Fiber Molded Part Surface Design for Steam Extraction Marks
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Solution Overview
Problem
Fiber-containing materials used in manufacturing molded parts often develop elevations due to steam extraction during pressing, which are aesthetically disruptive and hinder functional performance, particularly in applications like coffee capsules and beverage containers.
Innovation Solution
Design elements and functional elements in molded parts are created with regions of reduced material thickness, integrating elevations into the surface design to minimize protrusion and ensure seamless integration with surrounding surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam extraction openings are provided in molding surfaces to remove steam during pressing, then steam extraction is enabled, but elevations form on the molded part surface
Solution Approach 1:
The patent applies local quality by creating a recess in the molding surface at the steam extraction opening location. This recess is designed with specific dimensions (depth of 0.1-5 mm, diameter of 0.5-5 mm) to locally accommodate the elevation-forming material, allowing steam extraction to proceed while preventing surface protrusions on the final molded part.
Solution Approach 2:
The patent converts the harmful effect of steam extraction (which causes elevations) into a beneficial outcome by designing a recess that anticipates and accommodates the elevation-forming material. The steam extraction process still occurs effectively, but the recess ensures the elevation is contained within the mold cavity rather than forming a surface defect.
2Productivity
If elevations are formed on molded part surface due to steam extraction, then steam can be discharged, but aesthetic appearance and sealing performance deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming a recess in the molding surface before the molding process begins. This recess is specifically designed to accommodate the material that would otherwise form an elevation during steam extraction, thereby preventing surface quality defects while maintaining effective steam discharge capability.
3Reliability
If steam extraction openings are made larger to improve steam removal, then steam extraction efficiency increases, but larger elevations form on the surface
Solution Approach 1:
The patent applies local quality by creating a recess with specific dimensional parameters (depth of 0.1-5 mm, diameter of 0.5-5 mm) at the steam extraction opening location. This localized structural modification allows the opening to be sufficiently large for effective steam removal while the recess contains any resulting elevation, preventing it from becoming a surface defect.
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 provides visually appealing and functionally effective molded parts with reduced elevations, ensuring proper sealing and ease of use by integrating design elements without noticeable protrusions.
Implementation Method 1
the evaporating water is extracted as standard during a pressing process at high temperatures and high pressure
Implementation Method 2
produced in a manufacturing process under pressure and thermal influence
Implementation Method 3
pressing process at high temperatures and high pressure
Data Source
AI summary
A three-dimensional molded part made of fiber-containing material and a molding tool for producing molded parts made of fiber-containing material are described. The three-dimensional molded part is produced in a manufacturing process under pressure and thermal influence. A surface of the molded part has at least one design element and/or functional element that is formed by at least one region with reduced material thickness. The material thickness of the at least one region decreases with an increasing molded part height in a molding direction.