Molded fiber manufacturing

a technology of molded fibers and molded bodies, applied in the field of molded fiber manufacturing, can solve the problems of reducing the adhesion of the molded fiber shaped body to the thermo-, and the ineffective vacuum dewatering, so as to reduce the amount of water, reduce the energy consumption of manufacturing, and reduce the effect of thermal energy

US20050150624A1Inactive Publication Date: 2005-07-14GRENIDEA TECH PTE
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Patent Information

Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
Publication Date
2005-07-14
Estimated Expiration
Not applicable · inactive patent

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Abstract

Molded fiber products using agriculture residues are economical and environmentally beneficial. Molded fiber manufacturing is different from molded pulp. The present invention discloses a method of and an apparatus for the manufacturing of molded fiber shaped body (10) using low consistency fiber slurry (12) subject to vacuum-forming and thermo-curing. The use of porous material as mold inserts for both vacuum-forming (101) and thermo-curing (102) stations provides improved productivity and enables ease of mold release. The incorporation of self-cleaning techniques further ensures consistent performance of the manufacturing system.
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Description

[0001] This invention relates to a method of and an apparatus for improving the manufacturing of molded fiber shaped body. BACKGROUND

[0002] Products made of molded fiber are environmental friendly. Raw materials for manufacturing molded fiber products are derived from agriculture residues which are usually treated as waste. Unlike pulp, fibers from agriculture residues do not need to be rigorously treated before they are used. When molded fiber products are disposed, they are biodegradable and are emission neutral.

[0003] Molded fiber shaped bodies can be used as packaging for food, industrial goods, consumer products and many others. It has very good cushioning property and is ready to be used without the need to cut, bend and fold. It is also light and stackable which reduce storage and shipping space. Molded fiber packaging is a cost economical and environmental friendly choice to replace existing plastics and paper packaging.

[0004] Vacuum thermoforming method using low-consist...

Examples

Embodiment Construction

[0025] The improved molded fiber shaped body manufacturing process consists of four major steps. These are (1) fiber slurry preparation; (2) vacuum-forming and (3) thermo-curing and (4) post-processing.

[0026] The manufacturing process begins with the preparation of fiber slurry. Sufficiently refined plant fibers such as fibers obtained from palm oil, coconut coir, hemp, kenaf and other fibrous plants are added to a mixer tank. The mixer tank can be pre-filled with water or water can be added simultaneously with the fiber. The amount of fiber is 0.1 to 5 percent (wt) with respect to 99.9 to 95 percent (wt) of water. The fibers are agitated by an agitator such as an impeller to disperse them in the water. The low consistency fiber mixture is sufficiently agitated until a homogenous slurry is obtained. Water based adhesive binder is then added to the mixer tank and the entire mixture is continuously agitated. The agitation action causes the adhesive binder to attach to the fiber. Func...