stabilization system of Figure 9 with a transparent substrate 420, such as glass, inserted within channel 334 in order to cover optical channel 20.
• Substrate 420 prevents debris from accumulating within optical channel 20 which can adversely affect sensor measurements and distort the web profile.
• Upper surface 432 of substrate 420 which presents a smooth surface, eliminates these potential problems.
• Transparent substrates can also be employed with any of the air stabilization systems described above.
• Upper surface 432 is preferably coplanar with upper surfaces 334A and 334B so that the surfaces of the stabilizer are flush.
• Plate 17 forms baffles 17A and 17B.
• Figure 11 illustrates an embodiment of air stabilization system 510 that includes a body that is segmented into a central region 12, lateral region 14A, with upper surface 334A, and lateral region 14B, with upper surface 334B.
• Upper surfaces 334A and 334B are preferably parallel and coplanar.
• Central region 12 is set back so that central operative surface 532 is farther away from moving web 22, than are upper surfaces 334A and 334B, to reduce the likelihood that web 22 comes into contact with operative surface 532.
• Plate 17 forms baffles 17A and 17B.
• Central operative surface 532 is preferably about 0.025 in. (0.64 mm) to 0.011 in.

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• 2009
  • 2009-08-25 US US12/547,323 patent/US8083896B2/en active Active
  • 2009-09-16 EP EP09816712.5A patent/EP2326583B1/en active Active
  • 2009-09-16 JP JP2011529116A patent/JP5466706B2/ja active Active
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