Molding fiber product line using fluid finishing operations

Abstract

The present invention relates to a molded fiber product production line utilizing a fluid trimming operation. A molded fiber part former includes a first forming mold defining a first mold area and at least one fluid inlet. The molded fiber part former further includes a wall substantially surrounding the first mold area. The molded fiber part former includes a first fluid channel adjacent and surrounding the wall, wherein the channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet.

Description

Technical Field

[0001] This application claims priority and benefit to U.S. Provisional Patent Application Serial No. 62 / 933,593, filed November 11, 2019, entitled “Production Line for Molded Fiber Products Using Water Trimming Operation,” the disclosure of which is incorporated herein by reference. Background Technology

[0002] Pollution caused by single-use plastic containers and packaging materials is now a globally recognized problem. Proposing to replace single-use packaging with biodegradable and compostable materials is one way to reduce plastic pollution. However, for new, environmentally friendly alternatives to succeed, they must compete with the existing plastic technologies they replace in both cost and performance.

[0003] As a brief background, molded pulp (also known as molded fiber) has been used to manufacture containers, trays, and other packaging since the 1930s. The pulp can be made from recycled materials such as old newsprint and corrugated cardboard boxes, or directly from tree and other plant fibers. Today, molded pulp packaging is widely used in electronics, household goods, automotive parts, and medical products.

[0004] The mold is made using a metal tool that processes the mirror shape of the finished part. Holes are drilled in the tool, and then a mesh is attached to the surface of the tool. A vacuum is drawn through the holes while the mesh prevents the slurry from clogging them. To manufacture the molded fiber part, the mold is immersed in fiber slurry and a pressure gradient is applied, while water is pumped out through the holes in the mold. Fibers from the slurry are collected on the mesh, and after the fiber layer has been formed to the desired thickness, the mold with the molded fiber part is removed from the slurry. The molded fiber part is then detached from the mold and can be further processed (e.g., molding, heating, drying, surface coating, etc.).

[0005] Molded fiber packaging products can be biodegradable and compostable. However, currently known fiber technologies are not well-suited for food packaging in which food may come into contact with the packaging, particularly meat and poultry containers, pre-prepared foods, products, microwaveable food containers, and lids and cups for beverage containers. Summary of the Invention

[0006] In one aspect, the technology relates to a molding fiber component forming apparatus comprising: a first molding die defining a first die region and at least one fluid inlet; a wall substantially surrounding the first die region; and a first fluid channel adjacent to and surrounding the wall, wherein the channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet. In one example, the molding fiber component forming apparatus further comprises: a sealing ring at least partially covering the fluid channel outlet, wherein the sealing ring is isolated from the wall to at least partially define a fluid groove between the sealing ring and the wall. In another example, the sealing ring is fixed to the first die component. In yet another example, the sealing ring is detachably fixed to the first die component. In still another example, the fluid channel defines a maximum channel width, and the fluid groove defines a maximum groove width smaller than the maximum channel width.

[0007] In another example of the above aspects, the fluid channel is configured to direct fluid flow in a direction substantially perpendicular to the uppermost extent of the wall. In one example, the molding fiber component formulator further includes a second forming die defining a mating die region configured to mate with a first die region of the first forming die. In another example, the second forming die includes an outer edge surrounding the mating die region, wherein when the first die region and the mating die region are in a mating configuration, the outer edge is configured to deflect fluid flow ejected from the fluid channel in a direction away from the die region and the mating die region. In yet another example, the outer edge is curved. In still another example, the at least one fluid inlet includes a plurality of fluid inlets.

[0008] In another example of the above aspects, the plurality of fluid inlets are distributed around the outer edge of the first molding die. In one example, each of the plurality of fluid inlets is fluidly connected to the fluid channel.

[0009] In another aspect, the technology relates to a method for manufacturing a molded fiber component, the method comprising: placing a first molding die in a tank comprising a plurality of fibers and a liquid, wherein the first molding die includes a first die region, at least one fluid inlet, and a plurality of vacuum channels; actuating a vacuum container communicatively attached to the plurality of vacuum channels to draw at least some of the plurality of fibers onto the molding die to form a partially molded molded fiber component; removing the first molding die from the tank; applying a compressive pressure to the partially molded molded fiber component using a second molding die; substantially simultaneously applying the compressive pressure and separating a waste trimming material from the partially molded molded fiber component; and after separating the waste trimming material, transferring the partially molded molded fiber component to a downstream station. In one example, separating the waste trimming material includes receiving fluid from the at least one fluid inlet and ejecting the fluid from a fluid outlet at least partially defined by the first molding die. In another example, separating the waste trimming material includes ejecting fluid from a fluid outlet at least partially defining the second molding die. In yet another example, the plurality of vacuum channels are fluidly connected to the first mold region, and wherein at least one fluid inlet is fluidly connected to a fluid outlet located on the first molding die away from the first mold region. In still another example, the method further includes directing the ejected fluid away from the first mold region.

[0010] In another example of the above aspects, the method further includes grasping the waste trimming material and the fluid. In one example, the method further includes reprocessing the waste trimming material and the fluid after grasping them. In another example, separating the waste trimming material includes spraying fluid onto the edge of the partially formed molded fiber component. In yet another example, the fluid is sprayed in a substantially annular flow manner.

[0011] On the other hand, the technology relates to a molding fiber component production line, comprising: (a) a molding station including: a tank configured to receive a fiber slurry comprising a plurality of fibers and a liquid; a molding die including a die plate defining a plurality of vacuum channels and at least one fluid trimming channel; and a die actuation system for adjusting the position of the die plate relative to the tank; (b) a component transfer system including: a component transfer feature defining a plurality of component vacuum channels; and a transfer mechanism for moving the component transfer feature from a first position engaged with the molding die to a second position; and (c) a pressing station including: a core mold. The molding station comprises: a cavity mold that mates with the core mold; a press-actuation system for adjusting the position of the core mold relative to the cavity mold, wherein at least one of the core mold and the cavity mold defines a plurality of vacuum channels and at least one heating element; and wherein, in the second position, the part transfer feature engages with at least one of the core mold and the cavity mold; and (d) a removal system comprising: a removal feature defining a plurality of part vacuum channels and a plurality of trimming vacuum channels; and a transfer mechanism for moving the removal feature from a third position engaged with at least one of the core mold and the cavity mold to a fourth position. In one example, the mold plate includes a first mold region and at least one fluid inlet, and a wall substantially surrounding the first mold region, wherein the fluid channels are adjacent to and surround the wall, and wherein the at least one fluid trimming channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet. In another example, the molding station further includes: a sealing ring fastened to the mold plate and at least partially covering the outlet of the at least one fluid trimming channel, wherein the sealing ring is spaced apart from the wall, thereby partially defining a fluid groove between the sealing ring and the wall. In another example, the sealing ring is removably secured to the mold plate. In yet another example, the at least one fluid trimming channel defines a maximum channel width, and the fluid groove defines a maximum groove width smaller than the maximum channel width.

[0012] In another example of the above aspects, the fluid channel is configured to guide fluid flow in a direction substantially perpendicular to the uppermost extent of the wall. In one example, the component transfer feature includes a component transfer mold that mates with the molding die. In another example, the component transfer system transmission mechanism includes a robotic arm. In yet another example, the component transfer system transmission mechanism includes a shuttle placed on a frame. In still another example, the frame extends in a first direction away from the molding die and in a second direction opposite to the molding die.

[0013] In another example of the foregoing aspects, both the core mold and the cavity mold define the plurality of vacuum channels. In one example, the at least one heating element comprises a plurality of heating elements, and both the core mold and the cavity mold comprise at least one of the plurality of heating elements. In another example, the removal feature comprises a removal mold. In yet another example, the removal feature comprises a plurality of vacuum cups. In still another example, the removal system transfer mechanism comprises a robotic arm. In yet another example, the removal system transfer mechanism comprises a shuttle placed on a frame.

[0014] In another example of the foregoing aspects, the removal system is the component transfer system. In one example, the molded fiber component production line further includes a printing station, wherein the removal feature engages with the printing station when in the fourth position. In one example, the printing station includes a registration feature. In another example, the printing station includes at least one printing device. In yet another example, the at least one printing device includes at least one of a screen printer, a laser printer, an inkjet printer, and a pad printer. In yet another example, the molded fiber component production line further includes a stacking station.

[0015] In another example of the above aspects, at least one of the component transfer system and the removal system includes at least one of a robotic arm, a shuttle, and a conveyor. Attached Figure Description

[0016] The following discussion of at least one example, with reference to the accompanying drawings, is not intended to be drawn to scale. The drawings are included to provide illustration and further understanding of the aspects and examples, and are incorporated in and form part of this specification; however, they are not intended to be limiting definitions of any particular example. The drawings, along with the remainder of the specification, serve to explain the principles and operation of the described and claimed aspects and examples. For clarity, not every component is labeled in every figure.

[0017] Figure 1 A schematic diagram of an exemplary molded fiber component production line is depicted.

[0018] Figure 2 Depicting Figure 1 An example of a production line, which is arranged in a circular layout.

