Flexible Cutting Element for Dry-Forming Mould Lifespan
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Solution Overview
Problem
Existing dry-forming mould systems for cellulose products face challenges with cutting tool bluntness, leading to a limited lifespan of forming moulds and increased costs for frequent replacements.
Innovation Solution
A dry-forming mould system featuring a flexible cutting element with a cutting edge that is releasably attached to the first mould part, allowing for efficient cutting operations and easy exchange of the cutting element, thereby extending the life span of the mould parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cutting tool is integrated into the forming mould for cutting cellulose products, then the product edge structure can be formed, but the cutting tool blunts with regular use and the mould has limited lifespan
Solution Approach 1:
The cutting function is segmented from the forming mould body. A separate flexible cutting element is attached to the mould part, allowing the cutting edge to be replaced independently when blunted, while the main mould structure remains intact and reusable.
Solution Approach 2:
The flexible cutting element is designed as a consumable component that can be discarded when blunted. The expensive mould part is recovered and reused by simply replacing the inexpensive cutting element, minimizing waste and cost.
2Manufacturing precision
If the forming mould is replaced when the cutting tool blunts, then the cutting precision is maintained, but the operation is time consuming and costly
Solution Approach 1:
The cutting element is separated as an independent replaceable component from the mould body. This allows only the small cutting element to be replaced rather than the entire large and expensive mould assembly, significantly reducing replacement time and cost.
Solution Approach 2:
The flexible cutting element is designed as a low-cost, short-lifespan component that is easily replaceable. When it blunts, a new inexpensive element is attached to the expensive mould, avoiding the need to replace the entire mould and minimizing production downtime.
3Shape
If a rigid cutting tool is used in the forming mould, then the cutting edge can maintain shape, but the mould part cannot be easily adjusted or modified
Solution Approach 1:
The cutting element is made flexible rather than rigid, allowing it to be attached in different configurations and orientations. This flexibility enables the same mould part to be adapted for different product shapes and cutting requirements by simply repositioning or replacing the cutting element.
Solution Approach 2:
The flexible cutting element can be adjusted in terms of its position, orientation, and attachment method on the mould part. This allows the cutting parameters to be changed without modifying the mould structure itself, providing adaptability for different production needs.
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 system enables efficient cutting of cellulose products with a flexible cutting element that can be easily replaced, extending the life span of the mould parts and reducing the cost and time associated with frequent mould changes.
Implementation Method 1
the first mould part and the second mould part are configured for being pressed together in the pressing direction in a first pressing stroke to apply a forming pressure onto the cellulose blank structure
Implementation Method 2
The flexible cutting element is configured for cutting out the cellulose product from the cellulose blank structure by pressing the cutting edge towards and in contact with the anvil plate with a predetermined cutting force
Data Source
Figure 1a~1b
Figure 1c
Figure 2a~2b
AI summary
A dry-forming mould system and method for dry-forming a cellulose product from an air-formed cellulose blank structure. The dry-forming mould system comprises a first mould part and an opposing second mould part configured for cooperating with each other in a pressing direction upon forming of the cellulose product. The first mould part and the second mould part are configured for being pressed together in the pressing direction in a first pressing stroke to apply a forming pressure onto the cellulose blank structure. A flexible cutting element with a cutting edge configured for operating in the pressing direction is releasably attached to the first mould part, and the second mould part comprises an anvil plate arranged to cooperate with the cutting edge of the flexible cutting element. The flexible cutting element is configured for cutting out the cellulose product from the cellulose blank structure by pressing the cutting edge towards and in contact with the anvil plate with a predetermined cutting force, simultaneously with the first pressing stroke or in a second pressing stroke in the pressing direction after start of the first pressing stroke.