Systems and methods for producing fiber-molded articles

Abstract

A system for producing molded fiber articles includes a wet pressing subsystem comprising a forming platen for carrying a single forming die; and a wet pressing platen assembly for carrying a plurality of wet pressing dies, the plurality of wet pressing dies including at least a first wet pressing die and a second wet pressing die. The wet pressing platen assembly is movable relative to the forming platen to alternately align the first wet pressing die and the second wet pressing die with the forming die in a continuous cycle of the wet pressing subsystem, thereby producing a first wet-pressed fiber pad and a second wet-pressed fiber pad. The system further includes a dry press having at least a first dry pressing station and a second dry pressing station, the first dry pressing station and the second dry pressing station being configured to receive a first wet-pressed pad and a second wet-pressed pad, respectively, and the dry press being closable to simultaneously close the first dry pressing station and the second dry pressing station, thereby producing a dry-pressed first fiber pad and a second fiber pad.

Description

Technical Field

[0001] The teachings disclosed herein relate to systems and methods for producing fiber-molded articles, and more specifically, to automated, high-volume production systems. Background Technology

[0002] U.S. Patent No. 6,716,319 (Gale) discloses an apparatus for producing molded pulp products from fiber pulp. The apparatus includes an impregnation tank containing fiber pulp and having a liquid level. A pressure plate is provided. The pressure plate carries a porous mold. The pressure plate and the mold it carries are lowered downwards into the fiber pulp, with the pressure plate positioned above the mold such that the mold passes through the liquid level into the fiber pulp. When the mold is positioned in the fiber pulp, a vacuum is provided to the pressure plate and the mold to collect fibers from the fiber pulp onto the mold and form a wet molded pulp product. The pressure plate and the mold with the wet molded product are removed from the fiber pulp through the liquid level to drain water from the mold and the wet molded pulp product. The wet molded pulp product is then dried.

[0003] U.S. Patent No. 11,479,919 (Parker) discloses contour articles formed in a mold from fibrous slurry. The articles comprise blends of cellulose fibers and cellulose esters (e.g., short cellulose ester fibers). The articles are described as suitable for a wide range of end uses, including cups, lids, boxes or pouches, storage containers, trays, plates, food trays, cutlery, coffee cups, coffee cup lids, packaging, bowls, clamshell containers, bottle caps, straws, lids, and packaging inserts.

[0004] U.S. Patent Application Publication No. 2022 / 0388201 (Knoll) discloses a first molding station for partially molding and pre-molding a molded part made of fibrous material, a fiber molding system having the first molding station, a method for operating the first molding station or the fiber molding system, and a molded part produced using the method.

[0005] U.S. Patent Application Publication No. 2023 / 0243107 (Hagenauer) discloses a fiber forming process in a fiber forming system having a molding station for molding, a preforming station for preforming, and a hot pressing station for final forming of a molded part made of an environmentally friendly biodegradable fiber material. This fiber forming system produces molded parts having the aforementioned stations by means of a method performed as a fiber forming process within the system. Summary of the Invention

[0006] The following content is intended to introduce readers to various aspects of the applicant's teachings, but is not intended to limit any invention.

[0007] In one aspect, a system for producing molded fiber articles includes: (a) a wet pressing subsystem comprising a forming platen having a forming die mounting surface for carrying a single forming die, and a wet pressing platen assembly having a plurality of wet pressing stations for carrying respective wet pressing dies, wherein the plurality of wet pressing stations include at least a first wet pressing station and a second wet pressing station for carrying a first wet pressing die and a second wet pressing die, respectively, the wet pressing platen assembly being movable relative to the forming platen to alternately align the first wet pressing die and the second wet pressing die with the forming die in a continuous cycle of the wet pressing subsystem, thereby producing a first wet pressing fiber pad and a second wet pressing fiber pad respectively in the continuous cycle, wherein the first fiber pad and the second fiber pad correspond in size and shape to one or more of the molded fiber articles being produced; and (b) A dry pressing subsystem includes a dry press having a plurality of dry pressing stations equal in number to the plurality of wet pressing stations, and including at least a first dry pressing station and a second dry pressing station, the first dry pressing station and the second dry pressing station being configured to receive a first wet pressing pad and a second wet pressing pad, respectively, and the dry press being closable to simultaneously close the first dry pressing station and the second dry pressing station, thereby producing a dry-pressed first fiber pad and a second fiber pad.

