A biomass tray forming mold and forming method

Abstract

The present invention provides a forming mold for a biomass tray, comprising an outer template, a culture plate and an inner template; the outer template is provided with at least one U-shaped cavity for loading biomass raw materials, the inner template is provided with first protrusions whose number matches the number of the U-shaped cavity, and the culture plate is provided with first holes whose number and shape match the number and shape of the first protrusions; when the biomass raw materials are extruded, the culture plate is located between the outer template and the inner template, and the first protrusions passing through the first holes are placed in the U-shaped cavity; after the biomass raw materials are extruded and formed, the biomass raw materials are placed on the culture plate, and the outer template and the inner template are separated from the culture plate. By changing the mold structure and the forming and culture method of the biomass tray, the time that the biomass tray occupies the entire mold is reduced, the reuse efficiency of the mold is greatly improved, and the total production cost of the biomass tray is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of biomass disc processing and forming, and in particular to a biomass disc forming die and a forming method. Background Art

[0002] When agricultural waste such as straw is used to inoculate fungi to grow into materials of a specific shape, molds are usually required. However, before the fungal mycelium is formed in large quantities, the culture material is in granular form and there is no stickiness between the particles, so it needs to be cultured in the mold for about a week. If mass production is required, a large number of molds are required, which has high investment costs and greatly increases the production cost of biomass trays, limiting the application and development of biomass trays. Summary of the invention

[0003] The technical problem to be solved by the present invention is to reduce the production cost of biomass discs.

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0005] A forming mold for a biomass disk comprises an outer template, a culture plate and an inner template; the outer template is provided with at least one U-shaped cavity for loading biomass raw materials, the inner template is provided with first protrusions whose number matches the number of the U-shaped cavities, and the culture plate is provided with first holes whose number and shape match the number and shape of the first protrusions; when the biomass raw materials are extruded, the culture plate is located between the outer template and the inner template, and the first protrusions passing through the first holes are placed in the U-shaped cavity; after the biomass raw materials are extruded and formed, the biomass raw materials are placed on the culture plate, and the outer template and the inner template are separated from the culture plate.

[0006] Furthermore, the distance from the opening connection between the two U-shaped cavities to the side of the outer template close to the culture plate is A, and the depth of the U-shaped cavity is B, wherein 0.2 cm ≤ A ≤ 0.6B.

[0007] Furthermore, it also includes a stripping plate, on which is arranged second protrusions whose number matches the number of the U-shaped cavities; the bottom of the U-shaped cavity is provided with second holes whose shapes match the second protrusions; when the second protrusions passing through the second holes press against the formed biomass raw material, the outer template is separated from the culture plate by moving upward.

[0008] Furthermore, it also includes a first supporting plate, on which are arranged third holes whose positions and numbers match the number of the second holes, and the aperture of the third holes is smaller than the aperture of the second holes; the first protrusion is conical; when the biomass raw material is extruded, the outer template is located between the culture plate and the first supporting plate, and the tip of the first protrusion is placed in the third hole.

[0009] Furthermore, it also includes a second supporting plate, on which is provided a fourth hole whose shape and number match the shape and number of the first protrusions; when the biomass raw material is extruded, the second supporting plate is located between the culture plate and the inner template, and the first protrusion that passes through the fourth hole and the first hole in sequence is placed in the U-shaped cavity.

[0010] Furthermore, first limit blocks for preventing relative movement between the outer template and the first loading plate are arranged on the four edges of the first loading plate, and second limit blocks for preventing relative movement between the outer template and the second loading plate are arranged on the four edges of the second loading plate.

[0011] Furthermore, it also includes a robotic arm, a gripper for driving the outer template to move upward is provided at the front end of the robotic arm; the stripping template is provided with a fifth hole whose shape and number match the shape and number of the gripper, and the gripper passing through the fifth hole is fixed to the outer template.

[0012] Furthermore, the robot arm is also provided with a first cylinder for driving the robot arm and a second cylinder for driving the gripper, the second cylinder is fixed on the stripping plate, and the second protrusion and the second cylinder are separated on both sides of the stripping plate.

