Breathable Shaping Mold for Uniform Pulp Foam Dehydration
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Solution Overview
Problem
Existing methods for producing pulp foam cushioning materials result in nonuniform dehydration, leading to variations in porosity distribution, which affects the quality and consistency of the final product.
Innovation Solution
A production method involving a shaping mold composed entirely of breathable material, where the foamy substance is filled to exceed the volume of the final product, compressed, and dehydrated with uniform surface contact, using flexible components to ensure even dehydration and a mesh panel for design transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic mold is used for molding pulp foam cushioning material, then the mold provides structural support and durability, but the dehydration becomes nonuniform across different regions leading to nonuniform porosity distribution
Solution Approach 1:
The patent applies porous breathable material for the mold main body instead of metallic material. This porous structure allows water to permeate uniformly through the entire mold surface during dehydration, eliminating the nonuniform porosity distribution that occurs with metallic molds. The breathable material enables consistent dehydration across all regions while maintaining sufficient structural support for the molding process.
2Manufacturing precision
If the mold main body is entirely composed of breathable material, then uniform dehydration is achieved, but the mold requires an external frame unit for structural support
Solution Approach 1:
The patent segments the mold structure into two functional parts: a breathable mold main body for uniform dehydration and an external frame unit for structural support. This segmentation allows each component to perform its specific function optimally without compromising the other, achieving both dehydration uniformity and structural integrity.
Solution Approach 2:
The external frame unit acts as an intermediary structural support system that enables the use of breathable material for the mold main body. The frame provides the necessary mechanical strength while the breathable material handles the dehydration function, creating a coordinated system that resolves the contradiction between material properties.
3Manufacturing precision
If the foamy substance is filled to exceed the volume of the final product and compressed, then uniform contact with the mold surface is achieved, but additional compression step is required
Solution Approach 1:
The patent applies preliminary action by filling the mold with excess foamy substance before compression. This ensures that the mold cavity is completely filled and all surfaces are in uniform contact with the foamy material before the dehydration process begins. The compression step then consolidates this uniform contact state to achieve consistent porosity throughout 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 method reduces uneven dehydration regions, ensures consistent porosity, and allows for a designed surface pattern, enhancing the quality and functionality of the pulp foam cushioning material.
Implementation Method 1
the mold main body is entirely composed of a breathable material... the foamy substance can be dehydrated through the entire surface of the mold main body
Data Source
AI summary
Provided is a method for producing a pulp foam cushioning material in which unevenly dehydrated regions are reduced from those in prior art. The method for producing a pulp foam cushioning material includes the steps of mixing and kneading a pulp feedstock, composed of shredded pieces of a pulp raw material, with water and a foaming agent to obtain a foamy substance, filling a shaping mold (mold main body and an external frame unit) with an amount of the foamy substance that is greater than a volume of the pulp foam cushioning material, compressing the filled foamy substance, and dehydrating and drying the foamy substance. The shaping mold includes a mold main body entirely composed of a breathable material. In the drying step, the foamy substance is dehydrated and dried in a state where all surfaces of the foamy substance are surrounded by the mold main body.