3D Pulp Molding Vacuum Pressure Adjustment
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Solution Overview
Problem
Current methods for producing molded pulp products are not energy efficient, particularly in the 3D molding process, which consumes significant energy due to high vacuum levels required in multiple pressing steps.
Innovation Solution
A method involving a 3D molded pulp product production process where the pulp slurry is applied to a porous mold, with varying vacuum pressures in successive forming steps, where the first pressure is lower than the second pressure, optimizing energy usage by reducing the energy consumption of vacuum equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high vacuum levels are used in multiple pressing steps, then water removal efficiency is improved, but energy consumption increases significantly
Solution Approach 1:
The vacuum level is dynamically adjusted between different pressing steps. In the first pressing step, a first vacuum level is applied to remove water from the pulp slurry. In the second pressing step, a second vacuum level is applied which is lower than the first vacuum level. This dynamic adjustment optimizes energy consumption while maintaining effective water removal throughout the molding process.
Solution Approach 2:
The vacuum parameter is changed between pressing steps. The patent specifies that the vacuum level should be reduced in the second pressing step compared to the first pressing step. This parameter change allows the system to achieve adequate water removal without requiring continuously high vacuum levels, thereby reducing energy consumption by the vacuum equipment.
2Reliability
If high vacuum levels are maintained throughout the process, then water removal is effective, but vacuum equipment energy consumption increases
Solution Approach 1:
The vacuum application is made periodic rather than continuous at high levels. The patent describes a multi-step process where high vacuum is applied in the first pressing step, then reduced to a lower vacuum level in the second pressing step. This periodic variation in vacuum level maintains water removal effectiveness while reducing the overall energy load on the vacuum equipment.
3Manufacturing precision
If multiple pressing steps with high vacuum are used, then product quality is improved, but energy efficiency deteriorates
Solution Approach 1:
The vacuum level is dynamically adjusted to match the requirements of different pressing steps. The first pressing step uses a higher vacuum level to establish the basic product structure and remove excess water. The second pressing step uses a lower vacuum level to finish the product quality without requiring excessive energy input, thus maintaining energy efficiency while ensuring product 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
This approach significantly saves energy by adjusting vacuum levels between forming steps, enhancing the energy efficiency of the pulp molding process while maintaining product quality and throughput.
Implementation Method 1
drawing a vacuum through the porous forming face of the first mold
Implementation Method 2
heating the pulp slurry layer and drawing a vacuum through the porous forming face
Implementation Method 3
heating the pulp slurry layer
Implementation Method 4
heating the pulp slurry layer and drawing a vacuum through the porous forming face
Implementation Method 5
pressing the pulp slurry layer against the porous forming face of the first mold
Implementation Method 6
pressing the pulp slurry layer against the porous forming face
Data Source
AI summary
A method of producing a 3D molded product comprises applying a pulp slurry layer to a porous forming face of a first mold, pressing the pulp slurry layer against the porous forming face of the first mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the first mold, transferring the pulp slurry layer to a porous forming face of a second mold, in a subsequent forming step, pressing the pulp slurry layer against the porous forming face of the second mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the second mold. In the method, a first pressure at the rear side of the forming face of the porous forming face of the first mold is lower than a second pressure at the rear side of the porous forming face of the second mold.