Fibrous Material Web Preforming for Complex 3D Shapes
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Solution Overview
Problem
Paper-like material webs are limited in mold depth and product geometry due to their properties, restricting the production of complex three-dimensional products, as they can only be slightly stretched and are prone to damage during forming.
Innovation Solution
A method involving pre-shaping of material webs in three dimensions without stretching or compression, allowing for elevation and alignment to create complex geometries, combined with selective fixing, cutting, and pretreatment to enhance deformability and prevent material damage during shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If paper-like material web is subjected to conventional thermoforming process, then three-dimensional products can be produced, but the forming depth is limited and the material is prone to tearing and damage
Solution Approach 1:
The patent applies preliminary action by pre-forming the material web three-dimensionally before the final pressing step. The material web is deformed in at least one direction to create raised sections that will become side walls or bottom areas of the final product. This pre-forming occurs without stretching or compressing the material, preparing the geometry in advance so that the subsequent pressing step only requires minimal deformation, thereby preventing tearing while achieving large forming depths
Solution Approach 2:
The forming process is segmented into two distinct stages: a pre-forming stage where the material web is deformed to create three-dimensional geometry without stretching, and a final pressing stage where minimal compression is applied. This segmentation allows the material to be prepared in a stress-free manner first, then finalized with minimal deformation, resolving the contradiction between achieving deep forms and preventing material damage
2Shape
If paper-like material web is stretched during forming process, then three-dimensional shape can be achieved, but the material can only be stretched within a very restricted range (2-5%) and is prone to weakening
Solution Approach 1:
The patent performs preliminary three-dimensional deformation of the material web before the final pressing step. By creating raised sections and geometric features in advance without stretching the material, the bulk of the shaping is accomplished through stress-free deformation. This leaves only minimal deformation required in the final pressing step, keeping the total stretching within the safe 2-5% range and preserving material strength
Solution Approach 2:
The patent changes the deformation parameters by distinguishing between pre-forming (no stretching or compressing) and final pressing (minimal compression). This parameter change allows the material to undergo large geometric transformations through displacement rather than stretching, maintaining material strength while achieving complex three-dimensional shapes
3Shape
If material web is deformed to create large forming depths, then complex product geometries can be achieved, but the material is prone to tearing and damage
Solution Approach 1:
The patent applies preliminary action by pre-forming the material web into three-dimensional configurations with raised sections that define future product geometries. This pre-arrangement of material geometry allows complex shapes to be achieved through minimal final deformation, preventing tearing while achieving the desired product complexity
Solution Approach 2:
The pre-formed raised sections act as an intermediary structure between the flat material web and the final pressed product. These intermediate three-dimensional features guide the final pressing process, allowing complex geometries to be achieved with minimal additional deformation, thereby preventing material tearing
Data Source
Figure 1a)~2b)
Figure 2c)~3b)
Figure 4
AI summary
A method for processing planar material webs made of a fibrous material, which are supplied as material web sections or endless material webs, for the production of three-dimensional products is described, wherein, prior to pressing a material web for shaping, the material web is pre-formed three-dimensionally by deforming the material web in at least one direction essentially without stretching or compressing.