Transfer Screens With Deterministic Pores for Even Vacuum Dewatering
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Solution Overview
Problem
Existing pulp molding processes face challenges in accurately forming complex shapes with precise pore placements, leading to uneven suction pressure distribution and potential damage to the wet part during de-watering, which affects drying time and quality.
Innovation Solution
A 3D fabrication system is used to create transfer screens with deterministically placed pores that are complementary to forming screens, allowing for even suction pressure distribution and efficient de-watering of wet parts, reducing warpage and drying time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mesh crafting methods are used, then manufacturing simplicity is maintained, but manufacturing precision of pore placements deteriorates
Solution Approach 1:
The patent changes the fabrication method parameter from traditional mesh crafting to 3D printing technology, enabling precise control of pore placement coordinates, sizes, and distributions while maintaining manufacturing feasibility through digital model modification
Solution Approach 2:
The patent replaces mechanical mesh crafting processes with digital 3D fabrication, where pore placements are determined algorithmically and fabricated additively, substituting manual or mechanical screen making with automated digital manufacturing
2Force
If vacuum force is applied during formation, then material suction onto mesh is improved, but uneven suction pressure distribution causes damage to wet part
Solution Approach 1:
The patent applies local quality by varying pore sizes and placements in different regions of the transfer screen, creating zones with different suction characteristics that distribute vacuum force evenly across the wet part surface, preventing localized damage while maintaining overall suction effectiveness
Solution Approach 2:
The patent optimizes the pneumatic vacuum system by designing specific pore configurations in the transfer screen that regulate air and liquid flow patterns, ensuring uniform pressure distribution during the de-watering process
3Loss of time
If de-watering is performed efficiently, then drying time is reduced, but uneven suction pressure increases drying energy requirements
Solution Approach 1:
The patent performs preliminary de-watering action during the transfer process itself by optimizing pore placements and sizes in the transfer screen, removing excess liquid before drying begins, which reduces subsequent drying time and energy 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
The solution enables faster production of high-quality wet parts with vertical walls and detailed features by ensuring even suction pressure, minimizing damage and reducing energy and time required for drying.
Implementation Method 1
when a vacuum pressure is applied to the transfer mold to cause the wet part to be removed from the forming screen and become engaged with the transfer screen
Implementation Method 2
allow liquid to be suctioned from the wet part
Data Source
AI summary
According to examples, a non-transitory computer-readable medium may have stored thereon instructions that may cause a processor to obtain a digital model of a transfer screen to be 3D fabricated. The processor may also determine placements of pores in the digital model, in which the transfer screen is to be mounted on a transfer mold via an attachment mechanism and to engage a surface of a wet part formed on a corresponding forming screen. The forming screen may have a first shape and the transfer screen may have a second shape that is complementary to the first shape, and the locations of the pores may be determined to allow liquid to be suctioned from the wet part when a vacuum pressure is applied to the transfer mold. The processor may further modify the digital model of the transfer screen to include the pores at the determined placements.