Fiber Container Molding with Early Overpressure Flow Forming
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Solution Overview
Problem
Existing methods for manufacturing containers from fiber-containing materials, such as pulp, are time-consuming and inefficient.
Innovation Solution
A method and device that utilize a mold with a cavity and a first device for introducing an aqueous solution containing fibers, applying overpressure to the supply line before closing the valve, ensuring that most fibers are in place before pressurization, and using compressed air to complete the flow, along with optional centrifugal force and heat to accelerate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied within the mold cavity by inserting a pressurized balloon or introducing compressed air to force liquid components out and press fiber material against the cavity surface, then the container wall thickness uniformity is improved, but the manufacturing time is excessively long
Solution Approach 1:
The patent applies preliminary action by pre-forming the fibrous material into a semi-formed container shape before the final molding process. The fibrous material is first shaped into a preliminary container form, then liquid is introduced and pressed against this pre-formed structure. This preliminary shaping reduces the time required for the final pressing operation while maintaining wall thickness uniformity, as the material is already partially configured rather than being pressed from a flat sheet.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: first forming the fibrous material into a semi-formed container, then introducing liquid, and finally applying pressure to complete the molding. This segmentation allows each stage to be optimized independently - the pre-forming stage prepares the material structure, while the pressing stage focuses solely on achieving uniform wall thickness, thereby reducing total manufacturing time without sacrificing precision.
2Manufacturing precision
If an aqueous solution containing fibers is introduced into a mold and pressure is applied to force liquid out and press fibers against the cavity surface, then the container shape is formed, but the process requires relatively long time to manufacture
Solution Approach 1:
The fibrous material is pre-formed into a semi-formed container structure before being placed in the mold. This preliminary action means that when the aqueous solution is introduced and pressure is applied, the fibers are already positioned to form the basic container shape, requiring less time for the pressing operation to achieve the final accurate shape, thus reducing manufacturing time while maintaining shape accuracy.
Solution Approach 2:
The process maintains continuous useful action by having the fibrous material already in a three-dimensional semi-formed state that closely resembles the final container shape. This continuity means the pressing operation doesn't need to create the entire shape from scratch but only needs to refine and finalize the form, significantly reducing the time required while maintaining shape accuracy.
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 significantly accelerates the production of fiber-based containers by ensuring uniform fiber distribution and rapid liquid removal, resulting in a faster and more efficient manufacturing process.
Implementation Method 1
the first device applies an overpressure to the supply line so that the fibers are pressed against the inner surface of the cavity to form the container
Implementation Method 2
compressed air from the reservoir is fed into the mold via the valve and the supply line as soon as the first valve is closed and the compressed air valve is opened. The aqueous solution located in the supply line between the valve and the mold is then forced into the mold by the compressed air
Implementation Method 3
heat is introduced into the cavity at least temporarily during and/or after the application of overpressure to the supply line. This additionally removes excess liquid from the fibers exposed to the flow on the inner surface of the cavity
Implementation Method 4
a centrifugal force is exerted on the aqueous solution in the cavity during the flow. This ensures a uniform distribution of the fibers and a reliable reduction of the liquid content within the cavity during the flow
Data Source
Figure 1a~1e
AI summary
The present invention relates to a method for producing a container from fiber-comprising material by means of a device comprising a mold with a cavity for receiving an aqueous solution comprising the fibers and a first device for letting the aqueous solution flow into the mold and for pressurizing the mold, wherein the method comprises a flow of the fibers onto an inner surface of the cavity, wherein the first device for the flow comprises a supply line to an opening of the cavity of the mold, into which the aqueous solution is introduced into the mold via a first valve, and wherein the first device applies an overpressure to the supply line so that the fibers are pressed against the inner surface of the cavity to form the container.According to the invention, it is provided that the first valve is closed and the overpressure is applied to the supply line before an entirety of the fibers, which form a fiber component of the container, is located in the cavity.