Method for forming a cellulose product from a cellulose blank structure in a forming die system, forming die system and cellulose blank structure

Abstract

A method for forming a cellulose product from an air-formed cellulose blank structure (2) in a forming die system, wherein the forming die system comprises one or more forming dies (3). Each forming die comprises a first die part (3a) and a second die part (3b) which are configured to cooperate with each other during forming of the cellulose product. The method comprises the following steps: providing a cellulose blank structure, and defining one or more product segments (2a) and residual segments (2b) arranged around the one or more product segments or connected to the one or more product segments in the cellulose blank structure; compressing at least a portion of the residual segments to a first compression degree that is higher than the compression degree of the one or more product segments; feeding the cellulose blank structure along a feed direction to a forming position in a forming mold system, wherein in the forming position, each product segment is arranged between a corresponding first mold part and a second mold part; forming a cellulose product from the cellulose blank structure between the first mold part and the second mold part by heating the cellulose blank structure to a forming temperature in the range of 100-300°C; and pressing the cellulose blank structure with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.

Description

Technical Field

[0001] The present disclosure relates to a method for forming a cellulose product from an air-formed cellulose blank structure in a forming die system. The forming die system includes one or more forming dies, each of which includes a first die part and a second die part configured to cooperate with each other during the forming of the cellulose product. The present disclosure also relates to the forming die system and the cellulose blank structure. Background Art

[0002] Cellulose fibers are often used as a raw material in the production or manufacture of products. Products made from cellulose fibers can be used in many different applications where sustainable products are needed. Cellulose fibers can be used to produce a variety of products, such as disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.

[0003] When manufacturing cellulose products from raw materials containing cellulose fibers, forming molds are typically used, and cellulose products have traditionally been produced using wet forming techniques. A common material used for wet-formed cellulose fiber products is wet-molded pulp. Wet-molded pulp has the advantage of being considered a sustainable packaging material, as it is made from biomass and can be recycled after use. Consequently, wet-molded pulp has rapidly gained popularity in a variety of applications. Wet-molded pulp products are typically formed by immersing a suction forming mold into a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers. When suction is applied, the bulk of the pulp is deposited onto the forming mold through the fibers, forming the desired product shape. All wet-forming techniques require drying the wet-molded product, which is a very time-consuming and energy-intensive process. Demands on the aesthetic, chemical, and mechanical properties of cellulose products are increasing, and due to the properties of wet-formed cellulose products, mechanical strength, flexibility, material thickness, and chemical properties are limited. High-precision control of the product's mechanical properties is also difficult in wet-forming processes.

[0004] A development in the field of producing cellulose products is the formation of cellulose fibers without the use of wet forming techniques. Instead of forming the cellulose product from a liquid or semi-liquid pulp suspension or slurry, an air-formed cellulose blank structure is used. The air-formed cellulose blank structure is inserted into a forming die, and during the forming process of the cellulose product, the cellulose blank is subjected to high forming pressures and high forming temperatures. When the cellulose blank structure is inserted into the forming die, there is a risk that the cellulose blank structure breaks in an undesirable manner, which leads to improper forming of the cellulose product. This is a common problem with conventional cellulose high-pressure forming methods, in particular for deep-drawn products, resulting in low product quality. Another problem with conventional forming methods using standard cellulose blank structures, in particular when forming deep-drawn products, is the occurrence of cracks, fiber separation, material breakage or other undesirable structural weakening of the cellulose blank structure during the insertion of the cellulose blank structure into the forming die and during the forming process in the forming die.

[0005] Therefore, there is a need for an improved method, forming die system, and cellulosic blank structure for forming a cellulosic product from an air-formed cellulosic blank structure. Summary of the Invention

[0006] One object of the present disclosure is to provide a method for forming a cellulose product from a cellulose blank structure in a forming die system, a forming die system, and a cellulose blank structure, wherein the aforementioned problems are avoided. This object is achieved at least in part by the features of the independent claims. The dependent claims contain further developments of the method for forming a cellulose product from a cellulose blank structure in a forming die system.

[0007] The present disclosure relates to a method for forming a cellulose product from an air-formed cellulose blank structure in a forming die system. The forming die system includes one or more forming dies, wherein each forming die includes a first die part and a second die part, which are configured to cooperate with each other during the forming process of the cellulose product. The method includes the following steps: providing a cellulose blank structure, and defining one or more product segments and a residual segment arranged around or connected to the one or more product segments in the cellulose blank structure; compressing at least a portion of the residual segment to a first compression level that is higher than the compression level of the one or more product segments; feeding the cellulose blank structure along a feed direction to a forming position in the forming die system, wherein in the forming position, each product segment is arranged between the corresponding first die part and the second die part; forming the cellulose product from the cellulose blank structure between the first die part and the second die part by heating the cellulose blank structure to a forming temperature in the range of 100-300°C; and pressing the cellulose blank structure with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.

[0008] The advantage of these features is that the risk of the cellulose blank structure breaking in an undesirable manner is prevented when it is conveyed and inserted into the forming die. This solution allows for better forming of cellulose products and improved product quality, in particular for deep-drawn products. When the cellulose blank structure is inserted into the forming die and during the forming process in the forming die, the method minimizes cracks, fiber separation, material breakage or other undesirable structural weakening of the cellulose blank structure by forming the product segments and the residual segments. In the case where the residual segments are compressed to a first degree of compression that is higher than the degree of compression of one or more product segments, the conveying of the cellulose blank structure is simplified, and the residual segments pass through a higher degree of compression, thereby allowing the cellulose blank structure to be conveyed at a higher feed speed without damaging the structure. The less compressed product segments allow flexible fibers to be conveyed into the forming die. The higher feed speed reduces the product forming cycle time.

[0009] According to one aspect of the present disclosure, the cellulose blank structure further includes one or more transition sections disposed between one or more product sections and a residual section. In the one or more transition sections, the degree of compression varies between a first degree of compression and the degree of compression of the one or more product sections. The transition sections support the fiber feed into the forming die. The transition sections further prevent fiber breakage in the cellulose blank structure between the product section and the residual section.

[0010] According to another aspect of the present disclosure, the method further comprises the step of compressing at least a portion of the one or more product segments to a second degree of compression before feeding the cellulosic blank structure to the forming position, wherein the first degree of compression is higher than the second degree of compression. The second degree of compression may be different for different types of products being formed, with deeper drawn products generally requiring a lower degree of compression.

[0011] According to one aspect of the present disclosure, the method further comprises the step of: at a forming position, prior to forming the cellulose product, at least partially displacing the residual segment and one or more product segments relative to one another in a pressing direction of the forming die system. This displacement facilitates the forming of the cellulose product, in particular deep-drawn products, by allowing fibers in the cellulose blank structure to be displaced relative to one another.

[0012] According to another aspect of the present disclosure, the method further comprises the step of arranging a cutting pattern in the stub and / or transition section at least partially surrounding each product segment. Each cutting pattern forms at least one bridging structure in the stub and / or transition section for maintaining each product segment partially connected to the stub and / or transition section. The cutting pattern supports the forming of the cellulosic product by allowing the product segment to be more spaced relative to the rest of the cellulosic blank structure. The bridging structure effectively holds the product segment in place relative to the forming die during the product forming operation.

[0013] According to another aspect of the present disclosure, each cutting pattern includes a discontinuous first cut arranged around and connecting a corresponding product segment. The discontinuous first cut includes one or more first cutting lines with one or more first intermediate segments between the one or more first cutting lines. The one or more first intermediate segments form at least one bridging structure. This cutting pattern is simple in design.

[0014] According to one aspect of the present disclosure, each cutting pattern comprises a first cut arranged around and connected to a corresponding product segment. The first cut comprises a first cutting line, wherein the first intermediate segment forms at least one bridge structure.

[0015] According to another aspect of the present disclosure, each cutting pattern includes a non-continuous first cut arranged around and connected to a corresponding product section, and a non-continuous second cut arranged around and outside the non-continuous first cut relative to the product section. The first cut and the second cut effectively cooperate to form at least one bridge structure.

