Bamboo Shaving Molded Tray Processing Method
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Solution Overview
Problem
Industrial molded trays made from waste materials often have poor quality, high defective rates, and short lifespans due to uncontrolled moisture content and process instability, leading to increased costs and transportation issues.
Innovation Solution
A method for processing molded trays using bamboo shavings that involves extracting, crushing, drying, purifying, heat balance treatment, mixing with glue, hot pressing, and cooling to ensure uniform moisture and temperature, resulting in durable and high-quality trays with improved strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional waste materials are used for manufacturing molded trays, then production costs are reduced, but product quality and durability deteriorate
Solution Approach 1:
The patent applies parameter changes by strictly controlling moisture content (drying to 8-12%) and performing heat balance treatment (heating to 40-50°C for 24-48 hours) of the bamboo shaving materials. These parameter controls ensure uniform material properties that directly improve product quality and durability while maintaining cost-effectiveness through efficient processing
2Quantity of substance
If moisture content of raw materials is not well controlled, then production cost is reduced, but product strength and stability deteriorate
Solution Approach 1:
The patent applies preliminary action by performing drying and heat balance treatment on the bamboo shaving materials before molding. The materials are pre-dried to controlled moisture content (8-12%) and pre-heated to uniform temperature (40-50°C) to ensure they have the required strength and stability properties before the molding process begins
Solution Approach 2:
The patent controls moisture content parameter to 8-12% and temperature parameter to 40-50°C during heat balance treatment. These parameter changes ensure the material achieves optimal physical properties for strength and stability while avoiding excessive processing that would increase costs
3Loss of time
If conventional drying methods are used, then processing time is reduced, but moisture content uniformity deteriorates
Solution Approach 1:
The patent applies preliminary action by conducting heat balance treatment after drying, where the bamboo shaving materials are heated to 40-50°C and maintained for 24-48 hours. This preliminary heat treatment ensures uniform moisture distribution throughout the material before molding, achieving both time efficiency and composition uniformity
Solution Approach 2:
The patent uses specific parameter changes: drying temperature of 60-80°C followed by heat balance treatment at 40-50°C for 24-48 hours. These controlled parameter changes achieve uniform moisture content (8-12%) throughout the material while maintaining reasonable processing time
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 method significantly enhances the quality and durability of molded trays, increasing their weight-bearing capacity by at least 1.5 times and extending their service life to 3 to 5 years, while maintaining low production costs and simplifying the processing steps.
Implementation Method 1
drying in a drying oven... the moisture content of shavings after drying does not exceed 1% in mass percent
Implementation Method 2
subjected to secondary purification by cyclone separation and pulse dust removal, to remove bamboo scraps and impurities
Implementation Method 3
perform hot pressing, with an upper mold temperature of 150° C., lower mold temperature of 130° C... at a pressure of 10 MPa
Data Source
AI summary
The present invention provides a method for processing a molded tray based on bamboo shavings, comprising: extracting, crushing, mixing, drying, separating by wind separation, heat balance treatment, mixing glue, paving and hot pressing, cooling and grinding, inspecting and warehousing. In the invention, the industrial trays are manufactured by bamboo materials. The bamboo materials do not include bamboo peels and other impurities. The use of bamboo materials can improve the quality of trays from raw materials and increase the strength of trays. The industrial trays made by the processing method of the present invention have increased the weight supporting capacity by at least 1.5 times compared to ordinary trays, and the product's service life is 3 to 5 years in normal uses (no water soaking, no overpressure).