[0019] Figure 3 An example of a method for manufacturing fiber pulp is shown.

[0020] Figure 4 Is execution Figure 3 A schematic diagram of the pulp production line of the method.

[0021] Figure 5An example of a shaping and finishing station is depicted.

[0022] Figure 6 A partial schematic diagram of a forming and trimming station with a fluid gripping system is depicted.

[0023] Figure 7 An enlarged cross-sectional view of a portion of the mold for the forming and finishing station is depicted.

[0024] Figure 8 A partial schematic diagram of two molds in a mating engagement of the pressing station is shown.

[0025] Figure 9A and 9B Perspective views and enlarged perspective views of the upper forming and finishing molds are shown respectively.

[0026] Figure 10A and 10B Perspective views and partial cross-sectional views of the upper forming and finishing molds are shown respectively.

[0027] Figure 11 A method for producing molded fiber components is described.

[0028] Figure 12 An example is shown in which one or more of the present examples can be implemented.

[0029] Figure 13 These are examples of networks in which the various systems and methods disclosed in this application can be run. Detailed Implementation

[0030] Before disclosing and describing a production line for producing molded fiber products, it should be understood that this disclosure is not limited to the specific structures, processes, or materials disclosed in this application, but extends to their equivalents that would be recognized by one of ordinary skill in the relevant art. It should also be understood that the terminology used herein is used only to describe specific examples of the production line and its components and is not intended to be limiting. It should be noted that, unless the context clearly indicates otherwise, the singular forms “a,” “an,” “the,” etc., used in this specification include plural references. Therefore, for example, with respect to “an operation,” it may include multiple operations, and with respect to the “production” or “product” of an operation or action, it should not be considered as all products.

[0031] The various examples of the techniques described below relate to the manufacture of fiber-based or paper-based products for use within and outside the food and beverage industry. By way of non-limiting examples, this disclosure relates to the automated, efficient, and high-speed production of fiber-based containers. Fiber-based products are suitable replacements for their plastic counterparts in a variety of applications, such as: frozen, refrigerated, and non-refrigerated foods; medical, pharmaceutical, and biological applications; microwaveable food containers; beverages; edible and non-edible liquids; substances that release water, oil, and / or water vapor during storage, transport, and preparation (e.g., cooking); horticultural applications, including consumables and landscaping / gardening plants, flowers, herbs, shrubs, and trees; disposable or single-use storage and dispensing devices (e.g., paint trays, food trays, brush handles, protective caps for transport); agricultural products (including human and animal foods such as fruits and vegetables); salads; prepared foods; meat, poultry, and fish. Packaging; lids; cups; bottles; agricultural products (including human and animal foods such as fruits and vegetables); salads; prepared foods; packaging for meat, poultry and fish; lids; cups; bottles; guides and dividers for processing and displaying the aforementioned items; corner pieces for packaging, storing and transporting electronic devices, mirrors, works of art and other fragile parts; pipes; industrial, automotive, marine, aerospace and military components such as gaskets, washers, seals, cushioning pads, etc.; and related molds, wire mesh forms, formulations, processes, chemical formulations, tools, slurry dispensing, chemical monitoring, chemical infusion, and related systems, equipment, methods and technologies for manufacturing the aforementioned components.

[0032] A conventional production line for manufacturing molded fiber parts or products is described in Chinese Patent Application No. 201711129438.X (hereinafter referred to as "Application 438"), entitled "Flexible Production Line for Producing Pulp Molded Products," which is incorporated herein by reference in its entirety. Application 438 generally describes a forming station comprising a forming device that produces a wet part by immersing a first mold in a fiber pulp tank, drawing fibers onto the mold until a desired amount of fiber is collected on a screen, and then removing the mold with the attached fiber layer from the pulp. In the system described in Application 438, the forming station also performs a forming operation on the wet part in which, after removing the first mold with the attached fiber layer from the pulp, it is pressed into a second mold. This forming operation removes some water from the wet part and contours the surface of the wet part opposite to that of the first mold. In the production line of Application 438, the molded fiber part, after being made by the forming station, is pressed in a pressing station. Multiple pressing stations may operate in parallel. In one example from application 438', four pressing stations are used. Each of the four pressing stations in application 438' includes a pressing machine. After pressing, the part is sent to a stacking station. The forming station, pressing station, and stacking station are arranged in a circle around a central robot that controls an extendable robotic arm. The robot and robotic arm are configured to remove the formed parts from the forming station and transfer them to any of the four pressing stations. The robotic arm is also configured to remove the pressed parts from any pressing station and transfer them to another pressing station or to the stacking station. Although this application describes many of the basic components and stations of a molded fiber part production line, unfortunately, it reveals many areas of inefficiency.

[0033] Figure 1A schematic diagram of an exemplary molded fiber component production line 100 is depicted. The depicted production line 100 has multiple stations and systems for moving partially molded and molded components between the various stations of the production line 100. The various stations and systems, as well as specific configurations of the production line 100 itself, are further described herein. The combined molding and trimming station 102 includes a molding die, a slurry tank, and an actuation system that moves the molding die relative to the slurry tank (this movement is typically achieved by lowering the die into the slurry tank). The slurry tank contains fiber slurry comprising wood fibers in a liquid. The molding and trimming die itself includes a plurality of vacuum channels connected to a vacuum source, which are used during the molding process. The molding and trimming die also includes a plurality of fluid channels defined therein, which are used for the fluid trimming process described herein. The molding and trimming die may have multiple discrete dies for manufacturing multiple identical fiber components, although molding and trimming dies for forming different components are also contemplated. In one example, the molding and trimming die may include a die body or plate that includes the required contours, features, etc., for a particular product. The vacuum channels within the mold body can have a deliberate path or layout, or they can be randomly formed therein as part of the mold-making process. Some mold bodies may include a sieve or screen that forms a surface onto which fibers are drawn during the molding process. In use, an actuation system lowers the molding die into a slurry tank and activates the associated vacuum source. This draws slurry into the vacuum channels, thereby placing the fibers onto the surface of the molding die or the screen (if present). When the desired number of fibers have been drawn onto the surface or screen, the actuation system lifts the molding die from the slurry. At this point in the process, the fibers placed on the molding die are referred to herein as a partially molded fiber component because it includes the general outline and features of the finished molded fiber component but does not show the performance characteristics of the finished component.

[0034] The partially molded fiber component can then be partially compressed and trimmed. These operations can be performed in part by the molding and trimming station 102 in conjunction with the component transfer system 104. The component transfer system 104 includes a component transfer feature, which can be a component transfer die substantially corresponding to or matching the molding and trimming die. In this respect, the component transfer die also functions to form a surface of the partially molded fiber component, which is arranged relative to the surface of the partially molded fiber component that contacts the molding die. Trimming operations, such as those described herein, can also be performed by the molding and trimming station 102 during this partial molding operation. The component transfer die may also include or define a plurality of vacuum channels (as described above in the context of the molding die) connected to a vacuum source. In use, the component transfer die is positioned to contact the partially molded fiber component. This contact forms the opposite surface of the partially molded fiber component. When the vacuum source is actuated, the partially molded fiber component is removed from the molding die. The component transfer system 104 includes a conveying system that transfers the component transfer mold from the forming station 102 to a downstream station (in this case, the pressing station 106). In this respect, the forming station 102 and the pressing station 106 can form the end of the range of motion of the component transfer system 104, which in this example may be referred to as a first position and a second position, respectively. Depending on the cycle time of the forming station 102 and the pressing station 106, the second position may be an intermediate waiting station in which the component transfer feature can be positioned to wait for the pressing station 106 to become available.

[0035] Production line 100 includes a pressing station 106 that utilizes a combination of compression pressure and elevated temperature to substantially cure a partially molded fiber component into a molded fiber component (meeting the general performance requirements for use). A component transfer system 104 can transfer the partially molded fiber component to the pressing station 106 (as indicated by arrow 112). The discrete pressing station 106 includes two molds, commonly referred to as a core mold and a corresponding and mating cavity mold. Regardless of the terminology used, the core mold and the cavity mold form two opposite surfaces of the molded fiber component. To form the partially molded fiber component into a molded fiber component, the structures of these two molds are generally similar to the forming and trimming molds and the transfer molds described above, as needed. However, since the trimming operation is performed on the forming and trimming molds, a configuration allowing for trimming is not required in the molds used in pressing station 106. Transfer 112 can occur via a component transfer feature of the component transfer system 104, which substantially matches the core mold or the cavity mold. A vacuum channel can be formed in one or both of the core mold and the cavity mold and is connected to a dedicated vacuum source. A vacuum source can be activated during transfer 112 to engage the mold with the transfer feature, thereby transferring the partially molded fiber part onto the appropriate mold of the press. A heating element can be disposed in one or both of the core mold and the cavity mold. The core mold and the cavity mold move relative to each other via a pressure actuation system, which in this example is a hydraulic press. As the pressure actuation system reduces the separation distance between the core mold and the cavity mold (with the partially molded fiber part in between), the increased compression pressure helps to form this part into a molded fiber part. The increased compression pressure squeezes additional liquid from the partially molded fiber part, which can be removed from the press station by one of a plurality of vacuum sources connected to the vacuum channels present in one or both of the core mold and the cavity mold. Furthermore, the elevated temperature generated by the heating element helps to further form and dry the partially molded fiber part until a part more consistent with the molded fiber part is produced.

