Particle Board Density Control via Selective Mat Formation
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Solution Overview
Problem
Existing methods for producing particle boards with varying density in the longitudinal and lateral dimensions either waste valuable raw material, result in undesired density increases at intersections, or are not suitable for high production speeds, and fail to achieve sharp boundaries between areas of normal and increased density.
Innovation Solution
A method and apparatus that form a particle mat by providing a movable support and a curtain of falling particles, with retractable particle removing means positioned to temporarily remove particles at predetermined points, allowing for the creation of areas with distinct thickness and density patterns, enabling the production of particle boards with sharp edges and efficient material use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stripper devices are used to strip off particles in the mat above a certain height to produce varying density, then density distribution can be controlled, but production speed is reduced and the method is not suitable for very high production speed
Solution Approach 1:
The invention applies preliminary action by creating the desired density distribution pattern in the particle mat before the pressing stage. The particle distributing means deposits particles in a predetermined pattern during mat formation, so that when the mat is pressed, the density variation is already established, eliminating the need for post-formation stripping operations that reduce production speed
Solution Approach 2:
The invention extracts the density control function from the pressing stage and moves it to the particle distribution stage. By taking out the particle removal operation (stripping) and replacing it with selective particle deposition, the process achieves density control without the speed-penalty associated with stripping devices
2Manufacturing precision
If stripper devices are used to create stripes of different height in the mat, then varying density can be achieved, but stripes extending in the lateral dimension cannot be produced
Solution Approach 1:
The invention applies local quality by enabling different particle distribution characteristics in different regions of the mat. The particle distributing means can be configured to deposit particles with varying local densities in longitudinal, lateral, or radial directions, creating well-defined areas of increased density with sharp boundaries, including lateral stripes that were previously impossible
Solution Approach 2:
The invention extends density control from one dimension to multiple dimensions. While traditional stripping devices could only create longitudinal variations, the particle distribution system can create density patterns in longitudinal, lateral, and radial dimensions simultaneously, enabling complex multi-dimensional density distributions including lateral stripes
3Ease of manufacture
If conventional particle board production methods are used, then production is simple, but valuable raw material is wasted
Solution Approach 1:
The invention changes the particle distribution parameters during mat formation to achieve the desired density distribution without material removal. By controlling particle deposition parameters (quantity, position, timing) rather than removing particles afterward, the process eliminates raw material waste while maintaining operational simplicity through automated distribution control
Solution Approach 2:
The invention replaces the mechanical particle removal system (stripper devices) with a particle deposition system. Instead of mechanically stripping particles from the mat, the system uses controlled particle distribution to achieve the same density variation effect without waste, substituting a additive approach for a subtractive one
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 allows for the production of particle boards with well-defined areas of increased density, avoiding material waste and achieving high production speeds while maintaining sharp boundaries between normal and high-density areas, thus addressing the limitations of previous methods.
Implementation Method 1
providing a curtain of downfalling particles, said curtain extending from said particle providing means towards said movable support
Data Source
Figure 1~2B
Figure 3A~3C
Figure 4A~4C
AI summary
The present invention is in the technical field of producing particle boards. More specifically, the present invention relates to the production of particle boards having varying density in the longitudinal and/or in the lateral dimension of the board. The present invention further relates to apparatuses for in the production of such particle boards, and to methods of using same.