A fiber forming facility for manufacturing a molded article made of an environmentally friendly degradable fiber material

Abstract

The invention relates to a forming station (20) for forming (210), a pre-forming station (30) for pre-forming (220), a hot-press station (40) for final forming (230), a formed component (10) made of an environmentally friendly degradable fiber material (11) in a fiber forming process in a fiber forming plant (100), and such a fiber forming plant (100) for producing formed pieces (10) having the above components (20, 30, 40) in a fiber forming process in a fiber forming plant (100) by a method (200).

Description

Technical Field

[0001] This invention relates to a molding station for molding parts made of environmentally friendly biodegradable fiber materials, a preforming station for preforming, a hot pressing station for final molding, and such a fiber forming facility for manufacturing parts by using the above-mentioned components and methods performed in the fiber forming facility as a fiber forming process. Background Technology

[0002] The aim is to protect the public and the environment from plastic pollution. Single-use plastic products, especially packaging materials, tableware, and cookware, generate a significant amount of waste. In this regard, there is a growing demand for alternatives to plastic packaging materials and containers, which can be made from recyclable plastics, materials with low plastic content, or even materials that are plastic-free.

[0003] The concept of using natural fibers instead of typical plastics in extrusion processes has existed since at least the early 1990s, as illustrated in patent document EP 0447 792 B1. As with most fiber processing processes, the raw material base here is a slurry. In principle, the slurry consists of water, natural fibers, and binders such as industrial starch (potato starch) and has a paste-like consistency.

[0004] Document US 2003 / 051845 A1 discloses an apparatus for producing molded pulp products from fiber pulp, the apparatus comprising an impregnation tank containing fiber pulp and having a liquid level. Rollers are provided. A porous die is carried by the rollers. A press plate and the die it carries are lowered into the fiber pulp, wherein the press plate is positioned above the die, so that the die is introduced into the fiber pulp through the liquid surface. While the die is in the fiber pulp, a vacuum is applied to the press plate and the die to cause fibers in the fiber pulp to aggregate on the die and form a wet molded pulp product. The press plate and the die thereon with the wet molded product are removed from above the liquid surface of the fiber pulp to allow water to drain from the die and the wet molded pulp product. The wet-formed pulp product is then dried.

[0005] Document EP1197596A1 discloses a papermaking mold for producing molded pulp articles, which includes a core of a predetermined shape having a plurality of holes for connecting internal and external fluid channels. The outer surface of the core is made of an elastically deformable material and a fluid-permeable material covering, which allows the fluid-permeable material to form fluid channels in its thickness direction even when deformed under pressure.

[0006] Document WO03 / 035981A1 discloses a method for producing paper molded articles, such as those used as packaging containers and packing mats, and a hot-pressing apparatus for their production. The hydrated paper molded article is held between an upper and lower mold and subjected to hot pressing, causing the lower mold to descend and leaving a small gap between the upper and lower molds. Hot air is blown out from the upper mold, and a vacuum is drawn from the lower mold. The hot air and vacuuming are alternately repeated between the upper and lower molds, causing the hydrated paper molded article to oscillate up and down.

[0007] Document WO 93 / 17183 A1 discloses an apparatus comprising a perforated plate and a suction mold covered with a wire mesh. A series of protrusions in the form of hollow plastic bodies, such as B. high-density polyethylene, are connected by suitable openings in the plate and the wire mesh. The hollow bodies are perforated and covered externally with the wire mesh and are selected from a first modular system comprising a relatively small number of prefabricated protrusions of different sizes and shapes. The apparatus may also include a mold (not shown) for hot-pressing pulp products made by means of a suction mold, the mold comprising a first molded component having protrusions complementary to the cavity of the pulp product and indentations of the same size and shape as those produced by protrusions on a suction mold and a second mold component, the indentations being complementary to the protrusions on the first mold component but larger in size than the thickness of the hot-pressed pulp product of the latter. The first-formed protrusions are prefabricated and selected from a second modular system comprising a relatively small number of protrusions of different sizes and shapes, which, after shrinkage, correspond to the size of the grooves used in the pulp product after the protrusions to be produced by the first modular system.

[0008] Because consumers are interested in a variety of eco-friendly products of different sizes, shapes and requirements, but do not necessarily need a large number of products, there is a demand for a manufacturing process and corresponding machines for environmentally friendly molded parts made of natural fibers that can efficiently, flexibly, with high quality and reproducible production of such products (molded parts). Summary of the Invention

[0009] The purpose of this invention is to provide a method and machine for manufacturing environmentally friendly molded parts made of natural fibers, thereby enabling the efficient, flexible, high-quality and reproducible manufacture of such products (molded parts).

[0010] According to a first aspect of the present invention, the solution for achieving the above-mentioned objective is a molding station of a fiber molding facility for molding parts made of environmentally friendly and biodegradable fiber materials in a fiber molding process, comprising:

[0011] - A suction mold for drawing environmentally friendly biodegradable fiber material from a reservoir containing a slurry as an environmentally friendly biodegradable fiber material for molding parts, wherein the suction mold includes a suction head having a three-dimensional suction side whose shape conforms to the contour of the subsequently molded part, and the part is molded in the suction mold on the suction side by negative pressure (suction pressure); and

[0012] - A moving unit on which a suction mold is mounted, the moving unit being configured to at least place the suction mold on or in the slurry or to partially immerse the suction mold in the slurry.

[0013] The term "environmentally friendly biodegradable fiber material" refers to a fibrous material that can decompose under environmental influences such as humidity, temperature, and / or light, wherein the decomposition process occurs within a short period of time, such as within days, weeks, or months. For simplicity, "environmentally friendly biodegradable fiber material" will sometimes be referred to simply as "fiber material" hereinafter. Preferably, neither the fiber material nor its decomposition products cause harm or pollution to the environment. Fiber materials representing environmentally friendly biodegradable fiber materials within the scope of this invention are, for example, natural fibers derived from pulp, paper, paperboard, wood, grass, plant fibers, bagasse, hemp, etc., or from components or portions thereof and / or corresponding recycled materials. However, environmentally friendly biodegradable fiber materials can also refer to man-made fibers corresponding to or possessing the properties of the aforementioned fiber materials, such as PLA (polylactic acid). Environmentally friendly biodegradable fiber materials are preferably compostable. Environmentally friendly biodegradable fiber materials and containers made therefrom are preferably suitable for material recycling in German organic waste bins and as resources for biogas plants. According to EU standard EN 13432, fiber materials and containers made therefrom are preferably biodegradable.

[0014] The term "slurry" refers to a fibrous fluid substance, here meaning an environmentally friendly biodegradable fibrous material. The term "liquid" refers to the aggregated state of the slurry, where the liquid slurry comprises the environmentally friendly biodegradable fibrous material in fibrous form (a liquid solution containing the environmentally friendly biodegradable fibrous material). Here, the fibers can be presented as single fibers, fibrous structures, or groups of fibers composed of multiple connected fibers. Fibers represent fibrous materials, whether they are present in the slurry as single fibers, fibrous structures, or groups of fibers. Here, the fibers are dissolved in the liquid solution such that they float throughout the liquid solution at as uniform a concentration as possible, for example, as a mixture or suspension of the liquid solution and the fibrous material. For this purpose, in some embodiments, the slurry may be adjusted in temperature and / or circulated accordingly, for example. The slurry preferably has a low consistency, i.e., the proportion of fibrous material is less than 8%. In one embodiment, in the method according to the invention, a slurry with a proportion of less than 5%, preferably less than 2%, and particularly preferably 0.5% to 1.0% of the environmentally friendly biodegradable fibrous material is used. This low proportion of fiber material effectively prevents clumping in the liquid solution, allowing the fiber material to still be molded effectively on the suction mold. While the suction mold can draw in clumped fiber material, this can lead to variations in the layer thickness of the molded part, which should be avoided as much as possible during production. Therefore, the proportion of fiber material in the slurry should be low enough to prevent clumping or chaining, or to occur only to a negligible degree. The liquid solution can be any solution suitable for fiber molding processes. For example, the slurry can be an aqueous solution containing environmentally friendly, biodegradable fiber material. Aqueous solutions are particularly easy to handle.

[0015] Fiber molding process refers to the process steps involved in molding a part. It begins with providing a slurry, molding the part from the fiber material in the slurry in a molding station, pre-molding the part in a pre-forming station, and hot-pressing the part in a hot-pressing station. Optionally, a functional layer is coated on the part, wherein the coating can be placed at any location in the fiber molding process suitable for the corresponding application layer.

[0016] The molded part can have any shape, also referred to herein as a profile, provided that the shape (or profile) is fabricable in the method according to the invention or that the method is suitable for fabricating the shape (or profile). Here, the components used in the fiber forming process can be matched to the corresponding shape (or profile) of the molded part. In cases where different molded parts have different shapes (or profiles), different corresponding matching components can be used, such as suction molds, suction heads, pre-pressing stations, hot press stations, etc. Preferably, the target profile of the molded part and the corresponding forming components are designed such that the various surfaces of the molded part form an angle α of at least 3 degrees with the pressing direction during hot pressing. For example, the surface perpendicular to the pressing direction (maximum pressure) has an angle α = 90 degrees. This ensures that hot pressing pressure can be applied to the various surfaces of the molded part. During hot pressing, pressure cannot be applied to surfaces parallel to the pressure direction. The final molded part can represent a variety of products for various uses, such as cups, containers, utensils, lids, plates, partial utensils, shells, or outer containers.

[0017] A suction mold, in this context, refers to a mold having one or more suction heads arranged for molding parts. A single suction head is also a suction mold. If multiple suction heads operate simultaneously, they are all arranged within a common suction mold, so that as the suction mold moves, each suction head within the mold moves by an equal amount. The supply medium to the suction mold with multiple suction heads is guided appropriately to each suction head within the mold.

[0018] Placing the suction mold onto the slurry means that the slurry comes into contact with all the suction heads in the mold. These suction heads are designed to mold the part, thereby drawing out the fibrous material or aspirating the slurry and the fibrous material dissolved therein due to the negative pressure or suction pressure applied to the slurry by the suction mold. When the suction mold is partially immersed in the slurry, the mold is not only placed on the slurry but also immersed in it. The immersion depth of the suction mold in the slurry depends on the respective application and the respective fiber forming process, and can vary depending on the application and the part that may be molded.

[0019] Here, the suction head can be female. A female shape refers to a suction side (i.e., the side where the fibrous material is deposited and molded into a part due to the suction force of the suction head) located inside the suction head. This creates a cavity on the inside after the suction head is placed on or immersed in the slurry, into which the fibrous slurry is drawn (as shown in Figure 1). In the case of a female shape, the outer side of the subsequently molded part faces the inner side of the suction head. Therefore, the molded part is located on the inner side of the suction head after molding.

