Intelligent Drying Apparatus for Pulp Molding
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Solution Overview
Problem
The existing dry-type pulp-molding process is inefficient due to high energy consumption, uneven drying, and manual handling, leading to poor product quality and low production efficiency, as it requires extensive manual handling and inconsistent drying conditions, resulting in uneven moisture content and mechanical property issues in cushion pieces.
Innovation Solution
A semi-wet pulp-molding process with in-line automatic production stages, utilizing an intelligent drying apparatus that combines infrared irradiation and hot-wind blowing for self-adaptive drying and controlled moisture addition to achieve even drying and optimal moisture content, integrated with programmable control for precise processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If outdoor solarized field drying is used for desiccation, then energy consumption is reduced, but drying time becomes excessively long (24-48 hours)
Solution Approach 1:
The patent applies dynamics by transitioning from static outdoor solar drying to a dynamic indoor drying system with controllable temperature and humidity conditions. The drying chamber can adjust environmental parameters to optimize both energy efficiency and drying time, resolving the contradiction between low energy consumption and short drying time.
Solution Approach 2:
The patent changes the drying parameters from natural outdoor conditions to controlled indoor environmental conditions (temperature, humidity, air circulation). This parameter change enables faster drying while maintaining energy efficiency, as the controlled environment prevents energy loss and accelerates moisture removal without requiring excessive energy input.
2Ease of manufacture
If consistent desiccating conditions are applied to entire structure, then processing simplicity is maintained, but local moisture content becomes uneven due to different thicknesses and heights
Solution Approach 1:
The patent applies local quality by differentiating drying conditions for different regions of the semi-finished product based on their thickness and height characteristics. The system can selectively adjust temperature, humidity, and air circulation in different zones to achieve uniform moisture content throughout the product, resolving the contradiction between simple processing and precise moisture control.
Solution Approach 2:
The patent segments the drying process into multiple zones or stages that can be independently controlled. By dividing the drying chamber into regions with different environmental conditions tailored to local requirements, the system achieves uniform drying while maintaining overall processing simplicity through automated control.
3Ease of operation
If manual handling is used for production stages, then operational flexibility is maintained, but production efficiency becomes low and labor costs increase
Solution Approach 1:
The patent applies self-service by implementing an automated drying system that operates without continuous manual intervention. The system automatically controls temperature, humidity, and air circulation, and can monitor and adjust conditions based on preset parameters, thereby increasing production efficiency while maintaining operational flexibility through programmable control.
Solution Approach 2:
The patent incorporates feedback mechanisms that allow the drying system to automatically monitor and adjust conditions based on real-time measurements. This feedback loop enables the system to maintain optimal drying conditions while operating autonomously, resolving the contradiction between manual operational flexibility and automated production efficiency.
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
This approach significantly reduces production time and labor costs, enhances product yield and quality by ensuring consistent, even drying and optimal moisture content, improving mechanical properties and processing efficiency.
Implementation Method 1
a number of infrared lamps located at different locations within said at least one conveying line, for respectively irradiating infrared rays onto said different portions of said semi-finished product
Implementation Method 2
at least one first desiccating fan, which has a number of outlets located at different locations within said at least one conveying line
Data Source
AI summary
A pulp-molding process and an in-line intelligently drying apparatus therefor, comprise: implementing intelligent-circulation desiccating step and intelligently-wetting step in sequence, between pulp-dredging and forming step and thermo-compression forming step. Intelligent-circulation desiccating step comprises: in accordance to structure and/or outer contour of pulp-molding article, implementing combination of both infrared irradiation step and hot-wind blowing step, thereby self-adaptive eliminating different moistures contained within different portions of initially-compressed semi-finished product, to form evenly-dried semi-finished product. Intelligently-wetting step comprises: in accordance to structure and/or outer contour of pulp-molding article, spray-sprinkling predetermined different adaptive amount of water over different local location within dried semi-finished product, thereby forming wetted semi-finished product having averaged moisture content.