Rotating Hub Forming Unit for Paper-Plastic Product Production
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Solution Overview
Problem
Conventional production processes for rotating hub type paper-plastic products are inefficient, occupying excessive space and leading to decreased productivity due to time-consuming drying processes and high labor and energy consumption.
Innovation Solution
The proposed production process and apparatus feature a rotating hub forming unit, an array unit with profiling jigs, and transfer mechanisms that enable continuous, efficient production of paper-plastic products by reducing space occupancy and enhancing productivity through optimized material handling and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional hot air dryer is used to dry primary blanks, then the primary blanks can be dehumidified, but the drying process is time-consuming and occupies excessive space
Solution Approach 1:
The patent extracts the drying function from the conventional hot air dryer and integrates it directly into the hub forming machine. The primary blanks are dried in-situ within the molding cavity using heating elements, eliminating the need for a separate drying station and reducing both time and space requirements.
Solution Approach 2:
The drying function is merged with the hub forming machine by incorporating heating elements within the molding cavity. This combination allows the primary blanks to be dried during the molding process itself, rather than requiring a separate drying step in a dedicated hot air dryer.
2Quantity of substance
If a conventional hot air dryer is used to dry primary blanks, then the primary blanks can be dehumidified, but the apparatus occupies excessive space
Solution Approach 1:
The drying function is merged with the hub forming machine by incorporating heating elements within the molding cavity. This combination allows the primary blanks to be dried during the molding process itself, rather than requiring a separate drying step in a dedicated hot air dryer, thereby reducing the overall apparatus footprint.
Solution Approach 2:
The heating elements are nested within the molding cavity of the hub forming machine. This nesting approach allows the drying function to be embedded within the existing structure, eliminating the need for external drying equipment and reducing space occupation.
3Ease of manufacture
If conventional production process is used with separate drying and hot pressing stations, then the production steps can be performed, but labor and energy consumption are high
Solution Approach 1:
The patent merges multiple functions (molding, drying, and hot pressing) into a single integrated hub forming machine. This consolidation eliminates the need for separate drying and hot pressing stations, reducing both labor requirements and energy consumption while maintaining complete production functionality.
Solution Approach 2:
The integrated system enables continuous operation where primary blanks are molded, dried, and hot-pressed in sequence within the same machine without requiring transfer between stations. This continuity eliminates idle time and reduces energy losses associated with moving blanks between separate equipment.
4Ease of manufacture
If conventional production process with multiple separate stations is used, then the production steps can be performed, but productivity is decreased
Solution Approach 1:
The patent merges multiple functions (molding, drying, and hot pressing) into a single integrated hub forming machine. This consolidation enables all production steps to be completed in one continuous operation, significantly improving productivity compared to conventional processes that require transfer between separate stations.
Solution Approach 2:
The integrated system enables continuous operation where primary blanks are molded, dried, and hot-pressed in sequence within the same machine without requiring transfer between stations. This continuity eliminates idle time and improves overall production efficiency.
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 solution reduces space occupancy, decreases energy and labor consumption, and enhances productivity by enabling continuous, efficient production of paper-plastic products, thus lowering production costs.
Implementation Method 1
a suction device is used to vacuum the slurry in the pulp box through the suction mold, so that the mold surface of the suction mold is formed into a 'shell' material layer
Implementation Method 2
When the suction die absorbs the billet layer and rises out of the box, the billet layer is gradually dehumidified due to the continuous suction
Implementation Method 3
Generally, the hot air drying production process is adopted, so that the primary blanks can be quickly dehumidified
Implementation Method 4
The primary blanks removed from the drying area are immediately sent to a 'hot pressing and setting mechanism' to perform hot pressing and setting operations on the primary blanks in a relatively low-humidity state, so that they are completely dried and shaped
Data Source
AI summary
Provided are a production process for a rotating hub type paper-plastic product, and a device utilizing the production process. The device comprises: a rotating hub forming unit, which can continuously generate a primary blank; an array unit, which forms, by means of an uplink lifting mechanism, a downlink descending mechanism, an uplink array channel and a downlink array channel, a carrier capable of moving in a circulating and reciprocating manner for a profiling jig plate moving in a reciprocating manner thereon; a left forming area unit and a right forming area unit which are respectively arranged at two sides of the array unit and are internally provided with machining areas for a plurality of hot-pressing shaping mechanisms and a plurality of edge cutting mechanisms for use in hot-pressing shaping and edge cutting of the primary blank; a first transfer mechanism and a second transfer mechanism which stretch across the array unit and the left and right forming area units and are provided with a plurality of conveying molds in a suspended manner, so that the primary blank can be transferred; two discharging conveyors which are respectively arranged on the outermost sides of the left and right forming area units; and two defective product conveyors which are arranged between each of the left and right forming area units and each of the discharging conveyors for outputting a defective product which is subjected to screening.