Description:FIELD OF DISCLOSURE
[0001] The present disclosure generally relates to a molding machine and specifically relates to an automatic pulp molder.
BACKGROUND OF THE DISCLOSURE
[0002] Embodiments of the present invention generally relate to an automatic pulp molder.
[0003] In recent years, there has been a growing global emphasis on replacing single-use plastic and non-biodegradable packaging materials with eco-friendly and sustainable alternatives. Pulp-molded products, manufactured from renewable agricultural residues such as bagasse, bamboo, wheat straw, and rice straw pulp, have emerged as a leading alternative for producing disposable tableware, packaging trays, and various industrial components. The pulp molding process, which converts natural fibers into three-dimensional molded articles, offers several ecological benefits including biodegradability, and low carbon footprint. However, despite these advantages, the current manufacturing technologies used for pulp molding remain energy-intensive, labor-dependent, and inconsistent in quality output, thereby limiting their economic feasibility for large-scale industrial production.
[0004] Conventional semi-automatic pulp molding machines typically involve multiple manual operations between stages. Each stage often requires separate supervision and handling, making the overall process time-consuming and prone to inconsistencies. Manual transfer of semi-formed products from one stage to other leads to variable drying times, deformation of the product, and uneven surface finishing. These inefficiencies directly affect production throughput and raise labor costs. Moreover, manual processes are not easily scalable and cannot consistently meet the high demand for biodegradable packaging products in commercial markets.
[0005] Another major limitation of traditional pulp molding systems lies in their energy inefficiency. The heating stage, which involves heating the molds to remove moisture and define the final product shape, is one of the most power-consuming stages in the entire process. In most conventional machines, heaters operate continuously at high temperatures without precise thermal control. This results in significant energy wastage, overheating of mold surfaces, and reduced heater life. Furthermore, uneven temperature distribution often leads to inconsistent product density, poor dimensional accuracy, and surface defects such as roughness or uneven gloss.
[0006] Wire mesh breakage is another recurring problem in semi-automatic pulp molding machines. The wire mesh used on forming molds plays a critical role in filtration and shaping the wet pulp. During repeated cycles of suction, compression, and release, the mesh experiences high mechanical stress and frictional wear, leading to frequent breakage or deformation. This not only increases maintenance frequency but also causes downtime, affecting the overall productivity of the manufacturing line. In many existing systems, the mold design does not adequately support the mesh, causing localized strain during dewatering and demolding. Frequent replacement of wire meshes also raises operational costs and interrupts production continuity.
[0007] Labor dependency remains one of the most critical challenges in existing pulp molding operations. Semi-automatic and manually assisted systems typically require several operators to handle tasks such as product transfer, mold cleaning, and alignment between stages. This dependency not only increases operational cost but also introduces variability in product handling, leading to defects such as cracks or warping. Furthermore, reliance on human labor restricts production scalability and consistency, especially in regions facing workforce shortages or high labor costs. The absence of automation also limits the machine’s ability to run continuous production cycles, reducing overall throughput.
[0008] Another challenge observed in traditional designs is their bulky and segmented structure, which consumes significant floor space. Dedicated units for pulping, forming, drying, and trimming is often installed as a separate module, connected by manual or semi-manual conveyors. This layout is not space-efficient and makes maintenance, cleaning, and synchronization of production stages difficult. In high-volume manufacturing environments, space optimization becomes essential for cost-effectiveness and operational efficiency.
[0009] In addition, the maintenance and operational downtime of conventional pulp molding machines are relatively high. Frequent replacement of wire meshes, non-modular heating systems, and manual adjustments during production contribute to unplanned stoppages. As a result, operators experience reduced uptime and increased maintenance costs, further affecting the economic viability of pulp-molded product manufacturing. There is, therefore, a clear need for a fully automatic pulp molding system that can address these shortcomings by integrating advanced automation, energy-efficient heating, and durable mold design.
[0010] Therefore, there disclosed invention presents an energy-efficient fully automatic pulp molding machine.
SUMMARY
[0001] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0002] Embodiments in accordance with the present invention provide is an automatic pulp molder.
[0003] Embodiments of the present invention may provide a number of advantages depending on its particular configuration. First, embodiments of the present application provide an automatic pulp molder.
[0004] The present disclosure solves all the major limitation of traditional system.
[0005] An objective of the present disclosure is to overcome the limitations associated with existing semi-automatic and manual pulp molders by offering a fully integrated, energy-efficient, and labor-saving solution for manufacturing molded products.
