Pinned Bar Mat Densification for Uniform Fiber Density
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Solution Overview
Problem
Conventional apparatuses for densifying fibrous mats in engineered wood production fail to achieve uniform density across the width of the mat, leading to inconsistent moisture content and strength, which can result in delamination, insufficient bonding, and inconsistent wood dimensions.
Innovation Solution
An apparatus featuring parallel bars with pins, accordion linkages, and a linear positioning assembly that uniformly compresses the fibrous mat by adjusting the spacing between the bars, ensuring consistent compressive force across the mat width, and a stripper assembly for removing adherent fibers, controlled by a processor calculating densification values based on weight and surface area data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional parallel vertical plates are used to compress the mat, then the mat can be densified, but the compressive force is not evenly applied across the width resulting in nonuniform density
Solution Approach 1:
The continuous plate compression system is segmented into multiple discrete pin elements distributed across the mat width. Each pin applies localized compressive force, transforming the uniform plate pressure into distributed point loads that collectively achieve uniform densification across the entire mat width.
Solution Approach 2:
Instead of applying uniform compression through continuous plates, the system uses locally distributed pins that apply compressive force at specific discrete locations across the mat width. This local quality approach ensures that each region of the mat receives appropriate compressive force, resulting in uniform density distribution.
2Reliability
If the mat has nonuniform density, then the manufacturing process is simpler, but the moisture content becomes inconsistent leading to delamination or insufficient bonding
Solution Approach 1:
The system incorporates sensors that detect mat characteristics and provide feedback to the control system. This feedback enables real-time adjustment of pin compression forces to achieve uniform density, ensuring consistent moisture content and reliable bonding in the final wood product.
Solution Approach 2:
The system dynamically adjusts compression parameters (force, duration, pin positioning) based on detected mat properties. By changing these parameters in response to varying mat conditions, the system achieves uniform density and consistent moisture content, preventing delamination and bonding failures.
3Productivity
If immature trees are used to provide limitless wood source, then the supply is increased, but the fiber density variation is greater requiring improved densification methods
Solution Approach 1:
The densification system is designed to be dynamic and adaptive, adjusting pin compression forces in real-time based on detected variations in fiber density. This dynamic response allows the system to handle the greater variability inherent in immature tree fibers, maintaining uniform density output despite varying input material quality.
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 apparatus achieves a uniformly densified and uniformly moistened fibrous mat, enhancing the strength and predictability of the final wood product by ensuring consistent density and moisture content across the entire mat width.
Implementation Method 1
a reciprocating drive mechanism coupled to one of the bars which can move the bars in response to an actuation signal. As the drive mechanism retracts the bar to which it is coupled the spacing between the rows of bars is decreased uniformly and the rows of pins draw the fibers together and compress them uniformly across the width of the mat
Data Source
AI summary
An apparatus and method for densifying a fibrous mat, such as scrim, to achieve a uniform mat density, comprising a set of parallel bars each having a row of pins extending downward therefrom which can engage the mat fibers, a plurality of shafts along which the bars slide so as to maintain the bars parallel, a plurality of extendable accordion linkages connecting the set of bars, and a linear positioning assembly having a reciprocating drive mechanism coupled to one of the bars which can move the bars in response to an actuation signal. As the drive mechanism retracts the bar to which it is coupled the spacing between the rows of bars is decreased uniformly and the rows of pins draw the fibers together and compress them uniformly across the width of the mat.