Cellulose Mould Dust Extraction During Dry Forming
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Solution Overview
Problem
Existing dry-forming techniques for manufacturing rigid cellulose products face challenges in reliably removing the pressed cellulose product from the moulding tool, leading to dust/fibre pollution in the ambient space, which affects operator safety and tool operation, and results in miscolouring and uneven surfaces.
Innovation Solution
A product forming unit with a dust removing arrangement featuring a suction nozzle located at the interface between mould parts to capture loose cellulose fibres during the opening of the moulding tool, combined with a sealing element to prevent fluid communication and enhance fibre removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dry-forming techniques are used to manufacture rigid cellulose products, then production speed and energy efficiency are improved, but dust/fibre pollution occurs during moulding tool opening
Solution Approach 1:
The invention captures the harmful dust and loose fibres generated during moulding tool opening and redirects them into a collection container rather than allowing them to pollute the ambient space. The suction nozzle system converts the harmful blow-out effect into a controlled material transfer, where the same air pressure that causes fibre dispersion is now used to direct fibres into a collection system.
Solution Approach 2:
The invention introduces a dust removing arrangement with suction nozzles and a collection container as an intermediary system between the moulding tool and the ambient space. This intermediary captures and contains the dust and fibres, preventing them from becoming a pollution problem while maintaining the benefits of dry-forming technology.
2Use of energy by moving object
If dry-forming techniques are used to manufacture rigid cellulose products, then energy consumption is reduced, but miscolouring and uneven surfaces occur on the product
Solution Approach 1:
The invention removes dust and loose fibres from the moulding tool area before they can contaminate the cellulose product. By actively suctioning away potential contaminants during the moulding process, the system prevents miscolouring and uneven surfaces from occurring in the first place, rather than trying to correct these defects afterward.
Solution Approach 2:
The invention converts the potentially harmful effect of air pressure during moulding, which can cause fibre dispersion and surface defects, into a beneficial force by using the same pressure dynamics to direct fibres toward the collection container rather than onto the product surface.
3Object-generated harmful factors
If dust removing arrangement is added to the product forming unit, then fibre pollution is prevented, but device complexity increases
Solution Approach 1:
The invention extracts the dust and loose fibres from the moulding process at the source, using suction nozzles positioned at critical locations where fibres are generated. By removing the harmful elements at their origin rather than trying to manage them throughout the entire system, the solution prevents pollution without requiring complex filtration or containment systems throughout the facility.
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 effectively prevents loose cellulose fibres from contaminating the ambient space, protecting operators and the moulding tool while maintaining the environmental and efficiency benefits of dry-forming techniques.
Implementation Method 1
a suction nozzle (29) arranged at the interface between the first mould part (15) and the second mould part (16) and configured to remove dust from the moulding tool
Implementation Method 2
the product forming unit comprising heating means for heating the cellulose blank to a forming temperature T
Implementation Method 3
at least one of the first mould part and the second mould part is displaceable in the axial direction in relation to the other in order to press the cellulose blank therebetween into final shape by applying a forming pressure P
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a method and a product forming unit for dry manufacturing rigid cellulose products (2) having essentially non-flat general shape from a cellulose blank. The product forming unit comprising a moulding tool having a first mould part (15) and a second mould part (16), wherein at least one of the first mould part (15) and the second mould part (16) is displaceable in the axial direction in relation to the other in order to press the cellulose blank therebetween into final shape by applying a forming pressure P in the axial direction of the moulding tool, the product forming unit (11) comprising heating means for heating the cellulose blank (10) to a forming temperature T. The product forming unit further comprises a dust removing arrangement (28), wherein the dust removing arrangement (28) comprises a suction nozzle (29) arranged at the interface between the first mould part (15) and the second mould part (16) and configured to remove dust from the moulding tool in connection with the end of the pressing of the cellulose blank (10) into final shape.