[0036] The removal system 114 removes the molded fiber component from the pressing station 106, for example, along path 116. The removal system may include a removal feature comprising multiple vacuum channels. These multiple vacuum channels in the removal feature can be used to remove the component from the pressing station 106. The removal feature may be in the form of a removal die configured to mate with either a core die or a cavity die. In that case, the vacuum channels communicate with one or more ports on the surface of the removal die, such that vacuum pressure can extract the molded fiber component from the core die or the cavity die. In another example, the removal feature may be multiple vacuum cups connected to the vacuum channels. Vacuum pressure applied to the channels by a vacuum source can also remove the molded fiber component from the core die or the cavity die. The removal system 114 includes a transfer mechanism that, for example, moves the removal feature from a location engaged with a specific die of the pressing station to a downstream station along path 120. In this case, the downstream station may be one or more of a waste station 118, a printing station 122, a quality control station 124, and a stacking station 126, which are described below respectively. However, in general, a downstream station includes any station downstream of a specially identified station, and an upstream station includes any station upstream of a specially identified station.

[0037] Before further downstream processing, obviously defective or damaged molded fiber products can be treated using waste station 118. Waste station 118 may include a system for reintroducing damaged molded fiber products into the slurry system. In one example, the waste station may be a bin, chute, or other structure into which damaged products can be released from removal system 114. When removal system 114 is properly positioned relative to waste station 118, a vacuum source can be shut off or terminated, allowing defective products to detach from the removal feature or otherwise fall off. Proper positioning may correspond to a physical engagement between the removal feature and waste station 118, or may be detected via proximity, optical, or other sensors relative to waste station 118. A partial vacuum pressure can be maintained at waste station 118 so that acceptable molded fiber components are not released into waste station 118 but are instead transported to a more downstream station.

[0038] After waste station 118, the molded fiber parts are generally considered to be fully formed and ready for use. However, other downstream stations can be used to add graphics, logos, or other visual information to each molded fiber part, check the quality of the final part, or stack or package the molded fiber parts for shipment. Therefore, downstream printing station 122, quality control station 124, and stacking station 126 are depicted. These optional stations will be described in further detail below.

[0039] As shown in the figure, the entire production line 100 can be automated and controlled by a control system 128. The control system 128 can be connected to each station, and even to sub-components of each station, as well as transfer and removal systems (in the form of conveyors, robots, and other equipment, as described elsewhere herein), and controls the operation of each station. As discussed further below, the control system 128 can continuously monitor the operation and conditions on the production line 100 and adjust the operation to ensure the proper function and quality of the final parts.

[0040] Control (which anticipates all operating parameters) will improve the quality of the formed fiber parts and increase the output of production line 100. To achieve this control, a sensor network throughout production line 100 is conceivable. In this example, various sensors are provided at each station and each conveying system to monitor any relevant parameters of the operation of production line 100. One example of such monitoring is a sensor at the forming and finishing station that detects excess fibers to be finished from the partially formed fiber parts; another example is the temperature control of the heated mold at the pressing station. Signals from these and other sensors can be sent to and processed by the control system 128. As another example, the forming and finishing station or pressing station 106 can be dynamically controlled based on sensors in the respective stations 102, 106. In this example, finishing operations can be performed by the forming and finishing station until its associated sensors no longer detect the presence of finishing material to be removed. In a more complex example, pressing station 106 can be operated until the desired state is achieved in the formed fiber parts. In one example, one of the molds in the pressing station 106 may be equipped with one or more sensors that directly or indirectly monitor the state of the formed fibrous part. For example, a temperature sensor may be provided on the surface of the mold to monitor the temperature of the formed part at its contact point with the mold. Similarly, pressure sensors, humidity sensors, light emitter / sensor pairs, conductivity sensors, one or more electrodes that monitor the current passing through the formed part, or any other such monitoring devices may be provided at one or more locations on the mold. Based on the sensor outputs, the time allocated to pressing the formed part can be dynamically controlled by the control system 128. For example, the pressing operation may be terminated when a desired temperature (e.g., a predetermined temperature threshold) determined by the temperature sensor is reached.

[0041] Such monitoring sensors are not limited to being located within or above the forming and finishing station 102 or the pressing station 106, but can be located anywhere in the production line 100. In one example, the white water flow rate associated with the forming and finishing station 102 can be monitored via one or more flow rate sensors. This allows for monitoring over time the flow rate and amount of white water removed from the partially formed fiber parts at various stations throughout the production line 100. This allows for control of the pressing station, for example, based on the amount and flow rate of water observed during operation. When it is determined that the water flow rate or amount has reached a predetermined threshold (e.g., the flow rate has decreased by 90% since the start of operation, or 10 ml of water has been collected from the part during the pressing operation), the pressing operation can be terminated regardless of how long the operation has been in progress.

[0042] Beyond simply controlling the operating time of the pressing station 106 or any other component, this monitoring data can be used for much more. In one example, the pressing station 106 can dynamically increase or decrease pressure based on the collected data. In this way, it is conceivable that any controlled operating parameter (e.g., pressing operation time, pressing pressure, die temperature, slurry temperature, vacuum pressure, slurry flow rate, slurry quality, mixing tank temperature, conveyor belt speed or temperature, dryer temperature, ink flow rate, or any other operating setting related to time, temperature, pressure, or movement of production line components) can be controlled in response to data obtained from one or more sensors.

[0043] Figure 1 Production line 100 can operate in continuous mode. Various stations and part transfer systems can move continuously, forming, trimming, pressing, printing, and drying parts on production line 100 in motion. For example, in one instance, a quality control station could be a simple through station, as described herein, through which a conveyor belt passes when parts are being tested. A printing station could be one or more removable or fixed printheads that print on the part as it passes beneath them.

[0044] Other configurations are also possible. For example, a semi-continuous configuration can be set up in which one or more stations remove parts from production line 100 over a period of time and then replace them after the operation of a subsequent station is completed. In different semi-continuous configurations, the part transfer system 104 can operate in a stop-start mode, in which the part transfer system 104 moves a predetermined distance according to a prescribed schedule and then stops. In this way, each part moves between workstations over time. In one example, one or more of the part transfer system 104 and the removal system 114 can have part transfer features incorporated in the appropriate systems 102, 114 in the form of a mold (e.g., a core mold as described herein). The mold can provide reliable retention of the part during its movement. The pressing station can then have an external mold that receives the part when it arrives at the station.

[0045] Figure 1 Production line 100 offers several advantages. It possesses inherent scalability because multiple parallel pressing stations 106 and scrap stations 118 can operate simultaneously, with component transfer systems 104 and removal systems 114 providing support for each station. In such a parallel configuration, each parallel section can be referred to as a "sub-line." In another example, each parallel sub-line can be dedicated to different customers with different printing requirements, finished product requirements (and therefore different pressing and / or drying requirements). Furthermore, as another example, multiple stacking stations 126 would allow for the separate stacking of different customer components in an easily automated manner. The parallel configuration of multiple sub-lines adds resilience to production line 100 because the failure of any station in a sub-line will not bring the entire production line 100 to a halt. Further resilience can be provided by including a second forming station 102. At any given time, different sub-lines can be taken out of service without affecting the operation of other sub-lines. Therefore, a sub-line dedicated to a specific product may become unusable until that product is needed, meaning that reprocessing time can be saved.

[0046] Figure 2 Another example of production line 200 is shown. (See above for reference.) Figure 1Many components and their features have been described, and therefore will not be repeated. In this production line 200, the various stations are arranged in a circular configuration around a central component transfer system 204. Here, the component transfer system 204 includes an articulated robotic arm 205 having a maximum range of motion that generally corresponds to the circle C depicted. The component transfer system 204 moves a transfer feature 207 (in this case, a component transfer die) located at one end of the robotic arm 205 from the forming and trimming station 202 to one of four pressing stations 206. The movement in this example would typically involve removing the transfer feature 207 from the forming and trimming station 202 of the pressing station 206 (e.g., by retracting the robotic arm 205 and then rotating it to align the transfer feature with the entry area (generally the area facing the component transfer feature 204)), and then extending the robotic arm 205 to insert the transfer feature 207 into the pressing station 206. During this movement, the component transfer system 204 also moves a partially formed fiber component placed on the component transfer feature 207. Once the formed fiber components are pressed, the component transfer system 204 moves these components (re-placed on the transfer feature 207) from the pressing station 206 to the waste station 208 in a roughly similar motion pattern, where obviously damaged or defective products can be discarded. Then, in this example, as described above... Figure 1 The component transfer system 204 also serves as a removal system. Although only stacking station 226 is shown, acceptable molded fiber components can be transferred to one or more downstream stations after non-conforming products are deposited at the waste station. A transfer system from waste station 208 to stacking station 226 may be required. For example, stacking system 226 may include a dedicated arm or other feature that removes molded fiber components from component transfer system 204 and stacks them directly at stacking station 226. This allows acceptable molded fiber components to move through waste station 208 to stacking station 226. This can be performed using one or more conveyors, a second robotic arm, a servo shuttle, or a ramp.