[0006] Another objective of the present disclosure is to automate the transfer of molded articles/objects between successive processing stages to eliminate manual handling and minimize human intervention.
[0007] Another objective of the present disclosure is to reduce overall energy consumption during the molding by employing precision heating to ensure uniform temperature distribution, shorter heating duration, and extended heater life.
[0008] Another objective of the present disclosure is to decrease production cycle time through optimized coordination between stages.
[0009] Another objective of the present disclosure is to enhance durability, reduce maintenance downtime, and ensure longer operational life of the pulp molder.
[0010] Yet another objective of the present disclosure is to overcome the limitation of frequent wire mesh breakage commonly observed in conventional semi-automatic machines.
[0011] Yet another objective of the present disclosure is to reduce labor dependency and production cost during pulp molding.
[0012] Yet another objective of the present disclosure is to lower the overall operational and maintenance costs.
[0013] In the light of above disclosure, in an aspect of the present disclosure an automatic pulp molder is disclosed herein. The molder comprising a body frame assembly. The body frame assembly is divided into multiple stages to form a single continuous production line. The molder also comprising at least one servo-motor assembly mounted on the body frame assembly and the one servo-motor assembly further comprising at least one servo motor configured to provide accurate torque and position control of a plurality of platen. The servo-motor assembly also comprise a precision gearbox coupled with the servo motor and the precision gearbox configured to control the platen movement. The precision gearbox translates rotary motion into linear vertical movement for the platen. The servo-motor assembly also comprise a clamping mechanism associated with the precision gearbox 108 and the clamping mechanism configured to ensure firm mold closure with consistent pressure. The molder also comprises at least a pair of linear motion guide rails adjacent to the precision gearbox and the linear motion guide rails configured to ensure mold alignment, and ensure smooth travel during pressing and transfer. The molder also comprises a plurality of precision-controlled electric heaters adjacent to the linear motion guide rails and the precision-controlled electric heaters configured to perform thermos-forming. The molder also comprises a water shower trimming unit in proximity to the linear motion guide rails and the water shower trimming unit configured to integrate a directed water jet to remove excess fibers and edges after thermo-forming. The molder also comprises a control unit placed on the body frame assembly and the control unit configured to coordinate automatic product transfer, control operations of the water shower trimming unit, control operations of the servo-motor assembly, and optimize heating cycles of the precision-controlled electric heaters. The molder also comprises a half rotary dip forming-based mechanism controlled by the control unit and the half rotary dip forming-based mechanism configured to ensure uniform pulp distribution. The molder also comprises at least two hot presses controlled by the control unit and the hot presses arranged consecutively to produce both side smooth products. The two hot presses are modular. The first of the two hot presses rotates on its axis and is capable of vertical movement. The second of the two hot presses is capable of vertical movement and lateral movement.
[0014] In one embodiment, the body frame assembly is divided into pulp-dredging stage, pre-press stage, thermo-forming stage, and trimming stage.
[0015] In one embodiment, the molder also includes a slurry tank configured to hold fiber pulp, and a plurality of molds configured to collect pulp through suction/vacuum from the slurry tank.
[0016] In one embodiment, the precision gearbox coupled with the servo motor performs pre-pressing to removes excess water from the pulp collected by the molds.
[0017] In one embodiment, the control unit is bilaterally connected to a user interface placed on the body frame assembly.
[0018] In one embodiment, the user interface enables hybrid operation of the molder, as per the operational parameters set by an operator.
[0019] In one embodiment, the molder also integrates a plurality of servo-driven arms/conveyors controlled by the control unit to move products without manual interference.
[0020] In one embodiment, the control unit further includes an energy optimization algorithm configured to regulate heater power output of the precision-controlled electric heaters, as per the mold occupancy, material moisture content, and ambient conditions.
[0021] In one embodiment, the slurry tank contains non-wood pulp selected from bagasse pulp, wheat or rice straw pulp, and bamboo pulp, or mixed agro-waste fibers.
[0022] In one embodiment, the molds are designed to minimize wire mesh breakage by incorporating a reinforced mold base and optimized mesh support framework that evenly distributes mechanical stress during the pre-pressing and heating cycles.
[0023] These and other advantages will be apparent from the present application of the embodiments and solves abovementioned limitations in the traditional system.