[0016] According to another aspect of the present disclosure, a discontinuous first cut comprises one or more first cut lines with one or more first intermediate segments between the one or more first cut lines. A discontinuous second cut comprises one or more second cut lines with one or more second intermediate segments between the one or more second cut lines. The one or more first intermediate segments and the one or more second intermediate segments form at least one bridge structure. This type of cut pattern effectively allows for displacement of the product segments relative to the remainder of the cellulose blank structure during the product forming operation and is suitable for deep-drawing products.

[0017] According to one aspect of the present disclosure, the non-continuous first cut and the non-continuous second cut are arranged in an overlapping relationship relative to each other. One or more first cut lines overlap with one or more second intermediate sections, and one or more second cut lines overlap with one or more first intermediate sections.

[0018] According to another aspect of the present disclosure, each cutting pattern further includes at least one non-continuous additional cut, arranged around and outside the non-continuous second cut relative to the product segment. Each of the at least one non-continuous additional cut includes one or more additional cutting lines with one or more additional intermediate segments between the one or more additional cutting lines. This type of cutting pattern effectively allows for displacement of the product segment relative to the remainder of the cellulose blank structure during the product forming operation and is suitable for deep-drawing products.

[0019] According to another aspect of the present disclosure, each cut extends through the cellulose blank structure. In this way, each cut forms an opening in the cellulose blank structure for efficient displacement of the product section.

[0020] According to one aspect of the present disclosure, at least one intermediate section comprises a cutout extending partially through the cellulose blank structure. The partially extending cutout can support positioning of the product section relative to the forming die during transport of the cellulose blank structure.

[0021] According to another aspect of the present disclosure, the method further comprises the step of arranging one or more cutting patterns in the residual segment and / or transition segment around each product segment using a cutting unit. The cutting unit is used to form the cutting pattern and can have different configurations, such as a rotary die cutter or a punch cutting device.

[0022] According to another aspect of the present disclosure, the cutting unit is configured as a rotary die cutter. The method further comprises the steps of: forming one or more cutting patterns and compressing at least a portion of the residual segment with the rotary die cutter in a single operation step; or forming one or more cutting patterns, compressing at least a portion of the residual segment, and compressing at least a portion of one or more product segments with the rotary die cutter in a single operation step.

[0023] According to one aspect of the present disclosure, the method further comprises the step of cutting the cellulose product from the cellulose blank structure in the forming die system during the forming process of the cellulose product. With this method, the cellulose product can be cut from the cellulose blank structure directly connected to the forming die when the cellulose blank structure is arranged in the forming position.

[0024] According to another aspect of the present disclosure, the product sections are arranged in the cellulosic blank structure in a pattern corresponding to the arrangement of one or more forming dies in the forming die system.

[0025] The cellulose blank structure can be transported in the feed direction by one or more feed belts. The feed belts provide an efficient and simple way of transporting the cellulose blank structure.

[0026] The present disclosure also relates to a forming die system for forming a cellulose product from an air-formed cellulose blank structure. The cellulose blank structure includes one or more defined product segments and a defined residual segment arranged around or connected to the one or more product segments. The forming die system includes one or more forming dies, wherein each forming die includes a first die part and a second die part, which are configured to cooperate with each other during the forming process of the cellulose product. The forming die system also includes: a compacting unit, which is configured to compress at least a portion of the residual segment to a first compression degree that is higher than the compression degree of the one or more product segments; and a feeding unit, which is configured to feed the cellulose blank structure along a feeding direction to a forming position in the forming die system. At the forming position, each product segment is arranged between the corresponding first die part and the second die part. One or more forming dies are configured to form a cellulose product from the cellulose blank structure between a first and a second die part by heating the cellulose blank structure to a forming temperature in the range of 100-300°C; and to press the cellulose blank structure with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa. These system features have the advantage of preventing the risk of undesirable cracking of the cellulose blank structure when it is inserted into the forming die. This solution results in better forming of the cellulose product, particularly for deep-drawn products.

[0027] The present disclosure also relates to a cellulose blank structure for forming a cellulose product in a forming die system. The cellulose blank structure is air-formed and includes one or more defined product segments and a defined residual segment disposed around or connected to the one or more product segments. At least a portion of the residual segment has a first degree of compression that is greater than the degree of compression of the one or more product segments. The cellulose blank structure also includes one or more transition segments disposed between the one or more product segments and the residual segment. In the transition segments, the degree of compression varies between the first degree of compression and the degree of compression of the one or more product segments. The cellulose blank structure also includes a cutting pattern in the residual segment and / or the transition segment that at least partially surrounds each product segment. Each cutting pattern forms at least one bridging structure in the residual segment and / or the transition segment. When the cellulose blank structure is inserted into the forming die and during the forming process in the forming die, the system minimizes cracks, fiber separation, material breakage, or other undesirable structural weakening of the cellulose blank structure by shaping the product segments and the residual segment. By compressing the residual section to a first degree of compression which is higher than the degree of compression of the one or more product sections, transport of the cellulosic blank structure is simplified. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present disclosure will be described in detail below with reference to the accompanying drawings, in which:

[0029] Figure 1a -b schematically shows a perspective view of a cellulose blank structure and a forming die system with a compacting unit according to the present disclosure;

[0030] Figure 2a -c schematically shows a perspective view of a cellulose blank structure with a cutting pattern and a forming die system with a cutting unit according to the present disclosure,

[0031] Figure 3a -b schematically illustrates a top view and a front view of a cellulose blank structure having a cutting pattern in a multi-cavity configuration according to the present disclosure;

[0032] Figure 4a -b schematically illustrates a top view and a front view of a cellulose blank structure having a cutting pattern in a section of a single-cavity configuration or a multi-cavity configuration according to the present disclosure;

[0033] Figure 5a -e schematically shows a front view of a forming die system according to the present disclosure,

[0034] Figure 6a -c schematically shows a perspective view of a forming mold system without a first mold part and a feed unit with a feed belt according to the present disclosure;

[0035] Figure 7a -e schematically shows a top view of a cellulose blank structure with different cutting patterns according to the present disclosure,

[0036] Figure 8a -c schematically illustrates a perspective view and a front view of a cellulose blank structure and a forming die system according to an alternative embodiment of the present disclosure, and

[0037] Figure 9a -b schematically shows a front view of a forming die system with a cutting unit according to an alternative embodiment of the present disclosure. DETAILED DESCRIPTION

[0038] Various aspects of the present disclosure will be described below in conjunction with the accompanying drawings to illustrate rather than limit the present disclosure, wherein like reference numerals represent like elements, and variations in the described aspects are not limited to the specifically shown embodiments but may be applied to other variations of the present disclosure.

[0039] Those skilled in the art will understand that the steps and functions explained herein can be implemented using separate hardware circuits, using software running in conjunction with a programmed microprocessor or general-purpose computer, using one or more application-specific integrated circuits (ASICs), and / or using one or more digital signal processors (DSPs). It should also be understood that when the present disclosure is described in terms of methods, it can also be implemented in one or more processors and one or more memories coupled to the one or more processors, wherein the one or more memories store one or more programs that, when executed by the one or more processors, perform the steps, services, and functions disclosed herein.

[0040] Figure 1b 、 Figure 2b 、 Figure 5a -e and Figure 9a Figure 2-b schematically shows a forming die system S for forming a cellulose product 1 from an air-formed cellulose blank structure 2. The forming die system S comprises one or more forming dies 3, wherein each forming die 3 comprises a first die part 3a and a second die part 3b, which are configured to cooperate with each other during the forming process of the cellulose product 1. A control unit connected to the forming die system S is suitable for controlling the different forming steps.

[0041] Figure 1a 、 Figure 2a 、 Figure 3a -b and Figure 4a Figure 2-b schematically illustrates an air-formed cellulose blank structure 2. An air-formed cellulose blank structure 2 according to the present disclosure refers to a substantially air-formed fiber web structure made of cellulose fibers. Air-forming of the cellulose blank structure 2 refers to forming the cellulose blank structure during a dry forming process, wherein the cellulose fibers are air-formed to produce the cellulose blank structure 2. When the cellulose blank structure 2 is formed during the air-forming process, the cellulose fibers are supported by air as a carrier medium and formed into the fiber blank structure 2. This differs from conventional papermaking processes or traditional wet-laid forming processes, in which water is used as a carrier medium for the cellulose fibers when forming the paper or fiber structure. During the air-forming process, if desired, a small amount of water or other substances can be added to the cellulose fibers to modify the properties of the cellulose product, but air is still used as a carrier medium during the forming process. If appropriate, the cellulose blank structure 2 can have a dryness that corresponds primarily to the ambient humidity of the atmosphere surrounding the air-formed cellulose blank structure 2. Alternatively, the dryness of the cellulose blank structure 2 can be controlled so that the appropriate dryness level is achieved when the cellulose product 1 is formed.