[0008] In some examples, the system further includes a wet-to-dry transfer subsystem having a first wet-to-dry carrier alignable with the first wet pressing station to receive the first fiber mat therefrom, and a second wet-to-dry carrier alignable with the second wet pressing station to receive one of the second fiber mats therefrom, and the wet-to-dry transfer subsystem is configured to move each of the first wet-to-dry carrier and the second wet-to-dry carrier to the first dry press and the second dry press, respectively, and to load the first fiber mat and the second fiber mat into the first dry pressing station and the second dry pressing station, respectively.

[0009] According to some aspects, a system for producing molded fiber articles includes: (a) a wet pressing subsystem comprising a single forming platen and a wet pressing platen assembly defining a plurality of wet pressing stations, the wet pressing subsystem being configured to produce a plurality of wet-pressed fiber pads, each wet pressing station producing a single wet-pressed fiber pad in a corresponding single cycle of the wet pressing subsystem; and (b) a dry pressing subsystem comprising a plurality of dry pressing stations, each dry pressing station being configured to receive a corresponding one of the wet-pressed fiber pads produced by a corresponding wet pressing station of the plurality of wet pressing stations, and simultaneously closing the dry pressing station to produce a corresponding plurality of dry fiber pads.

[0010] In some examples, the system further includes a wet-to-dry transfer subsystem comprising a plurality of wet-to-dry carriers, each corresponding to one of the plurality of wet pressing stations. The wet-to-dry transfer subsystem is configured to load a wet-pressed fiber pad from the corresponding wet pressing station into the corresponding wet-to-dry carrier, and to move each wet-to-dry carrier to a dry press and load the wet-pressed fiber pad into the corresponding one of the dry pressing stations.

[0011] According to some aspects, a method of operating a fiber molding system to produce molded fiber articles includes: opening a dry press to simultaneously open a first dry pressing station and a second dry pressing station; loading a first wet fiber pad and a second wet fiber pad into the first dry pressing station and the second dry pressing station in parallel, respectively; and unloading the first dry fiber pad and the second dry fiber pad from the first dry pressing station and the second dry pressing station in parallel, respectively; wherein the loading and unloading of the dry press are at least partially simultaneous.

[0012] In some examples, the first wet fiber pad and the second wet fiber pad are loaded into a first mold portion on one side of each dry pressing station, and the first dry fiber pad and the second dry fiber pad are unloaded from a second mold portion opposite to the first mold portion at each dry pressing station.

[0013] In some examples, the method further includes operating a wet press located upstream of the dry press to produce the first wet fiber pad and the second wet fiber pad in alternating continuous cycles of the wet press.

[0014] In some examples, producing the first wet fiber mat includes engaging a first wet pressing die with a molding die, and producing the second fiber mat includes engaging a second wet pressing die with the molding die.

[0015] In some examples, loading the first wet fiber pad and the second wet fiber pad into the first dry pressing station and the second dry pressing station respectively includes moving the first carrier and the second carrier of the wet-to-dry transfer system into the first dry pressing station and the second dry pressing station respectively.

[0016] In some examples, unloading the first dry fiber pad and the second dry fiber pad from the first dry pressing station and the second dry pressing station, respectively, includes moving the first and second carriers of the dry-to-trimming transfer subsystem to the first dry pressing station and the second dry pressing station, respectively.

