Sieve Sheet Wave Motion for Building Material Density Control
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Solution Overview
Problem
Existing building material manufacturing apparatuses face challenges in varying the raw material deposit amount in the receiver width direction, leading to density nonuniformity and difficulty in forming end portions with high density and sufficient thickness, which can result in cracking and compromised waterproof performance.
Innovation Solution
The apparatus includes a sieve portion with a series of sheets that perform a wave motion, featuring a first sieve sheet with uniform meshes and a second sieve sheet with varying mesh sizes or mesh and non-mesh regions, allowing for adjustable raw material deposition and mechanical classification, enabling uniform density and thickness across the receiver width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a template with depression/protrusion pattern is used as receiver, then the design surface pattern can be formed, but density nonuniformity occurs between depression and protrusion parts
Solution Approach 1:
The patent applies local quality by using a sieve sheet with non-uniform mesh distribution where mesh sizes are specifically designed to vary in different regions. The mesh size is larger in regions corresponding to depressions and smaller in regions corresponding to protrusions, allowing each region to receive appropriate material density to compensate for the template's geometric variations and achieve uniform final density.
Solution Approach 2:
The patent changes the parameter of mesh size across the sieve sheet to compensate for the template's geometric variations. By varying the mesh size parameter spatially, the system adjusts material flow to different regions, ensuring that depressions receive more material and protrusions receive less material, thereby achieving uniform density distribution in the final product.
2Productivity
If existing sieve portion is used, then raw material can be screened, but it is difficult to vary raw material deposit amount in receiver width direction
Solution Approach 1:
The patent implements local quality by designing a sieve sheet with spatially varying mesh characteristics. Different regions of the sieve sheet have different mesh sizes or mesh densities, enabling selective control of raw material deposition in different width directions while maintaining overall screening functionality.
Solution Approach 2:
The patent segments the sieve sheet into multiple regions with different mesh characteristics. This segmentation allows independent control of material flow to different parts of the receiver, enabling variation in deposit amount across the receiver width direction while preserving the overall screening capability.
3Strength
If end portions are formed with high density, then strength and waterproof performance improve, but sufficient thickness cannot be achieved
Solution Approach 1:
The patent applies local quality by designing the sieve sheet with specifically tailored mesh characteristics at end portions. The mesh size and distribution are optimized for end regions to facilitate high density material deposition while maintaining sufficient thickness, distinguishing end portion requirements from central region requirements.
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 configuration allows for the formation of building materials with low density nonuniformity, resisting cracking and achieving high strength and waterproof performance by varying the raw material deposit amount and ensuring uniform thickness and density, particularly at end portions.
Implementation Method 1
a series of sheets that are each capable of performing a wave motion when the apparatus is operating
Data Source
AI summary
A building material manufacturing apparatus includes a sieve portion 10 and a receiver 30 that receives a building raw material M that has passed through the meshes of the sieve portion 10. The sieve portion 10 includes a series of sheets that are each capable of performing a wave motion when the apparatus is operating, that have an inclination, and that are arranged in a direction of the inclination. The series of sheets include a sieve sheet 12 and a sieve sheet 13 positioned below the sieve sheet 12. In the sieve sheet 12, meshes having an identical size are arranged at a regular pitch in a sheet width direction W. In the sieve sheet 13, meshes having two or more different sizes are arranged or a mesh region R1 and a non-mesh region R2 are arranged, in the sheet width direction W. The receiver 30 is movable below the series of sheets. The building material manufacturing method includes, by using the apparatus, forming a mat on the receiver 30, the mat including a first layer formed from a part of the building raw material M that has passed through the meshes of the sieve sheet 12 and a second layer formed from a part of the building raw material M that has passed through the meshes of the sieve sheet 13.