Dual Pulp Suction Molding for Thick Shock-Absorbing Packaging
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Solution Overview
Problem
Conventional molded product manufacturing methods are limited by slow manufacturing speed, difficulty in increasing product thickness, and uneven surface quality, which restricts their use for packaging high-value items.
Innovation Solution
An automatic molding machine with upper and lower pulp suction molds that simultaneously suck pulp and merge into a thicker formed blank, followed by high-pressure gas dehydration and hot pressing to enhance thickness and surface smoothness, allowing for increased shock absorption and improved packaging capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single mold suction molding is used, then the manufacturing process is simple, but the manufacturing speed is slow
Solution Approach 1:
The single molding process is segmented into two simultaneous molding operations using upper and lower molds. Each mold independently forms a formed blank from pulp, allowing parallel production without significantly increasing overall system complexity.
Solution Approach 2:
Two molding operations are merged into a single production cycle by coordinating upper and lower molds to operate simultaneously. The molds share common support structures and control systems, achieving doubled productivity with minimal increase in device complexity.
2Length of stationary object
If single pulp layer is formed, then the manufacturing process is simple, but the product thickness is limited
Solution Approach 1:
The solution transitions from forming a single pulp layer to stacking multiple pulp layers in the vertical dimension. By closing upper and lower molds simultaneously, the system creates formed blanks with increased thickness through layered pulp accumulation, effectively utilizing the vertical space dimension.
Solution Approach 2:
Multiple pulp layers are combined to form a composite structured formed blank with enhanced thickness. The layered pulp structure maintains the fibrous material properties while achieving greater dimensional thickness through the superposition of multiple layers.
3Strength
If single mold suction is used, then the device structure is simple, but the shock absorption effect is insufficient
Solution Approach 1:
The shock absorption capability is enhanced by adding vertical dimension through multiple stacked pulp layers. The increased thickness in the vertical direction provides greater energy absorption capacity while maintaining the simple fibrous material composition.
Solution Approach 2:
The shock absorption effect is improved by creating a composite layered structure from multiple pulp layers. The stacked layers work together to provide enhanced cushioning and shock absorption properties compared to a single layer structure.
4Manufacturing precision
If conventional suction molding is used, then the equipment is simple, but the surface quality is uneven
Solution Approach 1:
Surface quality is improved by utilizing the vertical dimension with stacked pulp layers. The upper and lower mold surfaces simultaneously contact and shape the top and bottom of the formed blank, ensuring uniform compression and surface finish on both faces through vertical layering.
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 solution significantly accelerates manufacturing speed, increases product thickness for enhanced shock absorption, and achieves a smooth surface finish, making the molded products suitable for packaging high-value items.
Implementation Method 1
the pulp in the pulp box is vacuum-pumped by the suction device through the pumping holes to adsorb the pulp on the outer surface of the fine metal mesh
Implementation Method 2
the first pumping device stops the pumping action, which is changed to a blowing action, to blow in a high pressure gas, so that the formed blank can be dehydrated
Implementation Method 3
the hot pressing and shaping equipment (including the crimping mold and heating equipment) carries out the hot pressing and shaping of the formed blank, the hot pressing temperature is between 150° C.±10° C.
Data Source
AI summary
An automatic molding machine for a molded product, a manufacturing method and a finished product includes an upper pulp suction mold and a lower pulp suction mold configured to simultaneously suck the pulp in a pulp box, wherein the molds are closed and formed into a formed blank which becomes the finished product of the molded product after dehydration, hot pressing and shaping. Advantages include speeding up manufacturing, increasing the thickness of the finished product, increasing the shock absorption effect, and making an excellent surface.