Biodegradable Wheat-Bran Mouldings With Staged Vapour Release
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Solution Overview
Problem
Existing methods for manufacturing biodegradable mouldings, such as tableware and packages, are inefficient due to high material loss, unpredictability, and variability in product density and color, limiting production rate and quality.
Innovation Solution
A method involving loose wheat bran mixed with additives, subjected to controlled temperature and pressure within an impenetrable mould, with cycles of depressurization and controlled mould movement to manage water vapor pressure, allowing for programmable physical and mechanical properties and improved product characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the mould is completely opened after each pressure cycle to release water vapour, then water vapour can escape, but the product tears and production loss increases to 50%
Solution Approach 1:
The pressure release process is segmented into multiple stages: initial pressure release to a first level, then mould opening to a first degree, followed by second pressure release to a second level, and finally mould opening to a second degree. This staged approach prevents abrupt pressure changes that cause product tearing while effectively managing water vapour buildup.
Solution Approach 2:
The mould opening degree is made dynamic and variable during the pressure release cycle. The mould opens to different degrees at different stages of pressure release, allowing controlled adaptation to the evolving pressure conditions within the mass rather than a single static opening state.
2Manufacturing precision
If high pressure is applied inside the mould to improve product density, then product density increases, but the product tears completely
Solution Approach 1:
The system prepares for pressure management by implementing controlled pressure release stages before complete mould opening. The gradual pressure reduction and staged opening act as a cushioning mechanism that prevents sudden pressure differentials from tearing the product while still achieving high density during the pressurization phase.
Solution Approach 2:
The pressure application and release follows a periodic cycle with distinct phases: pressurization to achieve density, then controlled pressure release in stages, followed by staged mould opening. This periodic action allows the product to withstand high pressure for density while preventing tearing through controlled pressure management cycles.
3Stress or pressure
If the mould is sealed completely to maintain pressure, then pressure can be maintained, but water vapour cannot escape and process control is lost
Solution Approach 1:
The mould sealing state is made dynamic rather than static. The mould transitions between sealed and partially opened states in a controlled sequence, allowing pressure to be maintained when sealed and released when partially opened. This dynamic control enables both pressure maintenance and process controllability.
Solution Approach 2:
The process incorporates feedback control through monitoring pressure levels and adjusting mould opening degree accordingly. Pressure sensors detect water vapour buildup and trigger appropriate pressure release and mould opening actions, maintaining pressure when needed while preventing uncontrolled pressure buildup through automated feedback mechanisms.
4Manufacturing precision
If multiple piston strokes are used to apply repeated pressure, then product density can be improved, but production time increases and productivity decreases
Solution Approach 1:
The pressure application is made continuous rather than intermittent with multiple separate piston strokes. A single continuous pressurization phase maintains pressure throughout the necessary duration to achieve density, eliminating the time losses associated with repeated piston retraction and advancement while maintaining effective density control.
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 method significantly reduces production losses, enhances density and fragrance, and increases production rate, resulting in stiffer, more resistant products with consistent quality and appearance, suitable for food service applications.
Implementation Method 1
the mixture is submitted to the simultaneous operation of temperature in the scope from 20 to 450°C and pressure in the scope of 1-10 MPa
Implementation Method 2
water vapour formed during the temperature and pressure or force operation
Implementation Method 3
evoking the pressure of water vapour inside the mould
Data Source
AI summary
Method for manufacturing biodegradable mouldings in particular tableware and packages with application of the method of evoking the water vapour pressure inside the form involves that loose bran, in particular the wheat one of granulation from 0.01 up to 2.80 mm in the amount of 95-100% of weight containing 14% of water structurally bound in the form of moisture, if the need be, is mixed in the dry form with additional substances in the volume of up to 5% of weight in total and the measured amount of dry material obtained in that way is placed in one of the parts of multipart form then the form is closed and the mixture is subject to the simultaneous operation of temperature and pressure of the scope 1-10 MPa. The form is heated up to temperature above 120°C then the form is closed and then depressurised forming the crack between the edges of the form not wider than 0.5 mm and then the form if the need be is closed again and the depressurisation cycles are repeated. After the last cycle the form is opened and the number of depressurisations is minimum 1 and the entire process of depressurization and closing the form takes few seconds and is completed according to the programme of the machinery digitally controlling the form movement depending on the expected parameters of the final product.