Screen Pore Layout for Uniform Flow in Pulp Molding
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Solution Overview
Problem
Existing pulp molding processes face challenges in achieving uniform liquid flow through screen devices due to non-uniform distribution of pores, leading to uneven material accumulation and extended formation times for parts.
Innovation Solution
A processor identifies and removes specific pores and pillars from the screen device based on relative locations and flow characteristics to optimize liquid flow uniformity, using a 3D fabrication system to fabricate the modified screen device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pores are uniformly distributed in the screen device, then material accumulation is more even, but liquid flow uniformity deteriorates due to non-uniform pore sizes and locations
Solution Approach 1:
The patent applies local quality by varying pore characteristics (size, location, density) in different regions of the screen device. Specifically, pores are strategically positioned and sized to account for varying distances to the mold cavity, with closer pores being smaller and farther pores being larger, creating region-specific pore properties that optimize both material accumulation uniformity and liquid flow uniformity simultaneously
2Productivity
If vacuum force is applied through the pulp molding die, then material is sucked onto the wire mesh and forms the desired shape, but non-uniform pore distribution causes uneven material accumulation and extended formation times
Solution Approach 1:
The patent implements local quality by creating region-specific pore characteristics in the screen device. Pores in different locations have different sizes and densities matched to their specific functional requirements - closer pores are smaller for precise material deposition, while farther pores are larger for efficient liquid removal, enabling both fast formation and uniform part thickness
Solution Approach 2:
The patent applies preliminary action by pre-configuring the pore structure in the screen device before the molding process. The pores are strategically positioned and sized in advance to predictively compensate for variations in liquid flow paths and material accumulation rates, ensuring uniform part formation without requiring real-time adjustments during the molding process
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
Enhances the uniformity of liquid flow across the screen device, reducing the time required to form parts with consistent thickness and material distribution.
Implementation Method 1
During formation of the product, a vacuum force may be applied through the pulp molding die which may cause the material in the pulp to be sucked onto the wire mesh and form into a shape that matches the shape of the pulp molding die
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
According to examples, an apparatus may include a processor that may access information about a screen device having pores, in which the screen device is to be employed to filter liquid from a slurry composed of the liquid and material elements to form a part from the material elements. The processor may also access information about a main body, in which the main body is to support the screen device during formation of the part and has a plurality of openings that are larger than the pores in the screen device. The processor may identify, based on relative locations of the pores and the openings, pores that are to be removed from the screen device to increase uniformity of liquid flow through the pores across the screen device and may modify the accessed information about the screen device to remove the identified pores from the screen device.