[0024] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0025] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0027] FIG. 1 illustrates a block diagram of an automatic pulp molder 100, according to an embodiment of the present invention;
[0028] FIG. 2A illustrates a back view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0029] FIG. 2B illustrates a bottom view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0030] FIG. 2C illustrates a front view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0031] FIG. 2D illustrates a left-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0032] FIG. 2E illustrates a perspective view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0033] FIG. 2F illustrates a right-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0034] FIG. 2G illustrates a top-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0035] FIG. 2H illustrates a detailed back view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0036] FIG. 2I illustrates a detailed bottom view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0037] FIG. 2J illustrates a detailed front view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0038] FIG. 2K illustrates a detailed left-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0039] FIG. 2L illustrates a detailed perspective view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention;
[0040] FIG. 2M illustrates a detailed right-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention; and
[0041] FIG. 2N illustrates a detailed top-sided view of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention.
[0042] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0043] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention as defined in the claims.
[0044] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.
[0045] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0046] FIG. 1 illustrates a block diagram of an automatic pulp molder 100, according to an embodiment of the present invention.
[0047] The molder 100 may be comprising a body frame assembly 102, at least one servo-motor assembly 104, at least a pair of linear motion guide rails 112, a plurality of precision-controlled electric heaters 114, a water shower trimming unit 116, a control unit 118, a plurality of servo-driven arms/conveyors 120, a slurry tank 122, a plurality of molds 124, a half rotary dip forming-based mechanism 128, and at least two hot presses 130.
[0048] The body frame assembly 102 may be divided into multiple stages to form a single continuous production line.
[0049] The body frame assembly 102 may be divided into pulp-dredging stage, pre-press stage, thermo-forming stage, and trimming stage.
[0050] In an embodiment of the present disclosure, the body frame assembly 102 may be structurally divided into a plurality of functional stages including a pulp-dredging stage, a pre-press stage, a thermo-forming stage, and a trimming stage. Each stage may be operatively connected in a sequential arrangement within the same frame to facilitate smooth transfer of the molded article/object between operations. The pulp-dredging stage is configured to receive and form the initial wet pulp preform, the pre-press stage partially removes moisture and consolidates the shape, the thermo-forming stage applies controlled heat and pressure to achieve the final form and surface finish, and the trimming stage performs edge finishing and removal of excess material. In some embodiments, each stage may be supported on modular subframes to allow easy maintenance, alignment, and scalability.
[0051] In some embodiments, the body frame assembly 102 may form the structural foundation of the molder 100. The body frame assembly 102 may be fabricated from materials such as stainless steel, carbon steel, aluminium alloy, or combination thereof, to ensure rigidity, corrosion resistance, and long service life in a high-moisture manufacturing environment. In some embodiments, the body frame assembly 102 may be modular in design, allowing individual components or stages to be removed, replaced, or serviced independently. In some embodiment, the body frame assembly 102 may incorporate vibration-damping pads or levelling mounts to ensure operational stability and precision alignment of all moving assemblies.
[0052] The servo-motor assembly 104 may be mounted on the body frame assembly 102 and the one servo-motor assembly 104 further comprising at least one servo motor 106, a precision gearbox 108, and a clamping mechanism 110.
[0053] The one servo motor 106 may be configured to provide accurate torque and position control of a plurality of platen.
[0054] The precision gearbox 108 may be coupled with the servo motor 106 and the precision gearbox 108 configured to control the platen movement.
[0055] The precision gearbox 108 may translate rotary motion into linear vertical movement for the platen.
[0056] The precision gearbox 108 may be coupled with the servo motor 106 performs pre-pressing to removes excess water from the pulp collected by the molds 124.
[0057] The clamping mechanism 110 may be associated with the precision gearbox 108, and the clamping mechanism 110 configured to ensure firm mold closure with consistent pressure.
[0058] In an embodiment of the present disclosure, the servo-motor 106 may be selected from high-torque AC servo types, brushless DC servo types, or stepper motors with closed-loop control, depending on load and speed requirements. The servo motors 106 may provide precise torque and positional control to the platen assembly, enabling accurate and repeatable pressing operations. In some embodiments, the servo-motor assembly 104 may include a dual-motor configuration, one motor for vertical motion of the platen and another for clamping or ejecting operations, to increase throughput and mechanical efficiency.
