Selective Cellulose Layer Moulding for Localized Reinforcement
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Solution Overview
Problem
Existing double layer thermoforming technologies result in resource waste and lack flexibility in application and personalization, particularly in structural and aesthetic terms, and do not allow targeted reinforcement of mechanical or aesthetic features.
Innovation Solution
A selective double layer moulding process and apparatus that deposits a cellulose reinforcement layer only where needed, using targeted suction and deposition of cellulose pulp in a single moulding process, allowing independent control of mechanical and aesthetic properties of each layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double layer thermoforming is used to provide complete layers for the whole surface extension, then mechanical strength and structural integrity are improved, but material waste and resource consumption increase
Solution Approach 1:
The patent applies local quality by transitioning from complete double layers covering the entire surface to selective localized reinforcement zones. The reinforcement layer is deposited only in specific areas where mechanical strength is needed, such as bases, handles, or structural supports, while other areas maintain single-layer construction. This resolves the contradiction by providing strength exactly where required without the material waste of universal double-layer coverage.
Solution Approach 2:
The patent segments the double layer structure into distinct functional zones: single-layer areas for non-critical regions and localized reinforcement zones for structural requirements. This segmentation allows the reinforcement layer to be applied in discrete patches rather than as a continuous complete layer, reducing overall material consumption while maintaining necessary mechanical strength in critical areas.
2Stability of the object's composition
If complete double layers are used for the whole product surface, then structural integrity is improved, but flexibility in application and personalization is reduced
Solution Approach 1:
The selective localization of reinforcement layers enables different aesthetic and functional properties in different areas of the same product. Designers can vary the presence, thickness, and material composition of reinforcement zones to create unique visual patterns, tactile variations, and functional characteristics for each application, thereby achieving high flexibility and personalization while maintaining structural integrity where needed.
Solution Approach 2:
The patent introduces dynamic configurability by allowing the reinforcement pattern to be adjusted and customized for different product applications, uses, and aesthetic requirements. The selective deposition process can be programmed to create varying reinforcement configurations, enabling the same base technology to adapt to diverse structural and aesthetic needs across different product lines and applications.
3Strength
If complete double layers are used for the whole product surface, then mechanical resistance is improved, but energy consumption increases
Solution Approach 1:
By concentrating reinforcement material only in areas requiring enhanced mechanical resistance rather than applying complete layers universally, the patent reduces the total material processing energy, drying energy, and manufacturing energy associated with producing and treating extensive double-layer surfaces, thereby lowering overall energy consumption while maintaining necessary mechanical resistance.
4Loss of substance
If selective reinforcement is implemented only where needed, then material waste is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical masking and manual application systems with a controlled deposition mechanism that uses suction and material ejection systems to achieve selective reinforcement. This substitution of mechanical approaches with a more integrated deposition technology simplifies the overall manufacturing process while enabling precise selective application, thereby reducing material waste without proportionally increasing manufacturing complexity.
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
Minimizes material waste and energy consumption while enabling high flexibility and personalization of products with unique mechanical and aesthetic properties, achieving performance comparable to plastic materials.
Implementation Method 1
a suction is implemented through the sleeve (8) of the thermoforming mould (7)... through the functional face (2) of the first moulding counter-mould (1), the cellulose pulp (4) is sucked
Data Source
AI summary
The present invention relates to a moulding process. In particular it relates to an improved double layer moulding process allowing to deposit, in a selective and localized way, an additional cellulose layer only in the points detected as critical, with the purpose of increasing the mechanical and aesthetical features thereof.