[0017] According to some aspects, a method of operating a dry pressing subsystem to produce fiber molded products includes: loading a plurality of wet fiber pads in parallel into a plurality of corresponding dry pressing stations; and unloading a plurality of dry fiber pads in parallel from the respective plurality of dry pressing stations; wherein loading and unloading are performed at least partially simultaneously.

[0018] In some examples, loading the plurality of wet fiber pads into the plurality of dry pressing stations includes moving the respective upstream carriers of the wet-to-dry transfer system to the plurality of dry pressing stations.

[0019] In some examples, unloading the plurality of dry fiber pads from the respective plurality of dry pressing stations includes moving the respective downstream carriers of the dry to trimming transfer subsystem into the plurality of dry pressing stations.

[0020] According to some aspects, a system for producing fiber-molded articles includes a wet pressing subsystem comprising: an open container for receiving fiber pulp; a wet pressing support frame; a molding platen having an attached molding die shaped to form the article, wherein the molding platen is rotatably attached to the wet pressing support frame for rotating between an immersion orientation and a pressing orientation, wherein in the immersion orientation the molding die is positioned to contact the fiber pulp in the container, and in the pressing orientation the molding die is located outside the fiber pulp in the container; and a wet pressing platen assembly defining a plurality of wet pressing stations for holding a plurality of wet pressing dies, each wet pressing die shaped to cooperate with the molding die to form a fiber pad, the fiber pad being sized... The wet pressing plate assembly corresponds in shape to one or more of the articles being produced; the wet pressing plate assembly is rotatable relative to the wet pressing support frame to individually rotate each of the plurality of wet pressing molds to a pressing orientation, in which the wet pressing mold is disposed opposite to the forming mold in the pressing orientation; wherein the forming plate or at least one of the plurality of wet pressing stations is movably attached to the wet pressing support frame to move between a wet pressing open configuration and a wet pressing closed configuration, in which the forming plate and the plurality of wet pressing stations are spaced apart from each other, and in which the forming plate in the pressing orientation and one of the wet pressing stations in the pressing orientation are positioned to compress the fiber pad between them.

[0021] In some examples, the wet pressing subsystem further includes: a forming platen actuator coupled to the forming platen to drive the forming platen assembly to rotate between the immersion orientation and the pressing orientation; a wet pressing platen actuator coupled to the wet pressing platen assembly to selectively position one of the wet pressing platen stations in the pressing orientation; a compression actuator coupled to at least one of the forming platen and the wet pressing platen assembly to drive at least one of the forming platen and the wet pressing platen assembly to move between the wet pressing open configuration and the wet pressing closed configuration; and a wet pressing controller including a processor. The processor is operatively connected to the molding actuator, the wet press platen actuator, the compression actuator, and a memory, the memory including a non-transitory computer-readable medium storing instructions executable by the processor to control the molding actuator to rotate the molding platen between the immersion orientation and the pressing orientation, to control the wet press platen actuator to rotate each of the plurality of wet press platen stations to the pressing orientation, and to control the compression actuator to move the molding platen and at least one of the plurality of wet press platen stations between the wet press open configuration and the wet press closed configuration.

[0022] In some examples, the system further includes: a trimming pressing subsystem comprising a trimming press having a pair of trimming pressing plates adapted to trim the fiber pad; wherein the trimming press can be configured in (i) a trimming press open configuration and (ii) The system includes an actuated trimming press-close configuration, wherein in the trimming press-open configuration, the trimming press plates are spaced apart to allow the fiber pad to enter between the trimming press plates, and in the trimming press-close configuration, the trimming press plates are positioned to compress the fiber pad between them; and a dry-to-trimming transfer subsystem comprising a dry-to-trimming transfer support frame and a plurality of dry-to-trimming carriers equal in number to the number of dry presses, wherein each of the dry-to-trimming carriers is associated with a different one of the dry press stations; wherein each of the dry-to-trimming carriers is shaped to hold the product and is movably attached to the dry-to-trimming transfer support frame to move between a pick-up position for receiving the product from an associated one of the dry press stations, and a drop-off position for placing the product on the trimming press.

