A product forming unit (U) for manufacturing non-flat cellulose products (1) from an air-formed cellulose blank structure (2). The product forming unit (U) comprises a blank dry-forming module (4) with a moveable forming wire (4c), a toggle pressing module (6) with a toggle press (6a) and a forming mould (3), and an electronic control system (6h) operatively connected to the forming wire (4c) and the toggle press (6a). The blank dry-forming module (4) is configured for air-forming the cellulose blank structure (2) onto the forming wire (4c). The toggle press (6a) includes a pressing member (6d) movably arranged in a pressing direction, a toggle-mechanism (6e) drivingly connected to the pressing member (6d), a pressing actuator arrangement (6f) drivingly connected to the toggle-mechanism (6e). The forming mould (3) includes a moveable first mould part (3a) attached to the pressing member (6d) and a second mould part (3b). The electronic control system (6h) is configured for controlling operation of the pressing actuator arrangement (6f) for performing pressing operations, which involves driving the pressing member (6d) in the pressing direction by means of the toggle-mechanism (6e), and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part (3a) against the second mould part (3b). The electronic control system (6h) further is configured for intermittently feeding the forming wire (4c) between subsequent pressing operations.
B30B 1/16 - Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism operated by fluid-pressure means
B30B 11/00 - Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses or tabletting presses
Method for dry-forming cellulose products (1) from a cellulose blank structure (2) in a product forming unit. The product forming unit comprises a blank dry-forming module (4) and a pressing module (6). The cellulose blank structure (2) is air-formed in the blank dry-forming module (4) onto a forming wire (4c). The pressing module (6) comprises one or more forming moulds (3) for forming the cellulose products (1) from the cellulose blank structure in a pressing operation. The method comprises the step: arranging the forming wire in a stationary mode during the pressing operation.
B30B 1/10 - Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism
B30B 1/16 - Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism operated by fluid-pressure means
B31B 50/59 - Shaping sheet material under pressure
B31F 1/00 - Mechanical deformation without removing material, e.g. in combination with laminating
3.
A CELLULOSE PRODUCT TOGGLE PRESSING MODULE AND METHOD FOR USING THE SAME
A cellulose product toggle pressing module (6) for forming non-flat cellulose products (1) from an air-formed cellulose blank structure (2). The toggle pressing module (6) comprises a toggle press (6a) including pressing member (6d) movably arranged in a pressing direction, a toggle-mechanism (6e) drivingly connected to the pressing member (6d), a pressing actuator arrangement (6f) drivingly connected to the toggle-mechanism (6e), and an electronic control system (6h) operatively connected to the pressing actuator arrangement (6f). The toggle pressing module (6) further comprises a forming mould (3) including a moveable first mould part (3a) attached to the pressing member (6d) and a second mould part (3b). The electronic control system (6h) is configured for controlling operation of pressing actuator arrangement (6f) for driving the pressing member (6d) using the toggle-mechanism (6e) in the pressing direction and forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part (3a) against the second mould part (3b). Furthermore, the toggle press (6a) is installed with, or arranged for being installed with, the pressing direction of the pressing member (6d) arranged primarily in a horizontal direction, specifically with the pressing direction of the pressing member (6d) arranged within 20 degrees from the horizontal direction, and more specifically with the pressing direction in parallel with the horizontal direction.
B30B 1/10 - Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism
B30B 1/16 - Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism operated by fluid-pressure means
4.
A METHOD FOR MANUFACTURING CELLULOSE PRODUCTS AND A PRODUCT FORMING UNIT FOR MANUFACTURING CELLULOSE PRODUCTS
A method for manufacturing non-flat cellulose products from an air-formed cellulose blank structure in a product forming unit. The product forming unit comprises a buffering module and a pressing module comprising one or more forming moulds. The method comprises the steps: providing the cellulose blank structure and feeding the cellulose blank structure to the buffering module; buffering the cellulose blank structure in the buffering module, and feeding the cellulose blank structure from the buffering module to the pressing module; forming cellulose products from the cellulose blank structure in the one or more forming moulds by heating the cellulose blank structure to a forming temperature, and pressing the cellulose blank structure with a forming pressure. The cellulose blank structure is continuously fed to the buffering module in a first feeding direction, and intermittently fed from the buffering module in a second feeding direction, wherein the second feeding direction differs from the first feeding direction.
D21J 5/00 - Manufacture of hollow articles by transferring sheets, produced from fibres suspensions or papier-mâché by suction on wire-net moulds, to couch moulds
5.