[0020] Here, the suction head can also be male. A male shape refers to a suction side of the suction head (i.e., the side where the fibrous material is deposited and molded into a part due to the suction force of the suction head) located on the outside of the suction head, so that no cavity is formed on this outside after the suction head is placed on or immersed in the slurry (as shown in Figure 1). In the case of a male shape, the inner side of the subsequently molded part faces the outer side of the suction head. Therefore, the molded part is located on the outer side of the suction head after molding.

[0021] The molding of a molded part represents the first pre-forming of the part, wherein the part is formed from fibrous material previously randomly distributed in the slurry, which is achieved by accumulating the fibrous material in a corresponding contour on the profile of the suction head. The molded part still has a large proportion (e.g., 70%-80%) of liquid solution, such as water, and therefore its shape is not yet stable.

[0022] Molding stations readily produce molded parts from slurries containing fibrous materials, offering great flexibility in producing molded parts with various profiles depending on the suction head design. Here, the width or diameter-to-height ratio of the molded part does not represent a limitation or critical parameter regarding the manufacturing quality of the corresponding molded part. The molding station according to the invention allows for the highly reproducible manufacture of molded parts with high precision and quality in terms of shape and layer thickness of various parts. The molding station can handle various fibers, provided these fibers are soluble, to prevent large agglomeration of fibers in the liquid solution prior to processing. In particular, this method allows for the easy, efficient, and flexible manufacture of high-quality, highly reproducible, and stable molded parts from environmentally friendly, biodegradable fibrous materials.

[0023] Thus, the molding station according to the invention, together with subsequent molding steps according to other aspects of the invention, enables the efficient, flexible, high-quality, and reproducible manufacture of environmentally friendly molded parts from natural fibers.

[0024] In another embodiment, the suction side of the suction head is formed by a porous screen on its surface, wherein environmentally friendly biodegradable fibers adhere to the slurry side of the screen due to suction. The screen must have a certain porosity to allow slurry and fiber material to be drawn through it, and the liquid solution of the slurry can flow through the screen. However, the porosity of the screen cannot be too large so that the fiber material can adhere to the slurry side.

[0025] In another embodiment, the screen has a wavy structure with crests and troughs along its suction side surface, wherein the screen abuts against the suction side surface at least during suction with the crest of the side facing the suction side surface. This provides the screen with simple mechanical support during molding, preventing its shape from changing and ensuring the shape of the molded part can be replicated. Furthermore, the screen can be made porous enough to ensure good slurry suction performance.

[0026] In another embodiment, the suction mold includes several suction channels terminating on a suction side surface below the screen and distributed across the suction side surface such that substantially equal suction capacity is achieved throughout the entire area between the screen and the suction side surface. Through the several suction channels, slurry containing fibrous material can be suctioned, particularly across the entire surface of the screen, allowing the molded part to be molded into a flat shape on the screen. The term "substantially" here refers to the uniformity of suction capacity, sufficient to achieve a uniformly molded part without significant layer thickness variations at corners and edges or on the surface of the part. As a result, the layer thickness variation of the final molded part is less than 7% compared to the desired layer thickness. In another embodiment, the suction channels have openings with a diameter of less than 4 mm in the suction side surface.

[0027] In another embodiment, the suction channels are unevenly distributed on the suction-side surface, wherein the number of suction channels per unit area in the negative edge region of the molded part is reduced by 40%-60% compared to the flat surface and / or the number of suction channels per unit area in the positive edge region is increased by 10%-30% compared to the flat surface. This lower or higher density of suction channels in the edge regions (here referring to all corners and edges, indentations and other strong contour changes in the molded part, with negative or positive edges referring to the contours as inner or outer edges) results in the material in the edge regions being too thick or too thin relative to the other material on the edgeless surface.

[0028] In another embodiment, the screen is secured in the suction head solely by a reversible fastening mechanism, preferably a clamping mechanism. This allows the screen to be quickly and easily removed from the suction mold for cleaning or, if necessary, replacement. This replacement is particularly advantageous because the screen is already supported against the suction side surface, eliminating the need for additional holding mechanisms. In another embodiment, if necessary, the screen is secured in at least some suction channels.

[0029] In another embodiment, the suction head includes a collecting ring on its slurry-facing end for receiving the liquid slurry solution drawn through the suction side of the suction head, the collecting ring being connected to a drainage channel for the liquid solution. In particular, the liquid solution that has already flowed through the screen can be safely discharged from the suction head and then from the suction mold, so that the liquid solution does not negatively affect the suction force of the suction head.

[0030] In another embodiment, the suction side of the suction head is either female on the inside or male on the outside. For the terms "female" and "male," please refer to the explanations above. The female or male shape of the suction head may be advantageous depending on the desired shape or profile of the part to be formed and further processing.

[0031] In another embodiment, the suction mold is a multi-purpose mold with several suction heads. Using this multi-purpose mold, a large number of molded parts can be simultaneously molded from a common slurry bath according to the number of suction heads, which increases the output of the fiber forming facility, thus making the production of the fiber forming facility more economical.

[0032] In another embodiment, the suction heads in the suction mold can have at least partially different shapes, preferably with suction heads of the same shape arranged adjacent to each other in the suction mold. Different shapes can be arranged, for example, in a modular form in the suction mold. Such a suction mold can simultaneously produce different molded parts in the same fiber molding process. For example, utensils such as cups and their associated lids can be molded and further processed simultaneously in the same suction mold.

[0033] In another embodiment, the suction mold includes a substrate on which suction heads are mounted and a gas conduit system within the substrate, which at least distributes negative pressure provided by a vacuum pump to the suction heads to draw in fibrous material. The substrate can be connected to the moving unit in a simple, standardized manner, while the suction heads mounted thereon can vary depending on the desired molding. If necessary, the substrate allows for rapid replacement of the suction heads. The vacuum pump can be positioned remotely from the suction mold and distributes the generated negative pressure to the suction heads via the gas conduit system.

[0034] In another embodiment, the gas piping system also includes compressed gas piping for applying compressed air to the suction head. The injection of compressed air can eject the molded part from the suction mold, for example, after the molded part has been transferred to a hot press mold.

[0035] In another embodiment, the gas piping system for negative pressure includes a main gas line and an auxiliary gas line. The main gas line is configured to generate a pre-negative pressure, and the auxiliary gas line, as a supplement to the main gas line, is configured to achieve the suction negative pressure after the suction mold contacts the slurry. This allows a large amount of gas to be pumped out quickly to apply negative pressure at the suction head. The suction capacity of the auxiliary gas line (which represents an additional pumping line to the main line) then allows for rapid adjustment of the process negative pressure required for the molded part.

[0036] In another embodiment, one or more valves are suitably arranged in the gas piping system to cut off the suction pressure at the suction head at least immediately after the suction mold leaves the slurry, and / or to connect the auxiliary gas line to the main line at least immediately after the suction mold is immersed in the slurry. This enables the molding process to be carried out more quickly and economically.

[0037] In another embodiment, the moving unit includes a robotic arm that can move freely in space, on which a suction mold is mounted. As a result, the molding station can easily and flexibly supply molded or preformed parts to one or more preforming stations and / or one or more hot press stations. This allows for the acceleration or modification of the manufacturing process, particularly depending on the required productivity. In another embodiment, the moving unit is configured to transfer the molded part from the suction mold to the prepress station and / or hot press station of the preforming station.

[0038] In another embodiment, the robotic arm is connected to the suction mold via a suitable interface, including all media supply ports for the suction mold. This allows the use of standardized suction molds and enables rapid replacement if necessary.

[0039] In another embodiment, the moving unit is configured to fully immerse one or more suction heads in the slurry for contact. Full immersion is particularly suitable for male suction heads because, compared to female suction heads, there is no internal cavity in the suction head that can generate suction pressure (negative pressure) to draw in the fibrous material between the slurry and the suction side. To ensure as uniform aspiration of the fibrous material as possible, using a male suction head advantageously involves fully immersing the suction head in the slurry.

[0040] In another embodiment, the moving unit and suction mold are designed to transfer the molded part to the preforming station and then leave it in the suction mold for pre-compression in the pre-compression station.

[0041] Since the molded part is still relatively moist when it is being molded in the suction head, and therefore its dimensions are not very stable, for a trouble-free, high-quality process, the advantage of keeping the molded part in the suction head at least until the end is that it avoids shape defects that may be caused by mold changes. Since the suction mold represents the pre-pressed upper mold in the preforming station, it also speeds up the preforming process.

[0042] In another embodiment, the moving unit and suction mold are designed to eject the molded part from the suction mold into a hot press station for subsequent hot pressing. This can be achieved, for example, by applying pressure to the pre-formed part in the suction mold, thereby enabling rapid transfer of the part to the hot press station. In another embodiment, the moving unit and suction mold are designed to eject the part from the suction nozzle of the suction mold using compressed air.

[0043] According to a second aspect of the present invention, the solution for achieving the above-mentioned objective is a preforming station of a fiber forming facility for preforming molded parts made of environmentally friendly and biodegradable fiber materials in a fiber forming process, comprising:

[0044] - A storage tank containing a slurry as a liquid solution of an environmentally friendly, biodegradable fibrous material for molding parts (in the molding station according to the invention), preferably arranged as an upward-opening horizontal storage tank; and

[0045] - A pre-compression station is used to pre-form a molded part molded by means of a suction mold through a molding station according to any one of the preceding claims under pre-compression pressure, so as to reduce the proportion of liquid solution in the molded part and stabilize the shape of the molded part.

[0046] Here, the slurry may be free of organic binders, and preferably also free of non-organic binders. In the absence of binders, molded parts made from pristine environmentally friendly biodegradable fiber materials can degrade in a particularly environmentally friendly manner because no environmentally critical binders are used, preferably none at all. By combining molding, preforming, and hot-pressing steps, these steps generally ensure good mechanical interlocking of individual fibers in the fiber material of the molded part, eliminating the need for binders. In the method according to the invention, the strength of the mechanical interlocking is sufficient to achieve dimensional stability of the molded part even without binders. In one embodiment, the environmentally friendly biodegradable fiber material is essentially composed of fibers with a length of less than 5 mm. Using fibers of this length, a well-uniform solution of the fiber material in the liquid solution can be obtained, resulting in sufficiently low fiber agglomeration in the slurry to achieve a well-reproducible fiber molding process for the molded part. In one embodiment, the slurry is provided at a temperature below or equal to 80°C, preferably below or equal to 50°C, and particularly preferably room temperature. Such a low temperature particularly allows for simple process control, especially at room temperature. At higher temperatures, the hot-pressing process can be slightly accelerated.

