Hollow Board Forming Machine with Automatic Roll Exchange
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Solution Overview
Problem
Current methods for producing low-weight building elements for furniture are not cost-efficient and lack flexibility in production processes, particularly in forming hollow board materials using medium or high-density fiberboard.
Innovation Solution
A method and machine are developed to efficiently produce hollow board materials by unwinding medium or high-density fiberboard, flattening it, and attaching spacing elements to form a hollow structure, allowing for automatic roll exchange and compact production line design, enabling the production of strong yet lightweight boards with improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to produce hollow board materials, then production cost efficiency is poor, but the patent achieves cost-effectiveness through continuous unwinding and flattening processes
Solution Approach 1:
The patent implements continuous production by unwinding fiber board from rolls and immediately flattening it in a continuous process, eliminating intermittent stopping and starting. This continuous operation significantly improves both cost efficiency and productivity compared to traditional batch methods.
Solution Approach 2:
The fiber board is unwound and flattened before being used to form the hollow structure. This preliminary preparation action ensures the material is ready for immediate processing, eliminating delays and improving overall production efficiency.
2Adaptability or versatility
If fiber board is unwound from rolls, then production flexibility is improved, but the web may have curvature that affects surface quality
Solution Approach 1:
The curved web is flattened in a preliminary action before forming the hollow structure. This ensures the surface quality is corrected early in the process, allowing the material to be properly shaped without defects from previous curvature.
Solution Approach 2:
The physical state of the fiber board changes from a curved rolled state to a flattened sheet state through the flattening process. This parameter change (from curved to flat) resolves the surface quality issue while maintaining production flexibility.
3Strength
If spacing elements are attached to form hollow structure, then mechanical strength is improved, but production time increases
Solution Approach 1:
Spacing elements are prepared and positioned in advance before the final assembly step. This preliminary arrangement allows for rapid attachment to the hollow structure, minimizing the time required while ensuring proper spacing and structural strength.
4Ease of operation
If roll exchange is manual, then operation simplicity is maintained, but productivity decreases due to stopping
Solution Approach 1:
The system is designed to allow automatic roll exchange without requiring manual intervention to stop the production line. The mechanism enables self-service roll changing, maintaining continuous operation while keeping the process relatively simple.
Data Source
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AI summary
A machine and a method of forming an at least partly hollow board material, the method including: supplying medium and/or high density fiber board (20) wound up on at least one board element roll (1000), unwinding the medium or high density fiber board (20) from the roll (1000), and flattening the same to form at least a first flat fiber board element (23), forming spacing elements (25, 26) on the first flat fiber board element (23), and attaching at least a second flat fiber board element (24) on top of the spacing elements (25, 26) to form a hollow board (3) having the first and second fiber board elements (23, 24) connected to each other by means of the spacing elements (25, 26).