Modular Compression Moulding Tool for Custom Fibrous Pulp Trays
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Solution Overview
Problem
Existing manufacturing tools for fibrous pulp containers lack flexibility and efficiency, leading to high material waste and prolonged setup times, and do not adequately address the need for customizable and sustainable packaging solutions.
Innovation Solution
A modular compression moulding tool with interchangeable components, including a base element, bottom insert, and central insert, featuring slits for dewatering and vacuum-assisted water removal, and a frame for secure assembly, allowing for customizable tray designs and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fixed compression moulding tools are used, then manufacturing stability is maintained, but flexibility and customization capability are poor
Solution Approach 1:
The compression moulding tool is divided into modular components including a base element, bottom insert, central insert, and frame. Each component can be independently replaced or adjusted to create different tray configurations, enabling customization without redesigning the entire tool.
Solution Approach 2:
The tool incorporates adjustable elements such as the bottom insert and central insert that can be positioned at different locations and orientations. This dynamic configurability allows the same base tool to produce various tray designs by simply repositioning or replacing inserts.
2Adaptability or versatility
If entire tools are replaced to manufacture different tray configurations, then product customization is achieved, but material waste and production time increase
Solution Approach 1:
By segmenting the tool into reusable base elements and replaceable inserts, the invention enables production of different tray configurations using the same base tool, thereby avoiding the material waste associated with manufacturing entirely new tools for each product variant.
Solution Approach 2:
The modular insert components can be easily removed, recovered, and reused for producing different tray designs. This recovery and reuse of tool components eliminates the need to discard and replace entire tools, reducing material waste.
3Productivity
If traditional moulding tools without modular components are used, then manufacturing simplicity is maintained, but setup time for different products increases
Solution Approach 1:
The segmented modular design allows quick replacement of inserts between production runs. Operators can rapidly swap bottom inserts and central inserts to transition between different tray configurations, significantly reducing setup time compared to traditional fixed tools.
Solution Approach 2:
Different insert configurations can be prepared in advance and stored for quick exchange. This preliminary preparation of alternative inserts enables rapid tool reconfiguration without requiring time-consuming adjustments or redesigns during production changes.
4Use of energy by moving object
If adequate dewatering capability is not provided, then tool simplicity is maintained, but energy efficiency and drying time are adversely affected
Solution Approach 1:
The dewatering system is segmented into multiple slits distributed across the tool surfaces. These slits work together to efficiently remove water from the pulp product during compression, reducing drying time and energy consumption without requiring a single complex dewatering mechanism.
Solution Approach 2:
The slits in the base element and inserts create channels for water evacuation during the compression process. This passive hydraulic dewatering mechanism efficiently removes excess water from the pulp, improving energy efficiency and reducing drying time without adding active pumping systems.
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 rapid customization, reduced material waste, and improved energy efficiency in producing fibrous pulp trays with enhanced structural integrity and moisture removal, suitable for various food packaging applications.
Implementation Method 1
the base element and the bottom insert are configured to form a first slit between the bottom insert and the sidewall of the base element and second slit between the bottom insert and the central portion, each of the first and second slit being configured to dewater a fibrous pulp product arranged in the compression moulding tool
Implementation Method 2
the slits preferably lead to dewatering channels which in turn are connected to a pump forming a vacuum to thereby draw water from the pulp
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A modular compression moulding tool (100) for manufacturing a fibrous pulp tray, the moulding tool comprising: a base element (102) comprising a floor (104), sidewalls (106) and a central portion (108) being elevated from the floor; a bottom insert (110) configured to be arranged on the floor of the base element and attached to the base element, the bottom insert being configured to encircle the central portion; and a frame (112) configured to be arranged on top of the base element, the frame comprising a fastening arrangement (114) configured to mechanically secure the moulding tool to a support plate (116) to form a female moulding tool.