Three-dimensional fiber block product

Abstract

The present invention provides a three-dimensional fibrous block article which can be obtained by forming a heated fibrous blank (10) containing a thermally active binder into a three-dimensional fibrous block article in a fibrous block forming method. The fibrous block forming method comprises the following steps: receiving the fibrous blank (10) to be formed at a receiving position (210) of a conveying system (200); conveying the fibrous blank (10) by means of the conveying system (200) past a heater (300) for heating the fibrous blank (10) to activate the binder to a mold (100), the mold having a lower part (110) and an upper part (120), wherein a cavity (150) is formed between the lower part (110) and the upper part (120) of the mold for forming the fibrous blank (10) into a formed article when the mold is closed; delivering the heated fibrous blank (11) onto the lower part (110) of the mold (100); and closing the mold to provide the fibrous block article.

Description

[0001] This application is a divisional application of the patent application for invention with the application date of November 29, 2017, application number 201780073960.2 (PCT / EP2017 / 080805), and invention name "Forming of Fiber Blanks into Three-Dimensional Fiber Block Articles". Technical Field

[0002] The present invention relates to a fiber block forming device for forming a fiber blank containing a thermally active binder into a three-dimensional fiber block article, such as a non-woven fiber ball bat, and the thermally active binder is, for example, a two-component binder fiber. In addition, the present invention relates to a corresponding method. Background Art

[0003] The formed cushion members are used in furniture to provide elastic properties and comfort. As an example, the cushion members can be used in the seats of chairs and sofas and in the backrests. Polyurethane foam has been used in such cushion members. However, polyurethane foam produces toxic gases when burned. In addition, the recycling of polyurethane foam is difficult.

[0004] As an alternative to polyurethane foam in cushion members, formed fiber mixtures containing thermally active binders, such as melt binder fibers, have been used in the prior art. In US 6,033,607, a method for filling a fiber mixture into a mold cavity and then heating the fiber mixture in the mold cavity to provide a formed cushion member is disclosed. The disclosed method results in a random fiber orientation within the cushion member. Thus, within the cushion member, the elastic properties are substantially the same in any given direction.

[0005] In other applications (such as US 2005 / 0140059), fiber ball bats with a predetermined fiber orientation, such as a carded fiber web, have been positioned in a mold and formed into an elastic cushion member. In the resulting cushion member, the elastic properties within the cushion member will vary according to the fiber orientation. This can be significant in providing cushion members for chairs and sofas. However, fiber blanks with a predetermined fiber orientation have a lower mechanical resistance in some directions, such as in a direction perpendicular to the fiber direction, thus imposing limitations in positioning the fiber blanks into the mold.

[0006] Regardless of the forming technique used, it is meaningful to keep the residence time in the mold short and have flexibility in handling the fiber blank while still providing the required mechanical and elastic properties for the cushion member. Generally, the cycle time should be as short as possible to allow for efficient manufacturing. In addition, the elastic properties in a direction perpendicular to the extension direction of the cushion member, i.e., in the load direction of the cushion member, should preferably be as high as possible to provide comfort.

[0007] In EP 473 422, an apparatus for continuously manufacturing a fiber-reinforced mold charge blank for use in a molding process is disclosed. The apparatus includes a shuttle assembly for transferring the mold charge blank from a furnace conveyor to a press. The apparatus is for stamping, i.e., preforming, a reinforcement member to provide a fiber-reinforced mold charge blank, which is to be impregnated with a liquid resin to provide a composite structure. The fiber-reinforced mold charge blank is positioned in the press by scraping it from the shuttle assembly. This process is not suitable for processing and molding a fiber blank in which the fibers are arranged perpendicular to the longitudinal extension direction of the fiber blank and perpendicular to the transport direction in the process, whereby the fiber blank is very unstable.

[0008] Accordingly, there is a need for an effective fiber block forming apparatus and method for providing a formed mat member that includes a thermally active binder and has good elastic properties. SUMMARY OF THE INVENTION

[0009] Accordingly, the present invention seeks to provide an effective apparatus and method for forming a fiber blank that includes a thermally active binder into a three-dimensional fiber block article.

[0010] According to a first aspect of the present invention, there is provided a fiber block forming apparatus for forming a heated fiber blank that includes a thermally active binder into a three-dimensional fiber block article. The fiber block article is a formed three-dimensional fiber block article having elasticity. Such an elastic three-dimensional fiber block article is used as a comfort filler in furniture applications, for example as a mat member in the seat and / or backrest of a sofa and a chair. Preferably, the fibers in the fiber block article are arranged perpendicular to the longitudinal extension direction of the fiber block article.

[0011] The device includes a mold. The mold has a lower part and an upper part. The lower and upper parts of the mold form a cavity therebetween for forming a fibrous blank into a formed fibrous block product when the mold is closed. Preferably, at least one of the parts of the mold is provided by a cooling device that allows rapid cooling of the formed fibrous block product and thus shortens the residence time in the mold. Additionally, the surface of the formed fibrous block product can be provided with specific characteristics by the rapid cooling of the formed fibrous block product. By rapid cooling, improved consistency of the surface characteristics and three-dimensional shape of the formed fibrous block product can be provided. Moreover, rapid cooling allows for customized geometries and / or surface patterns. Accordingly, the lower part and / or the upper part of the mold can be provided with channels for a cooling fluid such as water or air. Additionally, at least one of the parts of the mold - such as the upper part - can be a formed perforated plate or a formed rigid mesh having high permeability to a fluid such as air to allow rapid cooling of the formed fibrous block product. If one of the parts of the mold is a perforated plate or a rigid mesh, the cooling fluid can be provided from the other part of the mold to the formed fibrous block product and released through the permeable part of the mold. If both parts of the mold are perforated plates or rigid meshes, a cooling fluid such as air can pass through the mold and the formed fibrous block product, for example by means of a fan, to cool the formed fibrous block product.

[0012] According to an embodiment, the lower part of the mold is provided with a first set of channels for a cooling fluid. Alternatively, the upper part of the mold is provided with a second set of channels for a cooling fluid. Preferably, the lower part of the mold is provided with a first set of channels and the upper part of the mold is provided with a second set of channels. By providing the mold with channels for a cooling fluid - such as air or water - the temperature of the mold can be controlled and kept low by passing the cooling fluid through the channels, whereby the formed fibrous block product can be rapidly cooled once it is formed.