A METHOD FOR FORMING CELLULOSE PRODUCTS IN A FORMING MOULD SYSTEM FROM A CELLULOSE BLANK STRUCTURE, A FORMING MOULD SYSTEM, AND A CELLULOSE BLANK STRUCTURE
A method for forming cellulose products in a forming mould system from an air-formed cellulose blank structure (2), where the forming mould system comprises one or more forming moulds(3). Each forming mould comprises a first mould part (3a) and a second mould part (3b) configured for cooperating with each other during the forming of the cellulose products. The method comprises the steps: providing the cellulose blank structure, and in the cellulose blank structure defining one or more product sections (2a) and a residual section (2b) surrounding or arranged in connection to the one or more product sections; compressing at least a portion of the residual section to a first degree of compression higher than a degree of compression of the one or more product sections; feeding the cellulose blank structure in a feeding direction to a forming position in the forming mould system, where in the forming position each product section is arranged between a corresponding first mould part and second mould part; forming the cellulose products from the cellulose blank structure between the first mould part and the second mould part by heating the cellulose blank structure to a forming temperature in the range of 100-300 °C; and pressing the cellulose blank structure with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.
B29C 51/00 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor
D21J 5/00 - Manufacture of hollow articles by transferring sheets, produced from fibres suspensions or papier-mâché by suction on wire-net moulds, to couch moulds
6.
A METHOD FOR EDGE-FORMING CELLULOSE PRODUCTS IN A FORMING MOULD SYSTEM, AND A FORMING MOULD SYSTEM FOR FORMING EDGES OF CELLULOSE PRODUCTS
A method for edge-forming cellulose products in a forming mould system, and a forming mould system (S), where the forming mould system is adapted for forming the cellulose products from an air- formed cellulose blank structure (2). The forming mould system comprises a first mould part (3) and a second mould part (4) arranged for cooperating with each other. The first mould part comprises an edge-forming device (5) with a protruding element (5a) configured for compacting and separating fibres of the cellulose blank structure. The edge-forming device is movably arranged in relation to a base structure (3a) of the first mould part, and the edge-forming device is adapted for interacting with a pressure member (6) arranged in the base structure. The method comprises the steps: providing the air- formed cellulose blank structure, and arranging the cellulose blank structure between the first mould part and the second mould part; forming a compacted edge structure of the cellulose products by separating fibres of the cellulose blank structure with the protruding element, applying an edge-forming temperature onto the cellulose blank structure, and compacting the cellulose blank structure by applying an edge-forming pressure by means of the pressure member onto the cellulose blank structure between the protruding element and the second mould part.
A multi-cavity forming mould system for forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure, where the forming mould system comprises a first mould part and a second mould part arranged for cooperating with each other during forming of the cellulose products. The first mould part comprises a plurality of first forming elements and the second mould part comprises a plurality of corresponding second forming elements, which are movably arranged in relation to a base structure. The system forming a plurality of cavities for the blank between each first forming element and corresponding second forming element during forming of the products. Each second forming element is arranged for interacting with a pressure member arranged in the base structure, where the pressure member establishes a pressure in each cavity onto the cellulose blank during forming of the products.
B29C 33/00 - Moulds or coresDetails thereof or accessories therefor
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles
B29C 43/32 - Component parts, details or accessoriesAuxiliary operations
B29C 43/36 - Moulds for making articles of definite length, i.e. discrete articles
B29C 43/40 - Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
B29C 51/00 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor
B29C 51/08 - Deep-drawing or matched-mould forming, i.e. using mechanical means only
The present invention relates to a method of manufacturing a cellulose product having a flat or non-flat product shape by a pressure moulding apparatus comprising a forming mould. The forming mould has a forming surface defining said product shape, The method comprises the steps of: arranging a cellulose blank containing less than 45 weight percent water in said forming mould;heating said cellulose blank to a forming temperature in the range of 100°C to 200°C; and pressing said cellulose blank by means of said forming mould with a forming pressure acting on the cellulose blank across said forming surface, said forming pressure being in the range of MPa to 100 MPa.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B65B 43/08 - Forming three-dimensional containers from sheet material
9.
METHOD FOR MANUFACTURING A CELLULOSE PRODUCT, CELLULOSE PRODUCT FORMING APPARATUS AND CELLULOSE PRODUCT
A method for manufacturing a cellulose product, comprising the steps: dry forming a cellulose blank in a dry forming unit; arranging the cellulose blank in a forming mould; heating the cellulose blank to a forming temperature in the range of 100°C to 200°C; and pressing the cellulose blank in the forming mould with a forming pressure of at least 1 MPa.
patents