[0013] Furthermore, the gripper is a suction cup connected to an air pump.

[0014] Or further, the gripper is an electromagnet, and an iron block matching the electromagnet is provided on the stripping plate.

[0015] A biomass disk molding method, using the above-mentioned biomass disk molding die, the molding method comprises the following steps:

[0016] S1: Place the outer template on the operating table with the U-shaped cavity opening facing upwards;

[0017] S2: Fill the outer template with biomass raw materials and compact them until the upper surface of the biomass raw materials is flush with the edge of the outer template;

[0018] S3: stacking the culture plate and the inner template in sequence; the first protrusion passes through the first hole and then squeezes the biomass raw material;

[0019] S4: Remove the inner template, turn the remaining components 180 degrees, and place the culture plate on the operating table;

[0020] S5: Move the stripping plate so that its second protrusion passes through the second hole and presses against the biomass raw material; lift the outer template to separate it from the biomass raw material, lift the culture plate loaded with the biomass raw material and transfer it to the culture room for culture.

[0021] Furthermore, in step S1, before placing the outer template, the first carrier plate is first placed on the operating table with the side where the first limit block is located facing upward, and then the outer template is placed on the first carrier plate; in S3, a second carrier plate is stacked between the culture plate and the inner template, with the side where the second limit block of the second carrier plate is located facing downward and the culture plate and the outer template are clamped; the first protrusion passes through the fourth hole and the first hole in turn and squeezes the biomass raw material until the tip of the first protrusion reaches the third hole; in step S4, after flipping, the second carrier plate contacts the operating table, and then the first carrier plate needs to be removed.

[0022] The beneficial effects of the present invention are as follows: after the biomass raw materials used to form the biomass tray are extruded and formed, the outer template and the inner template are removed, and the biomass raw materials are placed on a culture plate and cultured until they are covered with mycelium. During the molding process, the culture plate is placed between the outer template and the inner template, which facilitates the removal of the outer template and the inner template and the transportation of the biomass raw materials to the culture room. When the mold is used to make a biomass tray, a mode of separating the molding and the culture process is adopted, which does not require the outer template and the inner template to be occupied for a week, and only takes 1-2 minutes; only one culture plate is required, and the culture plate uses less material and is easy to make, which greatly improves the reuse efficiency of the mold and reduces the total production cost of the biomass tray. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The specific structure of the present invention is described in detail below with reference to the accompanying drawings

[0024] Figure 1 It is a schematic diagram of the stacking order of the partial structures of a forming mold of a biomass disk of the present invention;

[0025] Figure 2 A schematic diagram of a biomass tray forming mold of the present invention after being filled with biomass raw materials and then an inner mold plate is inserted;

[0026] Figure 3 It is a schematic diagram of a state in which the outer template in a forming mold of a biomass disk of the present invention is lifted;

[0027] Figure 4 It is an exploded view of the structure of each layer when the outer template in the forming mold of a biomass tray of the present invention is lifted;

[0028] Among them, 1-first supporting plate, 11-third hole, 12-first limiting block; 2-external template, 21-U-shaped cavity, 22-second hole; 3-culture plate, 31-first hole; 4-second supporting plate, 41-fourth hole, 42-second limiting block; 5-inner template, 51-first protrusion; 6-stripping template, 61-second protrusion, 62-fifth hole; 7-mechanical arm, 71-gripper, 72-second cylinder; 8-biomass raw material. DETAILED DESCRIPTION

[0029] The most critical concept of the present invention is to reduce the time that the biomass tray occupies the entire mold by changing the mold structure and the molding and cultivation method of the biomass tray, thereby achieving the purpose of reducing the production cost of the biomass tray.

[0030] In order to further discuss the feasibility of the concept of the present invention, specific implementation methods according to the technical content, structural features, achieved objectives and effects of the present invention are described in detail with reference to the accompanying drawings.

