Cellulose Toggle Pressing Module for Non-Flat Product Forming
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Solution Overview
Problem
The existing cellulose product forming technologies face challenges in producing non-flat cellulose products efficiently, as they require high-cost, large, and heavy pressing modules, which are costly and difficult to install, maintain, and integrate into compact production units.
Innovation Solution
A cellulose product toggle pressing module is introduced, which uses a toggle mechanism to generate pressing force, allowing for a compact, low-cost, and lightweight pressing module suitable for forming non-flat cellulose products from an air-formed cellulose blank structure. This module includes a pressing force indicating arrangement and an electronic control system to control the pressing operation accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional high capacity hydraulic or servo powered pressing machines are used, then forming pressure and productivity are sufficient, but cost, size, and weight become excessively high
Solution Approach 1:
The patent replaces conventional hydraulic or servo-powered pressing machines with a toggle mechanism-based pressing module. The toggle mechanism uses mechanical leverage to amplify the pressing force from a smaller actuator, eliminating the need for heavy hydraulic systems while achieving sufficient forming pressure for cellulose products.
Solution Approach 2:
The toggle mechanism dynamically adjusts the mechanical advantage ratio during the pressing cycle. As the toggle links approach alignment, the mechanical advantage increases dramatically, providing high pressing force only when needed during the forming process, while maintaining compact size and low weight throughout the cycle.
2Force
If conventional high capacity hydraulic or servo powered pressing machines are used, then forming pressure is sufficient, but device complexity and installation difficulty increase
Solution Approach 1:
The patent replaces complex hydraulic systems with a purely mechanical toggle mechanism. This substitution eliminates hydraulic pumps, valves, hoses, and control systems, resulting in a simpler pressing module with fewer components that is easier to install, maintain, and integrate into production lines.
Solution Approach 2:
The pressing module is segmented into modular components: the toggle mechanism, the actuator, and the forming molds. This segmentation allows for easier installation, maintenance, and replacement of individual components without affecting the entire system, reducing overall device complexity.
3Ease of manufacture
If wet-forming techniques are used, then cellulose products can be formed from pulp suspension, but drying time and energy consumption increase significantly
Solution Approach 1:
The patent changes the fundamental parameter of the forming process from wet-forming to dry-forming. Instead of using liquid or semi-liquid pulp suspension that requires subsequent drying, the process uses air-formed cellulose blank structures with controlled moisture content, eliminating the energy-intensive drying step while maintaining product quality.
4Ease of manufacture
If wet-forming techniques are used, then cellulose products can be formed, but mechanical strength and flexibility are limited
Solution Approach 1:
The patent changes the moisture content parameter of the cellulose material from high (wet-forming) to controlled low levels (dry-forming). The air-formed cellulose blank structures have optimized moisture content that enables superior mechanical strength and flexibility in the final products, while still allowing effective forming through the toggle pressing mechanism.
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 cellulose product toggle pressing module enables the efficient formation of non-flat cellulose products with improved mechanical properties, reduced energy consumption, and simplified installation, while maintaining a low production cost and compact unit design.
Implementation Method 1
A cellulose product toggle pressing module is introduced, which uses a toggle mechanism to generate pressing force
Implementation Method 2
forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part against the second mould part
Data Source
Figure 1a
Figure 1b
Figure 1c~1e
AI summary
A cellulose product toggle pressing module (6) for forming non-flat cellulose products (1) from an air-formed cellulose blank structure (2). The toggle pressing module (6) comprises a toggle press (6a) including pressing member (6d) movably arranged in a pressing direction, a toggle-mechanism (6e) drivingly connected to the pressing member (6d), a pressing actuator arrangement (6f) drivingly connected to the toggle-mechanism (6e), and an electronic control system (6h) operatively connected to the pressing actuator arrangement (6f). The toggle pressing module (6) further comprises a forming mould (3) including a moveable first mould part (3a) attached to the pressing member (6d) and a second mould part (3b). The electronic control system (6h) is configured for controlling operation of pressing actuator arrangement (6f) for driving the pressing member (6d) using the toggle-mechanism (6e) in the pressing direction and forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part (3a) against the second mould part (3b). Furthermore, the toggle press (6a) is installed with, or arranged for being installed with, the pressing direction of the pressing member (6d) arranged primarily in a horizontal direction, specifically with the pressing direction of the pressing member (6d) arranged within 20 degrees from the horizontal direction, and more specifically with the pressing direction in parallel with the horizontal direction.