[0013] To allow for rapid cooling not only of the surface of the molded article but also of the interior of the molded article, the group of channels may be in fluid communication with the cavity of the mold, whereby a cooling fluid may flow through the molded fibrous block article to cool the molded fibrous block article, since the molded fibrous block article is permeable due to its fibrous nature. Further, the mold may be provided with connection ports that serve as an inlet and an outlet for the cooling fluid, respectively. The connection ports are in fluid communication with the group of channels. According to one embodiment, both the lower part and the upper part of the mold are provided with connection ports. According to this embodiment, the cooling fluid may flow from one part of the mold, through the cavity of the mold, to the other part. According to an embodiment in which only one of the parts of the mold, which is either the lower part or the upper part, includes a group of channels, this part may be provided with at least two connection ports, one connection port serving as an inlet for the cooling fluid and the other connection port serving as an outlet for the cooling fluid.

[0014] In an embodiment in which the cooling fluid is to flow through the cavity of the mold and through the molded fibrous block article present in the cavity of the mold, the cooling fluid may be air. Although a liquid cooling fluid such as water may also be used, the use of a liquid cooling fluid will leave residues in the molded fibrous block article. The process of removing the liquid residues from the molded fibrous block article requires a separate drying step, thereby negatively affecting the overall process economy and cycle time.

[0015] In an embodiment where a cooling fluid is to flow through the cavity of a mold, a component of the mold may be provided with another set of channels for a liquid. This other set of channels is not in fluid communication with the cavity. By providing additional cooling for the component of the mold, the surface of the formed fibrous block article can be rapidly cooled to solidify. Additionally, by providing a set of channels for the cooling liquid, the temperature of the mold and its surface can be maintained constant throughout the molding cycle. Depending on the type of binder of the fibrous blank (e.g., the type of binder that affects the melting temperature of core-sheath fibers and bicomponent fibers), the bonding strength at the surface of the formed fibrous block article can be adjusted according to the surface temperature of the mold. A too low temperature of the mold may cause the surface of the fibrous blank to solidify, even before the mold has been closed, which is not preferred. Preferably, relevant parameters such as the temperature of the mold, the cycle time, and the temperature of the heated fibrous blank are controlled to provide the desired properties for the surface of the formed fibrous block article. In some embodiments, the temperature of the mold and its surface ranges from 20 °C to 65 °C, such as from 30 °C to 60 °C, or even in the interval of 35 °C to 45 °C, for example, about 40 °C. According to an embodiment where the lower component of the mold is provided with a first set of channels for a cooling fluid, the first set of channels may include a first number of channels arranged in a plane of the lower component of the mold. The first number of channels may be arranged between a second number of channels and a connection port. The second number of channels may be arranged perpendicular to the plane of the lower component of the mold and extending into the cavity. The first set of channels may be provided by drilling the first number of channels in the plane of the lower component of the mold. By drilling the second number of channels from the cavity perpendicular to the plane of the lower component of the mold into the first number of channels, a second number of channels in fluid communication with the mold cavity and the first number of channels can be provided. The cooling fluid may flow from the connection port through the first number of channels to the second number of channels and then into the cavity, or flow in the opposite direction. Preferably, the diameter of the orifice of the second number of channels extending into the cavity is smaller than the diameter of the rest of the channel. The orifice with a smaller diameter will act as a throttling device to equalize the pressure and flow rate within each channel.

[0016] According to an embodiment in which the upper part of the mold is provided with a second set of channels for a cooling fluid, the second set of channels may include a third number of channels arranged in a plane of the lower part of the mold. The third number of channels may be arranged between a fourth number of channels and a connection port. The fourth number of channels may be arranged perpendicular to the plane of the lower part of the mold and extending into the cavity. The third number of channels may be provided by drilling a certain number of channels in the plane of the upper part of the mold. By drilling a certain number of channels from the cavity perpendicular to the plane of the upper part of the mold into the third number of channels, a fourth number of channels providing flow communication between the cavity of the mold and the third number of channels may be provided. The cooling fluid may flow from the connection port via the third number of channels to the fourth number of channels and then into the cavity, or flow in the opposite direction. Preferably, the diameter of the orifice of the fourth number of channels extending into the cavity is smaller than the diameter of the remainder of the channel. The orifice with the smaller diameter will act as a throttling device to equalize the pressure and flow rate within each channel.

[0017] In an embodiment in which channels extending into the cavity are provided in both the lower and upper parts of the mold, the orifice of the channel extending into the cavity in the lower part may be displaced relative to the orifice of the channel extending into the cavity in the upper part, i.e., the orifice of the channel extending into the cavity in the lower part may be misaligned relative to the orifice of the channel extending into the cavity in the upper part. By moving the orifices relative to each other, the cooling fluid may be more effectively distributed throughout the molded fiber block article.

[0018] The shape of the cavity of the mold is defined by the upper and lower parts. To allow for an effective change in the shape of the cavity and the resulting fiber block article without having to change the entire mold, the lower part of the mold may include a main part and a replaceable insert part. The insert part may be provided with a surface structure defining the lower part of the cavity, such as a recess. Similarly, the upper part of the mold may include a main part and a replaceable insert part. The insert part may be provided with a surface structure defining the upper part of the cavity, such as a recess. By providing the mold with replaceable insert parts, only the replaceable insert parts need to be changed when changing the shape of the cavity. In an embodiment in which the mold is provided with the first to fourth numbers of channels as described above, the first number of channels and the third number of channels may be present in the lower main part and the upper main part, respectively, while the second number of channels and the fourth number of channels may extend from the lower main part and the upper main part and extend into the lower replaceable insert part and the upper replaceable insert part, respectively.

[0019] The lower and upper components of the mold are capable of vertical movement relative to each other to close the mold. Thus, the mold can be closed by lowering the upper component and / or raising the lower component of the mold. According to an embodiment, the mold can be closed by lowering the upper component of the mold so that the upper component of the mold contacts the lower component of the mold, thereby holding the lower component of the mold in its original vertical position.

[0020] In addition, the fiber block forming device includes a heater that is used to heat the fiber blank before forming the fiber blank to activate the binder. By heating the fiber blank, the binder—such as the sheath of a core-sheath type binder—melts and is thus activated. After the heated fiber blank has been formed into the desired shape and cooled, the three-dimensional fiber block product will retain its shape when the fibers are bonded together by the binder, whereby a three-dimensional fiber block product is provided starting from the fiber blank. By separating the heating step and the cooling step, the cycle time can be significantly reduced. Repeated heating and cooling of the mold is time-consuming. However, as discussed further below, the heated fiber blank has a very low tensile strength, and thus, a special device is used to position the heated fiber blank in the mold.

[0021] The heater is typically a furnace through which the fiber blank passes to be heated.

