Cellulose Pressing Mould for Single-Step Undercut Forming
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Solution Overview
Problem
Existing dry-forming methods struggle with producing cellulose products having complex shapes, such as those with negative draft angles or undercut sections, which often require multiple forming steps and are time and energy consuming.
Innovation Solution
A pressing module with a forming mould comprising a first and second mould part that are movably arranged relative to each other in a longitudinal direction, allowing a single pressing operation to form cellulose products with complex shapes by applying a forming pressure of 1-100 MPa, preferably 4-20 MPa, and a forming temperature of 100-300 °C, utilizing an overlapping relationship and lateral displacement of the second mould part section to create a forming cavity and apply pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple forming steps are used to produce cellulose products with complex shapes, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The forming mould is divided into multiple independent sections (first forming section, second forming section, third forming section) that can be independently moved and positioned. This segmentation allows each section to form different parts of the complex product simultaneously, achieving complex shape formation in a single operation rather than multiple sequential steps.
Solution Approach 2:
The invention introduces lateral displacement movement in addition to the conventional longitudinal pressing motion. The forming sections can move laterally to create forming cavities and apply pressure from multiple directions, enabling complex three-dimensional shapes to be formed in a single operation by utilizing multiple spatial dimensions.
2Manufacturing precision
If multiple forming steps are used to produce cellulose products with complex shapes, then the manufacturing precision is improved, but the use of energy deteriorates
Solution Approach 1:
Multiple forming operations that would traditionally be performed in separate steps are merged into a single pressing operation. All forming sections operate simultaneously to create the complete complex shape in one go, reducing the total number of heating cycles and energy consumption associated with multiple sequential forming steps.
Solution Approach 2:
The invention enables continuous forming action where all forming sections apply pressure and heat simultaneously throughout the entire product area in a single operation. This continuous simultaneous action eliminates the idle time and repeated heating/cooling cycles that would occur with multiple discrete forming steps.
3Ease of manufacture
If conventional dry-forming methods are used, then the manufacturing process is simplified, but the adaptability deteriorates
Solution Approach 1:
The forming sections are designed to be movable and dynamically positionable both longitudinally and laterally. This dynamic capability allows the same forming mould to adapt to different product configurations and complex shapes by repositioning the sections, maintaining process simplicity while greatly enhancing versatility.
Solution Approach 2:
The invention changes the operational parameters of the forming process by introducing lateral displacement in addition to longitudinal pressing. This parameter change enables the formation of complex shapes with negative draft angles and undercut sections that were previously impossible with conventional dry-forming methods, while maintaining the simplicity of a single pressing operation.
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
Enables efficient production of cellulose products with complex shapes in a single pressing step, reducing time and energy consumption while achieving precise mechanical and aesthetic properties.
Implementation Method 1
the cellulose blank is subjected to a high forming pressure and a high forming temperature
Implementation Method 2
the cellulose blank is subjected to a high forming pressure and a high forming temperature
Data Source
Figure 1a~1b
Figure 1c~2a
Figure 2b~2c
AI summary
A pressing module and method for forming cellulose products (1) from an air-formed cellulose blank structure (2), where the pressing module (PM) comprises a forming mould (3) with a first mould part (3a) and a second mould part (3b) configured for interacting with each other for forming the cellulose products (1) from the air-formed cellulose blank structure (2) in the forming mould (3). The first mould part (3a) and/or the second mould part (3b) are movably arranged relative to each other in a pressing direction (DP) parallel to a longitudinal direction (DLO) of the pressing module (PM). The first mould part (3a) and the second mould part (3b) are at least partly configured for being arranged in an overlapping relationship in the longitudinal direction (DLO) during forming of the cellulose products (1). The first mould part (3a) comprises a first mould part section (4a) and a second mould part section (4b) arranged in connection to the first mould part section (4a). The second mould part section (4b) is configured for being displaced relative to the first mould part section (4a) in a lateral direction (DLA) of the pressing module (PM) during forming of the cellulose products (1) in the forming mould (3). The first mould part section (4a) and the second mould part section (4b) are configured for applying a forming pressure (PF) onto the air-formed cellulose blank structure (2) in the range of 1-100 MPa, preferably in the range of 4-20 MPa, during a single pressing operation (OSP) upon forming of the cellulose products (1) in the forming mould (3).