[0031] Example 1

[0032] See also Figure 1 as well as Figure 2 A forming mold for a biomass disk comprises an outer template 2, a culture plate 3 and an inner template 5; the outer template 2 is provided with at least one U-shaped cavity 21 for loading a biomass raw material 8, the inner template 5 is provided with first protrusions 51 whose number matches the number of the U-shaped cavities 21, and the culture plate 3 is provided with first holes 31 whose number and shape match the number and shape of the first protrusions 51; when the biomass raw material 8 is extruded, the culture plate 3 is located between the outer template 2 and the inner template 5, and the first protrusion 51 passing through the first hole 31 is placed in the U-shaped cavity 21; after the biomass raw material 8 is extruded and formed, the biomass raw material 8 is placed on the culture plate 3, and the outer template 2 and the inner template 5 are separated from the culture plate 3.

[0033] After the biomass raw material 8 used to form the biomass tray is extruded and formed, the outer template 2 and the inner template 5 are removed, and the biomass raw material 8 is placed on the culture plate 3 and cultured until it is full of mycelium. During the molding process, the culture plate 3 is placed between the outer template 2 and the inner template 5, which is convenient for molding and removing the outer template 2 and the inner template 5 and then transporting the biomass raw material 8 to the culture room. When using this mold to make a biomass tray, a mode of separating the molding and the culture process is adopted, which does not require the outer template 2 and the inner template 5 to occupy a week, and only takes 1-2 minutes; only one culture plate 3 is required, and the culture plate 3 uses less material and is easy to make, which greatly improves the reuse efficiency of the mold and reduces the total production cost of the biomass tray.

[0034] Example 2

[0035] Based on the above structure, the distance from the opening connection between the two U-shaped cavities 21 to the side of the outer template 2 close to the culture plate 3 is A, and the depth of the U-shaped cavity 21 is B, wherein 0.2cm≤A≤0.6B. When the outer template 2 is filled with biomass raw materials 8, the upper surface of the biomass raw materials 8 is flush with the edge of the outer template 2. When the number of U-shaped cavities 21 is greater than or equal to 2, and the distance from the connection between the opening positions of two adjacent U-shaped cavities 21 to the side of the outer template 2 close to the culture plate 3 is greater than or equal to 0.2cm, the biomass raw materials 8 between each U-shaped cavity 21 are connected, and after the biomass disk is formed, each disk hole is connected to form a whole.

[0036] Example 3

[0037] Based on the above structure, please refer to Figure 3 as well as Figure 4 , further comprising a stripping plate 6, on which the stripping plate 6 is provided with second protrusions 61 whose number matches the number of the U-shaped cavities 21; the bottom of the U-shaped cavity is provided with second holes 22 whose shape matches the second protrusions 61; when the second protrusions 61 passing through the second holes 22 abut against the formed biomass raw material 8, the outer template 2 is separated from the culture plate 3 by moving upward. The second protrusions 61, on the one hand, are used to abut against the formed biomass raw material 8 to facilitate the separation of the biomass raw material 8 from the outer template 2, and on the other hand, they also have a guiding function to prevent the outer contour of the formed biomass raw material 8 from being damaged during the separation process of the outer template 2.

[0038] Example 4

[0039] Based on the above structure, it also includes a first supporting plate 1, on which are arranged third holes 11 whose positions and number match the number of the second holes 22, and the aperture of the third hole 11 is smaller than the aperture of the second hole 22, so as to prevent the biomass raw material 8 at the bottom of the U-shaped cavity from being squeezed out when the first protrusion 51 squeezes the biomass raw material 8; the first protrusion 51 is conical; when the biomass raw material 8 is squeezed, the outer template 2 is located between the culture plate 3 and the first supporting plate 1, and the tip of the first protrusion 51 is placed in the third hole 11, so as to ensure that a through hole is formed at the bottom of the cavity of the formed biomass disk.

