Pneumatic Flake Deposition on 3D Flocking Tool
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Solution Overview
Problem
Existing methods for producing molded parts from flakes are inefficient due to irregular deposition caused by gravity's varying effects on flakes, leading to complex tool technology requirements and low flow rates, resulting in inconsistent semi-finished products.
Innovation Solution
A method involving flakes and binders introduced into an air flow counter to gravity on a 3D air-permeable flocking tool with variable air pressure, followed by hot air activation and subsequent processing in a steam/vacuum tool to consolidate and shape the semi-finished products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flakes are filled into the mold at low flow rates by gravity, then the deposition is simple, but the depositing is strongly influenced by shape, size and local flow conditions resulting in irregular deposition
Solution Approach 1:
The patent applies pneumatic transport by introducing flakes into the mold cavity through a blowing device that generates a controlled air flow. This pneumatic approach replaces gravity-based filling, allowing uniform distribution of flakes regardless of their shape or size, while maintaining simple process control through pressure regulation.
2Length of stationary object
If side filling is used to introduce flakes laterally, then the tool height can be reduced, but the tool technology becomes complex with numerous injection channels requiring high control effort
Solution Approach 1:
The patent segments the tool into distinct functional zones: a receiving chamber for accumulating flakes, a blowing device for pneumatic transport, and a mold cavity for shaping. This segmentation allows each component to perform its function independently, reducing overall tool height while simplifying control compared to numerous injection channels.
Solution Approach 2:
The patent introduces an intermediary blowing device that acts as a mediator between the flake supply and the mold cavity. This intermediary component consolidates the feeding function into a single controlled air flow system, eliminating the need for multiple injection channels and reducing tool technology complexity.
3Ease of operation
If gravity acts on flocks with varying trajectories, then the filling process is simple, but the flocks are deposited irregularly on the flocking tool
Solution Approach 1:
The patent replaces gravity-based filling with a pneumatic system that introduces flakes into the mold cavity through controlled air flow. This approach ensures uniform flake distribution regardless of trajectory variations, while the process remains simple to operate through pressure control mechanisms.
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 method allows for controlled and consistent production of molded parts with uniform flake distribution and varied properties, enabling easy control over thickness and density, and efficient consolidation of fibers and PU foam flakes into molded components.
Implementation Method 1
flakes and binders are introduced into a separation chamber in an air flow counter to gravity
Implementation Method 2
flakes and binders are introduced into a separation chamber in an air flow counter to gravity
Implementation Method 3
a lower, spatially and/or temporally variable air pressure prevailing behind the flocking tool than in front of the flocking tool
Implementation Method 4
hot air is admitted into the separation space in order to activate the binder, and the semi-finished product is thus at least partially consolidated
Implementation Method 5
the binder is activated by introducing saturated steam, and then a vacuum is drawn to cool the semi-finished product
Implementation Method 6
a vacuum is drawn to cool the semi-finished product
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a method for producing a semi-finished product wherein flakes and binder are introduced in an air stream against gravity into a separation chamber and separated on a three-dimensional, air-permeable flocking tool, wherein a lower air pressure, which can be varied spatially and temporally, is present behind the flocking tool.