[0047] Figure 3An example of a method for producing fiber pulp is shown. Pulp production line 300, sometimes referred to as “wet preparation” or “raw material preparation,” produces fiber pulp from raw materials. Typical raw materials are wood or plant fibers, which are usually provided in rolls or sheets; and water. In addition to raw materials, defective, damaged, or other unacceptable products from the aforementioned waste stations may also be introduced along with the raw materials. In some cases, chemical additives may also be used to enhance or modify the properties of the final fiber product (e.g., resistance to grease penetration, water absorption, porosity, density, etc.). In the example shown, the incoming raw dry fibers are conveyed to a mill and cut to a predetermined size in milling operation 302. Sometimes referred to as a pulper or hydraulic pulper, the mill can be any conventional mill. Fiber milling is known in the art and can be performed using any conventional system or method now known or developed later. In one example, as part of milling operation 302, the fibers are mixed with at least some water, and the output product is a liquid stream containing a mixture of milled fibers and water. This improves milling efficiency and reduces fiber dust generated during operation.

[0048] In one embodiment, grinding can be performed in multiple stages. For example, a first grinder may perform coarse grinding and convey the coarsely ground fiber pulp to a second fine grinder, which produces final grinding and outputs the ground fiber pulp. After grinding, a mixture of ground fibers and water is conveyed to a first mixing tank, where a first mixing operation 304 is performed. In the first mixing operation 304, additional water is added if necessary. Chemical additives may also be added in the first mixing operation 304 if the final fiber component to be manufactured requires specific characteristics. As part of the first mixing operation 304, the quality of the pulp can be monitored periodically or continuously. The information obtained from the detection device can be used to control the addition of water, any additives, and temperature. In one embodiment, the detection device may include the use of one or more sensors, such as a temperature sensor, a water quality sensor (e.g., a hydrometer), a total dissolved solids (TDS) sensor, a pH meter, a density meter, a dissolved oxygen sensor, a salinity meter, a resistivity meter, a conductivity meter, etc. Many water quality sensors are known in the art, and any such monitoring device now known or hereafter invented can be used to monitor the quality of the pulp or any operation in the pulp production method 300.

[0049] Following the first mixing operation 304, an optional second mixing operation 306 can be performed. In this embodiment, the first mixing operation 304 can be considered a premixing or preparatory operation, which is controlled to bring the pulp to a certain range of pulp quality. The second mixing operation 306 is then used to adjust the pulp characteristics to a finer quality range. For example, in the first mixing operation 304, the pulp can be controlled to + / - 10% of the desired nominal pulp quality (e.g., if the desired pulp is 10% of the fiber pulp weight, the fixed mixing tank is controlled to keep the pulp within 9.0 to 11.0% of the fiber weight. The second mixing operation 306 can then be designed to keep the pulp within + / - 1% of the nominal range). The + / - 10% and + / - 1% ranges for the two operations 304 and 306 are merely simple examples, and any suitable range can be used. For example, the first mixing operation 304 can maintain the pulp at nominal + / -0.5%, + / -1.0%, + / -1.5%, + / -2.0%, + / -2.5%, + / -3.0%, + / -3.5%, + / -4%, + / -4.5%, + / -5.0%, + / -7.5%, + / -10.0%, + / -15.0%, + / -20.0%, and the second mixing operation 306 can maintain the pulp at... Any smaller range near the nominal value, such as + / -0.01%, + / -0.05%, + / -0.1%, + / -0.2%, + / -0.25%, + / -0.30%, + / -0.035%, + / -0.4%, + / -0.45%, + / -0.5%, + / -0.55%, + / -0.6%, + / -0.75%, + / -1.0%, + / -2.0%, + / -5.0% or higher.

[0050] In an embodiment of the second mixing operation 306, the intermediate pulp from the first mixing operation 304 is analyzed and passed through an intermediate mixer, where the addition of water and chemical additives (if any) is finely controlled to achieve pulp quality within a better range. The intermediate mixer can be a mixing tank or a plug flow reactor or a combination thereof. The second mixing operation 306 can be a batch, semi-batch, or continuous operation. The second mixing operation 306 outputs a final fiber pulp stream, which can then be stored in a storage tank in storage operation 308 until used as described above or directly transferred to a molding station for forming molded parts in molding operation 310. As part of molding operation 310, water is recovered from the pulp as it passes through the mesh on the molding die. The reclaimed water is referred to as "white water." By collecting the white water in collection operation 312, it can be reused in pulp production method 300. White water may include trimmed material obtained from the combined molding and trimming station described above and elsewhere herein, which typically has a moisture content that will not cause undesirable clumping of the trimmed material in white water, thus allowing it to be reintroduced without reprocessing. However, in other embodiments, the trimmed material may be filtered from or otherwise removed from the white water (at filtration operation 314) and reintroduced, for example, in grinding operation 302. The white water can then be returned and used as feed water in any of the grinding operation 302, the first mixing operation 304, and / or the second mixing operation 306.

[0051] In one embodiment, the water used in the fiber pulp production method 300 is pretreated to remove any unwanted organic or inorganic compounds. For example, in one embodiment, the water may be filtered to reduce the concentration of salts or total dissolved solids (TDS). If the raw water must be pretreated before being used in the pulp production method 300, it is particularly economical to form a closed loop by collection operation 312 and return the white water as pulp. In one embodiment, the water and the various intermediate and final pulps produced in the fiber pulp production method 300 are heated to maintain them at a desired temperature. In another embodiment, the final fiber pulp is heated as a final operation (not shown) before being transferred to a forming station. For example, in one embodiment, the milled fiber pulp, intermediate fiber pulp, and final fiber pulp are all maintained within a predetermined temperature range. That is, the temperature of the water and pulp is controlled throughout the production process. The temperature range may be from 90°F to 200°F or from 100°F to 150°F. In one embodiment, the predetermined temperature range is a temperature range of + / - 5°F selected from the nominal temperatures of 90°F, 95°F, 100°F, 105°F, 110°F, 115°F, 120°F, 125°F, 130°F, 135°F, and 140°F.

[0052] Figure 4 Is execution Figure 3 A schematic diagram of a slurry production line 400 is provided. In the diagram, a first mixing tank 406 follows a first grinder 402 and a second grinder 404. Grinders 402 and 404 have been described above. The first mixing tank 406 may be open or closed, exposed to or controlled by the atmosphere. While in the mixing tank 406, the slurry can be agitated. Any agitation method may be used, such as a mechanical agitator (e.g., a blade agitator, paddle agitator, or rotary screw agitator), to remove and re-inject the slurry to circulate the contents of the tank, or to reach the slurry in the tank by injecting a gas (e.g., heated or ambient air, nitrogen, argon, or other inert gas). The temperature of the tank 406 may be controlled by any suitable means known in the art (e.g., a heated jacket, internal heating elements, heated gas flow, infrared radiation, etc.). A temperature sensor may be provided to continuously monitor the temperature of the tank 406.

[0053] A second mixer 408 is provided to perform a second mixing operation 306. As mentioned above, the second mixer 408 need not be a tank and may be a plug flow reactor (e.g., a pipe section with injection points for water and chemical additives and sensors for monitoring pulp quality). Alternatively, it may be a second mixing tank 408 similar to the first mixing tank 406. A storage tank 410 is provided in the pulp production line 400 to buffer the final fiber pulp before transferring it to the forming and finishing station (shown elsewhere herein). As shown, the pulp production line 400 also includes white water returned from the forming and finishing station. A second storage tank 412 is provided to buffer the white water until water is needed in earlier operations of the pulp production line 400. Trimmed material from the forming and finishing station can be removed from the white water at a filter 414 and can be reintroduced separately, for example, at the first mill 402; however, the trimmed material can also be introduced into the second mill 404. Alternatively, the trimmed material can be introduced as a component of the white water. In one embodiment, the pulp production line 400 forms a closed loop, requiring little or no additional water after initial startup.

[0054] Figure 4 The schematic diagram does not include standard piping fixtures and equipment typically used for this operation, such as flow control valves, safety valves, bypass valves, sampling ports, pumps that need to move the slurry between components, conveyors or similar feeders for conveying raw fibers to the mill, sensors, etc. The reader will understand that such fixtures and equipment are contemplated and considered part of production line 400, but for clarity, they are omitted. Figure 4 Not shown. For example, in one embodiment, there is a pump between each component in production line 400.

[0055] Pulp production line 400 can be configured for batch, semi-batch, or continuous operation. In continuous operation, one or more components can store sufficient fiber pulp to act as a flow buffer, allowing for switching out of fiber sources or periodic (automatic or manual) fiber milling operations. For example, in one embodiment, the size of the first mixing tank 404 is determined to be a sufficient volume of pulp to maintain continuous operation of the fiber product production line 400 for eight hours at full capacity. In this way, a new batch of milled fiber pulp can be generated (automatically or manually) and added to the first mixing tank 406 every few hours. The second mixing tank or mixer 408 can be significantly smaller or simply pass through to continuously supply the final fiber pulp to the forming station. In one embodiment, the pulp production line 400 can be fully automated and controlled by a central control system, except for reloading raw fiber input material and maintenance activities. In another example, even autonomous robots are used to automatically handle raw fiber inputs, moving the raw fiber input port and mounting it onto the feeding system (e.g., inserting new rolls of raw fiber sheets into roller feeders or placing bundles of fiber sheets into feed hoppers).