[0047] Using a preforming station, mechanically unstable molded parts are pre-pressed in a simple manner to produce pre-formed parts that are sufficiently stable for further processing and have a further reduced liquid solution content, by pre-pressing. Here, the width or diameter-to-height ratio of the molded part does not represent a limitation or critical parameter regarding the manufacturing quality of the corresponding molded part. The preforming station according to the invention allows for the manufacture and further processing of molded parts in a highly reproducible manner, with high precision and high quality in terms of the shape and layer thickness of various parts of the molded part. In one embodiment, pre-pressing can be performed at a temperature below 80°C, preferably below 50°C, and particularly preferably room temperature at the pre-pressing station. By pre-pressing, the liquid content in the molded part is reduced to approximately 55%-65%, thus pre-curing the molded part and making its dimensional stability sufficient for transfer molding. Excessively high temperatures will result in excessive reduction of the liquid content in the molded part, which will make the material too hard for subsequent hot pressing. In particular, the combination of pre-pressing and hot pressing enables the manufacture of molded parts with high quality and low scrap rates. In another embodiment, at 0.2 N / mm... 2 Up to 0.3 N / mm 2 Preferably 0.23 N / mm 2 Up to 0.27 N / mm 2Pre-pressing is performed at a pre-pressing pressure. These moderate pressures, lower than the hot-pressing pressure, allow the molded parts to cure gently and reduce liquid content, which is beneficial for a low scrap rate during the hot-pressing process.

[0048] In particular, this method allows for the easy, efficient, and flexible manufacture of high-quality, reproducible, and stable molded parts from environmentally friendly and biodegradable fiber materials.

[0049] Thus, the preforming station according to the invention, together with the preceding and subsequent molding steps according to other aspects of the invention, enables the efficient, flexible, high-quality, and reproducible manufacture of environmentally friendly molded parts from natural fibers.

[0050] In one embodiment, the preforming station further includes a slurry preparation and replenishment unit for replenishing the slurry to the storage tank. This allows the slurry to be fed into the storage tank with controlled quality and a constant concentration during molding consumption. Consequently, the liquid solution discharged during molding can be recycled back to the storage tank, for example, by adding fiber material to adjust the required fiber material concentration in the slurry, thus enabling reuse in the fiber molding process. In another embodiment, the slurry preparation and replenishment unit fills the storage tank at least periodically, preferably continuously, according to the slurry consumption of the molded part to ensure the required tank fill level for molding.

[0051] In another embodiment, the pre-compression station is arranged relative to the storage tank such that the liquid solution removed from the molded part by pre-compression is fed back into the storage tank. This reduces slurry consumption. In another embodiment, the pre-compression station is arranged vertically above the storage tank, such that the liquid solution removed from the molded part by pre-compression flows directly from the pre-compression station back into the storage tank. Alternatively, the liquid solution flows back into the storage tank after being prepared by the slurry preparation and replenishment unit of the preforming station.

[0052] In another embodiment, the pre-compression station includes a pre-compression lower die whose shape matches a molded part retained in a suction die to enable attachment to the pre-compression lower die, such that the molded part is arranged between the pre-compression lower die and the suction die, thereby enabling the suction die to be pressed onto the pre-compression lower die with pre-compression pressure. Here, the suction die can be pressed onto a stationary pre-compression lower die, or the pre-compression lower die can be pressed onto a stationary suction die. The term "placement" refers only to the relative movement of the suction die relative to the pre-compression lower die. During pre-compression, the suction die represents the pre-compression upper die of the pre-compression station. In one embodiment, the suction die is placed on the pre-compression lower die and pressed onto the pre-compression lower die by a separate pressing unit, preferably a piston rod. Alternatively, the suction die can also be fastened to a robotic arm that itself applies pre-compression pressure to the pre-compression lower die via the suction die. Here, similar to a suction mold as a multi-purpose mold, the pre-compression station can also be configured as a multi-purpose mold, having several pre-compression lower molds matched to the suction mold as multi-purpose molds, so as to simultaneously apply pre-compression pressure to all the molded parts of the suction mold, and thus pre-compress all the molded parts at the same time. Alternatively, pre-compression is performed as membrane compression, wherein the pre-compression lower mold is configured as a flexible diaphragm, the pre-compression pressure is applied to the diaphragm as gas pressure, and then the diaphragm is pressed onto the outer contour of the molded part. Membrane compression is particularly suitable for the geometry of the molded part to which pressure is applied over a large area. With membrane compression, surfaces perpendicular to each other in any spatial direction can also be under the same pressure simultaneously, because during membrane compression, the pre-compression pressure generated by gas pressure (e.g., compressed air) acts on the diaphragm in any direction. This cannot be achieved, for example, with a pressure piston rod. The diaphragm can be, for example, a rubber diaphragm. The diaphragm should have a contour fidelity of less than 20%, and can be designed differently locally, for example, with thinner and thicker wall thicknesses and / or arranged close to or far from the contour.

[0053] In another embodiment, the pre-compression die has a pressing surface facing the molded part, which has a lower surface roughness than a screen. This applies uniform pressure to the molded part. Additionally, the adhesion between the pre-compression die and the molded part is lower than that of the structured surface of the pre-compression die. This ensures that the pre-compressed part can be retained in the suction die and transferred to thermoforming without further technical measures, and does not remain in the pre-compression die, which could otherwise cause production interruptions. If necessary, the suction die can generate a suitable negative pressure to transfer the pre-compressed part to the hot press station, thereby improving the adhesion of the part to the suction die.

[0054] In another embodiment, the pre-compression die is made of metal or at least partially of an elastomer, preferably silicone. Metal pre-compression dies are particularly suitable for applications requiring temperatures above room temperature or extremely high pre-compression pressures during pre-compression. Elastomers, or at least partially elastomers, are advantageous as multi-purpose dies for both suction and pre-compression purposes because the elastomer remains easily deformable under pressure and flexibly adapts to the multi-purpose die's ability to bend under pre-compression pressure, thereby improving the molding uniformity of various molded parts in the multi-purpose suction die. For increased pre-compression temperatures below 100°C, silicone, as an elastomer, is also well-suited as a temperature-resistant material within this range.

[0055] In another embodiment where the pre-compression die is at least partially made of an elastomer, the pre-compression die has a cavity surrounded by a wall made of an elastomer serving as the pressing surface, wherein the pre-compression station is designed to apply gas pressure to the cavity during pre-compression to generate or at least support pre-compression pressure. This "bulging" of the pre-compression die allows it to match the contours of the molded part particularly well, thereby improving the quality of the preforming process, especially for the reproducible manufacture of extremely identical molded parts.

[0056] In another embodiment, the pre-compression molds are arranged on a common carrier plate equipped with an interface to a pre-compression station for reversible fastening to the station and / or supplying gas pressure to each pre-compression mold. This allows for the rapid replacement of pre-compression molds used as multi-purpose molds, especially when necessary.

[0057] In another embodiment, the carrier plate additionally includes a heating element, preferably a heating element extending flatly above the carrier plate, for heating the pre-compressed lower mold. This modular configuration facilitates component handling and replacement.

[0058] In another embodiment, the molding station is part of the preforming station. Thus, the molding station can be connected to the preforming station via suitable piping, allowing the liquid solution and / or fibrous material flowing through the suction head to be fed back into the slurry via the preforming station.

[0059] In another embodiment, the suction mold is placed on the pre-compression lower mold (having a corresponding male shape) with the female shape as the suction head suction side, or placed in the pre-compression lower mold (as the corresponding female shape) with the male shape as the suction head suction side.

[0060] According to a third aspect of the present invention, the solution of the present invention for achieving the above-mentioned objective is a hot press station of a fiber forming facility for finally forming a molded part made of environmentally friendly biodegradable fiber material in a fiber forming process, comprising: a hot press lower die matching the contour of the molded part for receiving the molded part; and a hot press upper die corresponding to the molded part for being placed on or in the molded part along the closing direction of the hot press station, wherein the hot press lower die and / or the hot press upper die are configured to apply hot press pressure to the molded part arranged between the hot press lower die and the hot press upper die during hot pressing.

[0061] After pre-compression, the pre-compressed part is transferred to the hot press station via a suction mold, thereby removing the part from the suction mold for subsequent hot pressing. The advantage of this transfer is that hot pressing is performed at significantly higher pressures at high temperatures. If the part remains in the suction mold without being transferred for hot pressing, the fibrous material may become stuck in the screen of the suction mold and be difficult to remove, potentially causing damage only after hot pressing. Furthermore, the screen may suffer high-pressure damage, rendering the suction mold inoperable. The transfer can be accomplished by passively transferring one or more parts from the suction mold to the hot press station through ejection or by actively transferring the parts to the hot press station using the ejection pressure within the suction mold. By using hot pressing pressure to perform final molding on the pre-compressed part, the proportion of liquid solution in the part is further reduced, for example, to below 10%, preferably to about 7%, and the part then stabilizes without deformation. The lower and upper hot press molds are preferably made of metal. Hot pressing is performed at a pressure higher than the pre-pressing pressure, for example, 0.5 N / mm. 2 Up to 1.5 N / mm 2 Preferably 0.8 N / mm 2 Up to 1.2 N / mm 2 The pressurization time for applying the hot pressing pressure can be less than 20 seconds, preferably more than 8 seconds, particularly preferably 10 to 14 seconds, and more preferably 12 seconds. The hot pressing pressure is applied hydraulically to the hot press station, for example, via a piston rod, which presses against, for example, an upper hot press die, which in turn presses against a stationary lower hot press die, with the molded part located between the two. This arrangement can also be reversed.

[0062] Using a hot press, pre-formed but still slightly variable molded parts can be easily transformed into final molded parts for further processing using hot pressing, wherein the proportion of liquid solution is significantly reduced. Here, the width or diameter-to-height ratio of the molded part does not represent a limitation or critical parameter regarding the manufacturing quality of the corresponding molded part. The hot press according to the invention allows for the manufacture and further processing of molded parts in a highly reproducible manner, with high precision and high quality in terms of the shape and layer thickness of various parts of the molded part. In particular, this method allows for the easy, efficient, and flexible manufacture of high-quality, highly reproducible, and final stable molded parts from environmentally friendly biodegradable fiber materials.

[0063] Thus, the hot press station according to the invention, together with the prior molding steps according to other aspects of the invention, enables the efficient, flexible, high-quality, and reproducible manufacture of environmentally friendly molded parts from natural fibers.

[0064] In one embodiment, when the suction mold is female, the lower hot press mold is also female and provided as the inner mold, while the upper hot press mold is placed on the lower hot press mold as the outer mold for hot pressing. When the suction mold is male, the lower hot press mold is also male and provided as the outer mold, while the upper hot press mold is placed on the lower hot press mold as the inner mold for hot pressing. The upper and lower hot press molds can cooperate to apply high pressure to the molded part between them at high temperature.

[0065] In another embodiment, an electric heating cylinder heats the hot-pressing sides of both the lower and upper hot-pressing dies facing the molded part. The electric heating cylinder can rapidly heat the lower and upper hot-pressing dies when the mold is closed, and the final molded part can be removed by opening the hot-pressing station after the mold has cooled.

[0066] In another embodiment, the heating cylinders in the lower and upper hot-pressing dies are designed to heat the hot-pressing sides to a temperature above 150°C, preferably 180°C to 250°C. This enables the liquid (or moisture) in the molded part to be quickly and reliably reduced to below 10%.