[0022] To effectively heat the fiber blank, the heater can be arranged to pass hot air through the fiber blank. The hot air can be passed through the fiber blank in various ways. As an example, the heater can be provided with a fan for passing hot air through the fiber blank. In addition, the heater can be provided with a fan for sucking hot air through the fiber blank. The fiber blank is typically transported through the furnace by means of a conveying system including a conveyor belt. To facilitate the passage of hot air through the fiber blank, the conveyor belt can be permeable so that hot air can pass through the fiber blank and the conveyor belt. An example of a preferred permeable conveyor belt is a belt comprising a supporting aromatic polyamide mesh cloth coated with a fluoropolymer—such as polytetrafluoroethylene—such as Kevlar, Twaron, Technora, Kermel, Nomex or Teijinconex mesh cloth.

[0023] Once heated, the fibrous blank is to be transported to the mold. The fibrous block forming apparatus thus further includes a conveying system. The conveying system is arranged to receive the fibrous blank to be formed at a receiving position, to transport the fibrous blank past a heater for activating the binder, and to directly deliver the heated fibrous blank into the lower part of the mold by feeding the heated fibrous blank to the lower part of the mold. As already mentioned, the conveying system may include a conveyor belt. Although the conveyor belt may be permeable, e.g., perforated, the conveyor belt is still continuous not only in the conveying direction but also in a direction perpendicular to the conveying direction. Generally, the heater, e.g., a furnace, is positioned between the receiving end and the delivering end of the conveying system. The fibrous blank is positioned at the receiving position, transported past the heater to ultimately reach the delivering end located near the mold, and the heated fibrous blank is to be conveyed to the mold. The delivering end is thus arranged at the opposite end of the heater relative to the receiving position. In addition, the delivering end is arranged at a level vertically higher than the lower part of the mold so that the gravity-affected heated fibrous blank can be positioned into the lower part of the mold once it leaves the conveying system.

[0024] Once heated, the heated fibrous blank is very soft and has a low tensile strength, particularly if the fibrous blanks are stacked vertically such that the fibers in the fibrous blank are arranged "upright" - i.e., perpendicular to the longitudinal extension direction of the fibrous blank (e.g., V-shaped stacking or strut-like arrangement of the fibers). Generally, this arrangement means that the fibers in the fibrous blank are arranged in a direction perpendicular to the conveying direction. Since the upright fibers will provide more superior elastic properties for the cushioning member compared to laid fibers (e.g., cross-laid nonwoven fabric), it is important to be able to carefully convey the heated fibrous blank to the lower part of the mold. Therefore, the conveying system is provided with a horizontal position shifting device.

[0025] The horizontal position shifting device allows the horizontal position of the delivery end of the conveying system to shift between a first position and a second position relative to the lower part of the mold while laying a heated fiber blank on the lower part of the mold. In the first position, the delivery end of the conveying system is positioned between the distal end and the proximal end of the mold. Preferably, in the first position, the delivery end of the conveying system is positioned closer to the distal end than to the proximal end close to the lower part of the mold. The heated fiber blank arriving at the delivery end of the conveying system is thus positioned above the lower part of the mold to which the heated fiber blank is to be conveyed. In the second position, the delivery end of the conveying system is positioned closer to the proximal end than to the distal end close to the lower part of the mold, but not between the proximal end and the distal end. Thus, in the second position, the conveying system is not positioned above the surface structure, such as a recess, of the lower part of the defined cavity of the lower part of the mold. Once positioned in the second position, the mold can be closed when the conveying system has withdrawn.

[0026] By coordinating the supply of the heated fiber blank by the conveying system with the movement of the position of the delivery end, the heated fiber blank can be laid on the lower part of the mold, that is, the heated fiber blank can be placed on the lower part of the mold with very low mechanical impact applied to the heated fiber blank. Preferably, the supply rate and the movement rate are substantially the same, such that the heated fiber blank is neither stretched nor compressed while being laid on the lower part of the mold. However, in some embodiments, the supply rate is slightly higher than the movement rate, such that the heated fiber blank is compressed while being laid on the lower part of the mold. Slightly compressing the heated fiber blank can slightly improve the elastic properties. Thus, the conveying system includes a fiber blank laying device arranged to release the heated fiber blank from the conveying system at the delivery end in a manner coordinated with the horizontal position shifting device that moves the position of the delivery end from the first position to the second position, such that the heated fiber blank can be laid on the lower part.

[0027] Generally, the conveying system includes a conveyor belt that turns around a first rotating shaft at the delivery end of the conveying system. In addition, the conveying system generally includes a second rotating shaft located at the receiving end of the conveying system. The delivery end and the receiving end of the conveying system constitute opposite ends of the conveying system. In addition, the conveying system may include additional shafts for the conveyor belt, such as a tensioning shaft for keeping the conveyor belt stretched. The conveying system also includes a drive shaft for operating the conveyor belt.

[0028] According to one embodiment, the conveying system includes a conveyor belt that turns around a first rotating shaft at the delivery end of the conveying system and a stretching shaft. The stretching shaft can be arranged between the delivery end and the heater. The stretching shaft is used to keep the conveyor belt stretched. According to this embodiment, when supplying the heated fiber blank to the lower part of the mold to lay the heated fiber blank on the lower part of the mold, the horizontal position of the delivery end relative to the conveying system is moved by the horizontal position moving device by horizontally shifting the first rotating shaft. The conveyor belt is kept stretched by shifting the stretching shaft in a coordinated manner with the shift of the first rotating shaft.

[0029] According to an alternative embodiment, the conveying system includes a conveyor belt that turns around a first rotating shaft at the delivery end of the conveying system and a second rotating shaft at the receiving end of the conveying system. According to this embodiment, when supplying the heated fiber blank to the lower part of the mold to lay the heated fiber blank on the lower part of the mold, the horizontal position of the delivery end is moved by the horizontal position moving device by arranging the horizontal position moving device to horizontally shift the first rotating shaft. The conveyor belt is kept stretched by shifting the second rotating shaft in a coordinated manner with the shift of the first rotating shaft. Horizontally shifting the first rotating shaft can include shifting the entire conveying system relative to the mold. This can be achieved by mounting the conveying system on the carriage of a hoisting vehicle. In addition, the heater can be mounted on the carriage of the hoisting vehicle. Alternatively, the first rotating shaft and the second rotating shaft can be shifted relative to the conveying system.

