Cellulose Blank Buffering Module for Intermittent Mold Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cellulose product manufacturing methods face inefficiencies in feeding air-formed cellulose blank structures to forming molds, leading to potential breakage and difficulty in achieving precise mechanical properties due to the use of complex and non-efficient feeding systems in dry-forming processes.
Innovation Solution
A buffering module with three endless belt units is employed to continuously and intermittently transport cellulose blank structures, utilizing alternating movements and speed adjustments to ensure smooth feeding and minimize breakage, allowing for efficient integration with intermittently operating forming molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex feeding units are used for intermittent feeding of cellulose blank structure, then the feeding can be achieved, but the device complexity increases and the risk of breaking the cellulose blank structure increases
Solution Approach 1:
The feeding system is divided into multiple independent endless belt units (first, second, and third belt units) that operate in sequence. Each belt unit handles a specific segment of the feeding process, allowing the system to achieve intermittent feeding through coordinated operation of simpler individual components rather than a single complex feeding mechanism.
Solution Approach 2:
The second endless belt unit acts as an intermediary buffer between the continuous first belt unit and the intermittent third belt unit. This intermediate buffer zone allows the system to decouple the continuous supply from the intermittent demand, enabling smooth intermittent feeding without requiring complex control mechanisms in each individual belt unit.
2Ease of operation
If complex feeding units are used for intermittent feeding, then feeding can be achieved, but the risk of breaking cellulose blank structure increases
Solution Approach 1:
The second endless belt unit is designed to be movable relative to the first and third belt units, allowing dynamic adjustment of the buffering capacity. This dynamic configuration enables the system to adapt to varying feeding rates and maintain optimal tension on the cellulose blank structure, preventing breakage during intermittent operation.
Solution Approach 2:
The buffering module provides a cushioning zone where the cellulose blank structure is temporarily stored and gently held by the second belt unit. This beforehand cushioning allows the intermittent third belt unit to pick up blanks without creating sudden tension spikes or mechanical shocks that could cause breakage.
3Productivity
If wet-forming methods are used, then cellulose products can be formed, but the mechanical strength and flexibility are limited and drying process is time and energy consuming
Solution Approach 1:
The system transitions from wet-forming to dry-forming by changing the physical state parameter of the cellulose material. Air-formed cellulose blank structures with controlled moisture content are used instead of wet pulp suspensions, eliminating the drying step and enabling faster production while maintaining or improving mechanical properties through controlled fiber arrangement in the dry state.
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A method for transporting an air-formed cellulose blank structure to a forming mould via a buffering module, where the cellulose blank structure has a first side and an opposite second side. The forming mould is arranged for dry-forming cellulose products from the cellulose blank structure. The buffering module comprises a first endless belt unit, a second endless belt unit, and a third endless belt unit, where the second endless belt unit is arranged in-between and in a longitudinal overlapping relationship to the first endless belt unit and the third endless belt unit. The second endless belt unit is movably arranged relative to the first endless belt unit and the third endless belt unit. The method comprises the steps: continuously feeding the cellulose blank structure on the first endless belt unit in a first feeding direction, and redirecting the cellulose blank structure to the second endless belt unit; feeding the cellulose blank structure on the second endless belt unit in a second feeding direction being at least partly opposite the first feeding direction, where the second endless belt unit alternatingly is longitudinally moved in opposite directions relative to the first endless belt unit and the third endless belt unit, and redirecting the cellulose blank structure to the third endless belt unit; intermittently feeding the cellulose blank structure on the third endless belt unit in a third feeding direction at least partly coinciding with the first feeding direction.