Digital Pore Modification for Pulp Molding Screen Uniformity
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Solution Overview
Problem
In pulp molding processes, the pressure differences across pores in a screen due to varying distances from holes in a mold body can cause damage to wet parts being formed or removed, as uneven flow rates of liquid and air lead to potential damage during suction or blowing off.
Innovation Solution
A processor determines distances between digital pores on a screen and digital holes in a mold body, modifying pore parameters such as size and shape based on these distances to reduce pressure differences and prevent damage, by applying specific algorithms and thresholds to adjust pore dimensions and shapes accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform pore parameters are used across the screen, then manufacturing is simple, but pressure differences cause uneven flow rates that damage wet parts
Solution Approach 1:
The patent applies local quality by varying pore parameters (size, shape, orientation) at different locations on the screen based on distance from mold body holes. Pores closer to holes have different characteristics than pores farther away, creating location-specific properties that compensate for pressure differences and ensure uniform flow rates across the entire screen surface.
Solution Approach 2:
The patent changes physical parameters of pores (size, shape, orientation) as a function of position on the screen. Specifically, pore parameters are modified based on distance from the mold body holes to compensate for pressure gradients, transforming the uniform parameter design into a spatially varying parameter design that maintains flow uniformity.
2Quantity of substance
If pore size is increased to improve flow rate, then liquid passage is enhanced, but pressure differences cause greater damage to wet parts
Solution Approach 1:
The patent applies local quality by varying pore parameters (size, shape, orientation) at different locations on the screen based on distance from mold body holes. Pores closer to holes have different characteristics than pores farther away, creating location-specific properties that compensate for pressure differences and ensure uniform flow rates across the entire screen surface.
Solution Approach 2:
The patent changes physical parameters of pores (size, shape, orientation) as a function of position on the screen. Specifically, pore parameters are modified based on distance from the mold body holes to compensate for pressure gradients, transforming the uniform parameter design into a spatially varying parameter design that maintains flow uniformity.
3Productivity
If vacuum force is applied to suction material onto the screen, then product formation is achieved, but uneven pore distribution causes non-uniform material suction and part damage
Solution Approach 1:
The patent applies local quality by varying pore parameters (size, shape, orientation) at different locations on the screen based on distance from mold body holes. Pores closer to holes have different characteristics than pores farther away, creating location-specific properties that compensate for pressure differences and ensure uniform flow rates across the entire screen surface.
Solution Approach 2:
The patent changes physical parameters of pores (size, shape, orientation) as a function of position on the screen. Specifically, pore parameters are modified based on distance from the mold body holes to compensate for pressure gradients, transforming the uniform parameter design into a spatially varying parameter design that maintains flow uniformity.
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
This approach ensures even flow rates across the screen, reducing the risk of damage to wet parts during formation and transfer by modifying pore parameters to match the distance from mold body holes, thereby maintaining part integrity.
Implementation Method 1
During formation of the product, a vacuum force may be applied through the pulp molding die which may cause the material in the pulp to be sucked onto the wire mesh
Implementation Method 2
the pressure differences across pores in a screen due to varying distances from holes in a mold body can cause damage to wet parts being formed or removed, as uneven flow rates of liquid and air lead to potential damage during suction or blowing off
Data Source
AI summary
According to examples, computer-readable instructions may cause a processor to obtain a digital model of a screen to be fabricated by a 3D fabrication system, the digital model of the screen including digital pores. The processor may obtain a digital model of a mold body on which the screen is to be removably mounted, the digital model of the mold body including a plurality of digital holes. In addition, the processor may, for a digital pore, determine a distance between the digital pore and a digital hole when the digital model of the screen is positioned on the digital model of the mold body. The processor may further determine whether the determined distance falls below a first threshold and based on a determination that the determined distance falls below the first threshold, cause a parameter of the digital pore to be modified in a first manner.