[0042] The air-formed cellulose blank structure 2 can be formed from cellulose fibers in a conventional air-forming process and configured in different ways. For example, depending on the desired properties of the cellulose product 1, the cellulose blank structure 2 can have a composition in which the fibers are of the same origin or optionally comprise a combination of two or more types of cellulose fibers. The cellulose fibers used in the cellulose blank structure 2 are firmly bound to each other by hydrogen bonds during the forming process of the cellulose product 1. The cellulose fibers can be mixed with a certain amount of other substances or compounds, which will be further described below. Cellulose fibers refer to any type of cellulose fibers, such as natural cellulose fibers or artificial cellulose fibers. The cellulose blank structure 2 can specifically include at least 95% cellulose fibers, or more specifically include at least 99% cellulose fibers.

[0043] The air-formed cellulose blank structure 2 can have a single-layer or multi-layer structure. A cellulose blank structure 2 having a single-layer structure refers to a structure formed of one layer containing cellulose fibers. A cellulose blank structure 2 having a multi-layer structure refers to a structure formed of two or more layers containing cellulose fibers, wherein these layers can have the same or different compositions or structures.

[0044] Cellulose blank structure 2 can comprise the reinforcing layer that comprises cellulose fiber, and wherein reinforcing layer can be arranged as the load-bearing layer of other layers of cellulose blank structure 2.Reinforcing layer can have the tensile strength higher than other layers of cellulose blank structure 2.When one or more air forming layers of cellulose blank structure 2 have the composition of low tensile strength, this is useful, to avoid cellulose blank structure 2 to break in the forming process of cellulose product 1.Reinforcing layer with higher tensile strength serves as the supporting structure of other layers of cellulose blank structure 2 in this way.Reinforcing layer can have the composition different from the rest part of cellulose blank structure, for example, comprise the tissue layer of cellulose fiber, comprise the air-laid structure of cellulose fiber or other suitable layer structures.Therefore, reinforcing layer need not be air forming.If appropriate, cellulose blank structure 2 can comprise more than one reinforcing layer.

[0045] The one or more air-formed layers of the cellulose blank structure 2 are a loose and airy structure in which the cellulose fibers forming the structure are relatively loosely arranged relative to each other. The loose cellulose blank structure 2 is used for efficient shaping of the cellulose product 1, thereby allowing the cellulose fibers to be formed into the cellulose product 1 in an efficient manner during the shaping process.

[0046] For example Figure 1a 、 Figure 2a 、 Figure 3a -b, Figure 4a -b, Figure 7a -e, Figure 8a and Figure 9a As shown in FIG. 1 , the cellulose blank structure 2 includes one or more defined product segments 2a and a defined residual segment 2b. The one or more product segments 2a are defined as regions or portions of the cellulose blank structure 2 that correspond to the positions of one or more forming dies 3 when forming the cellulose product 1. The residual segment 2b is arranged around or connected to the one or more product segments 2a. Prior to the forming operation in the forming die system, at least a portion of the residual segment 2b is compressed to a first compression degree D. C1 , which first degree of compression is higher than the degree of compression D of one or more product sections 2a C , as will be understood from the accompanying drawings. One or more product sections 2a may be non-compressed, or alternatively at least a portion of one or more product sections 2a may be compressed to a second degree of compression D C2 .

[0047] In certain embodiments, the cellulosic blank structure 2 may include one or more defined residual segments 2b, wherein each residual segment 2b is arranged around or connected to one or more product segments 2a. Prior to the forming operation in the forming die system, at least a portion of each residual segment 2b is compressed to a first compression degree D C1 , which first degree of compression is higher than the degree of compression D of one or more product sections 2a C .

[0048] As shown in the embodiment shown, the residual section 2b is suitably compressed to a first degree of compression D C1 The residual section 2b may be compressed to a first compression degree D C1 , its density is 40-1300kg / m 3 The density of the residual section 2b can be measured by cutting a sample of the material directly after the cellulose blank structure 2 has been compressed, for example between compacting rollers. The thickness of the sample of the residual section 2b is measured with a caliper within one minute after compression and the sample is then weighed. The sample suitably has an area of ​​400-2000 mm 2 The sample is square or circular in shape. When measuring the thickness of the sample with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the sample. The weight [m] of the sample, as well as the thickness [t] and area [A], are used to calculate the density [ρ] according to the following formula:

[0049] exist Figure 1a In the embodiment shown, for the purpose of illustration, the first sample P1 of the residual section 2b is indicated by a dotted line, and in the embodiment shown, the first sample P1 has a square shape. The first area A1 and the first thickness direction T1 of the first sample P1 are Figure 1a Shown in.

[0050] The residual section 2 b may have an embossing pattern on one or both sides, such as a waffle surface structure, in order to increase the stiffness and strength of the cellulose blank structure 2 .

[0051] The cellulose blank structure 2 further comprises one or more transition sections 2c arranged between one or more product sections 2a and the residual section 2b. In the transition section 2c, the degree of compression may be between a first degree of compression D C1 and the degree of compression D of one or more product sections 2a C If appropriate, the transition section 2c may have other degrees of compression.

[0052] In certain embodiments, before feeding the cellulosic blank structure 2 to the forming position F POS Previously, one or more product sections 2a were compressed to a second degree of compression D C2 . First compression level D C1 Higher than the second compression level D C2 One or more product sections 2a may be suitably compressed to a second degree of compression D C2 , where the density is 15-400kg / m 3 The density of the one or more product sections 2a can be measured by cutting a sample of the material directly after the cellulose blank structure 2 has been compressed (e.g. between compacting rollers). The thickness of the sample from the one or more product sections 2a is measured with a caliper within one minute after compression and the sample is then weighed. The sample suitably has an area of ​​400-2000 mm 2 The sample is square or circular in shape. When measuring the thickness of the sample with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the sample. The weight [m] of the sample, as well as the thickness [t] and area [A], are used to calculate the density [ρ] according to the following formula:

[0053] exist Figure 1a In the embodiment shown, for illustration purposes, the second sample P2 of one or more product sections 2b is indicated by a dotted line, and in the embodiment shown, the second sample P2 has a square shape. The second area A2 and the second thickness direction T2 of the second sample P2 are Figure 1a Shown in.

[0054] like Figure 1b As shown, the forming die system S may further include a compacting unit 11 configured to compact or compress the residual segment 2b to a first compression degree D C1 , which first degree of compression is higher than the degree of compression D of one or more product sections 2a CThe compacting unit 11 comprises a first compacting roller 11a cooperating with a second compacting roller 11b. The compacting rollers are arranged on opposite sides of the cellulose blank structure 2 and perform compression of the cellulose blank structure 2 when the cellulose blank structure 2 is fed between the first compacting roller 11a and the second compacting roller 11b. Figure 1b As shown, the first compacting roller 11a includes a plurality of grooves 12 for forming product segments 2a. The areas of the first compacting roller 11a between the grooves 12 form the residual segments 2b of the cellulose blank structure 2 with a higher degree of compression. Each groove 12 has a shape and structure corresponding to the product segment 2a. The grooves 12 can be used to compress the product segment 2a to a second degree of compression D C2 , where the second compression degree D C2 Below the first compression level D C1 In an alternative, not shown, embodiment, the second compacting roller 2b may be provided with grooves corresponding to the grooves 12 of the first compacting roller 11a for forming the product sections 2a.