[0030] According to an alternative embodiment, the conveying system includes a conveyor belt that is used to receive the fiber blank to be formed at a receiving position and convey the fiber blank past a heater to the end of the conveyor belt. In addition, the conveying system includes a conveying shuttle that is separate from the conveyor belt and includes the delivery end of the conveying system. The conveying shuttle is arranged to receive the heated fiber blank from the conveyor belt at the end of the conveyor belt and then supply the heated fiber blank into the lower part of the mold. According to this embodiment, when supplying the heated fiber blank to the lower part of the mold to lay the heated fiber blank on the lower part of the mold, the horizontal position of the delivery end is moved from the aforementioned first position to the aforementioned second position by the horizontal position moving device by horizontally shifting the conveying shuttle.

[0031] According to yet another alternative embodiment, when feeding the heated fiber blank to the lower part of the mold to lay the heated fiber blank on the lower part of the mold, the horizontal position of the delivery end of the conveying system relative to the lower part of the mold is achieved by shifting the lower part of the mold. Thus, when operating the fiber block forming device, the horizontal position moving device moves the lower part of the mold from the first position to the second position. In the first position, the lower part of the mold is positioned such that the delivery end of the conveying system is arranged between the distal end and the proximal end of the lower part of the mold. Preferably, in the first position, the lower part of the mold is positioned such that the delivery end of the conveying system is positioned closer to the distal end than to the proximal end of the lower part of the mold. In the second position, the delivery end of the conveying system is positioned closer to the proximal end than to the distal end of the lower part of the mold, but not between the proximal end and the distal end. Further, in the second position, the lower part of the mold may be vertically aligned with the upper part of the mold. This is preferred especially in embodiments where the horizontal position of the lower part of the mold is to be moved. If the mold is closed by lowering the upper part of the mold, this is preferred.

[0032] According to a second aspect of the present invention, there is provided a fiber block forming method for forming a heated three-dimensional fiber block article from a fiber blank containing a thermally active binder. In the above description of the fiber block forming device herein, aspects related to the operation of the fiber block forming device are also included. These aspects are equally applicable to the fiber block forming method described below herein.

[0033] The fiber block forming method for forming a fiber blank includes the following steps:

[0034] - Receiving the fiber blank to be formed into a three-dimensional fiber block article at the receiving position of the conveying system;

[0035] - Transporting the fiber blank by means of the conveying system through a heater that heats the fiber blank to activate the binder to a mold for forming the heated fiber blank;

[0036] - Laying the heated fiber blank on the lower part of the mold; and

[0037] - Closing the mold to provide a three-dimensional fiber block article.

[0038] The receiving position of the conveying system is typically located between the receiving end of the conveying system and the heater, and the delivery end of the conveying system is located at the opposite end of the heater. As already described, the conveying system typically includes a conveyor belt. The fibrous blank, such as a fibrous blank in the form of a sheet, is placed on the conveyor belt at the receiving position. This placement can be carried out by a pick-and-place robot. A certain amount of fibrous blank can be placed on a roller to be cut into sheets and then used to be positioned on the conveyor belt.

[0039] The fibrous blank contains a thermally active binder and fibers. The fibers in the fibrous blank can include polyester fibers. Examples of polyester fibers include PET (polyethylene terephthalate) fibers, PBT (polybutylene terephthalate) fibers, PTT (polytrimethylene terephthalate) fibers, PLA (polylactic acid) fibers, and PEF (polyethylene furanoate) fibers. These fibers can also be made of other polymers, namely PA (polyamide) or PP (polypropylene), and made of any suitable combination of polymers or copolymers. The fibers in the fibrous blank can also include cellulose-based fibers such as Viskos, Modal, Lyocel, Tencel, or Danufill fibers to improve moisture management or improve fire resistance. In addition, high-performance fibers can be present in the fibrous blank. Examples of high-performance fibers providing fire-related properties include inherently flame-retardant PET (Trevira CS), meta-aramid (i.e., Nomex), carbon / carbonized fibers (i.e., Panox), or any other high-performance fiber having a high melting point or decomposition temperature and / or a high LOI (limiting oxygen index).

[0040] When activating the binder, the temperature should not cause the fibers in the fibrous blank to completely melt, resulting in the fibrous blank collapsing into a film. The temperature in the heater should therefore be lower than the melting point of the fibers in the fibrous blank, such as polyester fibers. In addition, the temperature in the heater should be higher than the activation temperature of the binder, such as the melting point. Generally, the melting point temperature can be 100 °C to 160 °C. For polyester fibers, the temperature used in the heater can be 120 °C to 220 °C. To provide specific properties, such as a low melting point for thermal bonding, improved fire retardant properties, increased elasticity and recovery after deformation, etc., the polyester can be a copolymer, such as a block copolymer. As an example, compared with the corresponding polyester, a block copolymer containing a polyester block and a polyolefin block has a lower melting point. In addition, the polyester composite can include additives and / or additional polyester to provide specific properties for the composite.

[0041] The fibrous blank can include binder fibers and filling fibers. The filling fibers provide elasticity. The filling fibers can be conjugate fibers with helical crimps, mechanically crimped fibers, non-crimped fibers, or a mixture of the above. In addition, fibers with high crystallinity and a high Tg can be present.

[0042] The fibrous blank may include bicomponent binder polyester fibers, such as core-sheath binder fibers or side-by-side binder fibers. As is known in the art, bicomponent fibers are fibers that comprise two polymers having different chemical and / or physical properties. A bicomponent binder fiber is a bicomponent fiber having a binder portion with a melting point lower than that of the other portion. In core-sheath binder fibers, the melting point of the sheath is lower than that of the core. Core-sheath binder fibers have the advantage of good adhesion properties because the binder portion, i.e., the sheath, surrounds the entire fiber, thereby maximizing the contact surface with other fibers in the blank.

[0043] In embodiments where the fibrous blank includes bicomponent binder polyester fibers, the fibrous blank may include from 10 wt% to 80 wt%, such as from 20 wt% to 60 wt%, of bicomponent binder polyester fibers. The bicomponent binder polyester fibers may be core-sheath binder polyester fibers, in which the sheath may constitute a thermally active binder.

[0044] Examples of binder fibers include: polyurethane elastomer-modified polyester (such fibers preferably account for no more than 40 wt% of the fiber content in the fibrous blank), such as Teijin ELK; crystalline copolyester fibers, such as Wellman M1439 (such fibers preferably account for 30 wt% to 40 wt% of the fiber content in the fibrous blank); and standard amorphous copolyesters (such fibers preferably account for up to 30 wt% of the fiber content in the fibrous blank).

