Segmented Solid Cellulose Foam Assembly for Uniform Drying
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Solution Overview
Problem
Existing cellulose foams experience non-uniform shrinkage and long drying times during production, especially for large objects, leading to thickness variations and reduced mechanical stability, which is a challenge for cost-effective and efficient manufacturing.
Innovation Solution
The method involves assembling multiple smaller cellulose foam portions with specific shapes that fit together to form a solid cellulose foam object, minimizing thickness variations and allowing simultaneous drying, thereby increasing mechanical stability and reducing drying time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large cellulose foam object is dried without restrictions, then the drying process is simple, but the foam shrinks non-uniformly in all directions leading to thickness variations
Solution Approach 1:
The large foam object is divided into multiple smaller foam portions that are dried separately. Each small portion is then assembled into the final large object configuration. This segmentation allows each small portion to be dried uniformly without the non-uniform shrinkage that occurs in large objects, while the final assembly achieves the desired large scale.
2Manufacturing precision
If a large cellulose foam object is dried under tension using a mould, then shrinkage is prevented, but the tension is limited to regions closest to the mould and shrinkage occurs in the middle
Solution Approach 1:
Instead of using a complex mould system that fails to provide uniform tension across large objects, the invention segments the foam into small portions. Each small portion can be dried under simple tension or in free-standing conditions, achieving uniform thickness without requiring complex mould systems.
3Productivity
If the drying time of cellulose foam is reduced by increasing heat input, then productivity increases, but energy consumption increases and the foam may collapse
Solution Approach 1:
The foam is divided into multiple small portions that can be dried simultaneously. This increases the total surface area exposed to drying conditions, allowing faster drying times without requiring excessive heat input on any single portion, thus reducing overall energy consumption while maintaining productivity.
4Manufacturing precision
If cellulose foam portions are assembled after drying, then dimensional stability is achieved, but additional assembly steps are required
Solution Approach 1:
The foam portions are pre-dried to their final dimensions in their small, stable configurations before assembly. This preliminary drying action ensures that each portion achieves its final dimensional stability before being combined with others, eliminating the need for complex drying systems that would need to handle the entire large object.
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
This approach results in a dimensionally stable cellulose foam with uniform thickness and improved mechanical properties, such as compression strength, while significantly reducing drying time and energy consumption.
Implementation Method 1
Drying the wet foam composition is often a critical step
Implementation Method 2
the capillary pressure build-up inside the material as the water level recedes during drying, leading to menisci forming between particles and as a result attractive inter particle forces
Implementation Method 3
aerating a paste comprising cellulose fibres and gluten
Data Source
AI summary
The present invention relates to a solid cellulose foam object comprising a first solid cellulose foam portion attached to a second solid cellulose foam portion. optionally at least one additional solid cellulose foam portion may be attached to the first and/or the second solid cellulose foam portion. The invention also relates to a method for producing said solid cellulose foam object.