[0067] In another embodiment, the heating cylinder is controlled such that the temperatures of the lower hot press die and the upper hot press die are different. This provides a better surface finish for the molded part, especially on the side with the higher temperature. Preferably, the temperature of the upper hot press die is higher than that of the lower hot press die, preferably the temperature difference is at least 25°C, preferably the temperature difference is no more than 60°C, and particularly preferably the temperature difference is 50°C.

[0068] In another embodiment, the heating cylinders are arranged close to the contour of the part in the respective upper and lower hot-press dies. The proximity of the heating cylinder to the contour allows for faster heating of the hot-pressing side to the process temperature, thereby accelerating the hot-pressing process. The respective upper and lower hot-press dies are preferably made of metal to support this through good thermal conductivity.

[0069] In another embodiment, at least one heating cylinder with a first heating power is arranged in the inner mold, while several heating cylinders with a second heating power are arranged around the hot-pressing side of the outer mold. This arrangement achieves rapid heating using a minimal number of heating cylinders. Therefore, the first heating power is preferably greater than the second heating power. In another embodiment, for this purpose, if there is a single heating cylinder in the inner mold, this heating cylinder is centrally arranged parallel to the closing direction within the inner mold, and / or if there are multiple heating cylinders in the inner mold, these heating cylinders are concentrically arranged around the hot-pressing side of the inner mold parallel to the closing direction. In another embodiment, in the outer mold, several heating cylinders are concentrically arranged around the hot-pressing side of the outer mold parallel to the closing direction.

[0070] In another embodiment, the lower hot press die and / or the upper hot press die include a heat-insulating material cover on the side facing away from the molded part in order to keep the process temperature as constant as possible and keep the heating power required by the heating cylinder as low as possible.

[0071] In another embodiment, the hot press die includes channels leading to its hot pressing side through which at least part of the liquid solution can be drained during hot pressing. A certain amount of liquid (or moisture) in the molded part is released by reducing it from about 55%-60% to below 10%, which is at least partially evaporated due to the high temperature during hot pressing. Therefore, this vapor is discharged through the channels so that the molded part is not particularly damaged by the vapor. For this purpose, the diameter of the channels, at least on the hot pressing side, is preferably less than or equal to 1.0 mm.

[0072] In another embodiment, both the lower and upper hot-pressing dies are configured as multi-purpose molds with multiple lower and upper hot-pressing dies, arranged on corresponding carrier plates of the respective lower and upper hot-pressing dies. In this way, all pre-formed parts can be simultaneously subjected to the hot-pressing pressure of the suction mold after transfer, thus allowing for simultaneous hot pressing of all parts.

[0073] In another embodiment, the carrier plate is positioned in the hot press station in a laterally movable manner, allowing for the replacement of the corresponding lower and upper hot press dies outside the process space of the hot press station, thus enabling multi-purpose molds. This allows for quick and space-saving changes.

[0074] In another embodiment, the carrier plate of the hot press upper die of the multi-purpose mold is equipped with gas lines to establish overpressure in the respective hot press upper die according to the process steps for maintaining negative pressure on the molded part and / or outputting the final molded part from the hot press upper die.

[0075] In another embodiment, an expansion mechanism is arranged between the carrier plate and the holding mechanism for the carrier plate, which can compensate for the high temperature and temperature fluctuations of the hot press station relative to the holding mechanism and other components when it is turned on / off.

[0076] In another embodiment, thermal insulation material is arranged between the carrier plate and the holding mechanism to keep the process temperature as constant as possible and to keep the heating power required by the heating cylinder as low as possible.

[0077] The present invention also relates to a fiber forming facility for manufacturing molded parts made of environmentally friendly biodegradable fiber materials, comprising at least one molding station according to the present invention, a preforming station according to the present invention, and a hot pressing station according to the present invention, for manufacturing molded parts made of environmentally friendly biodegradable fiber materials by means of a fiber forming process performed in the fiber forming facility.

[0078] By combining molding with a slurry and suction mold, pre-pressing with a preforming station, and hot pressing with a hot press, molded parts can be easily manufactured from fibrous materials, allowing for highly flexible production of molded parts with different profiles based on the suction head design. Here, the width or diameter-to-height ratio of the molded part does not represent a limitation or critical parameter regarding the manufacturing quality of the corresponding molded part. Combining the suction mold used for molding with the preforming and hot press stations allows for the highly reproducible manufacture of molded parts with high precision and quality in terms of shape and layer thickness in various parts of the molded part. The fiber molding facility according to the invention can process various fibers, provided that these fibers are soluble, so that large agglomerations of the fibers in the liquid solution can be avoided before processing. In particular, this method allows for the easy, efficient, and flexible production of high-quality, highly reproducible, and stable molded parts from environmentally friendly and biodegradable fibrous materials.

[0079] The fiber forming facility according to the present invention can efficiently, flexibly, produce environmentally friendly molded parts from natural fibers in a high-quality and reproducible manner.

[0080] In one embodiment, the fiber forming facility includes a control unit for controlling at least the molding station, preforming station, and hot pressing station, and their sub-components. The control unit may be configured as a processor, a separate computer system, or network-based, appropriately connected to the components of the fiber forming facility to be controlled, for example, via a data cable connection or wireless connection via WLAN, radio, or other wireless transmission mechanisms.

[0081] In another embodiment, the fiber forming facility additionally includes a coating unit for applying one or more functional layers to the formed article. Such functional layers, in particular, apply additional functions to the formed article, such as barriers against moisture, aroma, odor, or taste, or barriers against fats, oils, gases (such as O2 and N2), mild acids, and all substances that contribute to food perishability and / or non-food grade substances. For this purpose, the coating unit can be arranged at any location suitable for layer application during the process of manufacturing the formed article. Here, depending on the application, the functional layer can be arranged during suction, after pre-compression, or after hot-compression. The term "functional layer" herein refers to any additional layer applied to the original fibrous material, applied over a full area or partial area to the inner and / or outer sides of the formed article.

[0082] In another embodiment, the fiber forming facility additionally includes an output unit for outputting the final formed part. In this case, the output unit outputs the formed part for further conveying or further processing, for example by means of a conveyor belt, such as to a subsequent cutting station, labeling station, printing station, stacking station, and / or packaging station.

[0083] The present invention also relates to a method for manufacturing molded parts made of environmentally friendly biodegradable fiber materials by means of a fiber forming process in a fiber forming facility according to the present invention, comprising the following steps:

[0084] - A molded part is formed from a liquid solution containing slurry as an environmentally friendly biodegradable fiber material in a molding station according to the invention;

[0085] - The molded part is preformed in the preforming station according to the invention;

[0086] - The pre-formed part is final-formed in a hot press according to the invention; and

[0087] - Output the final molded part from the fiber forming facility.

[0088] It should be clearly stated that, in order to improve readability, the use of the expression "at least" should be avoided as much as possible. To be precise, indefinite articles ("one", "two", etc.) should generally be understood as "at least one", "at least two", etc., unless the context indicates that "exactly" refers to the number written.

[0089] It should also be noted that, within the scope of this patent application, the expression "especially" is to be understood throughout as introducing optional preferred features. Therefore, the expression should not be construed as "indeed" or "that is".

[0090] It should be understood that, as needed, features of the solutions described above or in the claims can be combined to accumulate feasible advantages and effects. Attached Figure Description

[0091] Furthermore, other features, effects, and advantages of the invention will be illustrated with reference to the accompanying drawings and the following description. In the drawings, components that are at least substantially functionally corresponding are labeled with the same reference numerals; these components are not necessarily referenced and explained in all the drawings.

[0092] In the picture:

[0093] Figure 1 shows an embodiment of a suction head with female and male shapes before (a) molding and after (b) molding of the molded part;

[0094] Figure 2 shows an implementation scheme for a slurry storage tank containing slurry;

[0095] Figure 3 shows a side sectional view of an embodiment of the suction head according to the present invention;

[0096] Figure 4 shows a side sectional view of an embodiment of the suction mold according to the present invention;

[0097] Figure 5 shows (a) a top view of the suction side and (b) a transverse sectional view along section AB of another embodiment of the suction mold with modules according to the present invention.

[0098] Figure 6 illustrates an embodiment of the molding station and preforming station according to the present invention;

[0099] Figure 7 shows (a) a perspective view of the multi-purpose mold and (b) a cross-sectional view of the individual pre-compression lower mold in the multi-purpose mold according to an embodiment of the pre-compression lower mold of the present invention as a multi-purpose mold;

[0100] Figure 8 shows (a) a side view and (b) a perspective view of another embodiment of the hot press station according to the present invention;

[0101] Figure 9 shows a schematic diagram of the implementation scheme of the hot pressing lower mold and hot pressing upper mold of the hot pressing station in Figure 8 during hot pressing;

[0102] Figure 10 shows a schematic diagram of another embodiment of the hot pressing lower mold and hot pressing upper mold of the hot pressing station in Figure 8 during hot pressing;

[0103] Figure 11 illustrates an embodiment of the fiber forming facility according to the present invention;

[0104] Figure 12 shows a schematic diagram of an embodiment of the method according to the present invention. Detailed Implementation

[0105] Figure 1 shows an embodiment with male and female suction heads in a molding station 20 of a fiber molding facility 100 for molding parts 10 made of environmentally friendly biodegradable fiber material 11, (a) before molding and (b) after molding. Figure 6 fully depicts the molding station, but here only the suction mold 2 is used to draw the environmentally friendly biodegradable fiber material 11 for molding parts 10 from a reservoir 6 containing slurry 1 as the environmentally friendly biodegradable fiber material 11. The suction mold 2 includes a suction head 21 with a three-dimensional suction head side 21s. The shape of the suction head side 21s is adapted to the contours 10i, 10a of the subsequent molded part 10, and the molded part 10 is molded in the suction mold 2 by negative pressure on the suction head side 21s. The suction side 21s of the suction head 21 is formed by a porous screen 22. On its slurry side 22p facing the slurry 1, environmentally degradable fibers 11 are adhered by suction for molding the part 10 (see part 10 in FIG. 2c). For this purpose, the suction mold 2 includes a plurality of suction channels 23, which terminate at the suction side surface 23s below the screen 22 and are distributed on the suction side surface 23s such that substantially equal suction capacity is achieved in the entire area between the screen 22 and the suction side surface 23s. For this purpose, the suction channels 23 may have openings with a diameter of less than 4 mm on the suction side surface 23s. The cross-section of the suction channel 23 may have any suitable shape, for example, the cross-section may be circular or elliptical. Therefore, the suction channels 23 are unevenly distributed on the suction side surface 23s, wherein the number of suction channels per unit area in the negative edge region of the molded part 10 is reduced by 40%-60% compared to the flat surface and / or the number of suction channels 23 per unit area in the positive edge region is increased by 10%-30% compared to the flat surface. The suction head for molding the molded part can be only slightly immersed in the slurry 1, thereby forming a closed cavity in the inner side 21i of the suction head. In other embodiments, the suction head 21 can also be completely immersed in the slurry 1. The liquid solution of slurry 1 flowing through the screen 22 during molding 130 is discharged from the suction mold 2. For this purpose, the suction head 21 includes a collecting ring 24 on its end side 21p facing the slurry 1 for receiving the liquid solution of slurry 1 drawn through the suction side 21s of the suction head, the collecting ring 24 being connected to the drainage channel 25 of the liquid solution. The suction side 21s of the suction head 21 can be configured either as a female (left side of FIG. 1) as the inner side 21i or as a male (right side of FIG. 1) as the outer side 21a. In the female case, the molded part 10 (the gray inner layer in the suction head 21, left side of FIG. 1b) molded towards the inner side 21i of the suction head under suction pressure SD is placed on the pre-pressing mold 31 for pre-pressing, wherein the pressing surface 31a serves as the outer surface of the pre-pressing mold 31. In the male case, the suction head 21 is fully immersed in the slurry 1 for contact 120 to draw up the slurry 1 containing the fibrous material 11.Subsequently, the molded part 10 (the gray outer layer on the suction head 21, right side of FIG. 1b), which is molded by the suction pressure SD applied to the outer side 21a of the suction head, is placed into the pre-compression mold 31 for pre-compression. Its shape matches the male shape of the suction head 21, wherein the pressing surface 31 serves as the inner surface of the pre-compression mold 31. The suction head 21 also includes a gas pipeline system 27, which transmits the negative pressure provided to the suction head 21 as the suction pressure SD.