[0045] The melting point of PET-based polyester fibers or their copolymers is higher than 200 °C, for example about 260 °C. Similarly, the melting point of the core of core-sheath PET-based polyester binder fibers is also higher than 200 °C, for example about 260 °C. In addition, the melting point of the sheath of core-sheath polyester binder fibers is lower than 200 °C, for example about 110 °C. However, some other types of binder fibers, such as amorphous fibers, crystalline fibers, and ELK, have high activation temperatures of up to 160 °C. Copolymerization with olefin groups can lower the melting point of the polyester sheath, thereby significantly reducing the melting point, for example, reducing it to about 110 °C. Preferably, the melting point of the sheath of core-sheath polyester binder fibers is at least 50 °C lower than the melting point of the core, for example at least 75 °C lower, or even at least 100 °C lower. Similarly, the melting point of the sheath of core-sheath polyester binder fibers is at least 50 °C lower than the melting point of the fibers of polyester fibers or their copolymers, for example at least 75 °C lower, or even at least 100 °C lower.

[0046] The fibers in the fibrous blank and the proportions of the various types of fibers will affect the elastic properties of the resulting three-dimensional fibrous block product. Additionally, the fibers in the fibrous blank will affect its elastic properties. According to an embodiment, the fibrous blank is stacked vertically and thus the fibers in the fibrous blank are arranged perpendicular to the direction of extension of the fibrous blank. In this document, the "direction of extension of the fibrous blank" will be considered as the direction perpendicular to the main load direction of the fibrous block product to be formed. For example, if the fibrous block product is a seat cushion for a chair, the "direction of extension of the fibrous blank" is the horizontal direction perpendicular to the vertical direction of the load exerted by a person sitting on the seat cushion. Upright fibers will provide improved elastic properties compared to, for example, laid fibers in a cross-laid fibrous blank.

[0047] Once the fibrous blank is positioned on the conveying system, the conveying system transports the fibrous blank to the mold. The mold has a lower part and an upper part, and when the mold is closed, the lower part and the upper part form a cavity between the lower part and the upper part. While the fibrous blank is being transported, the fibrous blank is heated by a heater, for example by a furnace, to activate the binder. The heater can pass hot air through the fibrous blank to effectively heat the fibrous blank. The hot air can be passed upward through the fibrous blank, thus reducing the risk of deforming the fibrous blank (the upward air flow affects the material in a direction different from the direction of gravity). The temperature of the hot air is higher than the activation temperature of the binder, for example the melting point. Additionally, the temperature of the hot air is lower than the melting point of the filling fibers and lower than the melting point of the core of the bicomponent binder fibers. The temperature of the hot air can be, for example, from 120 °C to 220 °C, such as from 120 °C to 190 °C, or even from 150 °C to 190 °C. According to a preferred embodiment, the temperature of the hot air is 150 °C or higher, more preferably 160 °C or higher, even 180 °C or higher. Additionally, according to a preferred embodiment, the temperature of the hot air is 215 °C or lower, more preferably 210 °C.

[0048] As already explained, the heated fibrous blank has a lower tensile strength. Thus, when a gentle delivery process is required, the heated fibrous blank cannot be positioned in the mold, for example, using a pick-and-place robot. However, an effective delivery method is still needed to keep the cycle time short.

[0049] The conveying system is thus arranged to lay the heated fiber blank on the lower part of the mold, thereby avoiding significant tensile stress along the extension direction of the blank. To lay the heated fiber blank on the lower part of the mold, the delivery end of the conveying system is arranged at a level vertically higher than the lower part of the mold when laying the heated fiber blank on the lower part of the mold, whereby the heated fiber blank can fall into the mold due to gravity. However, simply dropping or scraping the heated fiber blank will distort the fiber blank. Therefore, when supplying the heated fiber blank to the lower part of the mold to lay the heated fiber blank on the lower part of the mold, the horizontal position of the delivery end of the conveying system is moved relative to the lower part of the mold. When conveying the heated fiber blank to the lower part of the mold, the horizontal position of the delivery end of the conveying system is moved from a first position to a second position relative to the lower part of the mold. As already described with respect to this equipment, the supply is coordinated with the movement from the first position to the second position such that the heated fiber blank is laid on the lower part of the mold. In the first position, the delivery end of the conveyor is arranged between the distal end and the proximal end of the lower part of the mold. Preferably, in the first position, the delivery end of the conveyor is arranged closer to the distal end than to the proximal end close to the lower part of the mold. In the second position, the delivery end of the conveyor is arranged closer to the proximal end than to the distal end close to the lower part of the mold, but not between the proximal end and the distal end. Therefore, moving the horizontal position of the delivery end from the first position to the second position simultaneously with releasing the heated fiber blank from the conveyor enables the heated fiber blank to be gently placed on the lower part of the mold.

[0050] By coordinating the supply of the heated fiber blank by the conveying system with the movement of the position of the delivery end, the heated fiber blank can be laid on the lower part of the mold, that is, the heated fiber blank can be placed on the lower part of the mold with very low mechanical impact being applied to the heated fiber blank. Preferably, the supply rate and the movement rate are substantially the same such that the heated fiber blank is neither stretched nor compressed while being laid on the lower part of the mold. However, in some embodiments, the supply rate is slightly higher than the movement rate such that the heated fiber blank is slightly compressed while being laid on the lower part of the mold. Slightly compressing the heated fiber blank can slightly improve the elastic properties.

[0051] According to an embodiment, the horizontal position of the delivery end of the conveying system is moved relative to the horizontal position of the lower part of the mold by horizontally moving the delivery end of the conveying system.

[0052] Once the mold has been closed, the formed fibrous block article can be cooled by passing a cooling fluid, such as cooling air, through the formed fibrous block article while the mold is closed. Additional aspects of cooling the formed fibrous block article have been disclosed above herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] These and other aspects, features, and advantages of the present invention will become apparent from the following description of the embodiments of the present invention with reference to the accompanying drawings, and will be elucidated from the following description of the embodiments of the present invention with reference to the accompanying drawings, in which:

[0054] Figure 1a is an overall view of a fibrous block forming apparatus according to an embodiment;

[0055] Figures 1b to 1f is a series of views depicting laying a heated fibrous blank on a lower member of a mold by a fibrous block forming apparatus according to the embodiment depicted in Figure 1a ;

[0056] Figures 2a to 2b depicts a cross-section of a fibrous block forming apparatus according to an embodiment;

[0057] Figures 3a to 3b depicts a cross-section of a fibrous block forming apparatus according to an embodiment;

[0058] Figures 4a to 4b depicts a cross-section of a fibrous block forming apparatus according to an embodiment; and

[0059] Figures 5a to 5d depicts a mold according to an embodiment. DETAILED DESCRIPTION

[0060] The following description focuses on embodiments of a fibrous block forming method of the present invention applicable to forming a fibrous blank 10 containing a thermally active binder into a three-dimensional fibrous block article and embodiments of a fibrous block forming apparatus 1 applicable thereto. However, it will be understood that the present invention is not limited to the specific exemplary embodiments described.

