Multi-Cavity Forming Mould for Cellulose Products
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Solution Overview
Problem
Current forming systems for cellulose products from air-formed cellulose blank structures face limitations in production capacity and quality due to long cycle times and the need for expensive high-precision equipment, as well as challenges in achieving even forming pressure across multiple products.
Innovation Solution
A multi-cavity forming mould system with a first and second mould part, where the second mould part's forming elements are movably arranged with a pressure member to establish consistent forming pressure across multiple cavities, allowing for efficient production of high-quality cellulose products with varying pressure levels if needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If air-formed cellulose blank structure is used instead of wet-formed pulp, then mechanical strength and chemical properties are improved, but production capacity decreases due to long cycle times
Solution Approach 1:
The forming process is segmented into multiple independent cavities within a single press. Each cavity can be independently filled and formed, allowing multiple products to be produced simultaneously in one press cycle, thereby increasing production capacity while maintaining the quality benefits of air-formed cellulose
2Productivity
If multiple products are formed in a single pressure-forming step, then production capacity increases, but achieving even forming pressure becomes difficult
Solution Approach 1:
Each cavity is equipped with its own independently controllable pressure applying mechanism, allowing the forming pressure to be locally adjusted and optimized for each cavity. This ensures even forming pressure across all cavities while maintaining high production capacity
Solution Approach 2:
The system allows independent control of pressure parameters for each cavity. By adjusting pressure, temperature, and timing parameters individually for each cavity, uniform forming quality is achieved across multiple products formed simultaneously
3Manufacturing precision
If high precision pressing equipment is used to achieve even forming pressure, then product quality is improved, but equipment cost increases
Solution Approach 1:
The pressing system is divided into multiple independent pressure applying units, each serving a specific cavity. This segmentation allows the use of simpler, less expensive pressing mechanisms for each unit while collectively achieving even pressure distribution across all cavities, reducing overall equipment cost
Solution Approach 2:
Pressure distributing elements or intermediary components are introduced between the pressing mechanism and the cellulose blank. These intermediaries help distribute pressure evenly across multiple cavities, allowing the use of less expensive pressing equipment while maintaining forming precision
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 increases production capacity and ensures consistent quality by maintaining even forming pressure across multiple products, reducing cycle time and equipment costs, while enabling the production of diverse cellulose products with precise pressure control.
Implementation Method 1
The pressure member is configured for establishing a forming pressure in each forming cavity onto the cellulose blank structure during forming of the cellulose products
Data Source
AI summary
A multi-cavity forming mould system for forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure. The forming mould system includes a first mould part and a second mould part arranged for cooperating with each other during forming of the cellulose products. The first mould part includes a plurality of first forming elements and the second mould part comprises a plurality of corresponding second forming elements movably arranged in relation to a base structure of the second mould part. The forming mould system is configured for establishing a plurality of forming cavities for the cellulose blank structure between each first forming element and corresponding second forming element during formation of the cellulose products. Each second forming element is arranged for interacting with a pressure member arranged in the base structure, where the pressure member is configured for establishing a forming pressure in each forming cavity onto the cellulose blank structure during formation of the cellulose products.