Suction Transfer of Dry Cellulose Blanks for Crack-Free Moulding
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Solution Overview
Problem
Existing dry-forming techniques for manufacturing rigid cellulose products face challenges in reliably feeding discrete cellulose blanks into a cyclically operated moulding tool, leading to material draw, elongation, and crack generation, particularly for non-flat shapes, due to the fluffy nature of cellulose blanks and the need for precise handling.
Innovation Solution
An apparatus and method utilizing a suction device with a movable arm to engage and transfer cellulose blanks from a conveyor belt into a moulding tool, ensuring synchronized movement and full engagement without damaging the cellulose blanks, minimizing mutual movement and scrap material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If discrete cellulose blanks are fed into a cyclically operated moulding tool, then the fluffy cellulose blanks are prone to material draw, elongation, and crack generation, but continuous feeding is needed for production efficiency
Solution Approach 1:
The patent employs a suction device utilizing negative pressure (pneumatics) to engage and transfer the cellulose blank. The suction cup creates a vacuum field that securely holds the blank during transfer from the conveyor belt to the moulding tool, preventing material draw and crack generation while enabling continuous feeding for high productivity
Solution Approach 2:
The invention replaces traditional mechanical transfer mechanisms (such as grippers or belts that cause friction and stress) with a pneumatic suction system. This substitution eliminates direct mechanical contact and stress concentration points on the cellulose blank, preventing elongation and cracking while maintaining reliable continuous transfer
2Productivity
If the cellulose blank is rapidly accelerated from the buffering zone into the moulding tool, then production rate increases, but the continuous cellulose blank is pulled apart due to forces from rapid acceleration
Solution Approach 1:
The suction device creates a vacuum field that distributes acceleration forces uniformly across the entire cellulose blank surface. This pneumatic engagement prevents localized stress concentrations that would cause the fluffy blank to tear during rapid acceleration into the cyclically operated moulding tool
Solution Approach 2:
The invention changes the physical state of engagement from mechanical contact to pneumatic suction. By controlling the negative pressure parameter, the system can rapidly accelerate the blank while maintaining uniform force distribution across the cellulose fibres, preventing structural failure during high-speed transfer
3Reliability
If wet moulding technique is used, then sustainable material benefits are achieved, but large amounts of water are needed and drying is time and energy consuming
Solution Approach 1:
The invention utilizes the phase transition from wet to dry state by introducing the cellulose blank in a dry or partially dry condition directly into the moulding tool. This eliminates or significantly reduces the drying phase that would otherwise be required after wet moulding, saving substantial time and energy while maintaining the sustainability benefits of using cellulose as a renewable material
Solution Approach 2:
The patent extracts the water removal step from the traditional wet moulding process. By using dry-forming technology where the cellulose blank is moulded in a dry state, the invention removes the time-consuming and energy-intensive drying operation entirely, while preserving the environmental benefits of cellulose-based sustainable packaging
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 ensures reliable transfer of cellulose blanks without damage, reducing crack generation and increasing the success rate of undamaged products, while maintaining environmental and time-saving benefits of dry-forming techniques.
Implementation Method 1
The suction device is configured to engage the cellulose blank by means of negative pressure
Implementation Method 2
The heating unit is configured to heat the cellulose blank to an elevated temperature
Implementation Method 3
The pressing unit is configured to press the heated cellulose blank into a heated cellulose product having a desired shape
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention relates to a method and an apparatus for dry manufacturing rigid cellulose product (2) having essentially non-flat general shape from a cellulose blank (10). The apparatus (1) comprises a conveyor arrangement (20) comprising an endless conveyor belt (21) configured for continuously moving at a predetermined traveling speed, a product forming unit (11) that comprises a moulding tool having a first mould part (15) and a second mould part (16) displaceable in an axial direction in relation to each other in order to press the cellulose blank (10) therebetween, wherein the cellulose blank (10) comprises a product area (25). The apparatus further comprises an in-feed device (22) that comprises a suction device (24) configured to engage and transfer the cellulose blank (10) from the continuously moving conveyor belt (21) into the open moulding tool, the suction device (24) having a perforated area corresponding in size to at least the product area of the cellulose blank (10), and wherein the suction device (24) in the transport direction of the conveyor arrangement (20) during engagement with the cellulose blank (10), is configured to move in conformity with the traveling speed of the conveyor belt (21).