Fibrous Material Molding Tool for Targeted Edge Cleaning
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Solution Overview
Problem
Conventional methods for processing fibrous materials to produce three-dimensional products suffer from unwanted fiber deposits leading to frayed and wave-like edges, requiring rework, high resource consumption, and machine contamination, due to inefficient edge cleaning by spray bars that overspray non-critical areas and soften fibers.
Innovation Solution
A tool with a spray arrangement that directs a medium stream specifically to the edge region of the suction or pre-compression tool, using nozzles or outlets to align and remove fibers, ensuring targeted spraying and minimizing overspray, integrated with the fiber processing tool to enhance edge formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a spray bar is used to clean the edge area of cavities, then fiber deposits are removed, but the spray bar causes overspray that softens fibers, creates contamination, and requires high resource consumption
Solution Approach 1:
The patent applies local quality by using a spray arrangement that directs medium streams specifically at the edge area of cavities where fiber deposits occur. The spray outlets are positioned and angled to target only the critical edge region, avoiding overspray onto the carrier plate and other areas. This localized spraying approach maintains effective fiber deposit removal while minimizing resource consumption and avoiding the softening of fibers in non-edge areas.
2Object-affected harmful factors
If a spray bar moves along a linear axis to clean edges, then some fiber deposits are removed, but edges aligned perpendicular to spray movement are cleaned less reliably
Solution Approach 1:
The patent transitions from a linear spray bar approach to a two-dimensional spray arrangement with multiple outlets distributed across the carrier plate. The outlets are arranged in rows and columns with specific spacing, creating a planar spray pattern that can effectively clean edges oriented in different directions. This dimensional change allows simultaneous effective cleaning of edges aligned both parallel and perpendicular to any single spray direction.
3Object-affected harmful factors
If the entire carrier plate is sprayed to clean edges, then fiber deposits are removed, but the interior of cavities is also sprayed which softens fibers and causes re-contamination
Solution Approach 1:
The spray arrangement is designed with outlets positioned specifically to target only the edge areas of cavities. The outlets are located at a distance from the carrier plate surface and angled to direct streams onto the edge regions where fiber deposits form. This localized spraying approach removes fiber deposits from edges while avoiding spray contact with the interior of cavities, preventing fiber softening and re-contamination.
4Object-affected harmful factors
If conventional spray bar cleaning is used, then some edge cleaning is achieved, but frayed and wave-like edges persist requiring rework
Solution Approach 1:
The spray arrangement removes fiber deposits and protruding fibers from the edge area before the pre-pressing step. By cleaning the edges preliminarily, the subsequent pre-pressing process can form smooth, well-defined edges without the interference of protruding fibers that would otherwise be clamped off and create frayed or wave-like edges. This preliminary cleaning action eliminates the need for rework.
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 achieves clear edge formation without protruding fibers, reduces resource consumption, minimizes machine contamination, and streamlines the production process by eliminating the need for additional spraying steps, resulting in faster and more efficient production of high-quality products.
Implementation Method 1
the fibers are drawn in via a suction tool. The fibers then adhere to the surface (suction surface) of a suction body
Implementation Method 2
a spray arrangement via which a medium for aligning fibers in the edge region of the shaped body and/or for aligning fibers in the edge region of an opposite tool can be dispensed
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A tool for processing fibrous material for the production of three-dimensional products, a molding system for producing fibrous products and a method for producing fibrous products are described.