[0055] The forming die system S may further comprise a cutting unit 9 configured to create one or more cutting patterns 4 in the cellulose blank structure 2. Figure 2a -b, Figure 3a -b, Figure 4a -b, Figure 5a -e, Figure 6a -c and Figure 7a -e, the cellulose blank structure 2 can be provided with a cutting pattern 4 in the residual section 2b and / or the transition section 2c, which at least partially surrounds each product section 2a. In the embodiment shown, each cutting pattern 4 partially separates a portion of the cellulose blank structure 2 associated with the product section 2a from the rest of the cellulose blank structure 2. Each cutting pattern 4 forms at least one bridging structure 4a in the residual section 2b and / or the transition section 2c. The bridging structure 4a connects the portion of the cellulose blank structure 2 connected to the product section 2a and the rest of the cellulose blank structure 2, thereby allowing the portion of the cellulose blank structure 2 connected to the product section 2a to be displaced, for example, as shown in FIG. Figure 5b -c and Figure 6b The displacement facilitates the forming of the cellulosic product 1 in the one or more forming dies 3, in particular if the cellulosic product 1 has a deep-drawn configuration. The cutting pattern 4 may have any suitable configuration for forming the bridge structures 4a.

[0056] like Figure 2b As shown, the cutting unit 9 can be provided as a separate unit upstream of one or more forming dies 3, or as Figure 9a-b, is provided as one or more devices connected to one or more forming dies 3. The cutting unit described below can be used in combination with different embodiments of the forming die system S.

[0057] exist Figure 2b In the embodiment shown in Figure 1-c, the cutting unit 9 is configured as a rotary die cutter 10. The rotary die cutter 10 shown includes a die cutter 10a and an anvil roller 10b. The die cutter 10a includes a plurality of cutting elements 10c, which form a cutting pattern 4 in the cellulose blank structure 2 when the cellulose blank structure 2 is fed between the die cutter 10a and the anvil roller 10b. Therefore, the cutting element 10c has a configuration corresponding to the shape of the cutting pattern 4. The rotary die cutter 10 can also be used in a similar manner to the above-mentioned combination Figure 1b The described method has the function of a compacting roller. Figure 2b As shown, the die cutter 10a includes a plurality of grooves 12 for forming the product segment 2a, and the die cutter 10a forms a residual segment 2b of the cellulose blank structure 2 with a higher degree of compression in the area between the grooves 12. Each groove 12 has a shape and structure corresponding to the product segment 2a. The grooves 12 can be used to compress the product segment 2a to a second degree of compression D C2 , where the second compression degree D C2 Below the first compression level D C1 In an alternative embodiment, not shown, the anvil roll 2b can be provided with grooves corresponding to the grooves 12 of the die cutter 10a used to form the product section 2a. With this configuration, the formation of one or more cutting patterns 4 and the compression of the cellulose blank structure 2 are established in a single operating step by the rotary die cutter 10.

[0058] The cutting unit 9 may have other suitable configurations. Figure 9a In the embodiment shown in Figure 1-b, the cutting unit 9 is configured as a punching and cutting device 20 arranged in connection with the forming die 3 of the forming die system S. The punching and cutting device 20 comprises a movably arranged common plate structure 20a, which has a plurality of cutting elements 20b with cutting edges, which form a cutting pattern 4 in the cellulose blank structure 2 when the cellulose blank structure 2 is arranged between the first die part 3a and the second die part 3b. In the same way as described above, the cutting pattern 4 is formed at least partially around each product segment 2a in the residual segment 2b and / or the transition segment 2c, and the cutting element 20b therefore has a configuration corresponding to the shape of the cutting pattern 4. The plate structure 20a with the cutting elements 20b is in Figure 9a In the non-cutting position shown, the plate structure is arranged to be connected to the second mould part 3b. Figure 9aIn the embodiment, the preformed cellulose blank structure 2 having the product section 2a and the residual section 2b is arranged in connection with the first mold part 3a. The punching and cutting device 20 further comprises a pressure cylinder 20c, which is arranged to shift the plate structure 20a having the cutting element 20b from the non-cutting position to the cutting position. Figure 9b Cutting position shown. Figure 9b In the embodiment of the present invention, the cutting element 20b meets an anvil structure 20d which is arranged in connection with the first mould part 3a for establishing a cutting pattern 4 in the cellulose structure. The anvil structure 20d can be made of a suitable material, for example a flexible plate structure made of polyurethane. When the cutting pattern 4 has been formed in the cellulose blank structure 2, the plate structure 20a with the cutting element 20b is shifted back to Figure 9a The position shown allows the product forming operation to be performed.

[0059] In certain embodiments, each cutting pattern 4 comprises a first cut 5 arranged around and connected to a respective product section 2a, wherein the first cut 5 comprises a first cutting line 5a having a first middle section 5b forming at least one bridge structure 4a.

[0060] exist Figure 7a , schematically illustrates an exemplary cutting pattern 4 having a spiral shape, wherein a first cut 5 is arranged around and connected to a product segment 2a. As shown, the first cut 5 comprises a first cutting line 5a, with a first intermediate segment 5b located between overlapping segments of the first cutting line 5a. The intermediate segment 5b forms at least one bridge structure 4a.

[0061] In an alternative embodiment, each cutting pattern 4 includes a non-continuous first cut 5 arranged around and connected to the corresponding product section 2a, and a non-continuous second cut 6 arranged around and outside the non-continuous first cut 5 relative to the product section 2a. The non-continuous first cut 5 includes one or more first cut lines 5a, with one or more first intermediate sections 5b between them. The non-continuous second cut 6 includes one or more second cut lines 6a, with one or more second intermediate sections 6b between them. The one or more first intermediate sections 5b and the one or more second intermediate sections 6b form at least one bridge structure 4a.

[0062] exist Figure 2c 、 Figure 3a -b, Figure 4a -b, Figure 6b and Figure 7b, an exemplary cutting pattern 4 is shown, wherein the cutting pattern 4 includes a non-continuous first cut 5 arranged around and connected to a corresponding product segment 2a, and a non-continuous second cut 6 arranged around and outside the non-continuous first cut 5 relative to the product segment 2a. The non-continuous first cut 5 includes a plurality of first cut lines 5a with first intermediate segments 5b between them. The non-continuous second cut 6 includes a plurality of second cut lines 6a with second intermediate segments 6b between them. The first intermediate segments 5b and the second intermediate segments 6b form a bridging structure 4a. As shown in the figure, the non-continuous first cut 5 and the non-continuous second cut 6 can be arranged in an overlapping relationship relative to each other, wherein one or more first cut lines 5a overlap with one or more second intermediate segments 6b, and one or more second cut lines 6a overlap with one or more first intermediate segments 5b.

[0063] In an alternative embodiment, each cutting pattern 4 may further include at least one non-continuous additional cut 7, which is arranged around and outside the non-continuous second cut 6 relative to the product segment 2a, wherein each of the at least one non-continuous additional cut 7 includes one or more additional cutting lines 7a, and has one or more additional intermediate segments 7b between the one or more additional cutting lines 7a.

[0064] exist Figure 7c , an exemplary cutting pattern 4 is shown, wherein the cutting pattern 4 comprises a non-continuous first cut 5 arranged around and connected to the corresponding product segment 2a, a non-continuous second cut 6 arranged around and outside the non-continuous first cut 5 relative to the product segment 2a, and a non-continuous additional cut 7 arranged around and outside the non-continuous second cut 6 relative to the product segment 2a. The non-continuous additional cut 7 comprises a plurality of additional cutting lines 7a with additional intermediate segments 7b between the additional cutting lines 7a. Figure 7d , an exemplary cutting pattern 4 is shown, wherein the cutting pattern 4 includes a non-continuous first cut 5 arranged around and connected to a corresponding product section 2a, a non-continuous second cut 6 arranged around and outside the non-continuous first cut 5 relative to the product section 2a, and two non-continuous additional cuts 7 arranged around and outside the non-continuous second cut 6 relative to the product section 2a. The non-continuous first additional cut 7:1 is arranged around and outside the non-continuous second cut 6 relative to the product section 2a, and the non-continuous second additional cut 7:2 is arranged around and outside the non-continuous first additional cut 7:1 relative to the product section 2a. Each non-continuous additional cut 7 includes a plurality of additional cuts 7a with additional intermediate sections 7b between the additional cuts 7a.

[0065] In an alternative embodiment, each cutting pattern 4 may instead comprise only a discontinuous first cut 5 arranged around and connected to the corresponding product segment 2a. The discontinuous first cut 5 comprises one or more first cutting lines 5a, with one or more first intermediate segments 5b between the one or more first cutting lines 5a, and the one or more first intermediate segments 5b forming at least one bridge structure 4a.

