Pulp Forming Mold Layout for Faster Hot Pressing and Demolding
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Solution Overview
Problem
Existing forming machines for pulp products have inefficiencies in process time and equipment complexity, requiring multiple components and high costs due to independent operation of multiple molds and drive devices.
Innovation Solution
A forming machine design with a frame unit, forming unit, lower mold unit, and upper mold unit, where the upper mold unit moves between two positions to facilitate simultaneous forming, first and second hot pressing, and demolding of pulp blanks, reducing the need for multiple drive devices and simplifying the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two hot-press lower molds work independently using two drive devices, then the production capacity is increased, but the device complexity and equipment costs increase
Solution Approach 1:
The patent merges the drive mechanisms of the first and second hot-press lower molds into a single shared drive device. Both molds are coupled to the same drive mechanism, allowing them to be driven simultaneously or sequentially by one motor, thereby reducing equipment complexity and costs while maintaining the capability to process multiple blank units in parallel
Solution Approach 2:
The single drive device is designed to serve multiple functions by driving both the first hot-press lower mold and the second hot-press lower mold. This universal drive mechanism can independently control each mold's movement, enabling flexible operation modes (simultaneous or sequential processing) without requiring separate dedicated drives for each mold
2Ease of operation
If the first and second hot-press lower molds stay in three positions, then the scooping, hot pressing and demolding processes are achieved, but the process time is extended
Solution Approach 1:
The patent implements continuous parallel processing where the forming mold continuously forms blank units while the first and second hot-press lower molds simultaneously or sequentially process different blank units at different stages. The synchronized movement of multiple molds along the vertical direction enables overlapping operations, eliminating idle time and achieving continuous productive action throughout the system
Solution Approach 2:
The forming mold prepares blank units in advance and transfers them to the hot-press lower molds before the hot pressing cycle completes. This preliminary preparation and transfer of subsequent blank units allows the system to maintain continuous operation without waiting for each complete cycle to finish, thereby reducing overall process time
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 design allows for sequential forming, first hot pressing, second hot pressing, and demolding of pulp blanks, shortening processing time and reducing equipment costs by using a single drive source for the upper mold unit, thereby simplifying the structure and reducing costs.
Implementation Method 1
a forming mold movable relative to the frame unit toward and away from the pulp tank along a vertical direction. The forming mold is configured for scooping the pulp and forming a blank unit thereon for every scoop of the pulp
Implementation Method 2
one of the lower molds disposed in the other hot pressing zone is movable to engage the one of the upper hot-pressing central molds for hot pressing the blank unit
Implementation Method 3
the forming mold is configured to scoop the pulp from the pulp tank and form a blank unit and is movable to engage the one of the upper hot-pressing central molds for mold pressing the blank unit
Data Source
AI summary
A forming machine for a pulp product includes a frame unit defining a forming zone, two hot pressing zones, and two demolding zones; a forming unit disposed in the forming zone and including a forming mold for scooping pulp from a pulp tank and forming a blank unit thereon for every scoop of the pulp; a lower mold unit including four lower molds movable relative to the frame unit along a vertical direction, and an upper mold unit movable between two positions along a moving direction in a repetitive manner and including two upper hot-pressing central molds and two upper hot-pressing transfer molds. The upper mold unit is engageable with the forming mold and a corresponding one of the lower molds in different positions.