[0040] Example 5

[0041] On the basis of the above structure, a second carrier plate 4 is further included, on which a fourth hole 41 is provided, the shape and number of which match the shape and number of the first protrusion 51; when the biomass raw material 8 is squeezed, the second carrier plate 4 is located between the culture plate 3 and the inner template 5, and the first protrusion 51 that passes through the fourth hole 41 and the first hole 31 in sequence is placed in the U-shaped cavity 21. In order to save costs, the culture plate 3 is made thinner, but the first protrusion 51 needs to apply a large pressure to the biomass raw material 8 when squeezing, and the second carrier plate 4 can prevent the biomass raw material 8 from overflowing the outer template 2 during squeezing, and prevent the biomass disc from deforming.

[0042] Example 6

[0043] On the basis of the above structure, first limit blocks 12 for preventing relative movement between the outer template 2 and the first support plate 1 are arranged on the four edges of the first support plate 1, and second limit blocks 42 for preventing relative movement between the outer template 2 and the second support plate 4 are arranged on the four edges of the second support plate 4, so as to ensure that the first hole 31, the second hole 22, the third hole 11 and the fourth hole 41 are concentric from beginning to end during the insertion process of the inner template 5, so that the biomass disk produced is always consistent and square, and the through hole at the bottom of the disk cavity of the biomass disk is formed.

[0044] Example 7

[0045] On the basis of the above structure, it further comprises a mechanical arm 7, the front end of which is provided with a gripper 71 for driving the outer template 2 to move upward; the stripping plate 6 is provided with fifth holes 62 whose shape and number match those of the gripper 71, and the gripper 71 passing through the fifth holes 62 is fixed to the outer template 2. Mechanized operation is used to reduce manpower input.

[0046] Example 8

[0047] On the basis of the above structure, the robot arm 7 is further provided with a first cylinder for driving the robot arm 7 and a second cylinder 72 for driving the gripper 71. The second cylinder 72 is fixed on the stripping plate 6, and the second protrusion 61 and the second cylinder 72 are separated on both sides of the stripping plate 6. The front end of the robot arm 7 is fixed to the stripping plate 6. During demoulding, driven by the first cylinder, the robot arm 7 moves the stripping plate 6, the second cylinder 72 and the gripper 71 above the outer template 2 until the second protrusion 61 abuts against the formed biomass raw material 8. At this time, the second cylinder 72 starts and drives the gripper 71. The gripper 71 grabs the outer template 2 and lifts it upward, so that the outer template 2 is separated from the biomass raw material 8, the culture plate 3 and the second carrier plate 4.

[0048] Example 9

[0049] Based on the above structure, the gripper 71 is a suction cup connected to an air pump. When the suction cup is attached to the outer template 2, the gripper 71 can grasp the outer template 2 due to the negative pressure inside the suction cup; after the negative pressure is removed, the gripper 71 can be moved to separate from the outer template 2.

[0050] Example 10

[0051] Based on the structure of the above-mentioned embodiment 8, the gripper 71 is an electromagnet, and an iron block matching the electromagnet is provided on the stripper plate 2. When the electromagnet is attached to the outer plate 2, the gripper 71 can grasp the outer plate 2 due to the magnetic force generated by the electromagnet when it is powered on; after the power is turned off, the gripper 71 can be moved to separate from the outer plate 2.

[0052] In Example 9 or Example 10, in order to improve the stability when moving the outer template 2, corresponding gripper working positions are set at the four corners of the outer template 2, and the corresponding grippers 71 are driven by the same second cylinder 72 - the grippers 71 are all fixed on the same gripper fixing plate, and the second cylinder 72 indirectly drives the grippers 71 by driving the gripper fixing plate; at the same time, in order to reduce the weight of the outer template 2 and facilitate the moving of the outer template 2, the plate material on the outer template 2 that deviates from the U-shaped cavity 21 is removed, so as to achieve the effect of reducing the weight of the outer template 2 without affecting the mold forming function.

