Compressing Expanded Polyurethane Blocks with Hydraulic Presses
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Solution Overview
Problem
Existing packaging machines are not suitable for compressing and packaging blocks of expanded polyurethane effectively, as they fail to maintain the compressed state and protect the material from re-expansion during transport, unlike machines designed for rigid materials.
Innovation Solution
A packaging machine equipped with two hydraulic presses to compress blocks of expanded polyurethane and a vacuum packaging system using a flat plastic barrier film sealed on all sides, preventing air passage and re-expansion, while maintaining the product's cleanliness and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional packaging machines are used to compress expanded polyurethane blocks, then the blocks are compressed to reduce volume, but the blocks immediately re-expand during transfer and transport
Solution Approach 1:
The patent applies preliminary action by performing the compression of expanded polyurethane blocks within the packaging machine itself, and immediately sealing them in barrier film while still under compression. This prevents the blocks from re-expanding during transfer and transport, as the compression state is locked in before any movement occurs.
Solution Approach 2:
The patent introduces a barrier film as an intermediary medium that seals the compressed blocks. This film acts as a mediator that maintains the compression state by preventing air from re-entering the block structure during transfer and transport, thereby preventing re-expansion.
2Ease of operation
If multiple conveyor belts are used to transfer compressed blocks, then the blocks can be moved through the packaging process, but the blocks deform and re-expand during transfer
Solution Approach 1:
The patent merges the compression function and transfer function into a single integrated unit. The compression unit includes both the compression mechanism and the barrier film sealing system, allowing blocks to be compressed and sealed in one location without requiring transfer via conveyor belts that would cause deformation.
Solution Approach 2:
The patent uses flexible barrier film to wrap and seal the compressed blocks. This thin film maintains the compressed shape of the blocks during transfer by providing external pressure and preventing air from entering the block structure, thereby preventing re-expansion and deformation.
3Volume of moving object
If the blocks are compressed to minimum dimensions, then transport and storage costs are reduced, but the blocks are exposed to external agents and may become contaminated
Solution Approach 1:
The patent uses barrier film to wrap the compressed blocks, creating a protective shell that prevents exposure to external agents such as dust, moisture, and contamination. This film sealing maintains both the compressed state and the cleanliness of the blocks during transport and storage.
Solution Approach 2:
The barrier film creates an inert environment around the compressed blocks by preventing contact with external air and contaminants. This sealed environment protects the blocks from harmful external factors while maintaining their compressed state for efficient transport and storage.
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 machine achieves a 70-80% reduction in volume, significantly reducing transport and storage costs by ensuring the product remains compressed and clean until opening, allowing for efficient loading and storage without deformation.
Implementation Method 1
The machine according to the present invention enables pressing of the block by two hydraulic presses (14, 19) so as to eliminate the air contained in the block
Implementation Method 2
the machine according to the present invention generally enables pressing of the block by two hydraulic presses in order to eliminate the air contained inside the block
Implementation Method 3
The pressed block of expanded polyurethane is then wrapped in a plastic barrier film (28), that is, a film which prevents the passage of air, which in turn is sealed on its four sides by means of suitable sealing bars
Data Source
Figure 1~2
AI summary
A packaging machine (10) designed and equipped for the compression and packing of blocks of expanded material and in particular expanded polyurethane where the machine comprises: a) an infeed block "A" comprising an infeed unit (11) mounted on wheels, which has a first lower infeed conveyor belt (12) and a second upper infeed conveyor belt (13) which is fitted with a first hydraulic press (14); b) a central block "B" containing a crossways sealing bar (15) operating with a cold sealing system and a powered lower reel holder (16) and a powered upper reel holder (17); c) a rear block "C" comprising a second out feed conveyor which in turn comprises an upper conveyor belt (18) fitted with a central hydraulic press (19) counter opposing a further lower conveyor belt (20), and two side sealing bars (21) employing a cold sealing system.