[0059] In an embodiment of the present disclosure, the precision gearbox 108 may be mechanically coupled to the servo motor 106 through a spline or shaft connection. The precision gearbox 108 may be, but not limited to, planetary type, harmonic drive type, or worm gear type. The precision gearbox 108 may convert the rotary motion of the servo motor (106) into linear or vertical displacement suitable for platen. In some embodiments, the precision gearbox may be integrated with a ball screw or lead screw mechanism to enable precise up-and-down motion of the platen, with positional feedback provided by encoders or linear sensors. The precision gearbox may be enclosed within a protective housing filled with lubricant to minimize wear and ensure long operational life.
[0060] In an embodiment of the present disclosure, the clamping mechanism 110 may be operatively connected to the precision gearbox 108 and may function to hold the molds 124 firmly in position during pre-pressing or thermoforming stages. The clamping mechanism 110 may be of various types including, but not limited to, toggle clamps, pneumatic cylinders, hydraulic locks, or cam-lever systems, depending on the design configuration and force requirements. In some embodiments, the clamping mechanism 110 may include force sensors to measure and regulate clamping pressure to ensure consistent product thickness and surface finish. In some embodiments, the clamping mechanism 110 may also include an auto-release function to simplify mold separation after each operational cycle.
[0061] FIG. 2A-N illustrate various views of a prototype of an automatic pulp molder 100, according to an embodiment of the present invention.
[0062] In an embodiment of the present disclosure, the servo-motor assembly 104 may be connected to a plurality of platen, consisting of an upper platen and a lower platen. In some embodiments, the upper platen may be movable, while the lower platen remains stationary. Both platens may be fabricated from hardened aluminium, stainless steel, or composite materials for lightweight strength and thermal stability.
[0063] Referring to FIG. 1, the pair of linear motion guide rails 112 may be adjacent to the precision gearbox 108, and the linear motion guide rails 112 configured to ensure mold alignment, and ensure smooth travel during pressing and transfer.
[0064] In an embodiment of the present disclosure, the linear motion guide rails 112 may be positioned adjacent to the precision gearbox 108 and configured to support the vertical and horizontal travel of the mold 124. The linear motion guide rails 112 may ensure precise mold alignment and smooth travel during pressing, pre-pressing, and mold transfer operations. The linear motion guide rails 112 may be mounted on the body frame assembly 102 and coupled to bearing blocks or linear carriages, which provide guided motion of the molds 124 with minimal friction and high positional accuracy.
[0065] In some embodiments, the linear motion guide rails 112 may be of, but not limited to, ball-type, roller-type, or hydrostatic-type. In some embodiments, the ball-type guide rails may employ recirculating steel balls between the rail and carriage to achieve low-friction motion and high repeatability, making them suitable for high-speed and precision pressing applications. In some embodiments, the roller-type guide rails may utilize cylindrical rollers to increase load-bearing capacity and stiffness, providing enhanced stability during high-pressure thermoforming cycles. In some embodiments, the hydrostatic guide rails using a thin film of pressurized oil may be used to eliminate metal-to-metal contact.
[0066] In some embodiments, the linear motion guide rails 112 may include dual parallel rails mounted symmetrically on either side of the platens to prevent lateral deviation and maintain consistent mold alignment during operation. The linear motion guide rails 112 may be fabricated from, but not limited to, hardened alloy steel, stainless steel, or chrome-plated carbon steel for corrosion resistance and high rigidity. In some embodiments, a plurality of position sensors or linear encoders may be integrated along the length of the linear guide rails 112 to provide real-time positional feedback to the control unit 118.
[0067] The plurality of precision-controlled electric heaters 114 adjacent to the linear motion guide rails 112, and the precision-controlled electric heaters 114 configured to perform thermos-forming.
[0068] In a preferred embodiment, the precision-controlled electric heaters 114 may enable accurate thermal regulation within a range of approximately 150°C to 240°C. in an embodiment of the present disclosure, the precision-controlled electric heaters 114 maybe, but not limited to, cartridge-type, ceramic-type, infrared (IR) type, or resistive coil type, depending on the required heating rate and temperature uniformity. In some embodiments, the precision-controlled electric heaters 114 may be arranged in zoned configurations, for optimizing energy efficiency and maintaining consistent product quality.