[0053] Embodiment 11

[0054] A biomass disk molding method, using the above-mentioned biomass disk molding die, the molding method comprises the following steps:

[0055] S1: placing the first carrying plate 1 on the operating table, with the side where the first limit block 12 is located facing upward; placing the outer template 2 on the first carrying plate 1, with the opening of the U-shaped cavity 21 facing upward;

[0056] S2: Fill the outer template 2 with biomass raw materials 8 and compact them until the upper surface of the biomass raw materials 8 is flush with the edge of the outer template 2;

[0057] S3: stacking the culture plate 3, the second carrier plate 4 and the inner template 5 in sequence, with the side where the second limit block 42 of the second carrier plate 4 is located facing downward and clamping the culture plate 3 and the outer template 2; the first protrusion 51 passes through the fourth hole 41 and the first hole 31 in sequence and then squeezes the biomass raw material 8 until the tip of the first protrusion 51 reaches the third hole 11;

[0058] S4: Remove the inner template 5, turn the remaining components 180 degrees, make the second carrier plate 4 contact with the operating table, and remove the first carrier plate 1;

[0059] S5: Move the stripping plate 6 so that its second protrusion 61 passes through the second hole 22 and abuts against the biomass raw material 8; lift the outer template 2 to separate it from the biomass raw material 8, lift the culture plate 3 loaded with the biomass raw material 8 and transfer it to the culture room for culture.

[0060] During the cultivation process, the cultivation method does not occupy the outer template 2 and the inner template 5 in the mold, nor does it occupy the first carrier plate 1 and the second carrier plate 4. It only occupies one cultivation plate 3, thereby realizing the separation of the molding and cultivation processes and reducing the production cost of the biomass tray.

[0061] Example 12

[0062] A biomass disk molding method, using the above-mentioned biomass disk molding die, the molding method comprises the following steps:

[0063] S1: Place the outer template 2 on the operating table with the opening of the U-shaped cavity 21 facing upwards;

[0064] S2: Fill the outer template 2 with biomass raw materials 8 and compact them until the upper surface of the biomass raw materials 8 is flush with the edge of the outer template 2;

[0065] S3: stacking the culture plate 3 and the inner template 5 in sequence; the first protrusion 51 passes through the first hole 31 and squeezes the biomass raw material 8;

[0066] S4: Remove the inner template 5, turn the remaining components 180°, and place the culture plate 3 on the operating table;

[0067] S5: Move the stripping plate 6 so that its second protrusion 61 passes through the second hole 22 and abuts against the biomass raw material 8; lift the outer template 2 to separate it from the biomass raw material 8, lift the culture plate 3 loaded with the biomass raw material 8 and transfer it to the culture room for culture.

[0068] In this embodiment, the culture plate 3 is made thicker, and a third stopper may be provided on the side close to the outer template 2 if necessary to prevent relative movement between the culture plate 3 and the outer template 2 during the insertion of the inner template 5. After the biomass raw material 8 is cultured to form a biomass disk, the bottom of the disk hole can be punched.

[0069] In summary, in a forming mold and forming method of a biomass tray provided by the present invention, the outer template and the inner template are removed after the biomass raw material for forming the biomass tray is extruded and formed, and the biomass raw material is placed on a culture plate and cultured until it is full of mycelium. During the forming process, the culture plate is placed between the outer template and the inner template, which is convenient for carrying the biomass raw material to the culture chamber after the outer template and the inner template are removed. When the mold is used to make a biomass tray, a mode of separating the forming and culture processes is adopted, which does not require the outer template and the inner template to be occupied for a week, and only requires 1-2 minutes; only one culture plate is required, and the culture plate requires less material and is easy to make, which greatly improves the reuse efficiency of the mold and reduces the total production cost of the biomass tray. The demoulding process can be mechanized to reduce labor cost investment. The biomass tray obtained by culture is no different from the biomass tray obtained by the traditional formula method, and the qualified rate of the finished product is 100%.

[0070] Here, the first, second... only represent the distinction in their names, and do not represent any difference in their importance and position.