[0106] Figure 2 illustrates an embodiment of a slurry storage tank 6 containing slurry, wherein the environmentally friendly biodegradable fiber material 11 is indicated as “wave”. The slurry 1 may contain less than 5%, preferably less than 2%, and particularly preferably 0.5% to 1.0% of the environmentally friendly biodegradable fiber material 11 in a liquid solution (e.g., an aqueous solution). Advantageously, the slurry 1 does not contain any organic binders, and preferably does not contain any binders at all. The environmentally friendly biodegradable fiber material 11 may consist substantially of fibers with a fiber length of less than 5 mm. The slurry is provided at a temperature below or equal to 80°C, preferably below or equal to 50°C, and particularly preferably room temperature.

[0107] Figure 3 shows a side sectional view of an embodiment of the suction head 21 according to the invention, wherein the screen 22 has a corrugated structure with crests 22w and troughs 22t along the suction side surface 23s. During suction, the screen 22 is placed on the suction side surface 23s with the crest 22w of its side 22s facing the suction side surface 23s, thereby its shape is mechanically supported by the suction side surface 23s, thus preventing geometric changes in the screen 22 during molding and ensuring the shape accuracy of the subsequently molded part. The screen 22 is attached to the suction head 21 (shown below) by a reversible fastening device 28 (configured here as a clamping mechanism). Additionally or alternatively, the screen 22 may also be attached to at least some suction channels 23. Additionally, the fiber 11 is shown, for example, as a molded fiber material 11, such as the fiber material 11 molded on the screen 22, thereby molding the part as a whole by suction slurry.

[0108] Figure 4 shows a side sectional view of an embodiment of the suction mold 2 according to the present invention. Here, the suction mold 2 is a multi-purpose mold with a plurality of suction heads 21. These suction heads are arranged in a two-dimensional arrangement of four rows of five suction heads each on the suction side. In other embodiments, the multi-purpose mold 2 may also have suction heads 21 with different numbers of rows and columns. The suction mold 2 here includes a substrate 26 with suction heads 21 mounted thereon and a gas conduit system 27 in the substrate 26. The substrate 26 should not be understood here as a thin plate, but rather as the back structure of the suction mold 2 for connecting the moving unit 4 between the suction head 21 and the suction head 21. The gas conduit system 27 distributes the negative pressure provided by the vacuum pump 5 as the suction pressure SD to the suction head 21 for suctioning the fibrous material 11. The gas conduit system 27 here also includes a compressed gas conduit 27d for applying compressed air to the suction head 21 to, for example, release or output the molded or preformed part 11 from the suction head 21. Here, the gas piping system 27 for the negative pressure (suction pressure) of the molded part 11 includes one or more main gas lines 27h and auxiliary gas lines 27n. The main gas lines 27h are configured to generate a pre-negative pressure, and the auxiliary gas lines 27n are configured as a supplement to the main gas lines 27h to reach the suction pressure SD after the suction mold 21 contacts the slurry 1. Preferably, the main gas lines have a larger cross-section, while the auxiliary gas lines have a smaller cross-section. One or more valves 27v (two valves 27v in the main gas lines 27h are shown in the figure) are suitably arranged in the gas piping system 27 to cut off the suction pressure SD at the suction head 21 immediately after the suction mold leaves the slurry 1, and / or to connect the auxiliary gas lines to the main lines at least immediately after the suction mold 2 is immersed in the slurry 1. The multi-purpose mold 2 is connected to the moving unit 4 via an interface 4s by a robotic arm 4a, which includes all media supply ports for the suction mold 2. The moving unit 4 and the suction mold 2 are designed to eject the molded part 10 from the suction head 21 of the suction mold 2 by compressed air supplied by the compressed gas pipeline 27d and distributed to each suction head 21 via the substrate 26.

[0109] Figure 5 shows (a) a top view of the suction side and (b) a transverse sectional view along section AB of another embodiment of the suction mold 2 having modules 29 according to the present invention. The shapes of the suction heads 21 in the suction mold 2, which is a multi-purpose mold, can be at least partially different. Here, suction heads 21 of the same shape are arranged adjacent to each other in their respective individual modules 29 in the suction mold 2. For example, the first module 29 has four suction heads for making larger cups, the second module 29 has six suction heads for making smaller cups, the third module 29 has two suction heads for making smaller plates, and the fourth module 29 has one suction head for making larger plates.

[0110] Figure 6 illustrates an embodiment of the molding station 20 and preforming station 30 according to the present invention, wherein the molding station 20 is part of the preforming station 30. The molding station 20 includes a suction mold 2 (configured here as a multi-purpose mold) for drawing environmentally friendly biodegradable fiber material 11 from the storage tank 6 for molding 210 molded parts 10, wherein the slurry 1 is a liquid solution of the environmentally friendly biodegradable fiber material 11 (see Figures 1 to 5 for more details about the suction head). The molding station 20 also includes a moving unit 4 on which the suction mold 2 is mounted, and the suction mold 2 is at least placed on or partially immersed in the slurry 1. The preforming station 30 includes a reservoir 6 in which slurry 1, as a liquid solution of environmentally friendly biodegradable fiber material 11, is used to mold the part 10 in the suction mold 2. The reservoir 6 is arranged as an upward-opening horizontal reservoir. The preforming station 30 also includes a pre-pressing station 3 (configured here as a multi-purpose mold) for pre-pressing the part 10 that has been molded by the molding station 20 under pre-pressing pressure VD to reduce the proportion 10 of liquid solution in the part and stabilize the shape of the part 10. The preforming station 30 also includes a slurry pre-feeding unit 35 for feeding slurry 1 to the reservoir 6. In the slurry pre-feeding unit 35, the slurry is pre-mixed, for example, by solvent and fiber material 11, to finally form production slurry 1, which is fed into the reservoir and / or reused from the return flow from the suction mold 2 and / or the pre-pressing station 3. Here, the proportion of fiber material 11 must be adjusted back to the required proportion so that the production pump does not thin the fiber material 11 during operation. For this purpose, the slurry preparation and replenishment unit 35 includes one or more containers (two shown in the figure) for solvent and slurry mixing, and a reservoir for fiber material 11. The slurry preparation and replenishment unit 35 is therefore periodically, preferably continuously, filled into the reservoir 6 according to the slurry consumption of the molded part 10 to ensure the required filling level of the reservoir 6 for molding and the required proportion of fiber material 11 in the slurry 1. In this case, the pre-compression station 3 can be arranged relative to the reservoir 6 such that the liquid solution removed from the molded part by pre-compression is fed back into the reservoir 6. For this purpose, the pre-compression station 3 can be arranged vertically above the reservoir 6, so that the liquid solution removed from the molded part by pre-compression flows directly from the pre-compression station 3 back into the reservoir 6. The molding station 20 can also be connected to the pre-forming station 30 (not shown in the figure) via suitable piping, so that the liquid solution and / or fiber material 11 flowing through the suction head 21 are fed back into the slurry 1 via the pre-forming station 30 (here, by means of the slurry preparation and replenishment unit 35). The moving unit 4 here includes a robotic arm 4a that can move freely in space, on which the suction mold 2 is mounted. The robotic arm 4a is connected to the suction mold 2 via suitable interfaces 4s, including all media supply ports for the suction mold 2. Depending on the application and process, the moving unit 4 can be configured to fully immerse the suction head 21 in the slurry 1 for contact 120.The moving unit 4 is configured to transfer the molded part 10 from the suction mold 2 to the pre-pressing station 3 and the hot press station 40 of the pre-forming station 30, and eject it at the hot press station 40 for hot pressing. The moving unit 4 and the suction mold 2 are designed to leave the molded part 10 in the suction mold 2 for pre-pressing in the pre-pressing station 3. Thus, the pre-pressing is performed using the pre-pressing lower mold 31 and the suction mold 2 as the pre-pressing upper mold. Here, for example, by a hydraulically operated piston rod or by a robotic arm, the pre-pressing pressure can be applied to the molded part between the pre-pressing lower mold 31 and the suction mold 2. Pre-pressing can be performed at a temperature below 80°C, preferably below 50°C, and particularly preferably room temperature at the pre-pressing station 3, wherein the pre-pressing pressure VD is 0.2 N / mm. 2 Up to 0.3 N / mm 2 The preferred value is 0.23 N / mm. 2 Up to 0.27 N / mm 2 In an alternative embodiment, pre-pressing (pre-forming) can also be performed as membrane pressing (not shown) using a diaphragm 32 as a pre-pressing mold 31. The suction mold 2 is then placed in the correspondingly shaped pre-pressing mold 31 with the male-shaped suction head 21s. For membrane pressing 150, the diaphragm 32 is configured as a flexible diaphragm. The pre-pressing pressure VD is applied as gas pressure to the diaphragm 32, which is then pressed onto the outer contour of the molded part 10. As a result, pressure can also be applied to the surface of the molded part 10, which cannot be achieved hydraulically because the gas pressure applies the diaphragm to each surface with the same pressure, regardless of orientation. The moving unit 4 and the suction mold 2 are also designed to eject the molded part 10 from the suction mold 2 into a hot press station for subsequent hot pressing. This can be achieved, for example, by compressed air that ejects the molded part 10 from the suction head 21 of the suction mold 2.

