Fiber Board Pattern Accuracy via Simultaneous Positioning Member Formation
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Solution Overview
Problem
The fiber board compressed in the outer shape forming step shrinks and deforms significantly, leading to variations in the relative position of the patterned and non-patterned parts during the cutoff process, which affects the accuracy of forming the fiber formed body with a patterned outer surface.
Innovation Solution
A method that simultaneously forms a pattern and positioning members on the fiber board during the outer shape forming step, using cold pressing to minimize shrinkage and deformation differences, allowing precise positioning and cutting of the fiber board to maintain pattern accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the fiber board is compressed in the outer shape forming step to form a pattern, then the outer surface of the fiber board has a pattern formed, but the fiber board shrinks and deforms significantly, causing variations in the relative position of the patterned part and the part to be cut off
Solution Approach 1:
The positioning member is formed simultaneously with the pattern during the outer shape forming step, before the cutoff operation. This preliminary formation of the positioning member ensures that both the pattern and positioning reference are established together, eliminating subsequent positioning errors caused by differential shrinkage. The positioning member serves as a stable reference that was created at the same time as the pattern, so their relative positions remain consistent even as the fiber board shrinks during cooling.
2Shape
If the fiber board is compressed to form the pattern, then the pattern is formed on the outer surface, but the deformation varies significantly across different parts of the fiber board
Solution Approach 1:
The positioning member is designed with a local quality that differs from the patterned area - it has an uneven shape that provides stable positioning reference. By creating a distinct positioning member with specific geometric features (protrusions or recesses) rather than just compressing the entire surface uniformly, the patent establishes a stable local reference that is less susceptible to deformation variations. This localized positioning structure compensates for the non-uniform shrinkage that occurs across the fiber board during cooling.
3Productivity
If the cutoff step is performed after outer shape forming, then the unnecessary part is cut off, but variations in relative position lower the accuracy in forming the fiber formed body
Solution Approach 1:
The positioning member enables the fiber board to self-position relative to the cutoff device. The uneven shape of the positioning member (with protrusions or recesses) automatically aligns the fiber board in the correct orientation and position during the cutoff operation, eliminating the need for complex external positioning mechanisms. This self-positioning capability ensures that the patterned area is accurately located relative to the cutoff blade, maintaining high manufacturing precision while enabling efficient automated cutoff operations.
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 method ensures highly accurate formation of the fiber formed body with a patterned outer surface by limiting variations in the relative positions of the patterned and positioning members, enhancing the dimensional accuracy and yield of the manufacturing process.
Implementation Method 1
The fiber board compressed in the outer shape forming step shrinks and deforms when having a decreased temperature subsequent to the compression
Implementation Method 2
an outer shape forming step that forms a fiber board made of the fiber material into a predetermined outer shape while forming the pattern on an outer surface of the fiber board by compressing the fiber board
Data Source
AI summary
A method for manufacturing a fiber formed body includes forming a fiber board into a predetermined outer shape while forming a pattern on an outer surface of the fiber board by compressing the fiber board, a forming at least one positioning member by compressing the fiber board, and positioning, relative to a cutoff device, the fiber board using the positioning member, and cutting off a cutoff target part of the fiber board using the cutoff device. In the method for manufacturing the fiber formed body, formation of the pattern during the forming of the outer shape and formation of the positioning member during the forming of the positioning member are simultaneously performed.