Cellulose Blank Buffering Module for Intermittent Mold Feeding
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Solution Overview
Problem
Existing cellulose product manufacturing methods face inefficiencies in feeding air-formed cellulose blank structures to forming molds, particularly in dry-forming processes, leading to potential breakage and difficulty in controlling mechanical properties with precision.
Innovation Solution
A buffering module using three endless belt units is employed to continuously feed and intermittently redirect cellulose blank structures, ensuring efficient transportation and minimizing breakage, with optional application of additional layers and substances to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex feeding units are used for intermittent feeding of cellulose blank structure, then feeding capability is improved, but device complexity increases and risk of breakage occurs
Solution Approach 1:
The feeding system is segmented into three separate endless belt units (first, second, and third belt units) that operate in sequence. Each belt unit performs a specific function: continuous feeding, buffering/redirecting, and intermittent transfer to the forming mold. This segmentation allows each component to be simple while the overall system achieves complex feeding capability.
Solution Approach 2:
The second endless belt unit acts as an intermediary buffering element between the first continuous feeding belt and the third intermittent transfer belt. It temporarily holds and redirects cellulose blank structures, enabling the transition from continuous to intermittent feeding without requiring complex synchronization mechanisms.
2Productivity
If intermittent feeding operation is used for dry-forming, then product formation is enabled, but risk of breaking cellulose blank structure increases
Solution Approach 1:
The second endless belt unit serves as a cushioning buffer that temporarily stores cellulose blank structures before they are transferred to the forming mold. This buffering action absorbs the shock and stress of intermittent feeding operations, preventing breakage of the blank structures during the transition from continuous production to intermittent forming.
Solution Approach 2:
The endless belt units provide a flexible, continuous support surface for the cellulose blank structures throughout the feeding process. This flexible belt system gently handles the blank structures, maintaining their integrity during continuous feeding, buffering, and intermittent transfer operations.
3Productivity
If continuous feeding is used on first endless belt unit, then production efficiency is improved, but synchronization with intermittent forming mould becomes difficult
Solution Approach 1:
The second endless belt unit functions as an intermediary buffer that decouples the continuous feeding operation from the intermittent forming operation. It accumulates blank structures during continuous feeding and releases them at the required intervals for the forming mold, eliminating the need for complex synchronization mechanisms between the feeding system and forming mold.
Solution Approach 2:
The second belt unit performs preliminary buffering and storage of cellulose blank structures before they are transferred to the forming mold. This preliminary action allows the continuous feeding system to operate independently at high efficiency while the forming mold operates intermittently at its own pace, with the buffer absorbing any timing differences.
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 buffering module enables smooth and efficient transportation of cellulose blank structures to forming molds, reducing breakage risk and allowing for high-quality product formation with controlled mechanical properties.
Implementation Method 1
continuously feeding the cellulose blank structure on the first endless belt unit in a first feeding direction
Implementation Method 2
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
Implementation Method 3
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
Data Source
AI summary
A method for transporting an air-formed cellulose blank structure to a forming mould via a buffering module, includes the steps: continuously feeding the cellulose blank structure on a first endless belt unit in a first feeding direction, and redirecting the cellulose blank structure to a 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 a 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.