Fibrous Hollow Container Molding With Integrated Connecting Element
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Solution Overview
Problem
Existing methods for manufacturing hollow fibrous containers with a closable opening face challenges in achieving suitable mechanical properties and a secure bond between the opening and the connecting element, particularly for biodegradable materials, while being energy-efficient and time-effective.
Innovation Solution
A method involving a split suction mold with a porous wall and a holder for precise placement of a connecting element, followed by fiber deposition, compaction, and drying processes to create a strong bond between the connecting element and the hollow body, using biodegradable thermoplastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting element is manufactured separately and joined to the dried fiber-shaped body, then the production process is complex and time-consuming, but the connection between the connecting element and the hollow body may be secure
Solution Approach 1:
The invention combines the formation of the hollow body and the attachment of the connecting element into a single simultaneous process step. The connecting element is placed in the mold cavity before the fibrous material is introduced, allowing both components to be formed and bonded together in one operation, eliminating separate manufacturing and joining steps.
Solution Approach 2:
The connecting element is positioned and secured in the mold cavity before the fibrous material is introduced. This preliminary placement ensures proper positioning and allows the fibrous material to bond to the connecting element during the forming process itself, rather than requiring separate attachment operations afterward.
2Productivity
If the connecting element is injection-molded onto the dried fiber-shaped body, then the production process is simplified, but the mechanical properties and bond strength may be compromised
Solution Approach 1:
The invention merges the injection molding of the connecting element with the fiber casting process. Both operations occur simultaneously within the same mold cavity, allowing the thermoplastic connecting element to be formed and bonded to the fibrous hollow body in one continuous process, maintaining both efficiency and bond strength.
Solution Approach 2:
The invention uses the thermal properties of thermoplastic materials during the fiber casting process. The heat from the fibrous material or the mold causes the thermoplastic connecting element to soften and bond with the fibrous structure, creating a strong mechanical bond without requiring separate joining operations.
3Strength
If the fibrous material is reinforced to achieve high strength for caps, then the mechanical properties are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention creates a composite structure where the thermoplastic connecting element and the fibrous hollow body are bonded together to form a unified component with enhanced mechanical properties. The thermoplastic material provides structural strength and rigidity to the opening area, while the fibrous material maintains its biodegradable characteristics.
Solution Approach 2:
The invention applies reinforcement locally only at the opening area where the connecting element is attached, rather than reinforcing the entire hollow body. This localized approach provides the necessary mechanical strength for cap attachment while keeping the rest of the biodegradable container structure simple and lightweight.
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
Enables rapid, energy-efficient production of biodegradable containers with a secure and reliable connection between the connecting element and the hollow body, ensuring mechanical stability and ease of handling.
Implementation Method 1
drawing in fibrous material from a pulp through the wall of the suction mold, so that a hollow body of fibrous material is formed
Implementation Method 2
the holder protrudes through the suction mold opening and holds the connecting element in the suction mold opening
Implementation Method 3
compacting the formed hollow body with the connecting element attached to it
Implementation Method 4
drying the hollow body
Data Source
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AI summary
The invention relates to a method and a device for producing a container with a hollow body (1) made of fibrous material having an opening (2) and a connecting element (3) arranged on the hollow body and surrounding the opening (2). The object of the invention is to provide a method with a short process time and a low energy input. The method comprises the following method steps: - providing a partitioned suction mould (4) having a porous wall (5) that, in the closed state, surrounds at least one cavity (6) with a mould opening (7); - arranging the connecting element (3) on a holder (8) and inserting the holder (8) into the cavity (6) of the suction mould (4) in such a way that the holder (8) protrudes through the mould opening (7) and holds the connecting element (3) in the mould opening (7); - closing the partitioned suction mould (4) and sucking fibrous material from a pulp (13) through the wall (5) of the suction mould (4) in such a way that a hollow body (1) is formed between the holder (8) and the wall (5); - compacting the hollow body (1) with the connecting element (3) arranged thereon; and - drying the hollow body (1). To enable reliable handling of the hollow body, the hollow body (1) is removed from the partitioned suction mould (4) by the holder (8).