[0056] Figure 5 An example diagram of a forming and finishing station 500 is depicted. Specifically, as shown... Figure 5 As shown, the forming and finishing station 500 includes a frame 511 on which a lower part 512 and an upper part 513 are arranged. The upper part 513 includes a shuttle 531 (in this case, corresponding to the component transfer system described above), which has an actuation mechanism 533 that allows for raising and lowering of the transfer feature, in this case, a transfer mold 532. A dedicated vacuum source fixed to the shuttle 531 is not visible in the figure. A cylindrical rotating shaft 523 is rotatably connected between the lower part 512 and the upper part 513 to the middle of the frame 511 via a rack and pinion mount 528. The shaft 523 has a rotation angle of less than 360° and rotates back and forth. At both ends of the cylindrical rotating shaft 523 are elbows 526. The two ends of the rotating shaft 523 are fixed to the frame by rotating shaft seats, gears 527 are respectively fitted onto the two ends of the cylindrical rotating shaft 523, and the two sides of the middle portion of the frame 511 are provided with translational connections to the gears 527. Two opposing, symmetrical forming molds 524a and 524b are attached to a cylindrical rotating shaft 523. In this embodiment, the two molds 524a and 524b include a mold plate 530 (visible only on the upper part 513) on which a core mold is formed and a screen is provided on which fibers are drawn when the mold is in the lower forming cavity 521 or a pulp tank. Figure 5 In the middle, the lower mold 524b is in the slurry tank 521, referred to as the forming position, and the upper mold 524a, which is positioned relative to it, faces upward toward the shuttle 531 and is carried on the transfer mold (cavity mold) 532.

[0057] Two core molds 524a and 524b are rigidly connected to a rotating shaft 523 via multiple conduits 525a and 525b. Conduit 525a connects to a conduit within a hollow shaft 523, which is connected to a fluid source (not shown) for the trimming operations described herein. Conduit 525b connects to a conduit within the hollow shaft 523, which is connected to a vacuum pump system. Conduits 525a and 525b are further connected to perforations in the molds 524a and 524b, as described in more detail below. The vacuum pump system generates a pressure differential that draws the slurry towards the mold 524, causing fiber accumulation on the screen surface of the mold. As described above, the two core molds 524a and 524b are symmetrical. This allows them to rotate about the axis of the rotating shaft 523, thereby enabling rapid movement of the mold between the lower section 512 and the upper section 513. A fiber slurry pool is housed in a slurry tank 521. Figure 5 As shown, when mold 524 is located in tank 521, slurry is drawn through mold 524 by a vacuum pump system, and fibers are deposited on mold 524, thereby producing a partially formed fiber component (not shown) on mold 524. In one embodiment of forming and finishing station 500, after an appropriate amount of fiber is drawn onto mold 524 to achieve the desired thickness, a slurry tank 521 is lowered from mold 524 by an actuation system in the form of a vertical lift 522, releasing mold 524 to move to position 513. Mold 524 and the partially formed fiber component can then be rotated to position 513. Upper 513 includes transfer mold 532 attached to actuation mechanism 533. Activation mechanism 533 presses transfer mold 532 against an upward-facing lower mold 524a. Mechanism 533 may include one or more hydraulic cylinders, servo motors, gas cylinders, or any other known lifting device. By pressing molds 524 and 532 together, water is expelled from the partially molded fiber component and collected via shaft 523 through inner mold 524. Essentially simultaneously with this pressing operation, pressurized fluid for a trimming operation is supplied to mold 524 through conduit 525a, removing excess material from the trimmed part that may be extruded from mold 524 during the pressing operation. The trimming operation removes rough edges from the partially molded fiber product resulting from molding and pressing. In this context, the significant pressing force applied when forming a molded fiber product can cause the molded fibers to flow and be expelled from the mold. This expelled fiber material should be removed for aesthetic, performance, design tolerance, and other purposes. The trimming operation is performed substantially simultaneously with the pressing operation during molding, using jets of pressurized water or other fluids (e.g., white water, compressed air, etc.) to improve production time and reduce waste.

[0058] After the forming and trimming operations are completed, suction is applied to the partially formed fiber component through penetration in mold 532, and mold 532 retracts onto shuttle 531 via mechanism 533 to move to a downstream position. This releases mold 524 to rotate to lower section 512 to repeat the entire forming process. In one embodiment, the forming and trimming operations performed by transfer mold 532 are carried out for a fixed time period at a selected pressure, which is equal to the time spent pulling the formed component onto the mold in lower section 512. Alternative embodiments, which dynamically control the pressing time based on monitoring data from sensors at one or more locations in upper section 513, will be described in more detail below. In an alternative embodiment of forming and trimming station 500, pulp tank 521 may also include a removable external mold (not shown). In this embodiment, the external mold can be pressed onto mold 524 while in pulp tank 521 after the fibers from the pulp have been pulled onto mold 524. This provides an additional pressing operation to the partially formed fiber part, so that the part leaving the forming station 500 will undergo two pressing operations instead of just one as in the previous example. In any case, after the partially formed fiber part is produced by the transfer mold 532 and removed from the inner mold 524, the shuttle 531 transfers it to another station in the production line. In another embodiment, the transfer mold 532 may be located at the end of a robotic arm that extends into the upper part 513, and the part is received when the transfer mold 532, which is suctioned onto the partially formed fiber part, is activated. This is just one embodiment of how part transfer is performed by a robotic arm. Many such methods and systems are known in the art, and any suitable method and mechanism can be used in the forming station 500, the robotic arm, or any other component of the production line described herein.

[0059] Figure 6A forming and finishing station 600 is depicted, having a first forming die 604 and a mating part transfer system 606. The forming and finishing station 600 includes the first forming die 604, in this case a cavity die structure. As used herein, the term "cavity die" refers to a die having features generally designed to project inwardly into a die plate to form a "cavity," into which a fiber component 608 and a core die extend. The part transfer system 606 includes a part transfer feature, in this case, a part transfer die having a core die structure. As used herein, the term "core die" refers to a die having features generally designed to project away from the die plate to form a "core," into which the fiber component 608 at least partially surrounds. Each of the forming die 604 and the part transfer die 606 defines at least one (but typically multiple) vacuum channels 613. All vacuum channels 613 are connected to a dedicated vacuum source 615, which functions as described above. After the fibers are drawn onto the first molding die 604 by applying a vacuum via vacuum channel 613, the component transfer system 606 engages with the first molding die 604. This engagement applies slight pressure to the partially molded component, squeezing out liquid that can be captured by the vacuum source 615. Thus, the component transfer feature 606 can also be referred to as a "second molding die," although it also performs the function of transferring the partially molded fiber component to one or more stations downstream of the molding and finishing station 600.

[0060] In the depicted embodiment, the wet finishing feature is a fluid jet ring 602 integrated with an upper forming die 604. The upper forming die 604 is shaped to mate with a lower forming die, such as a part transfer system 606, to form a shaped fiber part 608 between them. The fluid jet ring 602 substantially surrounds a portion of the upper forming die 604 that forms the outer extent of the shaped fiber part 608. The fluid jet ring 602 may be a curved conduit or other conduit that is manufactured separately from the material of the upper forming die 604 and to obtain the aforementioned conduit or conduit. The conduit forming the fluid jet ring 602 may be substantially recessed within a channel 610 formed in the upper forming die 604, which prevents excess discharged fibers (referred to in some embodiments as “burrs”) from potentially clogging the fluid outlet in the fluid jet ring 602, prevents the fluid jet ring 602 from being unintentionally damaged, and raises the fluid jet ring 602 above the immersion level of the upper forming die 604 (again, to prevent clogging of the fluid outlet). Channel 610 can also serve as a guide for the fluid jet 612 exiting from the fluid jet ring 602. In other embodiments, the outlet itself can guide and orient the fluid jet 612; however, it should be understood that the direction of fluid flow can be guided and / or controlled in any suitable manner, including dynamic direction / orientation / structure. In embodiments, it is desirable to release the fluid jet 612 in a linear or fan-shaped configuration, as it can be precisely guided to a specific location within the shaping and trimming station 600. Water, white water, or other fluids or liquids used to perform trimming operations can be supplied to the fluid jet ring 602 via one or more channels 613 connected to a fluid source 615, which can be a pressurized reservoir, pump, compressor, or other component.