[0023] Other aspects and features of this disclosure will become apparent to those skilled in the art upon reading the following description of specific examples of this disclosure. Attached Figure Description

[0024] To better understand the described examples and more clearly demonstrate how they can achieve the desired effect, examples will now be illustrated with reference to the accompanying drawings, in which: Figure 1 This is a left rear perspective view of an embodiment of the system disclosed herein for producing molded products from fiber pulp.

[0025] Figure 2A yes Figure 1 The first part of the system relative to Figure 1 A magnified left rear perspective view.

[0026] Figure 2B yes Figure 1 The second part of the system relative to Figure 1 A magnified left rear perspective view.

[0027] Figure 3 yes Figure 1 A top-down plan view of the system.

[0028] Figure 4 yes Figure 1 The left front view of the system.

[0029] Figure 5A yes Figure 1 The first part of the system relative to Figure 4 The enlarged left-side front view.

[0030] Figure 5B yes Figure 1 The second part of the system relative to Figure 4 The enlarged left-side front view.

[0031] Figure 6 yes Figure 1 Functional block diagram of the system's actuators and controllers.

[0032] Figures 7A to 7H yes Figure 1 The right rear perspective view of the wet pressure subsystem shows the motion phases of the wet pressure subsystem. Figure 7A The image shows a molding platen in an immersion orientation and an immersion position, as well as a first wet pressing platen in a pressing orientation. Figure 7B The forming platen is shown raised to the middle position. Figure 7C The image shows the forming platen rotating from the immersion orientation toward the pressing orientation. Figure 7D The molded platen is shown in a pressing orientation. Figure 7E The image shows a molding plate in a pressing orientation and a first wet pressing plate in a pressing orientation, as well as a molding plate and a first wet pressing plate in a wet pressing closed configuration. Figure 7F The forming platen is shown lowered to the middle position. Figure 7GThe image shows a molding platen in the immersion orientation and immersion position, and a second wet pressing platen in the pressing orientation. Figure 7H The first and second wet pressure plates in their transfer orientation are shown.

[0033] Figure 8 yes Figure 1 Right rear perspective view of the wet pressure subsystem and wet-to-dry transfer subsystem of the system.

[0034] Figure 9 yes Figure 1 Right rear perspective view of the wet-to-dry transfer subsystem and dry pressure subsystem of the system.

[0035] Figure 10 yes Figure 1 Left rear perspective view of the wet-to-dry transfer subsystem and dry pressure subsystem of the system.

[0036] Figure 11 yes Figure 1 Left rear perspective view of the dry pressure subsystem of the system.

[0037] Figure 12 yes Figure 1 The left front perspective view of the dry pressure subsystem of the system.

[0038] Figure 13 yes Figure 1 The right front perspective view of the dry pressure subsystem of the system.

[0039] Figure 14 yes Figure 1 Right rear perspective view of the dry pressing subsystem and the dry-to-trimming transfer subsystem of the system.

[0040] Figure 15 yes Figure 1 Right rear perspective view of the dry pressing subsystem and the dry-to-trimming transfer subsystem of the system.

[0041] Figure 16 yes Figure 1 Left rear perspective view of the dry pressing subsystem and the dry-to-trimming transfer subsystem of the system.

[0042] Figure 17 yes Figure 1 The left rear perspective view of the dry-to-trimmed transfer subsystem of the system.

[0043] Figure 18 yes Figure 1 The left rear perspective view of the system to the trimming transfer subsystem, trimming subsystem and conveyor belt subsystem.

[0044] Figure 19 yes Figure 1 Right rear perspective view of the trimming subsystem and conveyor belt subsystem of the system.

[0045] Figure 20 yes Figure 1 Bottom right rear perspective view of the trimming subsystem and conveyor belt subsystem of the system.

[0046] Figure 21 yes Figure 1 Left rear perspective view of the trimming subsystem, trimming to conveyor transfer subsystem, and conveyor belt subsystem of the system.