[0111] Figure 7 shows (a) a perspective view of the multi-purpose mold and (b) a cross-sectional view of a single pre-compression die in the multi-purpose mold according to an embodiment of the pre-compression die as a multi-purpose mold (having several pre-compression dies 31 matched to the suction mold 2). The pre-compression die 31 is matched to the female shape of the suction head 21, so that the forming part 11 can be attached to the pre-compression die 31, such that the forming part 11 is arranged between the pre-compression die 31 and the suction mold 2, and the suction mold 2 can be pressed onto the pre-compression die 31 by a pre-compression pressure VD. Here, the pre-compression die 31 has a pressing surface 31a facing the forming part 10, which has a lower surface roughness than the screen 22 of the suction mold 2. The pre-compression die 31 can be made, for example, of metal or at least partially of an elastomer, preferably of silicone. In the embodiment shown in the figure, the pre-compression die 31 is partially made of an elastomer, in this case, silicone. In this configuration, the pre-compression die 31 has a cavity 33 surrounded by a wall 34 made of an elastomer serving as the pressing surface 31a. The pre-compression station 3 is designed to apply a gas pressure GD to the cavity 33 during pre-compression to generate a pre-compression pressure VD on the molded part 10 and the suction die 2, or at least support the pre-compression pressure applied by the suction die 2, with the gas pressure GD pointing in the opposite direction (see Figure 7b). In a multi-purpose die, each pre-compression die 31 is arranged on a common carrier plate 35, which is equipped with an interface to the pre-compression station 3 for reversibly fastening to the pre-compression station and / or supplying gas pressure to each pre-compression die 31. Here, the carrier plate 35 additionally has a heating element 36 extending flatly on the carrier plate 35 to heat the pre-compression die 31.

[0112] Figure 8 shows (a) a side view and (b) a perspective view of another embodiment of the hot press station 40 according to the present invention, which includes: a lower hot press die 41 matching the contour 10i of the molded part 10 for receiving the molded part 10; and a corresponding upper hot press die 42 matching the molded part 10 for being placed on or in the molded part 10 along the closing direction SR of the hot press station 40, wherein the lower hot press die 41 and the upper hot press die 42 apply a hot press pressure HD to the molded part 10 arranged between the lower hot press die 41 and the upper hot press die 42 during hot pressing. When the suction mold 2 is female, the lower hot press die 41 is also female (as shown), and is thus provided as an inner mold 40i in the hot press station 40, while the upper hot press die 42 is placed on the lower hot press die 41 as an outer mold 40a for hot pressing. When the suction mold 2 is male (not shown in the figure), the lower hot press mold is also male and is provided as the outer mold 40a, while the upper hot press mold 42 is placed as the inner mold 40i on the lower hot press mold 41 for hot pressing. The lower hot press mold 41 and the upper hot press mold 42 are both configured as complementary multi-purpose molds with several lower hot press molds 41 and upper hot press molds 42, arranged on corresponding carrier plates 45 of the respective lower hot press molds 41 and upper hot press molds 42. In this case, the carrier plate 45 is positioned in the hot press station 40 in a laterally movable manner (see Figure 8b) so that the corresponding lower hot press mold 41 and upper hot press mold 42 can be replaced as multi-purpose molds outside the process space of the hot press station 40. The carrier plate 45 of the multi-purpose hot press upper die 42 is equipped with gas lines to establish negative pressure in the respective hot press upper die 42 for holding the molded part 10 and / or overpressure for outputting the final molded part 10 from the hot press upper die 42 according to the process steps. This allows the final molded part 10 to be output from the hot press upper die 42 for further transfer, for example, to a conveyor belt 95 connected to the hot press station. For this purpose, the carrier plate 45 can be moved from the hot press position to the output position. An expansion mechanism 47 for compensating for thermal expansion effects is also arranged between the carrier plate 45 and the holding mechanism 46 for the carrier plate 45. Thermal insulation material 44 can be arranged between the carrier plate 45 and the holding mechanism 46, for example, see Figure 9.

[0113] Figure 9 shows a schematic diagram of an embodiment of the lower hot-pressing mold 41 and upper hot-pressing mold 42 of the hot-pressing station 40 in Figure 8 during hot pressing. Here, the lower hot-pressing mold 41 and the upper hot-pressing mold 42 are each heated by an electric heating cylinder 43 to the hot-pressing sides 41a and 42a facing the molded part 10. Here, the heating cylinder 43 in the lower hot-pressing mold 41 and the upper hot-pressing mold 42 is designed to heat the hot-pressing sides 41a and 42a to a temperature higher than 150°C, preferably 180°C to 250°C. Here, the heating cylinder 43 can be controlled so that the temperatures of the lower hot-pressing mold 41 and the upper hot-pressing mold 42 are different, wherein the temperature of the upper hot-pressing mold 42 can be higher than the temperature of the lower hot-pressing mold 41, preferably the temperature difference is at least 25°C, preferably the temperature difference is no more than 60°C, and particularly preferably the temperature difference is 50°C. For this purpose, the heating cylinder 43 is arranged close to the contour of the molded part 10 in the corresponding upper hot pressing die 42 and lower hot pressing die 41, which are made of metal. Here, a heating cylinder 43 with a first heating power is centrally arranged in the inner mold 40i parallel to the closing direction SR, while six heating cylinders 43 with a second heating power are concentrically arranged in the outer mold around the closing direction SR, parallel to the hot pressing sides 41a and 42a of the inner mold 40i, wherein the first heating power is greater than the second heating power. Here, the upper hot pressing die 42 also includes a heat insulation material cover 44 on the side facing away from the molded part 10.

[0114] Figure 10 shows a schematic diagram of another embodiment of the hot pressing lower die 41 and hot pressing upper die 42 of the hot pressing station 40 in Figure 8 during hot pressing. After pre-pressing, the pre-pressed molded part 10 is transferred to the hot pressing station 40 through the suction mold 2, thereby removing the molded part 10 from the suction mold 2 for subsequent hot pressing. The hot pressing station 40 includes a hot pressing lower die 41 and a hot pressing upper die 42 whose hot pressing side 41a matches the contour of the molded part 10, wherein, during the transfer, the molded part 10 is placed from the suction mold 2 onto the hot pressing lower die 41 (in this case, a female shape; in the case of a male shape, the molded part is placed into the hot pressing lower die). Then, during hot pressing, the hot pressing upper die 42 is pressed onto the hot pressing lower die 41, with the molded part 10 arranged between the two. Here, the hot pressing lower die 41 can be made of metal. The lower die 41 also includes channels 41k leading to its hot-pressing side 41a, through which liquid solution can be discharged at least partially from the molded part 10 during hot pressing. The diameter of these channels 41k, at least on the hot-pressing side, can be less than or equal to 1.0 mm. Here, the channels can have any suitable geometry as a cross-section. For example, the channels 41k have a circular or elliptical cross-section. The upper die 42 matches the contour of the molded part 10 at least on its side 42i facing the molded part; preferably, the upper die 42 is also made of metal. Different temperatures can be applied in the lower die 41 and the upper die 42 during hot pressing; preferably, the temperature of the upper die 42 is higher than that of the lower die 41, wherein the temperature difference is at least 25°C, preferably not more than 60°C, and particularly preferably 50°C. Hot pressing can be performed at temperatures above 150°C, preferably from 180°C to 250°C. Here, hot pressing is performed at a pressure HD higher than the pre-compression pressure VD. The hot pressing pressure HD can be 0.5 N / mm². 2 Up to 1.5 N / mm 2 The preferred value is 0.8 N / mm. 2 Up to 1.2 N / mm 2 The time for applying this hot pressure HD is less than 20 seconds or more than 8 seconds, particularly preferably 10 to 14 seconds, and more preferably 12 seconds.

[0115] Figure 11 illustrates an embodiment of a fiber molding facility 100 according to the present invention for manufacturing molded parts 10 made of environmentally friendly biodegradable fiber material 11. The fiber molding facility 100 includes a reservoir 6 for providing slurry 1 as a liquid solution of the environmentally friendly biodegradable fiber material 11, as part of a preforming station 30. In the molding station 20, a moving unit 4 is immersed in the slurry 1. A suction mold 2 attached to the moving unit 4 has a suction head 21 with a three-dimensional suction side 21s whose shape matches the contour of the subsequent molded part 10. Slurry is supplied by a slurry pre-feeding unit 35 and continuously replenished during operation. The moving unit 4 is configured here as a robot with a robotic arm 4a that can move freely in space. The robot 4 can perform precise, repeatable movements within a limited space, and is therefore particularly suitable for guiding the suction mold 2 between the slurry reservoir 6 and the pre-pressing station 30 of the preforming station 30. The suction mold 2 is connected to the robotic arm 4a via an interface 4s. This interface 4s allows for quick replacement of the suction mold 2 when necessary. The suction mold 2 is designed to mold the environmentally friendly biodegradable fiber material 11 onto the suction side 21s of the suction head using the suction pressure SD (negative pressure) in the suction mold 2. The pre-compression station 3 is configured to pre-compress the molded part 10 with a pre-compression pressure VD to reduce the proportion of liquid solution in the molded part 10 and stabilize its shape. The hot press station 40 extends with a hot press lower mold 41 (visible in the figure) to take the pre-molded part 10 from the suction mold 2 and hot presses the pre-compressed part 10 with a hot press pressure HD 150 to perform final molding of the part 10 and further reduce the proportion of liquid solution in the part 10. Then, the output unit 70 outputs the final molded part 10. To control the performed method, the fiber forming facility 100 includes a control unit 50 suitably connected to other components 20, 30, 35, 40, 60, 70, 80, and 90 of the fiber forming facility 100 to control these components, primarily the cutting unit 80 and / or the stacking unit 90 and / or the conveyor belt 95. In particular, the fiber forming facility 100 may additionally include a coating unit 60 for applying one or more functional layers to the formed part 10.

[0116] Figure 12 shows a schematic diagram of an embodiment of a method 200 according to the invention for manufacturing a molded part 10 made of environmentally friendly biodegradable fiber material 11 by a fiber molding process in a fiber molding facility according to the invention. The method 200 includes the following steps: molding a molded part from a reservoir 6 containing a liquid solution of slurry 1 as environmentally friendly biodegradable fiber material 11 in a molding station 20 according to the invention; pre-molding the molded part 10 in a pre-molding station 30 according to the invention 220; final molding the pre-molded part 10 in a hot press station 40 according to the invention 230; and outputting the final molded part 10 from the fiber molding facility 100 according to the invention 240.

[0117] In this regard, it is explicitly stated that, as needed, features of the solutions in the foregoing or claims and / or figures can be combined to accumulate or achieve the aforementioned features, effects and advantages.

[0118] It is understood that the above embodiments are only the first technical solution of the present invention, but the technical solution of the present invention is not limited to this embodiment.

[0119] List of reference numerals

[0120] 1. Slurry

[0121] 11 Environmentally friendly and biodegradable fiber materials

[0122] 2. Suction mold

[0123] 21 suction heads

[0124] 21a Outside of the suction head

[0125] 21i inner side of the suction head

[0126] 21p suction head facing the slurry end.