[0061] Furthermore, other functions can be incorporated into the forming and finishing station 600 to control the output of the fluid jet ring 612. For example, the fluid jet ring 612 may include a plurality of spaced nozzles, each of which can be independently controlled to direct fluid only when needed or desired. For example, only nozzles located near the detection section adjacent to excess discharged fibers can be activated, thereby reducing the amount of fluid jet used. The detector D can utilize image recognition or other technologies to detect excess discharged fibers to be removed. Certain nozzles can only be activated for certain molds, products, or processes. The fluid jet 612 may also be operated for a fixed period of time, or until the detector D or sensor indicates that the target burr has been removed. Additionally, the fluid pressure, the direction of fluid jet, and / or the jet pattern configuration can be controlled individually. In one embodiment, higher pressure can be directed to discharge from the burr at the "thicker" product, which is made by a mold used for both thick and thin products.

[0062] In the example, the fluid spray 612 is essentially vertically oriented (as in...). Figure 6In the case of the structure shown, the possibility of fluid seeping into the space between the upper mold 604 and the lower mold 606 is limited, which could lead to damage to the partially formed fiber component 608. To further reduce this possibility, the outer portion 614 of the lower mold 606 can be angled to aid in the detachment of the resulting fluid spray 612. In the example, the outer portion 614 can be angled at approximately 80°, approximately 75°, 70°, 65°, 60°, or approximately 50° to the horizontal direction. In other examples, the outer portion 614 can be significantly bent to allow the fluid spray 612 to smoothly redirect away from the mold 606.

[0063] During operation, because the upper forming die 604 and the lower forming die 606 are pressed together, some fiber pulp can escape from the forming station 600 through the outer edge of the forming station. Therefore, a fluid spray 612 is ejected from the fluid spray ring 602 to remove the overflowing pulp from the forming station 600. Due to the precise discharge pattern of the fluid spray 612, only the overflow portion of the fiber pulp is removed, leaving a clean edge of the partially formed fiber component 608 intact. The fluid spray 612 and the material removed as part of the wet finishing operation may fall into a collector 616, which can be arranged below the lower forming die 606. This mixing of materials can be handled by one or more processes (generally described in element 618, and above) Figure 3 and Figure 4(As described in the case of...). In other examples, the mixture of materials can be simply reintroduced into the slurry tank 620, into which the upper molding die 604 is introduced at the start of the molding process. Therefore, the fluid trimming operation shown and described also includes the additional advantage of removing wet slurry (relative to the downstream pressing operation). Wet material is easier to reintroduce into the slurry than dry material removed near the end of the manufacturing process. This reduces or even eliminates waste generated downstream during production. In another example, a fluid spray 612 can be ejected to trim portions prior to molding operations (e.g., before the upper molding die 604 and lower molding die 606 are pressed together), but in such examples, it may be difficult to maintain clean edges on the formed part 608. For example, the fluid spray 612 can be sprayed at pressures between 20 psi and approximately 120 psi. Typically, standard drinking water pressure from urban to typical commercial facilities can be used without further pressurization. Possible pressures include approximately 20 psi, 30 psi, 40 psi, 50 psi, 60 psi, 70 psi, 80 psi, 90 psi, 100 psi, 110 psi, and an expected pressure of approximately 120 psi. Further pressurization can be used if necessary, for example, via an additional fluid pump. In other examples, the fluid spray can be emitted from an outlet located on the component transfer system 606.

[0064] To achieve the desired edge (e.g., through the precision fluid trimming system and operation described herein), it can be advantageous to draw more slurry on specific portions of the forming die. For example, drawing a larger amount of slurry near the outer edge of the forming die may be desirable. This helps ensure that the slurry spreads evenly during the forming operation, thus preventing the forming die from being trimmed along its entire circumference by the forming and trimming station described herein. Figure 7The diagram shows an enlarged cross-sectional view of the upper forming die 700 of the forming and finishing station. As described elsewhere in this text, the upper forming die 700 includes a bottom structural support 702 covered by a mesh portion 704. The structural support 702 and the mesh portion 704 define the desired form of the shaped fiber product. The structural support 702 defines a number of vacuum conduits 706, 708 distributed therein. During the forming process, the upper forming die 700 is lowered into a slurry tank (not shown), and a vacuum is applied to the various conduits to draw the slurry onto the mesh portion 704. By providing enlarged pores or channels 710 below the mesh portion 704, more slurry can be drawn into specific portions of the mesh portion 704. In the example shown, the pores or channels may have a height H of approximately 5 mm, approximately 10 mm, approximately 15 mm, or approximately 20 mm. A plurality of vacuum conduits 708 may be distributed along the top of the channels 710, for example, approximately 5 mm, approximately 10 mm, approximately 15 mm, or approximately 20 mm from the center.

[0065] By more precisely shaping the edges of the fiber product during the initial shaping stage (e.g., using the liquid trimming feature described above), less excess edge material is present when the partially shaped fiber component is pressed on the pressing station. Therefore, the pressing station can utilize simplified techniques to ensure precise edges on the finished shaped fiber portion. Figure 8 A partial schematic diagram of two molds in mating engagement of a pressing station 800 is shown, utilizing this edge-forming technique. The pressing station 800 includes a lower mold 802, in this example a core mold structure. An upper mold 804 is in the form of a component transfer mold with a cavity structure. The terms "core mold" and "cavity mold" have been described above. A fiber section 806 is disposed between the lower mold 802 and the upper mold 804. The lower mold 802 and the upper mold 804 each define at least one (but typically multiple) vacuum channels 808. The vacuum channels 808 are each connected to a dedicated vacuum source 810, which functions as described above. Both the lower mold 802 and the upper mold 804 include a heating element 812. In the case of a dedicated pressing station 800, elements 802 to 812 are used.

[0066] During operation of the 800 pressing station, improved temperature control is expected to enhance the quality of the formed fiber components and increase production line output. In one example, each die 802, 804 has an internal heating element 812. Element 812 can be a simple internal channel through which heating fluid flows. In an alternative example, a resistance heater can be installed in each die 802, 804. Heating element 812 is known in the art, and any suitable heating technology now known or later can be used. Examples of heated dies 802, 804 can further include one or more temperature sensors T. Temperature sensors can monitor the temperature within dies 802, 804, the surface temperature of dies 802, 804, the temperature of the fiber component 806, or the temperature at any other location within, above, or near dies 802, 804. Furthermore, for finer temperature control, dies 802, 804 can be divided into multiple sections or parts, and the temperature of each section can be monitored and controlled independently. Each section can have one or more temperature sensors and one or more internal heating elements. By monitoring and controlling the temperature of various parts of the mold, it is believed that the mold's performance can be further improved.

[0067] Figure 9A and 9B A perspective view and a partially enlarged perspective view of the upper forming mold 900 are shown respectively. Meanwhile, [the following is also mentioned:] Figure 9A and 9B The description is incomplete, and the mesh covering is not clearly described. Upper molding die 900 (in...) Figure 9A and 9B (Seen in reverse) It is formed by a machined integral component 902. In the relevant component, the integral component 902 forms a mold region 904 therein, which, in the example shown, is defined in its outer extent by a wall 906. The wall 906 also defines the uppermost extent of the molded fiber product (not shown) formed in the mold region 904. Component 902 further defines a groove or channel 908 for fluid trimming operations described in other parts of this document. Channel 908 is in fluid communication with one or more supply inlets 910 into which fluid is injected for trimming operations. In the mold 900 shown, four supply inlets 910 are used, but other configurations are contemplated. Multiple supply inlets 910 can be desired to distribute the fluid evenly within the channel 908. The width of the channel 908 can define the size of the fluid spray ejected from the channel during trimming operations. In the example, channel 908 may have a maximum width of approximately 1 mm, approximately 2 mm, approximately 3 mm, approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, or approximately 10 mm (e.g., the dimension extending from wall 906).

[0068] Figure 10A and 10B Perspective views and partially enlarged cross-sectional views of the upper or first molding die 1000 are shown respectively. Figure 10A and 10B The description also omits the mesh covering typically used in molding dies, which is not clearly described. The upper or first molding die 1000 (in...) Figure 10A and 10B (Seen in reverse) is formed by a machined integral component 1002. In the relevant component, the integral component 1002 forms a mold region 1004, which, in the illustrated example, is surrounded by a wall 1006 that also defines the uppermost extent of the molded fiber product 1005 formed in the mold region 1004. Component 1002 further defines a groove or channel 1008 (hidden within) used in the fluid trimming operations described elsewhere herein. Figure 10A (Middle). Channel 1008 is in fluid communication with one or more supply connectors 1010a to inject fluid for trimming operations described elsewhere herein. In the illustrated mold 1000, four supply connectors 1010a with the same number of supply inlets are used, but other configurations are also contemplated. Multiple supply connectors 1010a and inlets are desired to distribute the fluid evenly within channel 1008. The width of channel 1008 can define the size of the fluid spray ejected from the channel during trimming operations. In the example, channel 1008 can have a maximum width of approximately 1 mm, approximately 2 mm, approximately 3 mm, approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, or approximately 10 mm (e.g., the dimension extending from wall 1006). Thus, if channel 1008 or fluid outlet channel 1014 substantially surrounds the mold area, the fluid ejected therefrom can exist in a substantially annular flow. The illustrated example and Figure 9A and 9BThe difference shown is that it includes a sealing ring 1012 that at least partially seals the sealing channel 1008. In this example, the sealing ring 1012 is a separate, replaceable component that covers the channel 1008 and defines a fluid outlet groove 1014 between the sealing ring 1012 and the wall 1006. The maximum width of the fluid outlet groove 1014 can be about 0.5 mm, about 0.75 mm, about 1 mm, about 1.25 mm, about 1.5 mm, or greater. Therefore, a wider channel 1008 is easier to form, mold, or machine, and the sealing ring 1012 can be used to fine-tune the size and performance of the fluid spray. The sealing ring 1012 is replaceable, so wear caused by fluid flow and pressure can be quickly remedied. The sealing ring 1012 can be made of aluminum, steel, or other materials. Furthermore, a baffle can be positioned near the connector 1010a to guide the injected fluid in a more desirable direction, thereby reducing unwanted pressure drops, turbulence, etc. Typically, the fluid can be oriented in a direction substantially parallel to the wall 1006, or in a direction substantially orthogonal to the uppermost portion of the wall 1006.