[0047] Figure 22 yes Figure 1 Right rear perspective view of the trimming subsystem, trimming to conveyor transfer subsystem, and conveyor belt subsystem of the system.

[0048] Figure 23A and Figure 23B This is a side view of a prior art dual-press machine, which can be used as... Figure 1 The dry pressure subsystem of the system. Figure 23A The dual compressor is shown in the open configuration. Figure 23B The image shows a dual compressor in a closed configuration.

[0049] Figure 24 yes Figure 1 A plan view of the dry pressing subsystem, the wet-to-dry transfer subsystem, and the dry-to-trimming transfer subsystem, wherein the dry pressing subsystem is in the open configuration.

[0050] The accompanying drawings contained herein are used to illustrate various examples of the apparatus and methods taught in this specification and are not intended to limit the scope of what is taught in any way. Detailed Implementation

[0051] Various apparatuses or processes will be described below to provide examples for each claimed invention. No example described below is intended to limit any claimed invention, and any claimed invention may encompass processes or apparatuses different from those described below. A claimed invention is not limited to apparatuses or processes having all the features of any one of the apparatuses or processes described below, or features common to the plurality or all of the apparatuses described below. An apparatus or process described below may not be an example of any claimed invention. Any invention disclosed in an apparatus or process described below but not claimed in this document may be the subject of other protective documents (e.g., continuation patent applications), and the applicant, inventor, or owner does not intend to waive, deny, or publicly offer any such invention through its disclosure in this document.

[0052] As used herein, “fiber pulp slurry” refers to a liquid in which fibers are suspended. In a non-limiting example, the liquid includes water, and the fibers include cellulose materials, which include (but are not limited to) fibers derived from paper materials (e.g., (but not limited to) recycled newsprint and / or cardboard).

[0053] As used herein, "pressure plate" refers to a component of a press to which pressure can be applied, causing the material between a pair of pressure plates to bear the applied pressure. In a non-limiting example, the pressure plate may be in a substantially flat (i.e., plate-like) form and made of steel. In other embodiments, the pressure plate may have other shapes and be made of other materials.

[0054] As used in this article, "mold component" refers to a part of a mold whose shape conforms to the side of the product to be produced. Mold components with complementary shapes can be associated in pairs. For example, in such a pair, one mold component may be referred to as side A or cavity side, while the other mold component may be referred to as side B or core side.

[0055] As used herein, "actuator" refers to a device that converts energy (such as voltage, pneumatic pressure, or hydraulic fluid pressure) into motion of a moving part. In some embodiments, an actuator may be a rotary actuator including an electric stepper motor or a servo motor. In some embodiments, an actuator may be a linear actuator including a hydraulic cylinder or a pneumatic cylinder.

[0056] As used herein, "processor" refers to one or more electronic devices capable of reading and executing instructions stored in memory to perform operations on data, which may be stored in memory or provided in the form of data signals. Non-limiting examples of processors include devices referred to as microprocessors, microcontrollers, microcontroller units (MCUs), central processing units (CPUs), digital signal processors, field-programmable gate arrays (FPGAs), and programmable logic controllers (PLCs).

[0057] As used herein, "memory" refers to a non-transitory tangible computer-readable medium used to store information and / or processor-readable instructions for implementing algorithms in a processor-readable format. Non-limiting types of memory include solid-state, optical, and magnetic computer-readable media. Memory can be non-volatile or volatile. Instructions stored in memory can be based on a variety of programming languages ​​known in the art, with non-limiting examples including C, C++, Python™, MATLAB™, and Java™ programming languages.