[0066] exist Figure 7e , an exemplary cutting pattern 4 is shown, which comprises only discontinuous first cuts 5 arranged around and connected to the corresponding product segments 2a. The discontinuous first cuts 5 comprise a plurality of first cutting lines 5a with first intermediate segments 5b between them. The first intermediate segments 5b form bridge structures 4a.

[0067] Each cutout 5, 6, 7 suitably extends through the cellulose blank structure 2. In an alternative, not shown, embodiment, at least one of the intermediate sections 5b, 6b, 7b comprises a cutout extending partially through the cellulose blank structure 2.

[0068] In an alternative, not shown, embodiment, some of the intermediate sections 5b, 6b, 7b may be made narrower and configured to break during the forming process of the cellulose product 1. The narrower configuration of the intermediate sections 5b, 6b, 7b allows for the conveyance of the cellulose blank structure 2 without breaking or separating for secure positioning of the cellulose blank structure 2 relative to the one or more forming dies 3.

[0069] As described above, the forming mold system S includes one or more forming molds 3, wherein each forming mold 3 includes a first mold part 3a and a second mold part 3b, which cooperate with each other during the forming process of the cellulose product 1. The first mold part 3a and the second mold part 3b are arranged movably relative to each other, and the first mold part 3a and the second mold part 3b are configured to move in the pressing direction D. P On the move relative to each other. Figure 5a In the embodiment shown in FIG-e, the second mold part 3b is fixed, and the first mold part 3a is relative to the second mold part 3b in the pressing direction D P The top is removable. Figure 5a As shown by the double arrow in FIG, the first mold part 3a is configured to be pressed along the pressing direction D P The upwardly extending axis moves in a linear motion towards and away from the second mould part 3b.

[0070] In alternative embodiments, the first mould part 3a may be fixed and the second mould part 3b may be movably arranged relative to the first mould part 3a, or both mould parts may be movably arranged relative to each other.

[0071] The molding die system S can be a single-cavity structure or a multi-cavity structure. A single-cavity molding die system includes only one molding die 3 having a first mold part and a second mold part. A multi-cavity molding die system includes two or more molding dies 3, each molding die having a first mold part and a second mold part. Figure 1b and Figure 2b In the embodiment, the forming mold system S is arranged as a multi-cavity forming mold system comprising a plurality of forming molds 3 having a first mold part and a second mold part, wherein the movements of the mold parts are suitably synchronized so that the forming operations are performed simultaneously. Figure 5a -e and Figure 6a The portion of the molding die system S shown in FIG. 1 may show a single-cavity configuration, or alternatively a segment of a multi-cavity configuration. Hereinafter, the molding die system S will be described in conjunction with a multi-cavity molding die system, but the present disclosure is equally applicable to a single-cavity molding die system.

[0072] It should be understood that for all embodiments according to the present disclosure, in the pressing direction D P The expression of the upward movement includes the movement along the pressing direction D P The movement of the axis extending in the pressing direction D is also possible, and the movement can occur along the axis in the opposite direction. For all embodiments, the expression also includes linear and nonlinear movement of the mold part, wherein the result of the movement during forming is the mold part in the pressing direction D P Repositioning on.

[0073] To form a cellulose product 1 from an air-formed cellulose blank structure 2 in a forming die system S, the air-formed cellulose blank structure 2 is first provided from a suitable source. The cellulose blank structure 2 can be air-formed from cellulose fibers and arranged on a roll or in a stack. Thereafter, the roll or stack can be arranged in connection with the forming die system S. Alternatively, the cellulose blank structure 2 can be air-formed from cellulose fibers connected to the forming die system S and fed directly to the die assembly.

[0074] The forming die system S further comprises a feeding unit 8, which is configured to feed the cellulose blank structure 2 along a feeding direction D F Feed to the forming position F in the forming die system S POS For example, Figure 1b 、 Figure 2b 、 Figure 5a -e and Figure 6a As shown in FIG. 1-c, the feeding unit 8 comprises one or more feeding belts 8a for feeding the cellulose blank structure 2 along a feeding direction D F Transported to the forming position F between the first mold part 3a and the second mold part 3b POSThe feed belt 8a also serves to hold the cellulose blank structure in place during the forming process. The feed belt 8a may have any suitable configuration for conveying the cellulose blank structure 2. Figure 6a In -b, the feed belt 8a is shown schematically in a perspective view. Figure 6a As shown in FIG. 8 -c, the feed belt 8a may be of vacuum type with suction channels 8b for holding the cellulose blank structure 2 during transport.

[0075] exist Figure 5a -e and Figure 6a In the embodiment shown in -c, feed belts 8a are arranged on each side of the first mold part 3a. The feed belts 8a work together to transport the cellulose blank structure 2 to the Figure 5a The molding position F shown POS In the forming position F POS The cellulose blank structure 2 is arranged between the first mold part 3a and the second mold part 3b. The feeding unit 8 may have other suitable configurations, such as a feeding roller.

[0076] The feeding unit 8 feeds the cellulose blank structure 2 along the feeding direction D F Feed to the forming position F in the forming die system S POS In the forming position F POS ,like Figure 1b and Figure 2b As shown, each product section 2a is arranged between a corresponding first mould part 3a and a second mould part 3b. Figure 1b and Figure 2b As shown, the product segments 2 a are therefore arranged in the cellulose blank structure 2 in a pattern corresponding to the arrangement of one or more forming dies 3 in the forming die system S.

[0077] The first mold part 3a is arranged to form the cellulose product 1 by interacting with the corresponding second mold part 3b. During the forming process of the cellulose product 1, the cellulose blank structure 2 is subjected to a product forming pressure P of at least 1 MPa in each forming mold 3. F , preferably in the range of 4-20 MPa, and a product molding temperature T in the range of 100°C to 300°C F Therefore, by heating the cellulose blank structure 2 to a forming temperature T in the range of 100-300°C F and by a molding pressure P in the range of 1-100 MPa, preferably 4-20 MPa FA cellulose blank structure 2 is pressed and formed into a cellulose product 1 from the cellulose blank structure 2 between each first mold part 3a and the corresponding second mold part 3b. As the cellulose product 1 is formed, strong hydrogen bonds form between the cellulose fibers in the cellulose blank structure 2 arranged between the first mold part 3a and the second mold part 3b. The temperature and pressure levels are measured, for example, in or in connection with the cellulose fibers in the cellulose blank structure 2 using appropriate sensors during the forming process.

[0078] When the cellulose blank structure 2 is arranged in the forming position F between the first mould part 3a and the second mould part 3b POS When the first mold part 3a is in the pressing direction D P Move upward toward the second mold part 3b, as Figure 5b As shown by the arrow in Figure 6b For illustration purposes, the first mold part 3a is schematically shown in a perspective view. Figure 5b Position of the cellulose blank structure 2. In the forming position F POS Before the cellulose product 1 is formed, the residual section 2b and one or more product sections 2a can be at least partially moved along the pressing direction D of the forming die system S. P are displaced relative to each other, e.g. Figure 6b As the first mould part 3a moves towards the second mould part 3b, the cellulose blank structure 2 is compacted between the mould parts. Figure 5d In the position shown, the first mold part 3a has moved further toward the second mold part 3b and has reached the product molding position, in which the molding pressure P F and molding temperature T F is applied to the cellulose blank structure 2. When each first mold part 3a is pressed against the corresponding second mold part 3b and the cellulose blank structure 2 is arranged between the mold parts, a molding cavity C for forming the cellulose product 1 is formed between each first mold part 3a and the second mold part 3b during the molding of the cellulose product 1. The molding pressure P F and molding temperature T F is applied to the cellulose blank structure 2 in each forming cavity C. The forming of the cellulose product 1 may further comprise a cutting operation, wherein during the forming of the cellulose product 1 the cellulose product 1 is cut from the cellulose blank structure 2 in the forming die system S. The die parts may, for example, be provided with cutting means for such an operation. Once the cellulose product 1 has been formed in the forming die system S, the first die part 3a is moved in a direction away from the second die part 3b, as Figure 5eAs shown by the arrow in , the cellulose product 1 can be removed from the forming mold system S, as shown in Figure 6c As shown, for example by using a ram or similar device.