[0069] In an embodiment of the present disclosure, a plurality of precision-controlled electric heaters 114 may be disposed adjacent to the linear motion guide rails 112 and configured to perform the thermo-forming of pulp-based molded products/articles. In some embodiments, the precision-controlled electric heaters 114 may provide uniform and localized heating to the mold’s 124 surfaces to achieve controlled drying and forming of the pulp material. In some embodiments, the precision-controlled electric heaters 114 may be individually controlled by the control unit 118 through temperature feedback sensors such as, but not limited to, thermocouples or RTDs. In some embodiments, the precision-controlled electric heaters 114 may incorporate heating elements such as, but not limited to, cartridge heaters, ceramic heaters, or embedded resistive coils to facilitate controlled drying or thermoforming of the pulp.
[0070] The water shower trimming unit 116 may be in proximity to the linear motion guide rails 112, and the water shower trimming unit 116 configured to integrate a directed water jet to remove excess fibers and edges after thermo-forming.
[0071] In an embodiment of the present disclosure, the water shower trimming unit 116 may be located in proximity to the linear motion guide rails 112, downstream of the thermo-forming stage. The water shower trimming unit 116 may be configured to integrate one or more directed water jets that remove excess fibers, flash edges, or irregular material from the molded products/articles after thermo-forming. The water shower trimming unit 116 may ensure a smooth edge profile and precise dimensional finish without damaging the product structure.
[0072] In some embodiments, the water shower trimming unit 116 may include nozzle assemblies arranged at adjustable angles to target specific areas of the molded products/articles. The nozzles may be designed to deliver high-pressure or fine mist water streams, depending on the material density and trimming precision required. The water shower trimming unit 116 may include recirculation and filtration subsystems that collect, filter, and reuse the trimming water to minimize wastage and maintain environmentally sustainable operation.
[0073] In some embodiments, the water shower trimming unit 116 may be controlled the control system 118, enabling automatic alignment with the product/article during each cycle. In some embodiments, the water shower trimming unit 116 may include sensors or vision modules to detect product/article position and adjust the water jet trajectory accordingly.
[0074] The control unit 118 may be placed on the body frame assembly 102 and the control unit 118 configured to coordinate automatic product transfer, control operations of the water shower trimming unit 116, control operations of the servo-motor assembly 104, and optimize heating cycles of the precision-controlled electric heaters 114.
[0075] The control unit 118 may further include an energy optimization algorithm configured to regulate heater power output of the precision-controlled electric heaters 114, as per the mold occupancy, material moisture content, and ambient conditions.
[0076] The control unit 118 may be bilaterally connected to a user interface 126 placed on the body frame assembly 102.
[0077] The user interface 126 may enable hybrid operation of the molder 100, as per the operational parameters set by an operator.
[0078] In an embodiment of the present disclosure, the control unit 118 may be any microcontroller or microprocessor, electronically coupled to the servo-motor assembly 104, the precision-controlled electric heaters 114, and the water shower trimming unit 116. The control unit 118 may include a programmable logic controller (PLC), and sensor array for monitoring temperature, pressure, and platen position. The control unit 118 may execute pre-programmed motion profiles, including pre-press, press, drying, and release sequences. In some embodiments, the control unit 118 may support adaptive feedback control, where data from sensors dynamically adjusts torque, temperature, and timing parameters in real-time.
[0079] In an embodiment of the present disclosure, the user interface 126 may be any human–machine interface (HMI) including, but not limited to, touch screen interface integrated on the main control cabinet panel. The user interface 126 may allow the operators to input and adjust key process variables such as temperature, pressure, time, cycle duration, clamping force, and servo motion speed. The user interface 126 may further include visual indicators, real-time system status displays, and alarm notifications for operational safety and efficiency.
[0080] In some embodiments, the user interface 126 may provide multi-level access control, where administrators can set operational configurations, while the operators can control basic operations ensuring data security and prevents unauthorized modifications to critical process parameters. In some embodiments. In some embodiments, the user interface 126 may include graphical dashboards and trend graphs displaying temperature curves, servo motor torque profiles, and cycle time histories. In some embodiments, the user interface.
[0081] The half rotary dip forming-based mechanism 128 may be controlled by the control unit 118 and the half rotary dip forming-based mechanism 128 configured to ensure uniform pulp distribution.
[0082] In an embodiment of the present disclosure, the half rotary dip forming-based mechanism 128 may allow the products with greater depths can be formed with better finish and strength.
[0083] The two hot presses 130 may be controlled by the control unit 118 and the hot presses 130 arranged consecutively to produce both side smooth products. The two hot presses 130 may be modular. The first of the two hot presses 130 may rotate on its axis and may be capable of vertical movement. The second of the two hot presses 130 may be capable of vertical movement and lateral movement.
