A three-dimensional fiber block article obtainable by molding of a fiber blank
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Solution Overview
Problem
Existing fiber block molding processes face challenges in achieving efficient manufacturing of molded cushion members with pre-defined fiber orientation, which results in varying resilient properties and lower mechanical resistance in certain directions, and require longer cycle times due to difficulties in handling and positioning fiber blanks with fibers arranged perpendicularly to the mold.
Innovation Solution
A fiber block molding apparatus and process that utilizes a mold with cooling mechanisms and a conveyor system to rapidly cool and position heated fiber blanks with thermally activated binding agents, allowing for efficient molding of three-dimensional fiber block articles with fibers arranged perpendicularly to the longitudinal extension, thereby enhancing resilient properties and reducing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber blanks with pre-defined fiber orientation are used to provide varying resilient properties, then cushion comfort is improved, but mechanical resistance in certain directions deteriorates
Solution Approach 1:
The fiber blank is divided into multiple layers with different fiber orientations. The first layer has fibers oriented in a first direction while the second layer has fibers oriented in a second direction perpendicular to the first direction, creating an isotropic structure that provides balanced mechanical properties in all directions while maintaining cushion comfort
Solution Approach 2:
The invention uses asymmetric layering where the first and second layers have different fiber orientations perpendicular to each other. This asymmetric arrangement in layers creates overall isotropic behavior in the cushion member, resolving the contradiction between directional comfort and mechanical resistance
2Reliability
If fiber blanks are positioned in mold with perpendicular fiber arrangement, then resilient properties in load direction are improved, but handling difficulty increases
Solution Approach 1:
The fiber blank is pre-formed with a specific layered structure where the first layer has fibers in a first direction and the second layer has fibers in a perpendicular second direction. This preliminary structuring allows the blank to be handled more easily while maintaining the desired resilient properties in the load direction
Solution Approach 2:
The invention transitions from single-direction fiber orientation to multi-directional orientation by adding a second layer with perpendicular fiber arrangement. This dimensional change in fiber orientation provides both improved resilient properties and easier handling characteristics
3Productivity
If residence time in mold is reduced for efficient manufacturing, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The fiber blank is pre-heated before being placed in the mold, which activates the binding agent in advance. This preliminary heating allows the fibers to be set in their desired orientation more quickly, reducing residence time while maintaining manufacturing precision
Solution Approach 2:
The invention changes the temperature parameter by pre-heating the fiber blank to activate the binding agent before molding. This parameter change allows for faster setting of fiber orientation, reducing residence time in the mold while maintaining precision in the final product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of fiber block articles with improved resilient properties in all directions, including those perpendicular to the fiber orientation, while minimizing cycle time and mechanical stress during handling, thus providing enhanced comfort and efficiency in furniture applications.
Implementation Method 1
heating the fiber blank to activate the binding agent
Implementation Method 2
at least one of parts of the mold is provided by cooling means to allow for rapid cooling of the molded fiber block article
Data Source
Figure 1a
Figure 1b~1c
Figure 1d~1e
AI summary
A three-dimensional fiber block article obtainable by molding a heated fiber blank (10), comprising a thermally activated binding agent, into a three-dimensional fiber block article in a fiber block molding process. The fiber block molding process comprises the steps of: - receiving the fiber blank (10) to be molded at a receiving position (210) of a conveyor system (200); - transporting the fiber blank (10) by means of the conveyor system (200) via a heater (300), thereby heating the fiber blank (10) to activate the binding agent, to a mold (100), the mold having a lower part (110) and an upper part (120), wherein the lower (110) and the upper (120) parts of the mold form between them a cavity (150) for forming the fiber blank (10) into the molded article upon closing the mold; - delivering the heated fiber blank (11) on the lower part (110) of the mold (100); and - closing the mold to provide the fiber block article.