Fibrous Structure Forming for Parallel-Wall 3D Features
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Solution Overview
Problem
Existing techniques for forming cellulose fiber structures struggle to efficiently create 3D features with facing parallel walls or surfaces, such as cylindrical protrusions, due to geometric constraints and shearing friction, limiting their application in sustainable alternatives to plastic products.
Innovation Solution
A method using a first forming tool with a porous surface and controlled fluid passage ports, combined with angled forming surfaces, allows for the formation of cellulose fiber structures with near-parallel or parallel features by employing vacuum or positive pressure to agglomerate fibers on a shaped surface, followed by compression with additional forming tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forming tools with parallel surfaces are used to create 3D features with facing parallel walls, then the manufacturing precision of such features is improved, but the process complexity and defects increase due to shearing friction
Solution Approach 1:
The forming process is divided into multiple sequential steps with different forming tools. Each step addresses specific geometric features, allowing complex 3D structures to be built incrementally rather than attempted in a single operation. This segmentation enables precise control over parallel wall formation while avoiding the complexity of single-step multi-directional compression.
Solution Approach 2:
The invention transitions from single-direction compression to multi-directional compression by introducing a second forming tool that applies force from a different dimension. This allows parallel surfaces to be formed through sequential compression in different directions, achieving the desired precision without the shearing friction problems of simultaneous multi-directional compression.
2Manufacturing precision
If multiple forming tools are used to compress pulp agglomeration from varying directions, then the manufacturing precision of 3D features is improved, but the device complexity and process inefficiency increase
Solution Approach 1:
The forming process is divided into sequential steps where each forming tool performs a specific compression function in a particular direction. This segmentation allows for precise control over the compression process, with each step optimized for its specific geometric requirements, thereby maintaining productivity while achieving high precision.
Solution Approach 2:
The first forming tool performs preliminary compression to establish the basic shape and aggregate fibers before the second forming tool applies additional compression from a different direction. This preliminary action prepares the pulp agglomeration for subsequent precise shaping, reducing the overall complexity and improving efficiency by breaking down the forming process into manageable stages.
3Manufacturing precision
If forming surfaces are angled less than 7 degrees to reduce displacement of pulp agglomeration, then the manufacturing precision is improved, but the ability to form parallel walls is limited
Solution Approach 1:
The forming process is segmented into multiple steps with different forming tools, each applying compression from different directions. This allows the accumulation of precise angular control to achieve parallel walls, as each step contributes a controlled angle that builds toward the final parallel surface configuration without requiring any single tool to achieve the full angle.
Solution Approach 2:
Instead of relying on a single forming surface angle, the invention uses multi-directional compression where forming tools apply force from different spatial dimensions. This allows parallel walls to be formed through the cumulative effect of controlled angles in multiple directions, overcoming the limitation of single-angle forming surfaces.
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 the efficient creation of cellulose fiber structures with complex 3D features, reducing defects and complexity, and providing a sustainable alternative to plastic products like tampon applicators.
Implementation Method 1
Pores or ports opening at the first forming surface are of a size that is suitably small enough to prevent passage of any substantial quantity of the fibers through the first tool, such that carrier fluid is drawn or pumped through the first tool and a majority of the fibers in the slurry are not. In effect, the first tool filters the fibers from the slurry, collects an agglomeration of the fibers on the first forming surface, and allows carrier fluid to pass therethrough.
Implementation Method 2
applying vacuum to fluid in contact with the first non-forming surface; and/or applying positive pressure to the slurry composition in contact with the first forming surface, thereby drawing or urging the slurry composition to the first forming surface, and drawing or urging a portion of the carrier fluid in the quantity through the first pattern of ports
Implementation Method 3
applying vacuum to fluid in contact with the first non-forming surface
Implementation Method 4
applying opposing force along the longitudinal axes thereby applying pressure on the fiber agglomeration between the first forming surface and the second forming surface, whereby a first remaining portion of the carrier fluid is expressed from the fiber agglomeration
Implementation Method 5
heating energy may be provided to one or both of the first forming tool and second forming tool to cause evaporation of carrier fluid and/or impart a set to the fibers, and thereby add stiffness and strength to the structure
Data Source
AI summary
A structure comprising a continuous agglomeration of cellulose fibers which includes an outer surface having an outer shape with a longitudinal axis and a length measured along a direction parallel to the longitudinal axis. The outer surface has at least a portion lying at a formation angle relative the longitudinal axis that is greater than 0 degrees and less than or equal to 2 degrees.