[0069] Figure 10B A plurality of vacuum channels 1016 connected to a vacuum source (not shown) are shown. Vacuum channels 1016 terminate in openings within mold region 1004 (as defined by the outer extent of wall 1006). Channels 1008 and outlet channels 1014 are provided outside mold region 1004 to ensure that fluid ejected therefrom is directed onto the portion of product 1005 extending beyond wall 1006.

[0070] Figure 11 A method 1100 for manufacturing a molded fiber part is illustrated. The method begins at operation 1102, in which a first molding die is placed in a slurry tank containing a plurality of fibers and a liquid. The first molding die can be any of the molding dies shown herein or variations thereof, as will be apparent to those skilled in the art upon reading this disclosure. Typically, the first molding die may include a first die region, at least one fluid inlet, and a plurality of vacuum channels. Typically, multiple first molding dies are simultaneously disposed (e.g., placed below) in the slurry tank, enabling the simultaneous formation of multiple fiber products. In operation 1104, a vacuum container communicatively coupled to the plurality of vacuum channels is actuated to draw at least a portion of the plurality of fibers onto the molding die to form a partially molded fiber part. Once a predetermined amount of fiber (based on vacuum application time, fiber thickness detected in the die region, etc.) has been drawn onto the first die region, the first molding die is removed from the slurry tank (operation 1106). A part transfer system, including features such as a second molding die, is then aligned with the first molding die, and pressure is applied to the partially molded fiber part (operation 1108).

[0071] Method 1100 continues with operation 1110, separating the trimming from the partially molded fibrous part, for example, by spraying fluid onto the edge of the partially molded fibrous part. Since trimming separated from the partially molded fibrous part is undesirable in the finished product, trimming that may be removed from the part can also be referred to as waste trimming. In the example, trimming separation can be performed substantially simultaneously with pressure application. As described elsewhere herein, this trimming separation can be performed using a fluid-based system. Fluid can be received from at least one fluid inlet and ejected from a fluid outlet at least partially defined by a first forming die (operation 1112). In another example, the trimming is separated from the partially molded fibrous product by ejecting fluid from a fluid outlet at least partially defined by a second forming die (operation 1114). Regardless of which forming die from which the fluid is ejected, the fluid can be directed away from the first die region (operation 1116). In the example, this may occur when the ejected fluid comes into contact with a contoured or angled surface of an opposite portion of the die. In the example, operations 1108 and 1110 can be performed substantially simultaneously due to the position and structure of the various vacuum ports and fluid outlets relative to the mold area of ​​the first molding die. More specifically, multiple vacuum channels are fluidly connected to the first mold area, wherein at least one fluid inlet is fluidly connected to a fluid outlet located on the first molding die at a position remote from the first mold area. The fluid used in the trimming process, and the trimmed material separated in these processes, can be obtained (operation 1118) and, if necessary, can be reprocessed (operation 1120). For example, in Figure 3 and Figure 4 The diagram illustrates the reprocessing of the trimmed material and the fluid. Once the trimmed material is separated from the partially molded fiber component, the component can be transferred to a downstream station (operation 1122).

[0072] Figure 12An example of a suitable operating environment 1200 is shown, in which one or more of the features described in this example can be implemented. This is merely an example of a suitable operating environment and is not intended to impose any limitation on its scope of use or functionality. Other well-known computing systems, environments, and / or suitable configurations include (but are not limited to) personal computers, server computers, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smartphones, network computers, minicomputers, mainframe computers, smartphones, tablet computers, distributed computing environments including any of the aforementioned systems or devices, etc. In the example, the computing system may include one or more product manufacturing management systems, which may be a single unit for all workstations, systems, and subsystems of the production line example described herein. In other examples, the computing system may be a network of single computing systems (e.g., one or more independent computing systems for each workstation, system, and subsystem).

[0073] In its most basic configuration, the operating environment 1200 typically includes at least one processing unit 1202 and a memory 1204. Depending on the precise configuration and type of computing device, the memory 1204 (which stores the instructions described herein for manufacturing molded fiber parts) may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.), or some combination of both. This most basic configuration in... Figure 12 The image is shown in dashed line 1206. Additionally, environment 1200 may include storage devices (removable 1208 and / or non-removable 1210), including but not limited to disks, optical discs, or magnetic tapes. Similarly, environment 1200 may also have input devices 1214 such as touchscreens, keyboards, mice, pens, voice input, etc., and / or output devices 1216 such as monitors, speakers, printers, etc. One or more communication connections (1212) such as LANs, WANs, peer-to-peer, Bluetooth, RF, etc., may also be included in the environment.

[0074] Operating environment 1200 typically includes at least some form of computer-readable medium. Computer-readable medium can be any available medium accessible to processing unit 1202 or other devices utilizing the operating environment. As examples (but not limited to), computer-readable medium can include computer storage media and communication media. Computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing computer-readable instructions, data structures, program modules, or other data. Computer storage media includes RAM, ROM, EEPROM, flash memory or other storage technologies, CD-ROM, digital versatile disk (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, solid-state storage, or any other medium capable of storing desired information. Communication media contains computer-readable instructions, data structures, program modules, or other data in modulated data signals (e.g., carrier waves or other transmission mechanisms), and includes any information delivery medium. The term "modulated data signal" refers to a signal having one or more of its characteristic sets, or a signal altered in a manner that encodes information in the signal. As examples (but not limited to), communication media include wired media such as wired networks or direct wired connections, and wireless media such as acoustic, RF, infrared, and other wireless media. Any combination of the above should also be included within the scope of computer-readable media.

[0075] Operating environment 1200 can be a single computer operating in a network environment, using logical connections to one or more remote computers. Remote computers can be personal computers, servers, routers, network PCs, peer-to-peer devices, or other public network nodes, and typically include many or all of the elements described above, as well as other elements not mentioned. Logical connections can include any method supported by available communication media. This networking environment is common in offices, enterprise-wide computer networks, corporate intranets, and the Internet.

[0076] In some examples, the components described herein include modules or instructions executable by computer system 1200, storable on computer storage media and other tangible media, and transmittable in communication media. Computer storage media include volatile and non-volatile, portable and non-portable media implemented in any method or technology for storing computer-readable instructions, data structures, program modules, or other data information. Any combination of the above should also be included within the scope of readable media. In some examples, computer system 1200 is part of a network that stores data in remote storage media for use by computer system 1200.

[0077] Figure 13This is an example of network 1300, in which various systems and methods disclosed herein can run. In this example, a portable device, such as client device 1302, can communicate with one or more servers, such as servers 1304 and 1306, via network 1308. In this example, the client device can be a laptop, tablet, personal computer, smartphone, PDA, netbook, or any other type of computing device, including a single controller for encapsulating various components of the system. Figure 12 The computing devices in the example. In this example, servers 1304 and 1306 can be any type of computing device, such as... Figure 12 The computing device shown. Network 1308 can be any type of network capable of facilitating communication between client devices and one or more servers 1304 and 1306. Examples of such networks include, but are not limited to, LANs, WANs, cellular networks, and / or the Internet.

[0078] In the examples, the various systems and methods disclosed herein can be executed by one or more server devices. For example, in the examples, a single server, such as server 1304, can be used to execute the systems and methods disclosed herein. Portable device 1302 can interact with server 1304 via network 1308 to send test results from the device under test for analysis or storage. In further examples, portable device 1302 can also perform the functions disclosed herein, such as by collecting and analyzing test data.

[0079] In alternative examples, the methods and systems disclosed herein may be executed using a distributed computing network or a cloud network. In these examples, the methods and systems disclosed herein may be executed by two or more servers, such as servers 1304 and 1306. Although specific network examples are disclosed herein, one skilled in the art will appreciate that other types of networks and / or network configurations may be used to execute the systems and methods disclosed herein.

[0080] The systems and methods disclosed herein are implemented and performed using the examples described herein by means of software, hardware, or a combination of software and hardware. Although specific means are enumerated throughout the disclosure as performing specific functions, one skilled in the art will understand that these means are provided for illustrative purposes and other means may be used to perform the functions disclosed herein without departing from the scope of the disclosure.

