Split Mould Vacuum Sharing for Pulp Bottle Forming
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Solution Overview
Problem
The existing methods for manufacturing moulded fibre urinal bottles face challenges in complexity, cost, and efficiency due to the need for independent vacuum sources and complex drainage systems in split mould tools, which increase production costs and complexity.
Innovation Solution
A pulp moulding apparatus with first and second mould tools that are movable between a closed and release configuration, featuring a fluid connection arrangement to share a single vacuum source, reducing complexity and enhancing drainage efficiency through angled tool orientation and drainage channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate vacuum sources are connected to both mould tools, then each mould tool can independently extract liquid, but the device complexity and cost increase
Solution Approach 1:
The patent merges the vacuum extraction function into a single centralized vacuum source that serves both upper and lower mould tools. The vacuum chamber receives liquid from both moulds through separate drainage channels, consolidating what would otherwise require two independent vacuum systems into one unified extraction system, thereby reducing device complexity while maintaining reliable liquid extraction capability
Solution Approach 2:
The single vacuum chamber serves multiple functions: it extracts liquid from both the upper and lower mould tools simultaneously, and it acts as a common collection point for drainage from both moulds. This multi-functional design eliminates the need for separate vacuum sources and drainage systems for each mould tool
2Reliability
If independent vacuum sources are used for each mould tool, then liquid extraction is effective, but the drainage system complexity increases
Solution Approach 1:
The patent combines the drainage systems of both upper and lower moulds into a single vacuum chamber. Drainage channels from both moulds converge into the common vacuum chamber, creating a unified drainage pathway that simplifies the overall drainage system architecture while maintaining effective liquid removal from both mould tools
3Ease of operation
If mould tools are separated for release, then the moulded item can be removed, but the production efficiency decreases
Solution Approach 1:
The moulding system is segmented into independent upper and lower mould tools that can be separated for release. This segmentation allows each mould half to be independently manipulated and removed, enabling efficient extraction of the moulded item while maintaining the ability to quickly re-close the moulds for the next production cycle
Solution Approach 2:
The moulded item is preliminarily formed within the closed mould configuration, allowing the majority of the forming process to occur while the moulds are together. The separation action is then performed only when necessary for release, minimizing the time the moulds are open and maximizing 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 simplifies the manufacturing process by using a single vacuum source and optimizing drainage, reducing production costs and improving the efficiency of forming and removing moulded pulp items, such as urinal bottles, while ensuring they are produced safely and efficiently.
Implementation Method 1
A vacuum source is connected to the first mould tool. The first and second mould tools include a fluid connection arrangement that fluidly connects the first and second mould tools when they are in the closed configuration such that the vacuum applied to the first mould tool is simultaneously applied to the second mould tool.
Implementation Method 2
A vacuum is applied to the vacuum cavity via an inlet at the base of the vacuum cavity and liquid from the wet pulp is drawn into the vacuum cavity via drainage channels in the mould tool.
Data Source
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AI summary
A pulp moulding apparatus comprises first and second mould tools (28, 30). The mould tools are movable between a closed configuration in which the first and second mould cavities combine to form a moulded pulp item and a release configuration in which the first and second mould tools are separated to enable release of the moulded pulp item. A vacuum source is connected to the first mould tool. The first and second mould tools (18, 30) include a fluid connection arrangement (54, 60) that fluidly connects the first and second mould tools when they are in the closed configuration such that the vacuum applied to the first mould tool is simultaneously applied to the second mould tool.