[0071] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A biomass tray forming mold, characterized in that: It comprises an outer template, a culture plate and an inner template; the outer template is provided with at least one U-shaped cavity for loading biomass raw materials, the inner template is provided with first protrusions whose number matches the number of the U-shaped cavities, and the culture plate is provided with first holes whose number and shape match the number and shape of the first protrusions; When the biomass raw material is extruded, the culture plate is located between the outer template and the inner template, and the first protrusion passing through the first hole is placed in the U-shaped cavity; after the biomass raw material is extruded and formed, the biomass raw material is placed on the culture plate, and the outer template and the inner template are separated from the culture plate; It also includes a stripping plate, on which is arranged second protrusions whose number matches the number of the U-shaped cavities; a second hole whose shape matches the second protrusion is arranged at the bottom of the U-shaped cavity; when the second protrusion passing through the second hole presses against the formed biomass raw material, the outer template is separated from the culture plate by moving upward.

2. The biomass tray forming mold according to claim 1, characterized in that: The distance from the opening connection between the two U-shaped cavities to the side of the outer template close to the culture plate is A, and the depth of the U-shaped cavity is B, wherein 0.2 cm ≤ A ≤ 0.6B.

3. The biomass disk forming mold according to claim 1, characterized in that: It also includes a first supporting plate, on which are arranged third holes whose positions and numbers match the number of the second holes, and whose apertures are smaller than those of the second holes; the first protrusions are conical; when the biomass raw material is squeezed, the outer template is located between the culture plate and the first supporting plate, and the tip of the first protrusion is placed in the third hole.

4. The biomass tray forming mold according to claim 3, characterized in that: Also included is a second carrier plate, on which a fourth hole having a shape and number matching the shape and number of the first protrusions is disposed; When the biomass raw material is extruded, the second supporting plate is located between the culture plate and the inner template, and the first protrusion passes through the fourth hole and the first hole in sequence and is placed in the U-shaped cavity.

5. The biomass tray forming mold according to claim 4, characterized in that: First limit blocks for preventing relative movement between the outer template and the first loading plate are arranged on the four edges of the first loading plate, and second limit blocks for preventing relative movement between the outer template and the second loading plate are arranged on the four edges of the second loading plate.

6. The biomass disk forming mold according to any one of claims 3 to 5, characterized in that: It also includes a mechanical arm, a gripper for driving the outer template to move upward is arranged at the front end of the mechanical arm; the stripping plate is provided with a fifth hole whose shape and number match the shape and number of the gripper, and the gripper passing through the fifth hole is fixed to the outer template.

7. The biomass tray forming mold according to claim 6, characterized in that: The robot arm is also provided with a first cylinder for driving the robot arm and a second cylinder for driving the gripper, the second cylinder is fixed on the stripping plate, and the second protrusion and the second cylinder are separated on both sides of the stripping plate.

8. The biomass tray forming mold according to claim 7, characterized in that: The gripper is a suction cup connected to an air pump; or the gripper is an electromagnet, and an iron block matching the electromagnet is arranged on the stripping plate.

9. A method for forming a biomass disk, characterized in that: Using the biomass disc forming mold according to any one of claims 5 to 8, the forming method comprises the following steps: S1: placing a first carrying plate on an operating table, with the side where the first limit block is located facing upward; placing an outer template on the first carrying plate, with the opening of the U-shaped cavity facing upward; S2: Fill the outer template with biomass raw materials and compact them until the upper surface of the biomass raw materials is flush with the edge of the outer template; S3: stacking the culture plate, the second supporting plate and the inner template in sequence, with the side of the second supporting plate where the second stop block is located facing downward and clamping the culture plate and the outer template; the first protrusion passes through the fourth hole and the first hole in sequence and then squeezes the biomass raw material until the tip of the first protrusion reaches the third hole; S4: remove the inner template, turn the remaining components 180 degrees, place the second carrier plate on the operating table, and remove the first carrier plate; S5: Move the stripping plate so that its second protrusion passes through the second hole and presses against the biomass raw material; lift the outer template to separate it from the biomass raw material, lift the culture plate loaded with the biomass raw material and transfer it to the culture room for culture.

Images