Moulded Pulp Forming System with Segmented Heads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for forming moulded pulp fibre products are limited by batch-type production and struggle to achieve high production rates, with existing methods resulting in moderate surface finishes and varying wall thicknesses, while also retaining a rough surface finish on one side of the product.
Innovation Solution
A process involving a porous mould with pre-form mould portions that are coated with pulp fibre slurry, where fluid is extracted through the mould using suction, and optionally heated to evaporate liquid, allowing for continuous production and improved surface finishes by varying suction pressure and slurry flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-type production is used with traditional forming heads, then equipment complexity is reduced, but productivity is limited
Solution Approach 1:
The forming system is segmented into multiple independent forming heads (first forming head, second forming head, third forming head) that can operate simultaneously or in sequence. Each forming head has its own suction source and control system, allowing parallel production of multiple pre-forms, thereby increasing overall productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The system enables continuous production by having multiple forming heads operating in parallel or sequence, eliminating the idle time between batches. The controller coordinates the operation of multiple suction sources and forming heads to ensure continuous formation of pre-forms, maintaining productive action without interruption
2Manufacturing precision
If traditional mesh moulds are used, then device complexity is minimized, but manufacturing precision of surface finish deteriorates
Solution Approach 1:
Different regions of the forming system use different mould types optimized for their specific function: mesh moulds are used where structural formation is needed, while solid moulds are used where smooth surface finish is required. The controller selectively activates specific forming heads based on the desired product characteristics, allowing local optimization of surface quality without requiring complete system redesign
Solution Approach 2:
The system employs a composite approach by combining multiple mould types (mesh and solid) within a single integrated forming system. Each mould type contributes its advantageous properties: mesh moulds provide structural integrity and drainage, while solid moulds provide smooth surface finishes. The controller manages the coordination of these different mould types to produce pre-forms with both structural soundness and desired surface quality
3Productivity
If single forming head is used, then device complexity is reduced, but productivity is limited
Solution Approach 1:
The forming system is segmented into multiple independent forming heads (first forming head, second forming head, third forming head) that can operate simultaneously or in sequence. Each forming head has its own suction source and control system, allowing parallel production of multiple pre-forms, thereby increasing overall productivity while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple forming heads are integrated into a single system that can produce different types of pre-forms with different surface finish requirements. The system universally handles both mesh-mould-formed and solid-mould-formed pre-forms, allowing a single multi-headed apparatus to replace multiple single-purpose devices, increasing productivity without proportionally increasing overall system complexity
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 process enables continuous production of moulded pulp fibre products with smoother surfaces and consistent wall thickness, addressing the limitations of batch-type production and surface finish issues in existing methods.
Implementation Method 1
extracting fluid from the slurry deposit through the porous mould to form the pre-form
Implementation Method 2
optionally heated to evaporate liquid
Data Source
AI summary
A process for forming a pre-form for a moulded pulp fibre product involves providing a porous mould that has one or more pre-form mould portions that each have an outer surface corresponding to a surface of the pre-form. Pulp fibre slurry is discharged from an outlet; each pre-form mould portion is coated with discharged pulp fibre slurry by moving the porous mould relative to the outlet. Thus, a slurry deposit for the pre-form is formed on the outer surfaces of the pre-form mould portions. Fluid from the slurry deposit is extracted through the porous mould to form the pre-form.