Thickened Angle Ring Manufacturing Process Prevents Delamination
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Solution Overview
Problem
Existing methods for manufacturing thickened angle rings often result in middle delamination, leading to poor product quality.
Innovation Solution
A process involving soaking 23 mm thick wet paper, beating the bonding surfaces to create rough fuzzed surfaces, using heat resisting polyester film and nylon nets on a mold, and employing a four-column hydraulic press with specific pressure and temperature controls to prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet paper is directly heated and pressed on a mold, then the manufacturing process is simple, but the angle ring becomes heavily delaminated in the middle and poor in quality
Solution Approach 1:
The patent applies preliminary action by soaking the wet paper in deionized water before pressing, and by pre-beating the bonding surfaces to create roughness. These preparatory steps ensure proper water distribution and surface adhesion before the actual pressing operation, preventing middle delamination while maintaining process simplicity.
Solution Approach 2:
The patent changes physical parameters by controlling the soaking time (1 hour), temperature progression (room temperature to 150°C), and pressure stages (5 MPa to 8 MPa). These parameter changes optimize water removal and bonding without causing delamination, resolving the contradiction between simple processing and high quality.
2Manufacturing precision
If thickened wet ground paper is pressed to remove water, then the shaping is improved, but middle delamination occurs and quality deteriorates
Solution Approach 1:
The patent applies local quality by creating roughness only on the bonding surfaces through beating, while keeping the internal structure intact. The fuzzy surface layer provides enhanced adhesion locally at the interfaces, preventing delamination during water removal and pressing operations.
Solution Approach 2:
The patent performs preliminary soaking in deionized water to evenly distribute moisture throughout the thickened paper before pressing. This preliminary water distribution prevents sudden water removal that would cause delamination, while still enabling effective shaping during the subsequent controlled pressing stages.
3Strength
If the bonding surfaces are beaten to create rough fuzzed surfaces, then the adhesion between paper layers is improved, but the processing time increases
Solution Approach 1:
The patent optimizes the beating parameter by applying just enough mechanical action to create the necessary surface roughness and fuzziness for adhesion. This controlled parameter change achieves sufficient bonding strength without excessive processing time, balancing strength improvement with time 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
The process effectively removes water from the wet paper, preventing delamination and enhancing the quality of the angle ring by ensuring proper fitting and shaping.
Implementation Method 1
Pressing may be performed first under the pressure of 5 MPa at room temperature for 20 minutes, followed by squeeze dewatering. Pressing may be performed then under the pressure of 8 MPa at mold temperature increased to about 150° C. for 3 hours
Implementation Method 2
A heat resisting polyester film and a nylon net may be placed on a mold, and one fuzzed wet paper may be placed on the mold in contact with the nylon net on smooth side thereof
Implementation Method 3
Bonding surfaces of two pieces of wet paper needed in pressing may be beaten such that the surfaces are fuzzed and become rough
Data Source
AI summary
Disclosed is a process of manufacturing a thickened angle ring. The process includes the steps of: soaking wet paper into deionized water for 1 hour; beating bonding surfaces of the two pieces of wet paper into fuzzed and rough surfaces; placing a heat resisting polyester film and a nylon net on a mold, and placing one fuzzed wet paper on the mold in contact with the nylon net on smooth side thereof; placing the other wet paper in contact with the fuzzed surface of the previous wet paper on fuzzed side thereof, and beating until the wet paper fits the mold; placing a further heat resisting polyester film and a further nylon net on the two pieces of wet paper for pressing.