[0058] System Overview Figures 1 to 5B An embodiment of system 2 for producing and processing molded fiber articles according to this disclosure is shown. As a non-limiting example, the molded fiber article can be a container for packaging food. System 2 includes the following subsystems arranged in the following order from upstream to downstream of the process: wet pressing subsystem 4; wet-to-dry transfer subsystem 6; dry pressing subsystem 8; dry-to-trimming transfer subsystem 10; trimming and pressing subsystem 12; trimming-to-conveyor transfer subsystem 14; and conveyor belt subsystem 16. Figure 6 As shown in the functional block diagram, system 2 also includes a controller 18 operatively connected to the actuators of the aforementioned subsystem. The subsystems are described in more detail below.

[0059] In the illustrated example, the process flow extends along a horizontal longitudinal axis (L) (see, for example, Figure 1 In this specification, reference is made to three mutually orthogonal axes: the horizontal longitudinal axis (L), the horizontal transverse axis (T), and the vertical axis (V). For ease of description, the terms longitudinal and transverse are used to refer to directions parallel to the longitudinal and transverse axes, respectively. Positive signs (+) and arrows on these axes indicate positive directions along these axes, while negative directions are the opposite. Positive longitudinal and negative longitudinal directions can be referred to as forward and backward directions, respectively. Positive transverse and negative transverse directions can be referred to as left and right directions, respectively.

[0060] wet pressure subsystem Figures 7A to 7H Embodiments of a wet pressing subsystem 4 at different operational stages are shown. The purpose of the wet pressing subsystem 4 is to produce wet-pressed articles with desired shapes from fibrous pulp. The wet pressing subsystem 4 includes an open container or pulp tank 20, a wet pressing support frame 22, a forming platen 24, a forming die assembly (forming die) 26, and a forming platen actuator 28. In the illustrated example, the wet pressing subsystem 4 further includes a wet pressing platen assembly 30 having a plurality of wet pressing die mounting surfaces that define a plurality of corresponding wet pressing stations 30a, 30b. A plurality of wet pressing dies (or die assemblies) 32a, 32b are provided, each wet pressing die associated with a corresponding wet pressing station. The wet pressing subsystem 4 further includes a shaft 34, a wet pressing platen actuator 36, and a compression actuator (pressing actuator) 38. The wet pressing subsystem 4 also includes... Figure 6 The controller 18 is shown in the functional block diagram.

[0061] Container 20 is used to contain fiber pulp. Container 20 is open to allow the forming platen 24 to be immersed in the fiber pulp in container 20.

[0062] The wet pressure support frame 22 is used to support the molding platen 24 and the wet pressure platen 30 on the floor surface or other structure, so that the molding platen 24 and the wet pressure platen 30 can rotate relative to the wet pressure support frame 22.

[0063] The forming platen 24 has an attached forming mold 26. Figure 7DThe molding die is used to form a fiber mat, which corresponds to a set of molded fiber articles produced in each cycle of the wet pressing system. In the illustrated example, the fiber mat corresponds to a set of sixteen molded fiber articles. In the illustrated example, the molding die component 26 typically defines the core side of the die.

[0064] The forming plate 24 is rotatably attached to the wet pressure support frame 22, for example, by a shaft 40 supported in a journal bearing attached to the wet pressure support frame 22 so that it can rotate about a transverse axis.

[0065] A forming plate actuator 28 (directly or indirectly via a shaft) is coupled to the forming plate 24 to drive the forming plate 24 to rotate relative to the wet pressure support frame 22. In the embodiment shown in the figures, the forming plate actuator 28 is a rotary actuator including an electric stepper motor or a servo motor. In other embodiments, the rotary actuator may be pneumatically or hydraulically driven. In yet another embodiment, the forming plate actuator 28 may be a linear actuator including a hydraulic cylinder coupled to the forming plate 24 via a cam mechanism to convert the linear motion of the hydraulic cylinder into the rotational motion of the forming plate 24.