[0084] In an embodiment of the present disclosure, the mold platen goes through two hot presses 130, which may achieve a higher output by achieving faster hot press and thus reducing the overall cycle time.
[0085] The molder 100 may also integrate a plurality of servo-driven arms/conveyors 120 controlled by the control unit 118 to move products without manual interference.
[0086] In an embodiment of the present disclosure, the servo-driven arms/conveyors 120 may ensure continuous production flow from the pulp-dredging stage to the pre-press, thermo-forming, and trimming stages, and eliminate downtime associated with manual handling and improve overall productivity. In some embodiments, the servo-driven arms/conveyors 120 may include, but not limited to, articulated robotic arms, gantry-type linear conveyors, or belt-driven transporters, depending on the layout and capacity of the production line. Motion synchronization among multiple arms or conveyors may be achieved through the control unit 118, which may execute coordinated movement algorithms to ensure smooth and collision-free transitions.
[0087] In some embodiments, the servo-driven arms/conveyors 120 may include smart sensors such as optical encoders, infrared sensors, or load sensors for detecting the position, orientation, and more for each product/article. In some embodiments, the servo-driven arms/conveyors 120 may incorporate quick-change gripper systems that allow the operator to replace the gripping or holding components when switching between stages.
[0087] The molder 100 may also include a slurry tank 122 configured to hold fiber pulp, and a plurality of molds 124 configured to collect pulp through suction/vacuum from the slurry tank 122.
[0088] The slurry tank 122 may contain non-wood pulp selected from bagasse pulp, wheat or rice straw pulp, and bamboo pulp, or mixed agro-waste fibers.
[0089] In a preferred embodiment, the slurry tank 122 may be located adjacent to or beneath the pulp-dredging stage, allowing easy and continuous supply of pulp to the molds 124 through a pulp feed line or vacuum-assisted suction system. In some embodiments, the slurry tank 122 may be fabricated from, but not limited to, stainless steel, fiber-reinforced plastic (FRP), or polymer-coated metal to prevent corrosion and contamination. The tank may include agitators, stirrers, or recirculation pumps to maintain homogeneous pulp consistency and prevent fiber settling. In some embodiments, the slurry tank 122 may be equipped with level sensors, flow meters, and temperature probes to monitor and control pulp quality in real time.
[0090] The molds 124 may be designed to minimize wire mesh breakage by incorporating a reinforced mold base and optimized mesh support framework that evenly distributes mechanical stress during the pre-pressing and heating cycles.
[0091] In some embodiments, the molds 124 may be designed to shape the pulp slurry into the desired product geometry. The molds 124 may include a perforated wire mesh or porous metallic insert that allows excess water to drain during the pre-press and pressing stages. In some embodiments, the molds 124 may be produced from nickel-plated aluminium, bronze, or stainless steel to ensure durability and corrosion resistance. In some embodiments, the molds 124 may be coated with PTFE or ceramic non-stick layers to facilitate easy demolding. The design of the molds 124 may be optimized to minimize wire mesh breakage by employing flexible mesh backing, optimized curvature transitions, and evenly distributed pressure zones during compression.
[0092] The disclosed invention offers several advantages over existing semi-automatic and conventional pulp molding systems. The disclosed invention ensures reduced energy consumption by applying localized heating only where necessary within the molds 124. This targeted heating approach, as controlled by the control unit 118, combined with optimized pre-press moisture removal, results in a considerable reduction in total power consumption. The control unit 118 further regulates heating duration and intensity based on real-time conditions, as set by the operator via the user interface 126.
[0093] The molder 100 has integrated arrangement of various stages eliminates manual transfer between machines, reduces downtime, and supports fully automatic operations. The servo-motor assembly 104 ensure higher repeatability in pressing force, with reduced energy consumption compared to hydraulic-only systems. The servo-motor assembly 104 also ensure longer machine lifespan due to reduced mechanical stress.
[0094] The linear motion guide rails 112 provide precise alignment of the molds 124 and reduce wear and tear from misalignment or vibration. The linear motion guide rails 112 improve surface finish and dimensional accuracy of molded products, as well as guarantee consistent quality even at high-speed, continuous production. The water shower trimming unit 116 produces clean-cut edges without mechanical wear of blades. The water shower trimming unit 116 reduces fiber dust, ensuring a cleaner working environment. The water shower trimming unit 116 improves product/object aesthetic appeal and surface finish. The water shower trimming unit 116 is especially useful for tableware products requiring food-grade smoothness.