[0127] 21s suction head suction side

[0128] 22-hole suction head screen

[0129] 22p Screen side facing the slurry (slurry side)

[0130] 22s Facing the suction side surface, 23s Screen side

[0131] 22W screen side peak at 22s

[0132] 22t screen trough

[0133] 23 Suction channel in the suction head

[0134] 23s suction head suctions side surface

[0135] 24. The collector ring in the suction head

[0136] 25. Drainage channel for liquid solution

[0137] 26 Suction mold base plate

[0138] 27 Gas piping system in the substrate

[0139] 27d Compressed gas pipeline in the gas pipeline system

[0140] 27h main gas pipeline in the gas pipeline system

[0141] 27n Auxiliary gas pipeline in gas pipeline system

[0142] Valves in a 27V gas pipeline system

[0143] 28. Reversible fastening mechanism for the screen, such as a clamping mechanism.

[0144] 29 Suction Head Module

[0145] 3 Preloading Station

[0146] 31 Pre-compression lower mold

[0147] 31a Pre-pressed lower die pressing surface

[0148] 33 Pre-compression lower mold cavity

[0149] 34. Wall as the pre-pressing surface of the die.

[0150] 35 carrier board

[0151] 36. Heating element of the carrier plate

[0152] 4 moving units

[0153] 4a A robotic arm that can move freely in space

[0154] 4s interface

[0155] 41 Hot pressing lower mold of hot press station

[0156] 41a The hot-pressing side of the lower die, for example, the outer side.

[0157] 41k hot press mold channel

[0158] 42 Hot pressing upper mold of hot press station

[0159] 42a Hot pressing side of the upper die, for example, the inner side

[0160] 43 Heating cylinder

[0161] 44. Heat shield or heat insulation material

[0162] 45 Carrier plate for hot press lower mold and hot press upper mold, both configured as multi-purpose molds

[0163] 46. ​​Maintenance mechanism

[0164] 47 Expansion Mechanism

[0165] 5 Vacuum pumps

[0166] 6. Slurry storage tank

[0167] 10 Molded parts made of environmentally friendly biodegradable fiber materials

[0168] 10a Inner contour (inner side) of the molded part

[0169] 10i Outer contour (outer side) of the molded part

[0170] 20 molding stations

[0171] 30 Preforming Stations

[0172] 35 Slurry Preparation and Feeding Unit

[0173] 40 Hot Press Station

[0174] 40i inner mold

[0175] 40a outer mold

[0176] 50 Controller Units

[0177] 60 Coating Units

[0178] 70 Output Unit

[0179] 80 cutting units

[0180] 90 stacked units

[0181] 95 Conveyor Belt

[0182] 100 Fiber Molding Facilities

[0183] 200 Method for manufacturing molded parts made of environmentally friendly and biodegradable fiber materials by fiber molding process in fiber molding facility

[0184] 210 Molding part in the molding station according to the invention

[0185] 220 Preforming the part in the preforming station according to the invention.

[0186] 230 The molded part is finally formed in the hot press station according to the invention.

[0187] 240 Output the final molded part from the fiber forming facility

[0188] AB Section lines in Figure 5

[0189] DG gas pressure

[0190] HD Hot Pressing Pressure

[0191] SD suction pressure (slurry to suction head)

[0192] The closing direction (pressing direction) of the SR hot press station.

[0193] VD preload pressure

Claims

1. A preforming station (30) of a fiber forming facility (100) for preforming (220) a molded part made of environmentally friendly biodegradable fiber material (11) for subsequent hot pressing in a hot pressing station (40) during a fiber forming process, said preforming station (30) comprising: The storage tank (6) contains a slurry (1) as a liquid solution of an environmentally friendly biodegradable fiber material (11) for molding the molded part (10); as well as A pre-compression station (3) is used to pre-form (220) a molded part (10) molded by a suction mold (2) through a molding station (20) at a pre-compression pressure (VD) (220) to reduce the proportion of liquid solution in the molded part (10) and stabilize the shape of the molded part (10). The pre-compression station (3) is configured as a multi-purpose mold structure with multiple pre-compression lower molds (31) matched to the suction mold (2) as a multi-purpose mold, wherein the suction mold presses against the stationary pre-compression lower mold, and The preforming station (30) is separate from the subsequent hot pressing station (40). The pre-compression station (3) includes a pre-compression lower mold (31), and pre-compression (140) is performed as membrane pressure. The pre-compression lower mold (31) is configured as a flexible diaphragm. The pre-compression pressure (VD) is applied to the diaphragm as gas pressure, and then the diaphragm is pressed onto the outer contour (10a) or inner contour (10i) of the molded part (10). The suction mold (2) includes a suction head (21), which has a suction side (21s). The suction side (21s) is formed by a porous screen (22) on the suction side surface (23s) of the suction head (21). The porous screen (22) has a wavy structure and has a crest (22w) and a trough (22t) along the suction side surface (23s). The porous screen (22) abuts against the suction side surface (23s) at least during suction with the crest (22w) of the side (22s) facing the suction side surface (23s).

2. The preforming station (30) according to claim 1. Its features are, The preforming station (30) also includes a slurry preparation and feeding unit for feeding the slurry (1) to the storage tank (6).

3. The preforming station (30) according to claim 2. Its features are, The slurry preparation and replenishment unit periodically fills the reservoir (6) at least according to the slurry consumption during molding the molded part (10) to ensure the required filling level of the reservoir (6) for molding.

4. The preforming station (30) according to claim 3. Its features are, The pre-compression station (3) is arranged relative to the storage tank (6) such that the liquid solution removed from the molded part by pre-compression is fed back into the storage tank (6).

5. The preforming station (30) according to claim 4. Its features are, The pre-compression station (3) is arranged vertically above the storage tank (6), so that the liquid solution removed from the molded part by pre-compression flows directly from the pre-compression station (3) back to the storage tank (6).

6. The preforming station (30) according to any one of claims 1 to 5. Its features are, The shape of the pre-compression lower mold (31) matches the molded part (10) retained in the suction mold (2) so that it can be attached to the pre-compression lower mold, such that the molded part (10) is arranged between the pre-compression lower mold (31) and the suction mold (2), thereby enabling the suction mold (2) to be pressed onto the pre-compression lower mold (31) by pre-compression pressure (VD).

7. The preforming station (30) according to claim 6. Its features are, The pre-pressing die (31) has a pressing surface (31a) facing the molded part (10), and its surface roughness is lower than that of the porous screen (22) of the suction die (2).

8. The preforming station (30) according to claim 7. Its features are, The pre-compression mold (31) is made of metal or at least partially of an elastomer.

9. The preforming station (30) according to claim 8. Its features are, The pre-compression lower mold (31) has a cavity (33) surrounded by a wall (34) made of an elastomer serving as the pressing surface (31a), wherein the pre-compression station (3) is designed to apply a gas pressure (GD) to the cavity (33) during pre-compression to generate or at least support the pre-compression pressure (VD).

10. The preforming station (30) according to claim 1. Its features are, The pre-compression molds (31) are arranged on a common carrier plate, which is equipped with an interface to the pre-compression station (3) for reversibly fastening to the pre-compression station and / or supplying gas pressure to each pre-compression mold (31).

11. The preforming station (30) according to claim 10. Its features are, The carrier plate additionally includes a heating element (36) for heating the pre-pressed lower mold.

12. The preforming station (30) according to claim 1. Its features are, The molding station (20) is part of the preforming station (30).

13. The preforming station (30) according to claim 12. Its features are, The molding station (20) is connected to the preforming station (30) via a suitable pipeline, so that the liquid solution and / or environmentally friendly biodegradable fiber material (11) flowing through the suction head (21) are fed into the slurry (1) via the preforming station (30).

14. A hot press station (40) of a fiber forming facility (100) for final forming (230) of a molded part made of an environmentally friendly biodegradable fiber material (11) in a fiber forming process, comprising: A lower hot press die (41) that matches the inner contour (10i) of the molded part (10) is used to receive the molded part (10); and a corresponding upper hot press die (42) that matches the molded part (10) is used to be placed on or in the molded part (10) along the closing direction (SR) of the hot press station (40), wherein the lower hot press die (41) and / or the upper hot press die (42) are configured to apply hot pressing pressure (HD) to the molded part (10) arranged between the lower hot press die (41) and the upper hot press die (42) during hot pressing. The lower hot-pressing mold (41) and the upper hot-pressing mold (42) are respectively configured as multi-purpose molds having multiple lower hot-pressing molds (41) and multiple upper hot-pressing molds (42), and the multiple lower hot-pressing molds (41) and the multiple upper hot-pressing molds (42) are respectively arranged on their respective support plates (45) for the lower hot-pressing molds (41) and the upper hot-pressing molds (42). The hot press station (40) is configured to hot press the molded part preformed by the preforming station (30) according to any one of claims 1-13 in the fiber forming process.

15. The thermal press station (40) according to claim 14. Its features are, When the suction mold (2) is female, the lower hot press mold (41) is also female and is provided as an inner mold (40i), while the upper hot press mold (42) is placed on the lower hot press mold (41) as an outer mold (40a) for hot pressing. When the suction mold (2) is male, the lower hot press mold (41) is also male and is provided as an outer mold (40a), while the upper hot press mold (42) is placed on the lower hot press mold (41) as an inner mold (40i) for hot pressing.

16. The thermal press station (40) according to claim 15. Its features are, The lower hot press die (41) and the upper hot press die (42) are heated by an electric heating cylinder (43) on their respective hot press sides (41a, 42a) facing the molded part (10).

17. The thermal press station (40) according to claim 16. Its features are, The electric heating cylinder (43) in the lower hot pressing mold (41) and the upper hot pressing mold (42) is designed to heat the hot pressing sides (41a, 42a) to a temperature higher than 150°C.

18. The thermal press station (40) according to claim 17. Its features are, The electric heating cylinder (43) is controlled to make the temperature of the lower hot pressing mold (41) different from that of the upper hot pressing mold (42).

19. The thermal press station (40) according to claim 18. Its features are, The temperature of the upper hot-pressing mold (42) is higher than that of the lower hot-pressing mold (41), wherein the temperature difference between the upper hot-pressing mold (42) and the lower hot-pressing mold (41) is at least 25°C.

20. The thermal press (40) according to any one of claims 16 to 19. Its features are, The electric heating cylinder (43) is arranged close to the inner and outer contours of the molded part (10) in the corresponding hot pressing upper mold (42) and hot pressing lower mold (41).

21. The thermal press station (40) according to claim 20. Its features are, The inner mold (40i) is provided with at least one electric heating cylinder (43) with a first heating power, while the outer mold (40a) is provided with a plurality of electric heating cylinders (43) with a second heating power around the hot pressing side (41a, 42a) of the outer mold, wherein the first heating power is greater than the second heating power.