[0061] In Figure 1aIn it, an overall view of the fiber block forming device 1 is provided. The device 1 includes a mold 100 for forming a heated fiber blank 11 into a formed product when the mold 10 is closed. The mold has a lower part 110 and an upper part 120. When the mold is closed, the lower part 110 and the upper part 120 of the mold form a cavity 150 between the lower part 110 and the upper part 120. In addition, the fiber block forming device 1 includes a conveying system 200 having a receiving end and a delivery end 220. The delivery end 220 is arranged close to the mold 100. In addition, the fiber block forming device 1 includes a heater 300, which can be, for example, a furnace, for heating the fiber blank 10 before forming to activate the binder. The receiving end and the delivery end 220 are arranged on opposite sides of the heater 300. A receiving position 210 is provided between the heater 300 and the receiving end, where the fiber blank is positioned at the receiving position 210 of the conveying system 200.

[0062] Figures 1b to 1e Relates to the following embodiment: In this embodiment, the conveying system 200 includes a conveyor belt 201 and a plurality of shafts over which the belt can pass. At the delivery end 220, the belt 201 turns around a first rotating shaft 221, and at the receiving end, the belt 201 turns around a second rotating shaft 211 (see Figure 1a ). In addition, the conveyor belt 201 passes over a stretching shaft 222, which is used to keep the conveyor belt 201 stretched. The stretching shaft 222 is arranged between the delivery end 220 of the conveying system 200 and the heater 300. The conveyor belt 201 is driven by a drive shaft 223, which is operated by a first electric motor 261. In addition, the first rotating shaft 221 and the stretching shaft 222 are connected by a swivel bracket 272, whereby the first rotating shaft 221 can be horizontally moved relative to the conveying system 200 while keeping the conveyor belt 201 stretched by also horizontally displacing the stretching shaft 222. The swivel bracket 272 is operated by a second electric motor 271. The swivel bracket 272 and the stretching shaft 222 are included in the following horizontal position moving device 260: The horizontal position moving device 260 is arranged to move the horizontal position of the delivery end 220 of the conveying system 200 relative to the lower part 110 of the mold 200 between a first position ( Figure 1c ) and a second position ( Figure 1e) move between. The fiber blank laying device 270 includes a conveyor control device 274, such as a programmable microprocessor, and the fiber blank laying device 270 controls the horizontal position moving device 260, the first motor 261, and the second motor 271. The fiber blank laying device 270 is arranged to coordinate the release of the heated fiber blank 11 from the conveying system 200 at the delivery end 220 - that is, the supply of the heated fiber blank 11 to the lower part 110 of the mold 100 - with the movement of the delivery end 220 from a first position to a second position. Coordinating the release includes: controlling the speed of the first electric motor 261 relative to the speed of the second electric motor 271.

[0063] At Figures 1b to 1f is schematically depicted an embodiment in which the horizontal position of the delivery end 220 of the conveying system 200 moves between a first position and a second position relative to the lower part 110 of the mold 100 to lay the heated fiber blank 11 on the lower part 110 of the mold 100. As can be seen, when the heated fiber blank 11 is conveyed onto the lower part 110 of the mold 100, the delivery end 220 is retracted so that the heated fiber blank 11 is laid on the lower part 110 of the mold 100. Thus, at Figure 1b , the heated fiber blank 11 has just left the heater 300 and is placed on the conveyor belt 201. The mold 100 has just been opened after the previous sequence. At Figure 1c , the delivery end 220 has been moved to a first position as illustrated by the arrow, in which the delivery end 220 is located between the distal end 116 and the proximal end 115 of the lower part 110 of the mold 100, but closer to the distal end (116). This movement, including the extension of the swivel bracket 272 away from the heater 330, is controlled by the fiber blank laying device 270, as Figure 1b illustrated, so as to coordinate the actions of the horizontal position moving device 260 and the first motor 261 that drives the conveyor belt 201. At Figure 1d , the fiber blank laying device 270 causes the swivel bracket 272 to retract towards the heater 300, so that the delivery end 220 moves from the first position towards a second position as illustrated by the arrow, in which the delivery end 220 is positioned closer to the proximal end 115 rather than closer to the distal end 116 of the lower part 110 of the mold 100 and is not located between the proximal end 115 and the distal end 116. The movement of the delivery end 220 from the first position towards the second position is coordinated with the first motor 261 that drives the belt 201, so that the heated fiber blank 11 is released from the belt 201 and laid on the lower part 110 of the mold 100, as Figure 1d illustrated. At Figure 1eIn this case, the delivery end 220 has reached the second position. The heated fiber blank 11 is placed on the lower part 110 of the mold 100. In Figure 1f In this case, the mold 100 has been closed by vertically moving the upper part 120 downward to contact the lower part 110, so as to provide the required shape for the heated fiber blank 11. In addition, the cooling of the fiber blank 11 is carried out within the mold 100 to solidify the fiber blank into a fiber block product.

[0064] Figures 2a to 2b Related to the following embodiment: This embodiment is similar to the embodiment of Figures 1a to 1f However, in this embodiment, when the heated fiber blank 11 is conveyed to the lower part 110 of the mold 100, the second rotating shaft 211 is also horizontally displaced. The conveyor belt 201 is kept stretched by displacing the second rotating shaft 211 in a manner coordinated with the horizontal displacement of the first rotating shaft 221. In Figure 2a In this case, the fiber block forming device 1 is depicted in the first position, in which the delivery end 220 of the conveying system 200 is located between the distal end 116 and the proximal end 115 of the lower part 110 of the mold 100, but closer to the distal end 116, while in Figure 2b In this case, the fiber block forming device 1 is depicted in the second position, in which the delivery end 220 of the conveying system 200, when in the second position, is positioned closer to the proximal end 115 than to the distal end 116 of the lower part 110 of the mold 100, but not between the proximal end 115 and the distal end 116. As can be seen, the relative positions of the rotating shaft 211 and the rotating shaft 221 are different in Figure 2a and Figure 2b respectively, and these two rotating shafts 211, 221 and the device for horizontally moving these two rotating shafts 211, 221 (which is not fully shown in Figures 2a to 2b but is optionally similar to the rotary bracket 272 illustrated in Figure 1b ) form part of the horizontal position moving device 260. The fiber blank laying device 270 is arranged to coordinate the operation of the horizontal position moving device 260 and the first motor 261 for driving the conveyor belt 201 to adapt to the laying of the heated fiber blank 11 on the lower part 110 of the mold 100 according to a principle similar to the principle of Figures 1b to 1e .