[0081] Unless otherwise stated, all figures indicating quantities of components, properties (e.g., molecular weight, reaction conditions, etc.) used in the specification and claims should in all cases be understood to be modified by the term "about". Therefore, unless otherwise stated, the numerical parameters listed in the following specification and appended claims are approximate values ​​and may vary depending on the desired characteristics sought.

[0082] Although the numerical ranges and parameters used to illustrate the broad scope of this technique are approximations, the values ​​presented in specific examples are reported as precisely as possible. However, any numerical value inherently contains some errors, which must be caused by the standard deviations found in their respective test measurements.

[0083] Clearly, the systems and methods described herein are well-suited to achieving the stated purposes and advantages, as well as those inherent therein. Those skilled in the art will recognize that the methods and systems described herein can be implemented in many ways and are therefore not limited to the exemplary examples and illustrations described above. In this regard, any number of features of the different examples described herein can be combined into a single example, and alternative examples with fewer or more features than all those described herein are possible.

[0084] Various examples have been described for the purposes of this disclosure, but various changes and modifications can be made within the scope contemplated by this disclosure. Many other changes can be made that will be conceived by those skilled in the art and will not depart from the spirit and scope of the invention.

Claims

1. A molding machine for forming fiber components, comprising: A first molding die defines a first mold area configured to receive fiber pulp and at least one fluid inlet configured to receive a fluid different from the fiber pulp. The wall, which basically surrounds the first mold area; A fluid channel adjacent to and surrounding the wall, wherein the fluid channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet connected to a fluid tank, and wherein the fluid tank is configured to eject a basic annular flow of the fluid; as well as A second molding die defines a mating die region configured to mate with a first die region of the first molding die. The second molding die includes an outer edge surrounding the mating die region, and wherein when the first die region and the mating die region are in a mating configuration, the outer edge is configured to deflect the fundamental annular flow of the fluid in a direction away from the die region and the mating die region.

2. The molding fiber component forming device according to claim 1, further comprising: A sealing ring that at least partially covers the fluid channel outlet, wherein the sealing ring is isolated from the wall, thereby at least partially defining the fluid groove between the sealing ring and the wall.

3. The molding fiber component forming device according to claim 2, wherein the sealing ring is fixed to the first molding die.

4. The molding fiber component forming device according to claim 2, wherein the sealing ring is detachably fixed to the first molding die.

5. The molding fiber component forming apparatus of claim 1, wherein the fluid channel defines a maximum channel width, and the fluid groove defines a maximum groove width smaller than the maximum channel width.

6. The molding fiber component forming apparatus of claim 1, wherein the fluid channel is configured to guide the substantially annular flow of the fluid in a direction substantially perpendicular to the uppermost extent of the wall.

7. The molding fiber component forming device according to claim 1, wherein the outer edge is curved.

8. The molding fiber component forming apparatus of claim 1, wherein the at least one fluid inlet comprises a plurality of fluid inlets.

9. The molding fiber component forming device of claim 8, wherein the plurality of fluid inlets are distributed around the outer edge of the first molding die.

10. The molding fiber component forming apparatus of claim 8, wherein each of the plurality of fluid inlets is fluidly connected to the fluid channel.

11. A method for manufacturing a molded fiber component, the method comprising: A first molding die is placed in a tank containing fiber pulp, the fiber pulp comprising a plurality of fibers and a liquid, wherein the first molding die includes a first mold area, at least one fluid inlet configured to receive a fluid different from the fiber pulp, and a plurality of vacuum channels; A vacuum container actuated and connected to the plurality of vacuum channels is used to draw at least some of the plurality of fibers onto the molding die to form a partially molded fiber component. Remove the first molding die from the material tank; A second molding die is used to apply compressive pressure to the partially molded fiber component; Essentially, the waste trimming material is separated from the partially molded fiber component while the compression pressure is applied, wherein the first molding die includes a fluid channel fluidly connected to the at least one fluid inlet and defining a fluid channel outlet connected to a fluid tank, and wherein separating the waste trimming material comprises injecting a substantially annular flow of fluid from the fluid tank into the waste trimming material to separate the waste trimming material from the partially molded fiber component, and After separating the waste trimmings, the partially molded fiber components are transferred to the downstream station.

12. The method of claim 11, wherein separating the waste trimming material further comprises receiving the fluid in the fluid passage from the at least one fluid inlet.

13. The method of claim 11, wherein the plurality of vacuum channels are fluidly connected to the first mold region, and wherein at least one fluid inlet is fluidly connected to the fluid channel outlet, the fluid channel outlet being located on the first molding die separated from the first mold region.

14. The method of claim 12, further comprising guiding the jetted fluid away from the first mold region.

15. The method of claim 11, further comprising grasping the waste trimming material and the fluid.

16. The method of claim 15, further comprising reprocessing the waste trimming material and the fluid after grabbing the waste trimming material and the fluid.

17. The method of claim 11, wherein separating the waste trimming further comprises the substantially annular flow of the fluid being sprayed onto the edge of the partially molded fibrous component.

18. A production line for molded fiber components, comprising: (a) A forming station, which includes: A feed tank, configured to receive fiber pulp comprising multiple fibers and liquid; A molding die comprising a die plate defining a plurality of vacuum channels and at least one fluid trimming channel, wherein the at least one fluid trimming channel is fluidly connected to at least one fluid inlet and defines a fluid channel outlet connected to a fluid tank, and wherein the fluid tank is configured to eject a substantially annular flow of a fluid different from the fiber pulp; and A mold actuation system for adjusting the position of the mold plate relative to the material tank; (b) A component transfer system, comprising: Component transfer features, which define multiple component vacuum channels, and A transfer mechanism for moving the component transfer feature from a first position engaged with the molding die to a second position; (c) A pressing station, which includes: Core mold; Cavity mold, which matches the core mold, and A press-actuated system for adjusting the position of the core mold relative to the cavity mold, wherein at least one of the core mold and the cavity mold defines a plurality of vacuum channels and at least one heating element, and wherein, in the second position, the component transfer feature engages with at least one of the core mold and the cavity mold. (d) Remove the system, including: Remove features that define multiple component vacuum channels and multiple trimming vacuum channels, and A transfer mechanism for moving the removal feature from a third position engaged with at least one of the core mold and the cavity mold to a fourth position.

19. The molding fiber component production line of claim 18, wherein the mold plate includes a first mold region and the at least one fluid inlet, and a wall substantially surrounding the first mold region, wherein the fluid trimming channel is adjacent to and surrounds the wall.

20. The molding fiber component production line according to claim 19, wherein the molding station further comprises: A sealing ring fastened to the mold plate and at least partially covering the outlet of the at least one fluid trimming channel, wherein the sealing ring is spaced apart from the wall, thereby at least partially defining the fluid groove between the sealing ring and the wall.

21. The molding fiber component production line of claim 20, wherein the sealing ring is removably fixed to the mold plate.

22. The molding fiber component production line of claim 20, wherein the at least one fluid trimming channel defines a maximum channel width, and the fluid groove defines a maximum groove width smaller than the maximum channel width.

23. The molding fiber component production line of claim 20, wherein the fluid tank is configured to guide a substantially annular flow of the fluid in a direction substantially perpendicular to the uppermost extent of the wall.

24. The molding fiber component production line of claim 18, wherein the component transfer feature includes a component transfer mold that matches the molding mold.

25. The molding fiber component production line according to claim 18, wherein the component transfer system transmission mechanism includes a robotic arm.

26. The molding fiber component production line of claim 18, wherein the component transfer system transmission mechanism includes a shuttle placed on a frame.

27. The molding fiber component production line of claim 26, wherein the frame extends in a first direction away from the molding die and in a second direction opposite to the molding die.

28. The molding fiber component production line of claim 18, wherein both the core mold and the cavity mold define the plurality of vacuum channels.

29. The molding fiber component production line of claim 18, wherein the at least one heating element comprises a plurality of heating elements, and wherein both the core mold and the cavity mold comprise at least one of the plurality of heating elements.

30. The molding fiber component production line of claim 18, wherein the removal feature includes removing a mold.

31. The molding fiber component production line of claim 18, wherein the removal feature comprises a plurality of vacuum cups.

32. The molding fiber component production line of claim 18, wherein the removal system transfer mechanism includes a robotic arm.

33. The molding fiber component production line of claim 18, wherein the removal system transfer mechanism comprises a shuttle placed on a frame.

34. The molding fiber component production line of claim 18, wherein the removal system is the component transfer system.

35. The molding fiber component production line according to claim 18, further comprising a printing station, and wherein, When in the fourth position, the removal feature engages with the printing station.

36. The molding fiber component production line of claim 35, wherein the printing station includes a registration feature.

37. The molding fiber component production line of claim 36, wherein the printing station comprises at least one printing device.

38. The molding fiber component production line according to claim 37, wherein the at least one printing device comprises at least one of a screen printer, a laser printer, an inkjet printer, and a pad printer.

39. The molding fiber component production line according to claim 38, further comprising a stacking station.

40. The molding fiber component production line of claim 18, wherein at least one of the component transfer system and the removal system comprises at least one of a robotic arm, a shuttle, and a conveyor.

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