Dry-Formed Cellulose Moulding Unit for Safe Suction Removal
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Solution Overview
Problem
Existing dry-forming techniques for manufacturing rigid cellulose products face challenges in reliably removing the final product from the moulding tool without damaging it or the out-feed device, particularly for non-flat shapes, due to the fluffy nature of cellulose fibres and the risk of vacuum conditions.
Innovation Solution
The use of an out-feed device with movable arms and suction devices that engage the cellulose product at a controlled distance from the mould part surfaces, preventing vacuum conditions and ensuring safe removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If suction devices are used to remove cellulose products from the moulding tool, then removal reliability is improved, but vacuum conditions may cause damage to the product or out-feed device
Solution Approach 1:
The patent applies preliminary action by positioning the suction device at a predetermined safe distance from the mould part surface before initiating suction. This pre-positioning prevents the suction device from creating harmful vacuum conditions that could damage the cellulose product or the out-feed device, while still maintaining reliable removal capability.
Solution Approach 2:
The patent uses the air gap between the suction device and the mould part surface as an intermediary element. This air gap prevents direct contact and harmful vacuum formation while allowing the suction device to effectively remove the cellulose product through controlled air pressure differential.
2Productivity
If the suction device is positioned close to the mould part surface, then removal effectiveness is improved, but the risk of vacuum damage increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning the suction device at a predetermined safe distance from the mould part surface before initiating suction. This pre-positioning ensures that the suction device can effectively remove the cellulose product while preventing harmful vacuum conditions from developing.
Solution Approach 2:
The patent changes the positional parameter of the suction device by maintaining a predetermined distance from the mould part surface. This parameter adjustment allows the system to achieve effective removal while operating below the harmful vacuum threshold, thus resolving the contradiction between effectiveness and safety.
3Productivity
If dry-forming techniques are used, then manufacturing speed is improved, but product removal becomes more difficult compared to wet-forming
Solution Approach 1:
The patent replaces mechanical removal methods with a pneumatic suction system. This substitution allows for easier and more reliable removal of dry-formed cellulose products from the moulding tool, addressing the difficulty associated with dry-forming techniques while maintaining high manufacturing speed.
Solution Approach 2:
The patent employs pneumatic principles by using controlled air pressure differentials through suction devices to remove the cellulose product. This pneumatic approach simplifies the removal process compared to mechanical methods, making dry-forming techniques as easy to operate as wet-forming techniques while preserving manufacturing speed advantages.
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
Ensures reliable and damage-free removal of cellulose products, maintaining environmental benefits and reducing time and energy consumption in the manufacturing process.
Implementation Method 1
a first suction device connected to said arm, the first suction device of the out-feed device being insertable into the moulding tool between the first mould part and the second mould part after the pressing of the cellulose product
Data Source
Figure 1
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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 predetermined pressure P in the axial direction of the moulding tool, wherein the first mould part (15) comprises a bottom surface (21) and the second mould part (16) comprises a bottom surface (19) and wherein the axial distance between the bottom surface (21) of the first mould part (15) and the bottom surface (19) of the second mould part (16) during the pressing of the cellulose product (2) is T millimetres. The product forming unit further comprises an out-feed device (25) having a movable arm (26) and a first suction device (27) connected to said arm (26), the first suction device (27) of the out-feed device (25) being insertable into the moulding tool between the first mould part (15) and the second mould part (16) after the pressing of the cellulose product (2), wherein the first suction device (27) is displaceable towards the bottom surface (21) of the first mould part (15) in order to engage the cellulose product (2) and has a stop position located X millimetres from the bottom surface (21) of the first mould part (15), wherein X > T and X ≤ 3T.