[0065] Figures 3a to 3bRelates to the following embodiment: In this embodiment, the conveying system 200 includes a conveyor belt 201 and a conveying shuttle 250. The conveyor belt 201 receives the fiber blank 10 to be formed at the receiving position 210 and transports the fiber blank through a furnace serving as a heater 300. After passing through the furnace, the conveyor belt 201 transports the heated fiber blank 11 to the conveying shuttle 250. After receiving the heated fiber blank 11, the conveying shuttle 250 is displaced to a first position (see Figure 3a ), in which the delivery end 220 of the conveying system 200 is located between the distal end 116 and the proximal end 115 of the lower part 110 of the mold 100, but closer to the distal end 116. Subsequently, the horizontal position of the delivery end 220 is moved by means of the following horizontal position moving device 260: The horizontal position moving device 260 displaces the conveying shuttle 250 to a second position (see Figure 3b ), in which the position of the conveying shuttle 250 of the conveying system 200 is positioned closer to the proximal end 115 than to the distal end 116 of the lower part 110 of the mold 100, but not between the proximal end 115 and the distal end 116. The fiber blank laying device 270 is arranged to coordinate the action of the horizontal position moving device 260 for controlling the position of the conveying shuttle 250 by means of the second motor 271 with the speed of the first motor 261 for driving the belt 202 of the conveying shuttle 250 to adapt to the laying of the heated fiber blank 11 on the lower part 110 of the mold 100. When supplying the heated fiber blank 11 to the lower part 110 of the mold 100, the horizontal position of the delivery end 220 is moved by displacing the conveying shuttle 250, and the heated fiber blank 11 is laid on the lower part 110 of the mold 100 in a manner similar to the manner described above with respect to Figures 1b to 1e .

[0066] In Figure 4a and Figure 4b 's embodiments, the lower part 110 of the mold 100 moves between a first position (see Figure 4a ) and a second position (see Figure 4b ), while the delivery end 220 of the conveying system 200 does not shift. Thus, on the one hand, there is still relative movement between the delivery end 220 of the conveying system 200 between the distal end 116 and the proximal end 115 of the lower part 110 of the mold 100, and on the other hand, the delivery end 220 of the conveying system 200 is, for example, with respect to the above Figures 1b to 1eThere is still relative movement between the described first position and the second position similar to the first position and the second position. The horizontal position of the lower part 110 of the mold 100 relative to the delivery end 220 of the conveying system 200 is moved by a horizontal position moving device 260 including a second motor 271, and the second motor 271 controls the horizontal position of the lower part 110. The fiber blank laying device 270 is arranged to coordinate the operation of the horizontal position moving device 260 and the first motor 261 that drives the conveyor belt 201 to adapt to the laying of the heated fiber blank 11 on the lower part 110 of the mold 100 according to a principle similar to the principle of Figures 1b to 1e The laying of the heated fiber blank 11 on the lower part 110 of the mold 100 according to a principle similar to the principle of

[0067] In Figure 5a a mold 100 according to an embodiment is provided. Figure 5b And Figure 5c are Figure 5a two vertical cross-sections of Figure 5d is Figure 5a Another cross-section of Figure 5d The cross-sectional view of Figure 5c is parallel to the cross-sectional view in

[0068] The mold 100 has a lower part 110 and an upper part 120. In addition, the lower part 110 of the mold 100 includes a first main part 117 and a replaceable first insert part 118. The first insert part 118 has a surface structure 118b that defines the lower part of the cavity 150 of the mold 100, and the surface structure 118b is a recess in this embodiment. Similarly, the upper part 120 of the mold includes a second main part 127 and a replaceable second insert part 128. The second insert part 128 has a surface structure that defines the upper part of the cavity 150 of the mold 100, and the surface structure is, for example, a recess 128b. It will be understood that in alternative embodiments, one of the insert parts 118 and 128 may be provided with a recess and the other may be provided with a protrusion, or, as long as the cavity 150 is still formed when the mold is closed, one or both of the two insert parts 118, 128 may be provided with both a recess and a protrusion.The first main component 117 is provided with a connection port 115 for a cooling fluid. In addition, the first main component 117 is provided with a first number of channels 113 arranged parallel to each other in the plane of the lower part 110 of the mold 100. The first number of channels 113 are connected to the connection port 115 through a connection channel 119 which extends at a side perpendicular to the first number of channels 113 but in the same plane of the lower part 110 of the mold, and the connection channel 119 connects each of the channels in the first number of channels 113 to the connection port 115. In addition, the first number of channels 113 are connected to a second number of channels 114. The second number of channels 114 are arranged perpendicular to the plane of the lower part 110 of the mold and extend through a replaceable first insert 118 into a recess defining the lower part of the cavity 150 of the mold 100.

[0069] Similarly, the second main component 127 is provided with a connection port 125 for a cooling fluid. In addition, the second main component 127 is provided with a third number of channels 123 arranged parallel to each other in the plane of the upper part 120 of the mold 100. The third number of channels 123 are connected to the connection port 125 through a connection channel 129 which extends at a side perpendicular to the third number of channels 123 but in the same plane of the upper part 120 of the mold 100, and the connection channel 129 connects each of the channels in the third number of channels 123 to the connection port 125. In addition, the third number of channels 123 are connected to a fourth number of channels 124. The fourth number of channels 124 are arranged perpendicular to the plane of the upper part 120 of the mold and extend through a replaceable second insert 128 into a recess of the upper part defining the cavity 150 of the mold 100.

[0070] The cooling fluid can be provided when the mold 100 has been closed to receive the heated fiber blank 11 (see Figure 1fAfter being enclosed within the cavity 150 of the mold and supplied to the connection port 115, the cooling fluid can be, for example, cooling air or cooling water. The connection port 115 distributes the cooling fluid among the first number of channels 113, and the first number of channels 113 further distributes the cooling fluid to the second number of channels 114. The second number of channels 114 distributes the cooling fluid into the heated fiber preform located within the cavity 150 and cools the heated fiber preform block such that the fiber block solidifies and thus assumes the shape of the cavity 150. The cooling fluid enters into the fourth number of channels 124 of the second insert member 128 after having passed through the cavity 150 and further enters the third number of channels 123 from the fourth number of channels 124 of the second insert member 128. Finally, the spent cooling fluid, which is at a higher temperature at this time, passes through the third number of channels 123 into the connection port 125 and then exits the mold 100. Preferably, the orifices of the second number of channels 114 - i.e., the openings through which the second number of channels 114 enter the cavity - are displaced relative to the orifices of the fourth number of channels 124 - i.e., the openings through which the fourth number of channels 124 enter the cavity 150. Thus, the cooling fluid, such as cooling air, will not pass vertically through the cavity 150 but will flow slightly laterally, thereby improving the cooling effect.