22. The thermal press station (40) according to claim 21. Its features are, In the case where there is a single electric heating cylinder (43) in the inner mold (40i), this electric heating cylinder (43) is centrally arranged in the inner mold (40i) parallel to the closing direction (SR), and / or In the case where there are multiple electric heating cylinders (43) in the inner mold (40i), these electric heating cylinders (43) are arranged concentrically around the closing direction (SR) parallel to the hot pressing side (41a, 42a) of the inner mold (40i).

23. The thermal press station (40) according to any one of claims 21 to 22. Its features are, In the outer mold (40a), a plurality of electric heating cylinders (43) are arranged concentrically around the hot pressing side (41a, 42a) of the outer mold (40a) parallel to the closing direction (SR).

24. The thermal press station (40) according to claim 14. Its features are, The lower hot press die (41) and / or the upper hot press die (42) include a heat-insulating material cover on the side opposite to the molded part (10).

25. The thermal press station (40) according to claim 14. Its features are, The hot-pressing die (41) includes a plurality of channels (41k) on its hot-pressing side, through which liquid solution can be at least partially discharged from the molded part (10) during hot pressing.

26. The thermal press station (40) according to claim 25. Its features are, The diameter of the channel (41k) on at least the hot-pressed side is less than or equal to 1.0 mm.

27. The thermal press station (40) according to claim 14. Its features are, The support plate (45) is placed in the hot press station (40) in a laterally movable manner so that the corresponding hot press lower mold (41) and hot press upper mold (42) can be replaced outside the process space of the hot press station (40) as a multi-purpose mold.

28. The thermal press station (40) according to claim 14. Its features are, The support plate (45) of the hot press upper mold (42) of the multi-purpose mold is equipped with a gas pipeline to establish, according to the process steps, a negative pressure for maintaining the molded part (10) and / or an overpressure for outputting the final molded part (10) from the hot press upper mold (42).

29. The thermal press station (40) according to claim 28. Its features are, An expansion mechanism (47) is arranged between the support plate (45) and the holding mechanism (46) for the support plate (45).

30. The thermal press station (40) according to claim 29. Its features are, A heat-insulating material is arranged between the support plate (45) and the retaining mechanism (46).

31. A fiber forming facility (100), comprising: At least one molding station (20) downstream of a fiber forming facility (100), the molding station (20) being used to mold (210) a molded part (10) made of an environmentally friendly biodegradable fiber material (11) in a fiber forming process, the molding station (20) comprising: A suction mold (2) is used to draw environmentally friendly biodegradable fiber material (11) for molding (210) the molded part (10) from a reservoir (6) containing slurry (1), wherein the slurry (1) is a liquid solution containing environmentally friendly biodegradable fiber material (11), wherein the suction mold (2) includes a suction head (21) having a three-dimensional suction head side (21s) whose shape is adapted to the inner or outer contour of the subsequent molded part (10), and the molded part (10) is molded in the suction mold (2) by negative pressure on the suction head side (21s); A movable unit (4) on which a suction mold (2) is mounted is configured to place the suction mold (2) on or in the slurry (1) or to partially immerse the suction mold (2) on or in the slurry (1); A preforming station (30) for a fiber forming facility (100) is used to preform (220) a molded part made of environmentally friendly biodegradable fiber material (11) in a fiber forming process. The preforming station (30) includes a storage tank (6) with slurry (1) as a liquid solution of the environmentally friendly biodegradable fiber material (11) for molding the molded part (10). A pre-compression station (3) is used to pre-form (220) a molded part (10) formed by a suction mold (2) under pre-compression pressure (VD) through a molding station (20), thereby reducing the proportion of liquid solution in the molded part (10) and stabilizing the shape of the molded part (10); and The hot press station (40) according to any one of claims 14 to 30 is used to produce molded parts made of environmentally friendly biodegradable fiber material (11) by means of a fiber forming process carried out in a fiber forming facility (100).

32. The fiber forming facility (100) according to claim 31. Its features are, The fiber forming facility (100) includes a control unit (50) for controlling at least the molding station (20), the preforming station (30) and the hot pressing station (40) and their sub-components (2, 3, 4, 5, 6).

33. The fiber forming facility (100) according to claim 31. Its features are, The fiber forming facility (100) additionally includes a coating unit (60) for applying one or more functional layers to the formed part (10).

34. The fiber forming facility (100) according to claim 31. Its features are, The fiber forming facility (100) further includes an output unit (70) for outputting the final formed part (10), and the forming facility further includes at least one cutting unit (80) and / or stacking unit (90) and / or conveyor belt (95) for the formed part (10).

35. A fiber forming facility (100), comprising: At least one molding station (20) for a fiber forming facility (100), the molding station (20) being used to mold (210) a molded part (10) made of an environmentally friendly biodegradable fiber material (11) during the fiber forming process, the molding station (20) comprising: A suction mold (2) is used to draw environmentally friendly biodegradable fiber material (11) from a storage tank (6) containing slurry (1) to mold (210) the molded part (10), wherein the slurry (1) is a liquid solution of the environmentally friendly biodegradable fiber material (11). The suction mold (2) has a suction head (21) with a three-dimensional suction head side (21s) whose shape is adapted to the inner or outer contour of the subsequent molded part (10). The molded part (10) is molded in the suction mold (2) by negative pressure on the suction head side (21s). A moving unit (4) on which the suction mold (2) is mounted, the moving unit (4) being configured to at least place the suction mold (2) on or in the slurry (1) or to partially immerse the suction mold (2) on or in the slurry (1). The preforming station (30) according to any one of claims 1 to 13, and A hot press station (40) for a fiber forming facility (100), the hot press station (40) being used for final forming (230) of a molded part (10) made of an environmentally friendly biodegradable fiber material (11), the hot press station (40) including a lower hot press die (41) adapted to accommodate the molded part (10) matching the inner contour (10i) of the molded part (10) and an upper hot press die (42) adapted to accommodate the molded part (10), the upper hot press die (42) being used for aligning the molded part (10) along the hot press station (230). The closed direction (SR) of the molded part (10) is placed or inserted into the molded part (10), wherein the hot press lower die (41) and / or the hot press upper die (42) are used to apply hot press pressure (HD) to the molded part (10) arranged between the hot press lower die (41) and the hot press upper die (42) during hot pressing, thereby producing a molded part (10) made of environmentally friendly biodegradable fiber material (11) in a fiber forming process performed in the fiber forming facility (100).

36. The fiber forming facility (100) according to claim 35. Its features are, The fiber forming facility (100) includes a control unit (50) for controlling at least the molding station (20), the preforming station (30) and the hot pressing station (40) and their sub-components (2, 3, 4, 5, 6).

37. The fiber forming facility (100) according to claim 35. Its features are, The fiber forming facility (100) additionally includes a coating unit (60) for applying one or more functional layers to the formed part (10).

38. The fiber forming facility (100) according to claim 35. Its features are, The fiber forming facility (100) further includes an output unit (70) for outputting the final formed part (10), and the forming facility further includes at least one cutting unit (80) and / or stacking unit (90) and / or conveyor belt (95) for the formed part (10).

39. A method (200) for manufacturing a molded part (10) made of environmentally friendly biodegradable fiber material (11) by fiber molding process in a fiber molding facility (100) according to claim 35, comprising the following steps: The molding part (10) is molded (210) in a molding station (20) for molding the part (10) using environmentally friendly biodegradable fiber material (11) in a fiber molding process. The molding station (20) includes a suction mold (2) for suctioning the environmentally friendly biodegradable fiber material (11) from a reservoir (6) containing slurry (1) for molding the part (10) (210). The slurry (1) is a liquid solution containing the environmentally friendly biodegradable fiber material (11). The suction mold (2) includes a suction head (21) having... A three-dimensional suction head suction side (21s), the shape of which is adapted to the inner or outer contour of the subsequent molded part (10), and the molded part (10) is molded in the suction mold (2) by negative pressure on the suction head suction side (21s); and the molding station (20) includes a moving unit (4), on which the suction mold (2) is mounted, the moving unit being configured to at least place the suction mold (2) on or partially immerse it in a slurry (1) from a reservoir (6) as a liquid solution of an environmentally friendly biodegradable fiber material (11); In any one of the preforming stations (30) according to claims 1 to 13, a plurality of pre-molded parts (10) are pre-molded (220) simultaneously; In a hot press station (40) of a fiber molding facility (100), a pre-formed part (10) is final-formed (230), wherein the hot press station (40) is used to final-form (230) a part made of environmentally friendly biodegradable fiber material (11) during the fiber molding process, the hot press station (40) includes a hot press die (41) adapted to the inner contour (10i) of the part (10) for receiving the part (10), and the... The hot press station (40) includes a hot press upper die (42) suitably adapted to the molded part (10), the hot press upper die (42) being positioned on or within the molded part (10) along the closing direction (SR) of the hot press station (40), wherein the hot press lower die (41) and / or the hot press upper die (42) are configured to apply hot pressing pressure (HD) to the molded part (10) arranged between the hot press lower die (41) and the hot press upper die (42) during hot pressing; and The final molded part (10) is output (240) from the fiber forming facility (100).

40. A method (200) for manufacturing a molded part (10) from an environmentally friendly biodegradable fiber material (11) by a fiber forming process in a fiber forming facility (100) according to claim 31, comprising the following steps: Molding (210) of a part is formed in a molding station (20) of a fiber forming facility (100), the molding station (20) being used to mold (210) a part (10) made of environmentally friendly biodegradable fiber material (11) during the fiber forming process, the molding station (20) including a suction mold (2) for suctioning environmentally friendly biodegradable fiber material (11) from a storage tank (6) containing slurry (1) for molding (210) the part (10), the slurry (1) being a liquid solution of the environmentally friendly biodegradable fiber material (11), the suction mold (2) having a suction head (21) having a three-dimensional shape. The suction head suction side (21s) is adapted to the inner or outer contour of the subsequent molded part (10) and the molded part (10) is molded in the suction mold (2) by negative pressure on the suction head suction side (21s), and the molding station (20) includes a moving unit (4) on which the suction mold (2) is mounted, the moving unit being configured to at least place the suction mold (2) on or in the slurry (1) of the liquid solution of the environmentally friendly biodegradable fiber material (11) contained in the reservoir (6) or to partially immerse the suction mold (2) on or in the slurry (1); In a preforming station (30) for a fiber forming facility (100), a molded part (10) is preformed (220). The preforming station (30) is used to preform (220) a molded part made of environmentally friendly biodegradable fiber material (11) during the fiber forming process. The preforming station (30) includes a reservoir (6) for molding the molded part (10) with a slurry (1) as a liquid solution. The preforming station (30) includes a pre-pressing station (3) for preforming (220) the molded part (10) molded by the molding station (20) with a pre-pressing pressure (VD) by a suction mold (2) to reduce the proportion of liquid solution in the molded part (10) and stabilize the shape of the molded part (10). In any one of the hot press station (40) according to claims 14 to 30, multiple pre-formed molded parts (10) are simultaneously subjected to final forming (230); and The final molded part (10) is output (240) from the fiber forming facility (100).

Images