[0066] The forming plate actuator 28 drives the forming plate 24 to rotate between immersion orientation and pressing orientation. Figure 7A The forming platen 24 is shown in the immersion orientation (facing down) and immersion position, in which the forming die component 26 is positioned to contact the fiber pulp slurry in the container 20. Figure 7B The forming platen 24, which has moved upward, is shown. Figure 7C The image shows the forming plate 24 rotating about the transverse axis to a middle orientation toward the pressing orientation. Figure 7D The molding platen 24 is shown rotated to the pressing orientation (facing upwards), wherein the molding die component 26 is arranged opposite to one of the wet pressing die components 32, as described below. Thus, in the embodiment shown in the figures, the immersion orientation and the pressing orientation are spaced apart by an angular displacement of 180 degrees.

[0067] In the illustrated example, the multiple wet pressing stations consist of two wet pressing stations, namely a first wet pressing station 30a and a second wet pressing station 30b. Other embodiments may have any integer number of wet pressing stations greater than two. Each wet pressing station has an attached wet pressing die component or die (i.e., a first wet pressing die 32a, a second wet pressing die 32b), which is shaped to cooperate with a forming die to produce the desired wet-pressed article. Figure 7AIn the illustrated embodiment, each wet pressing die 32a, 32b corresponds to a cavity side of the die. Wet pressing stations 30a, 30b are spaced apart from each other on the wet pressing assembly 30 and are respectively alignable with the forming die. In the illustrated example, the first and second wet pressing stations 30a, 30b are spaced apart on opposite sides of the wet pressing platen axis. Thus, when one wet pressing station is oriented upwards, the other wet pressing station is oriented downwards. The shaft 34 is rotatably attached to the wet pressing support frame 22, for example, via a journal bearing attached to the wet pressing support frame 22, which allows the shaft 34 and the attached wet pressing platen assembly 30 to rotate about the transverse wet pressing platen axis.

[0068] The wet press plate actuator 36 is connected via shaft 34 to drive the wet press plate assembly 30 to rotate relative to the wet press support frame 22. In the embodiment shown in the figures, the wet press plate actuator 36 is a rotary actuator including an electric stepper motor or a servo motor. In other embodiments, the wet press plate actuator 36 may have a different form similar to that described above with respect to the molding actuator.

[0069] The wet pressing plate actuator 36 drives the wet pressing plate assembly 30 to rotate, selectively (and sequentially) moving each wet pressing station (i.e., one at a time) to a pressing orientation in which the wet pressing station is positioned opposite the forming plate 24 when the forming plate is in the pressing position. For example, Figure 7D The first wet pressing station 30a is shown with the pressing orientation facing downwards, while the second wet pressing station 30b faces upwards. This is achieved by rotating the wet pressing plate assembly 180 degrees (…). Figure 7G The first wet pressing station 30a is oriented upwards, and the second wet pressing station 30b is oriented downwards.

[0070] The wet pressing plate assembly 30 can also be rotated to a transfer orientation, in which the wet pressing stations 30a and 30b are oriented to facilitate engagement with component handling equipment (e.g., via a transfer subsystem). For example, as Figure 7H As shown, when rotated to the transfer orientation, the first and second wet pressing stations 30a and 30b are vertically oriented and point laterally outward.

[0071] At least one of the forming platen 24 and the wet pressure platen assembly 30 is movably attached to the wet pressure support frame 22 to move between a wet pressure open configuration and a wet pressure closed configuration. A compression actuator 38 is directly or indirectly coupled to the forming platen 24 and / or the plurality of wet pressure plates 30 to drive the forming platen 24 and / or the plurality of wet pressure plates 30 to move between the wet pressure open configuration and the wet pressure closed configuration. In the embodiment shown in the figures, the compression actuator 38 is implemented by a rotary actuator that drives the rotation of a chain lifting mechanism attached to the forming platen 24 to raise or lower the forming platen 24. In the wet pressure open configuration, the forming platen 24 and the wet pressure platen assembly 30 are spaced apart from each other. For example, Figure 7D The forming platen 24 and wet pressing platen assembly 30 are shown in a wet pressing open configuration. In a wet pressing closed configuration, the forming platen 24 is in a pressing orientation (facing upwards), and one of the selected wet pressing stations 30a and 30b is in a complementary pressing position (facing downwards) for compressing the fiber pad between them to form a wet-pressed article. For example, Figure 7E A forming platen 24 in a pressing orientation and a first wet pressing station 30a in a complementary pressing orientation are shown, such that the forming die engages with the first wet pressing die. A compression actuator 38 pushes the forming platen upward to press the forming die against the wet pressing die and form a wet-pressed article. In other embodiments, the compression actuator 38 may drive only the movement of the wet pressing platen 30, or drive the movement of both the forming platen and the wet pressing platen assembly 30.