[0071] Optionally, and as illustrated in Figure 5c and Figure 5d , the lower member 110 of the mold 100 can be provided with another set of channels 133 for the cooling fluid, which are not in fluid communication with the cavity 150. The cooling fluid, which can be, for example, water or oil, conveyed in the channels 133 makes it easier to maintain a uniform and constant temperature of the mold 100. As an alternative to, or in combination with, the another set of channels 133 for the fluid of the lower member 110 of the mold 100, the upper member 120 of the mold 100 can be provided with another set of channels 143 for the cooling fluid, which are not in fluid communication with the cavity 150. Thus, a more uniform temperature of the upper member 120 of the mold 100 can be achieved.

[0072] Without further elaboration, it is believed that those skilled in the art can make full use of the present invention with the foregoing description. Accordingly, the foregoing preferred specific embodiments are considered illustrative only and not limiting of the disclosure in any way.

[0073] Although the present invention has been described above with reference to specific embodiments, this is not intended to limit the invention to the specific forms set forth herein. On the contrary, the invention is only limited by the appended claims, and other embodiments different from the described embodiments above can equally fall within the scope of the appended claims.

[0074] In the claims, the term "comprising / including" does not exclude the presence of other elements or steps. Additionally, although separate features may be included in different claims, these separate features can be advantageously combined, and the inclusion in different claims does not imply that the combination of features is not feasible and / or advantageous.

[0075] Furthermore, a singular reference does not exclude a plurality. The terms "a", "an", "first", "second", etc. do not exclude a plurality.

Claims

1. A method for forming a fiber block, the fiber block forming method comprising forming a heated fiber blank (10) comprising a bicomponent binder polyester fiber as a thermally active binder into a three-dimensional fiber block article, the bicomponent binder polyester fiber having a binder portion with a melting point lower than that of the other portion, wherein, the fiber blanks (10) are stacked vertically, and the fibers in the fiber blanks (10) are arranged perpendicular to the longitudinal extension direction of the fiber blanks (10), and the fiber block forming method comprises the following steps: receiving the fiber blank (10) to be formed at a receiving position (210) of a conveying system (200); transporting the fiber blank (10) by means of the conveying system (200) past a heater (300) for heating the fiber blank (10) to activate the binder to a mold (100), the mold having a lower part (110) and an upper part (120), wherein the lower part (110) and the upper part (120) of the mold form a cavity (150) therebetween for forming the fiber blank (10) into a formed article when the mold is closed; delivering the heated fiber blank onto the lower part (110) of the mold (100), the temperature of the mold and its surface ranging from 20 °C to 65 °C; and closing the mold to provide the fiber block article.

2. The fiber block forming method according to claim 1, wherein, the fibers in the fiber blank (10) are arranged perpendicular to the conveying direction of the fiber blank (10) on the conveying system (200).

3. The fiber block forming method according to any one of claims 1 to 2, wherein, the three-dimensional fiber block article is a cushion member.

4. The fiber block forming method according to claim 3, wherein, the three-dimensional fiber block article is a cushion member for a seat or a backrest of a sofa or a chair.

5. The fiber block forming method according to claim 3, wherein, the three-dimensional fiber block article is a seat cushion for a chair, and the fibers are arranged to stand upright in the seat cushion.

6. The fiber block forming method according to any one of claims 1, 2, 4, 5, wherein, the fiber blank (10) comprises polyester fibers, and wherein the activation temperature of the thermally active binder is 100 °C to 160 °C, and the activation temperature is lower than the melting point of the polyester fibers.

7. The fiber block forming method according to claim 6, wherein, the activation temperature is the melting point of the thermally active binder.

8. The fiber block forming method according to claim 6, wherein, the fiber blank (10) comprises a bicomponent binder polyester fiber, and the fiber blank (10) comprises 10 wt% to 80 wt% of the bicomponent binder polyester fiber.

9. The fiber block forming method according to claim 8, wherein, the fiber blank (10) comprises 20 wt% to 60 wt% of the bicomponent binder polyester fiber.

10. The method for forming a fibrous block according to claim 1 or 8, wherein, the bicomponent binder polyester fiber is a core-sheath type binder polyester fiber, and wherein the sheath constitutes the thermally active binder.

11. The method for forming a fibrous block according to any one of claims 1, 2, 4, 5, 7 to 9, wherein, the fibrous blank (10) is received at the receiving position (210) in the form of a sheet, and wherein the received sheet is formed into a formed fibrous block product once heated.

12. The method for forming a fibrous block according to any one of claims 1, 2, 4, 5, 7 to 9, wherein, in the step of transporting the fibrous blank (10) past the heater (300), hot air is passed through the fibrous blank (10).

13. The method for forming a fibrous block according to claim 12, wherein, the temperature of the hot air is from 120 °C to 220 °C.

14. The method for forming a fibrous block according to any one of claims 1, 2, 4, 5, 7 to 9, wherein, once the mold (100) has been closed, the formed fibrous block product is cooled by passing a cooling fluid through the formed fibrous block product.

15. The method for forming a fibrous block according to claim 14, wherein, the cooling fluid is air.

16. The method for forming a fibrous block according to any one of claims 1, 2, 4, 5, 7 to 9, wherein, when laying the heated fibrous blank on the lower part (110) of the mold (100), the delivery end (220) of the conveying system (200) is arranged at a level vertically higher than the lower part (110) of the mold (100), and when supplying the heated fibrous blank to the lower part (110) of the mold (100), the horizontal position of the delivery end (220) of the conveying system (200) is moved from a first position relative to the lower part (110) of the mold (100), in which the delivery end (220) of the conveying system (200) is arranged between the distal end (116) and the proximal end (115) of the lower part (110) of the mold (100), to a second position in which the delivery end (220) of the conveying system (200) is arranged closer to the proximal end (115) than to the distal end (116) of the lower part (110) of the mold (100) but not between the proximal end (115) and the distal end (116), and the supply is coordinated with the movement from the first position to the second position such that the heated fibrous blank is laid on the lower part (110) of the mold (100).

17. The method for forming a fibrous block according to claim 16, wherein, the supply rate and the movement rate are the same.

18. The method for forming a fibrous block according to claim 16, wherein, When laying the heated fiber blank on the lower part (110) of the mold (100), the horizontal position of the delivery end (220) of the conveying system (200) is moved relative to the horizontal position of the lower part (110) of the mold (100) by horizontally moving the delivery end (220) of the conveying system (200).

Images