[0079] exist Figure 5c -d, the position of an exemplary forming die system S is shown, wherein an edge forming operation is performed to form an edge structure 1a of the cellulose product 1. An edge forming operation may be used instead of a cutting operation for separating the cellulose product 1 from the cellulose blank structure 2 and simultaneously forming the edge structure 1a. Each first die part 3a comprises an edge forming device 14 having a protruding element 14a, which is configured for compacting and separating the fibers of the cellulose blank structure 2. The protruding element 14a is provided with an edge section 14b facing the second die part 3b. The protruding element 14a is suitably arranged as a continuous element extending around the edge forming device 14, wherein the protruding element 14a has an extension corresponding to the edge shape or outer contour of the cellulose product 1 produced in the forming die system S. However, it will be appreciated that the protruding element 14a may have any suitable extension, such as a discontinuous one, depending on the shape of the cellulose product 1 to be formed. As Figure 5d As shown, the protruding element 14a may also have a pointed cross-sectional configuration with an edge section 14b. In other embodiments not shown, the protruding element 14a with the edge section 14b may have other suitable cross-sectional configurations, such as a rounded or flat edge section.

[0080] like Figure 5a As shown in FIG. 1 , the edge forming device 14 can be movably arranged relative to the base structure of the first mold part 3 a and is adapted to interact with a pressure member arranged in the base structure. The edge forming device 14 can have any suitable shape and configuration depending on the shape and configuration of the cellulose product 1. The edge forming device 14 can be, for example, arranged relative to the base structure in the pressing direction D. P The pressure member may include one or more springs 14c disposed between the base structure and the edge forming device 14. The pressure member may alternatively be arranged as a hydraulic or pneumatic pressure device. In an optional embodiment not shown, the edge forming device 14 may also be configured as an immovable structure, wherein the protruding element 14a is disposed on the first mold part 3a. The edge forming device may alternatively be disposed on the second mold part 3b, or on both the first mold part 3a and the second mold part 3b.

[0081] During the movement of the first mould part 3a towards the second mould part 3b, the protruding elements 14a of each edge forming device 14 separate some of the fibres 2a of the cellulose blank structure 2 by means of the force exerted by the protruding elements 14a on the cellulose blank structure 2. Figure 5c -d, when the first mold part 3a reaches the second mold part 3b, as shown in Figure 5d As shown, a stop member 14d provided on each edge forming device 14 prevents direct contact between the protruding element 14a and the second mold part 3b during the forming process of the compacted edge structure 1a. Figure 5a In the embodiment shown in FIG-e, the stop member 14d is arranged as a protrusion on the edge forming device 14, which is in the pressing direction D P The extension on is greater than the extension of the protruding element 14a. Figure 5c As shown in FIG. 1-d, when the first mold part 3a reaches the second mold part 3b, each stop member 14d meets the corresponding second mold part 3b and is pressed in the pressing direction D P The greater extension on the 3D prevents direct contact between the protruding element 14a and the second mould part 3b. Figure 5d As will be appreciated, the cut pattern 4 in the cellulose blank structure 2 creates openings in the cellulose blank structure 2, thereby allowing direct contact between each stop member 14d and the corresponding second mold part 3b. The stop member 14d may be arranged as a continuous element extending around each edge forming device 14, or alternatively as one or more protrusions extending from each edge forming device 14. The stop member 14d may alternatively be arranged on the second mold part 3b, or on both the first mold part 3a and the second mold part 3b.

[0082] Each stop member 14d prevents the protruding element 14a and the corresponding second mold part 3b from coming into contact during the molding process of the compacted edge structure 1a, and with this arrangement, the protruding element 14a is arranged at a small distance from the second mold part 4. A small gap is formed between the protruding element 14a and the second mold part 3b. When the first mold part 3a is moved further toward the second mold part 3b, the edge molding device 14 is pushed into the first mold part 3a to Figure 5d The edge forming position is shown. When the edge forming device 14 is pushed into the first mold part 3a, the edge structure 1a of the cellulose product 1 is formed. When the edge structure 1a is formed, the fibers of the cellulose blank structure 2 are gathered in the area between each protruding element 14a and the corresponding second mold part 3b. At the same time, the edge forming pressure P EF and edge forming temperature T EF is applied to the cellulose blank structure 2. When the edge forming pressure P EF and edge forming temperature TEF When applied to the cellulose blank structure 2, a highly compacted edge structure 1a is formed. The edge structure 1a is appropriately formed as a thin edge extending around the periphery of the cellulose product 1, and the highly compacted edge structure 1a effectively prevents delamination and moisture absorption of the cellulose product 1. With the high edge forming pressure P applied to the cellulose blank structure 2 EF As well as the small distance between each edge segment 14b and the corresponding second mould part 3b, a very thin compacted cellulose structure is formed, which can be used to easily separate the cellulose product 1 and the cellulose blank structure 2 outside the moulding mould part. The thin highly compacted cellulose structure is exposed to high compressive stresses during the edge moulding operation and during the edge moulding process, when the edge moulding pressure P is applied, the cellulose product 1 and the cellulose blank structure 2 are easily separated. EF When high pressure levels are applied to the cellulose fibers, the cellulose fibers break due to the stored energy, high tension and / or tensile stress in the cellulose structure. After forming the cellulose product 1, the residual fibers remaining in the cellulose blank structure 2 can be reused. The edge forming operation is performed by the edge forming device 14 in conjunction with the product forming operation.

[0083] When forming the edge structure 1a, an appropriate edge forming pressure P is applied to the cellulose blank structure 2. EF The appropriate edge forming temperature T applied to the cellulose blank structure 2 when forming the edge structure 1a is at least 10 MPa, preferably in the range of 10-4000 MPa, or more preferably in the range of 100-4000 MPa. EF In the range of 50-300°C, preferably in the range of 100-300°C.

[0084] A deformation element E for establishing a product forming pressure can be arranged in connection with each first mold part 3a and / or second mold part 3b. Figure 5a In the embodiment shown in FIG-e, a deformation element E is attached to the first mold part 3a. By using the deformation element E, the molding pressure P F It can be a balanced molding pressure.

[0085] For all embodiments, the first mould part 3a and / or the second mould part 3b may comprise a deformation element E, and the deformation element E is configured to exert a forming pressure P on the cellulose blank structure 2 in the forming cavity C during forming of the cellulose product 1. F The deforming element E can be attached to the first mold part 3a and / or the second mold part 3b with suitable attachment means, such as glue or mechanical fastening members. During the molding process of the cellulose product 1, the deforming element E is deformed to exert a molding pressure P on the cellulose blank structure 2 in the molding cavity C. F, and by the deformation of the deformation element E, a uniform pressure distribution can be achieved even if the cellulose product 1 has a complex three-dimensional shape or if the cellulose blank structure 2 has a varying thickness. In order to exert the required forming pressure P on the cellulose blank structure 2 F The deformation element E is made of a material that can be deformed when a force or pressure is applied, and the deformation element E is suitably made of an elastic material that can recover its size and shape after deformation. The deformation element E can also be made of a material with suitable properties that can withstand the high forming pressure P used when forming the cellulose product 1. F and molding temperature T F level.

[0086] Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the deforming elements E are made of such materials, a uniform pressure distribution can be achieved during the forming process, wherein the pressure exerted by the deforming elements E on the cellulose blank structure 2 in the forming cavity C is equal or substantially equal in all directions between the mold parts. When each deforming element E is in its fluid-like state under pressure, a uniform fluid-like pressure distribution is achieved. The forming pressure P F Such materials are applied to the cellulose blank structure 2 from all directions, and in this way, the deformation elements E exert a uniform forming pressure on the cellulose blank structure 2 during the forming of the cellulose product 1. Each deformation element E can be made of a suitable structure of one or more elastic materials, and as an example, the deformation element E can be made of a block or substantially block structure of silicone rubber, polyurethane, polychloroprene, or rubber with a hardness in the range of 20-90 Shore A. Other materials for the deformation elements E can be, for example, suitable gel materials, liquid crystal elastomers, and MR fluids.