[0095] Therefore, the disclosed invention eliminates manual handling and reduces labor requirement. The disclosed invention improves cycle time and productivity. The disclosed invention ensures continuous automatic operation with minimal stoppage. The disclosed invention is versatile and capable of processing multiple raw materials. This adaptability allows manufacturers to produce eco-friendly biodegradable products such as, but not limited to, plates, bowls, trays, and packaging containers.
[0096] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0097] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims.
, Claims:CLAIMS
I/We Claim:
1. An automatic pulp molder (100), the molder (100) comprising:
a body frame assembly (102),
wherein the body frame assembly (102) is divided into multiple stages to form a single continuous production line;
at least one servo-motor assembly (104) mounted on the body frame assembly (102), the one servo-motor assembly (104) further comprising:
at least one servo motor (106) configured to provide accurate torque and position control of a plurality of platen;
a precision gearbox (108) coupled with the servo motor (106), the precision gearbox (108) configured to control the platen movement,
wherein the precision gearbox (108) translates rotary motion into linear vertical movement for the platen;
a clamping mechanism (110) associated with the precision gearbox (108), the clamping mechanism (110) configured to ensure firm mold closure with consistent pressure;
at least a pair of linear motion guide rails (112) adjacent to the precision gearbox (108), the linear motion guide rails (112) configured to:
ensure mold alignment; and
ensure smooth travel during pressing and transfer;
a plurality of precision-controlled electric heaters (114) adjacent to the linear motion guide rails (112), the precision-controlled electric heaters (114) configured to perform thermos-forming;
a water shower trimming unit (116) in proximity to the linear motion guide rails (112), the water shower trimming unit (116) configured to integrate a directed water jet to remove excess fibers and edges after thermo-forming; and
a control unit (118) placed on the body frame assembly (102), the control unit (118) configured to:
coordinate automatic product transfer;
control operations of the water shower trimming unit (116);
control operations of the servo-motor assembly (104); and
optimize heating cycles of the precision-controlled electric heaters (114),
a half rotary dip forming-based mechanism (128) controlled by the control unit (118), the half rotary dip forming-based mechanism (128) configured to ensure uniform pulp distribution; and
at least two hot presses (130) controlled by the control unit (118), the hot presses (130) arranged consecutively to produce both side smooth products,
wherein the two hot presses (130) are modular,
wherein the first of the two hot presses (130) rotates on its axis and is capable of vertical movement,
wherein the second of the two hot presses (130) is capable of vertical movement and lateral movement.
2. The molder (100) as claimed in claim 1, wherein the body frame assembly (102) is divided into pulp-dredging stage, pre-press stage, thermo-forming stage, and trimming stage.
3. The molder (100) as claimed in claim 1, wherein the molder (100) also include:
a slurry tank (122) configured to hold fiber pulp; and
a plurality of molds (124) configured to collect pulp through suction/vacuum from the slurry tank (122).
4. The molder (100) as claimed in claim 3, wherein the precision gearbox (108) coupled with the servo motor (106) performs pre-pressing to removes excess water from the pulp collected by the molds (124).
5. The molder (100) as claimed in claim 1, wherein the control unit (118) is bilaterally connected to a user interface (126) placed on the body frame assembly (102).
6. The molder (100) as claimed in claim 5, wherein the user interface (126) enables hybrid operation of the molder (100), as per the operational parameters set by an operator.
7. The molder (100) as claimed in claim 1, wherein the molder (100) also integrates a plurality of servo-driven arms/conveyors (120) controlled by the control unit (118) to move products without manual interference.
8. The molder (100) as claimed in claim 1, wherein the control unit (118) further includes an energy optimization algorithm configured to regulate heater power output of the precision-controlled electric heaters (114), as per the mold occupancy, material moisture content, and ambient conditions.
9. The molder (100) as claimed in claim 3, wherein the slurry tank (122) contains non-wood pulp selected from bagasse pulp, wheat or rice straw pulp, and bamboo pulp, or mixed agro-waste fibers.
10. The molder (100) as claimed in claim 1, wherein the molds (124) are designed to minimize wire mesh breakage by incorporating a reinforced mold base and optimized mesh support framework that evenly distributes mechanical stress during the pre-pressing and heating cycles.