Variable-Depth Forming Seats for Zoned Cellulose Blank Strength
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Solution Overview
Problem
Existing cellulose product forming methods struggle to produce products with variable basis weight and strength, particularly for items like coffee capsules and caps, and generate cellulose waste between products.
Innovation Solution
An apparatus with a forming wheel featuring discrete forming seats of varying depths and a leveling roller ensures precise control of cellulose fiber distribution, allowing for products with zones of different strengths and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a continuous mat of cellulose fibers is used for forming products, then the forming process is simple and continuous, but it is impossible to produce products with variable basis weight and strength in different zones
Solution Approach 1:
The continuous forming belt is segmented into multiple discrete forming seats arranged in a circular pattern around the forming wheel. Each forming seat is an independent cavity that can be filled with cellulose fibers separately, allowing different basis weights and strengths to be created in different zones of the final product while maintaining continuous operation.
Solution Approach 2:
Each discrete forming seat is designed with specific geometric characteristics (depth, volume, shape) that determine the basis weight and strength of the corresponding zone in the final product. By varying these geometric parameters across different forming seats, local quality variations are achieved without complicating the overall forming process.
2Productivity
If a uniform thickness cellulose mat is formed continuously, then the production process is efficient, but cellulose waste is generated in the space between adjacent products
Solution Approach 1:
The forming wheel is divided into discrete forming seats that are spaced to match the product output requirements. This segmentation allows the continuous forming process to be synchronized with discrete product formation, eliminating the need for buffer zones and reducing cellulose waste between adjacent products while maintaining continuous production efficiency.
3Adaptability or versatility
If discrete forming seats with variable depths are used, then products with variable basis weight and strength can be produced, but the device complexity increases
Solution Approach 1:
The variable depths of the forming seats are achieved through straightforward geometric design of the forming wheel cavities rather than complex mechanical adjustments. Each forming seat's depth is predetermined during manufacturing to create specific basis weight and strength characteristics, avoiding the need for complex adjustable mechanisms while maintaining product versatility.
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
Enables the production of cellulose products with variable basis weight and strength, reducing waste by forming discrete blanks with precise control and efficient use of materials.
Implementation Method 1
a defibrating mill (12) for defibrating cellulose sheets
Implementation Method 2
The bottom wall (27) of each of the discrete forming seats (24) may be provided with suction holes connected to a suction source to retain the loose cellulose fibers within the discrete forming seats (24) by suction.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Apparatus for dry forming cellulose products (P) comprising a forming wheel (20) having an external surface (22) provided with a plurality of discrete forming seats (24) having variable depth.