[0087] The molding die system S further includes a heating unit. The heating unit is configured to lower the molding temperature T F is applied to the cellulose blank structure 2 in each forming cavity C. The heating unit is also suitably configured to reduce the edge forming temperature T EF is applied to the cellulose blank structure 2. The heating unit may have any suitable configuration. A suitable heating unit (such as one or more heated forming die parts) may be used to establish the forming temperature T F and edge forming temperature T EF The heating unit may be integrated or cast in the first mould part 3a and / or the second mould part 3b, and suitable heating means are for example electric heaters, such as electrical resistance elements, or fluid heaters. Other suitable heat sources may also be used.

[0088] exist Figure 8aIn FIG, an alternative embodiment of a cellulose blank structure 2 is schematically shown. The cellulose blank structure 2 comprises one or more defined product segments 2a and a residual segment 2b, wherein the residual segment 2b is arranged to be connected to the one or more product segments 2a. Before the forming operation in the forming die system S, the residual segment 2b is compressed to a first compression degree D C1 , which first degree of compression is higher than the degree of compression D of one or more product sections 2a C As can be understood from the accompanying drawings, the cellulose blank structure 2 further comprises one or more transition sections 2c arranged between one or more product sections 2a and the residual section 2b. In the transition section 2c, the compression degree is at a first compression degree D C1 and the degree of compression D of one or more product segments 2a C In this embodiment, one or more product sections 2a may be compressed to a second compression degree D C2 , where the first compression degree D C1 Higher than the second compression level D C2 The individual segments may have densities as described above.

[0089] Figure 1a 、 Figure 2a and Figure 8a The cellulose blank structure 2 can be fed to the forming position F by the above-mentioned feeding unit 8. POS .exist Figure 8b In the alternative embodiment shown in FIG-c, the feed unit 8 alternatively has a plurality of means for conveying the cellulose blank structure 2 to the feed position F. POS The feeding unit 8 comprises a first roller 15a and a second mating roller 15b, and the cellulose blank structure 2 is arranged between the rollers, as shown in FIG. Figure 8b As shown. The first roller 15a and the second roller 15b compact the cellulose blank structure 2 to form a product segment and a residual segment 2b. The first roller 15a includes a concave portion 16a for combining with Figure 1b and Figure 2b The product section 2a is formed in a similar manner as described above. The non-recessed portion 16b of the first roller 15a is arranged on both sides of the recessed portion 16a for forming the residual section 2b. Connected to the recessed portion 16a, the first roller 15a includes a plurality of perforated cutters 17 in the non-recessed portion 16b for forming tractor feed holes 18 arranged in the row R of the cellulose blank structure 2. The tractor feed holes 18 are used to convey the cellulose blank structure 2. Figure 8bIn the embodiment shown, the first roller 15a is provided with five rows of perforation cutters 17, which are arranged on both sides of the corresponding recessed portion 16a. In this way, the perforation cutters 17 form five rows R of tractor feed holes 18 in the cellulose blank structure 2. The feed unit 8 also includes a sprocket 19, which is used to feed the cellulose blank structure 2 to the feed position F. POS , wherein the sprocket is engaged with the tractor feed hole 18. Figure 8c , a first roller 15a and a second roller 15b with a plurality of perforation cutters 17 are shown in more detail. The perforation cutters 17 are arranged as sharp protrusions which cut tractor feed holes 18 in the cellulose blank structure 2. Figure 8b As shown in the enlarged portion of the cellulose blank structure 2 in FIG, the tractor feed hole 18 can be partially cut by a perforation cutter to avoid loosely separated cut pieces 18a of residual material. During the feeding operation, the tractor feed hole 18 is engaged with the sprocket 19. Figure 8b As shown, the partially cut tractor feed hole 18 may be provided with a connecting portion 18b having a hinge-like configuration for holding the cut piece of fiber material 18a connected to the cellulosic blank structure 2. Figure 8b As shown in the enlarged portion of the cellulose blank structure 2 in FIG, the rotational position of the connecting portion 18b relative to the partially cut tractor feed hole 18 can be alternated in the cutting pattern to improve the registration between the tractor feed hole 18 and the sprocket 19. Figure 8b In the embodiment, the connecting portions 18 b of two adjacent tractor feed holes 18 are arranged on opposite sides relative to their respective tractor feed holes 18 .

[0090] The present disclosure has been presented above with reference to specific embodiments. However, other embodiments than those described above are possible and are within the scope of the present disclosure. Within the scope of the present disclosure, method steps different from those described above may be provided, the method being performed by hardware or software. Therefore, according to an exemplary embodiment, a non-transitory computer-readable storage medium storing one or more programs is provided, the one or more programs being configured to be executed by one or more processors of a control unit of a forming mold system S, the one or more programs comprising instructions for performing a method according to any of the above-described embodiments. Alternatively, according to another exemplary embodiment, a cloud computing system may be configured to perform any of the method aspects presented herein. The cloud computing system may include distributed cloud computing resources that jointly perform the method aspects given herein under the control of one or more computer program products. In addition, the processor may be connected to one or more communication interfaces and / or sensor interfaces for receiving and / or sending data to an external entity (such as a sensor, an off-site server, or a cloud-based server).

[0091] The one or more processors of the molding die system S may be or include any number of hardware components for performing data or signal processing or for executing computer code stored in a memory. The system may have an associated memory, and the memory may be one or more devices for storing data and / or computer code for completing or facilitating the various methods described in this specification. The memory may include volatile memory or non-volatile memory. The memory may include a database component, an object code component, a script component, or any other type of information structure for supporting the various activities of this specification. According to an exemplary embodiment, any distributed or local storage device may be used with the systems and methods of this specification. According to an exemplary embodiment, the memory is communicatively connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and includes computer code for executing one or more processes described herein.

[0092] It should be understood that the foregoing description is merely exemplary in nature and is not intended to limit the present disclosure, its application or use. Although specific examples have been described in the specification and specific examples are shown in the drawings, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure as defined in the claims. In addition, modifications may be made to adapt particular circumstances or materials to the teachings of the present disclosure without departing from the basic scope of the present disclosure. Therefore, the present disclosure is not limited to the specific examples shown in the drawings and described in the specification as the best modes of currently implementing the teachings of the present disclosure, but the scope of the present disclosure will include any embodiment falling within the foregoing description and the appended claims. The reference to the figure signs in the claims should not be construed as limiting the scope of what is protected by the claims, and their only function is to make the claims easier to understand.

[0093] Reference Mark List

[0094] 1: Cellulose products 1a: Edge structure

[0095] 2: Cellulose blank structure 2a: Product section

[0096] 2b: Remaining section 2c: Transition section

[0097] 3: Molding mold 3a: First mold component

[0098] 3b: Second mold part 4: Cutting pattern

[0099] 4a: Bridging structure 5: First incision

[0100] 5a: First cutting line 5b: First middle section

[0101] 6: Second incision 6a: Second cutting line

[0102] 6b: Second middle section 7: Additional cutout

[0103] 7a: Additional cutting line 7b: Additional middle section

[0104] 8: Feed unit 8a: Feed belt

[0105] 8b: Suction channel 9: Cutting unit

[0106] 10: Rotary die cutter 10a: Die cutter

[0107] 10b: Anvil roller 11: Compacting unit

[0108] 11a: First compacting roller 11b: Second compacting roller

[0109] 12: Groove 14: Edge forming device

[0110] 14a: protruding element 14b: edge segment

[0111] 14c: Spring 14d: Stopper

[0112] 15a: First roller 15b: Second roller

[0113] 16a: Recessed portion 16b: Non-recessed portion

[0114] 17: Perforation cutter 18: Tractor feed hole

[0115] 18a: Cutting piece 18b: Connecting part

[0116] 19: Sprocket 20: Punching and cutting device

[0117] 20a: Plate structure 20b: Cutting element

[0118] 20c: Pressure cylinder 20d: Anvil structure

[0119] C: Molding cavity D C1 : First compression level

[0120] D C2 : Second compression level D F : Feed direction

[0121] D P : Pressing direction E: Deformation element

[0122] F POS :Molding position P EF : Edge forming pressure

[0123] P F : Molding pressure R:

[0124] T EF : Edge forming temperature T F : Molding temperature

[0125] S: Molding mold system.

Claims

1. A method for forming a cellulose product (1) from an air-formed cellulose blank structure (2) in a forming die system (S), wherein the forming die system (S) comprises one or more forming dies (3), wherein each forming die (3) comprises a first die part (3a) and a second die part (3b), the first die part and the second die part being configured to cooperate with each other during forming of the cellulose product (1), wherein The method comprises the following steps: Providing the cellulose blank structure (2), and defining one or more product segments (2a) and a residual segment (2b) arranged around the one or more product segments (2a) or connected to the one or more product segments (2a) in the cellulose blank structure (2); Compressing at least a portion of the residual section (2b) to a higher degree of compression (D) than the one or more product sections (2a) C )'s first compression level (D C1 ); Along the feed direction (D F ) feeding the cellulose blank structure (2) to the forming position (F) in the forming die system (S) POS ), wherein at the molding position (F POS ), each product section (2a) being arranged between a respective first mould part (3a) and a second mould part (3b); By heating the cellulose blank structure (2) to a forming temperature (T F ), forming the cellulose product (1) from the cellulose blank structure (2) between the first mold part (3a) and the second mold part (3b); and using a molding pressure (P in the range of 1-100 MPa) F ) pressing the cellulose blank structure (2).

2. The method according to claim 1, The cellulose blank structure (2) further comprises one or more transition sections (2c) arranged between the one or more product sections (2a) and the residual section (2b), wherein in the one or more transition sections (2c), the degree of compression is greater than the degree of compression (D) of the one or more product sections (2a). C ) and the first compression degree (D C1 ) varies between.

3. The method according to claim 1 or 2, The method further comprises the following steps: When the cellulose blank structure (2) is fed to the forming position (F POS ), compressing at least a portion of the one or more product sections (2a) to a second degree of compression (D C2 ), wherein the first degree of compression (D C1 ) is higher than the second compression level (D C2 ).

4. The method according to claim 1 or 2, The method further comprises the following steps: Before forming the cellulose product (1), at the forming position (F POS ), so that the residual section (2b) and the one or more product sections (2a) are pressed along the pressing direction (D P ) are at least partially displaced relative to each other.

5. The method according to claim 2, The method further comprises the following steps: A cutting pattern (4) is arranged at least partially around each product segment (2a) in the residual segment (2b) and / or the transition segment (2c); wherein each cutting pattern (4) forms at least one bridging structure (4a) in the residual segment (2b) and / or the transition segment (2c) for keeping each product segment (2a) partially connected to the residual segment (2b) and / or the transition segment (2c).

6. The method according to claim 5, Each cutting pattern (4) comprises a discontinuous first cut (5) arranged around a corresponding product segment (2a) and connected to the product segment, wherein the discontinuous first cut (5) comprises one or more first cutting lines (5a) and one or more first intermediate segments (5b) between the one or more first cutting lines (5a), wherein the one or more first intermediate segments (5b) form the at least one bridging structure (4a).

7. The method according to claim 5, Each cutting pattern (4) comprises a first cut (5) arranged around a corresponding product section (2a) and connected to the product section, wherein the first cut (5) comprises a first cutting line (5a) having a first middle section (5b), the first middle section forming at least one bridge structure (4a).

8. The method according to claim 5, Each cutting pattern (4) includes: A discontinuous first cut (5) is arranged around the corresponding product section (2a) and connected to the product section; and a discontinuous second cut (6) is arranged around the discontinuous first cut (5) relative to the product section (2a) and on the outside of the discontinuous first cut.

9. The method according to claim 8, wherein the discontinuous first incision (5) comprises one or more first cutting lines (5a), one or more first intermediate sections (5b) being located between the one or more first cutting lines (5a), wherein the discontinuous second incision (6) comprises one or more second cutting lines (6a), one or more second intermediate sections (6b) being located between the one or more second cutting lines (6a), wherein the one or more first intermediate sections (5b) and the one or more second intermediate sections (6b) form the at least one bridging structure (4a).

10. The method according to claim 9, wherein the non-continuous first cut (5) and the non-continuous second cut (6) are arranged in an overlapping relationship relative to each other, wherein the one or more first cutting lines (5a) overlap with the one or more second intermediate sections (6b), and wherein the one or more second cutting lines (6a) overlap with the one or more first intermediate sections (5b).

11. The method according to any one of claims 9 to 10, Each cutting pattern (4) further comprises at least one discontinuous additional cut (7), which is arranged around and outside the discontinuous second cut (6) relative to the product segment (2a), wherein each of the at least one discontinuous additional cut (7) comprises one or more additional cutting lines (7a), and one or more additional intermediate segments (7b) are located between the one or more additional cutting lines (7a).

12. The method according to claim 11, Each of the cutouts (5, 6, 7) extends through the cellulose blank structure (2).

13. The method according to claim 11, Wherein at least one of the first intermediate section (5b), the second intermediate section (6b) and the additional intermediate section (7b) comprises a cutout extending partially through the cellulose blank structure (2).

14. The method according to any one of claims 5 to 10, The method further comprises the following steps: The one or more cutting patterns (4) are arranged in the residual section (2b) and / or the transition section (2c) around each product section (2a) by means of a cutting unit (9).

15. The method according to claim 14, wherein the cutting unit (9) is arranged as a rotary die cutter (10), wherein the method further comprises the following steps: In a single operation step, the one or more cutting patterns (4) are formed using the rotary die cutter (10) and at least a portion of the residual segment (2b) is compressed; or in a single operation step, the one or more cutting patterns (4) are formed using the rotary die cutter (10), at least a portion of the residual segment (2b) is compressed, and at least a portion of the one or more product segments (2a) is compressed.

16. The method according to any one of claims 1 to 2, The method further comprises the following steps: During the forming of the cellulose product (1), the cellulose product (1) is cut from the cellulose blank structure (2) in the forming die system (S).

17. The method according to any one of claims 1 to 2, The one or more product sections (2a) are arranged in the cellulose blank structure (2) in a pattern corresponding to the arrangement of one or more forming dies (3) in the forming die system (S).

18. A forming die system (S) for forming a cellulose product (1) from an air-formed cellulose blank structure (2), comprising one or more defined product segments (2a) and defined residual segments (2b) arranged around the one or more product segments (2a) or in connection with the product segments, wherein the forming die system (S) comprises one or more forming dies (3), wherein each forming die (3) comprises a first die part (3a) and a second die part (3b), the first die part and the second die part being configured to cooperate with each other during forming of the cellulose product (1), in, The forming die system (S) further comprises: a compacting unit (11) configured to compress at least a portion of the residual section (2b) to a first compression degree (D C1 ), said first degree of compression being higher than the degree of compression (D C ); and a feeding unit (8), the feeding unit being configured to feed the F ) feeding the cellulose blank structure (2) to the forming position (F) in the forming die system (S) POS ), wherein at the molding position (F POS ), each product section (2a) being arranged between a respective first mould part (3a) and a second mould part (3b); The one or more forming dies (3) are configured to: heat the cellulose blank structure (2) to a forming temperature (T F ), forming the cellulose product (1) from the cellulose blank structure (2) between the first mold part (3a) and the second mold part (3b); and using a molding pressure (P in the range of 1-100 MPa) F ) pressing the cellulose blank structure (2).

19. A cellulose blank structure (2) for forming a cellulose product (1) in a forming die system (S), wherein the cellulose blank structure (2) is air-formed and comprises one or more defined product segments (2a) and a defined residual segment (2b) surrounding the one or more product segments (2a), wherein at least a portion of the residual segment (2b) has a lower degree of compression (D) than the one or more product segments (2a). C ) High first compression degree (D C1 ), wherein the cellulose blank structure (2) further comprises: One or more transition sections (2c) are arranged between the one or more product sections (2a) and the residual section (2b), wherein in the transition section (2c), the degree of compression is between the first degree of compression (D C1 ) and the degree of compression (D C ) between the following periods: A cutting pattern (4) in the residual segment (2b) and / or the transition segment (2c) at least partially surrounding each product segment (2a); wherein each cutting pattern (4) forms at least one bridging structure (4a) in the residual segment (2b) and / or the transition segment (2c).

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