[0072] refer to Figure 6 The controller 18 (which may be referred to as the wet pressing controller in the context of controlling the wet pressing subsystem 4) includes a processor 42 operatively connected to the forming platen actuator 28, the wet pressing platen actuator 36, the compression actuator 38, and a memory 44. The memory 44 stores instructions executable by the processor 42 to control the forming platen actuator 28, the wet pressing platen actuator 36, and the compression actuator 38, such that these actuators coordinately control the movement of the forming platen 24 and the wet pressing platen 30 to form a product, as described below. Reference Figure 7A The forming platen 24 is in the immersion orientation and immersion position, so that the forming platen 24 contacts the fiber pulp in the storage tank. A vacuum is applied, and as a result, a layer of fiber pulp (fiber pad) is deposited on the forming mold 26.

[0073] refer to Figure 7B The compression actuator 38 then lifts the forming platen 24 to the middle position. (Reference) Figures 7C to 7D The forming plate actuator 28 rotates the forming plate 24 180 degrees around the transverse axis to enter the pressing and orientation phase. (Reference) Figure 7E The compression actuator 38 continues to lift the forming platen 24 to engage with the first wet pressing station 30a (and the mold 32a), such that the fiber pad on the forming mold 24 is compressed between them to form a first wet-pressed fiber pad. The releasable retention of the first fiber pad on the first wet-pressing mold 32a can be assisted by vacuum.

[0074] refer to Figure 7G The combined action of the forming platen actuator 28 and the compression actuator 38 returns the forming platen 24 to the immersion orientation and immersion position, allowing the forming mold 26 to be recoated by the second fiber pad. Simultaneously, the wet pressing platen actuator 36 rotates the wet pressing platen assembly 30 180 degrees about the transverse axis, placing the second wet pressing station 30b in the pressing orientation. (Compared to the previous reference...) Figures 7B to 7EIn a similar manner, the forming platen actuator 28 returns the forming platen 24 to the pressing orientation, and the compression actuator 38 lifts the forming platen 24 to engage with the second wet pressing platen 30b in the pressing orientation, such that the second fiber pad on the forming die 26 is compressed between them to form a second wet-pressed fiber pad. The releasable retention of the second fiber pad on the second wet-pressed die 32b can be assisted by vacuum.

[0075] As a result of this sequence of operations, the first wet pressing station 30a is loaded with the first fiber pad, while the second wet pressing station 30b is loaded with the second fiber pad. (See reference) Figure 7H The compression actuator 38 lowers the forming platen 24 to an intermediate position, and the wet platen actuator 36 rotates the wet platen 30 to a transfer orientation for pickup by the wet-to-dry transfer subsystem 6, as described below. The aforementioned sequence of motion can then be repeated to form additional instances of the first and second fiber pads.

[0076] Dry pressure subsystem Figures 11 to 13 Different views of the dry pressure subsystem 8 in isolated state are shown.

[0077] The purpose of the dry pressing subsystem 8 is to compress and reduce the moisture content of the fiber pad formed by the wet pressing subsystem 4. It should be understood that the terms "wet" in "wet pressing" and "dry" in "dry pressing" are used to distinguish these presses and are not limited by the moisture content of the products produced.

[0078] The dry pressing subsystem 8 includes a plurality of dry pressing stations 46a, 46b (collectively referred to as 46). In the illustrated example, each dry pressing station is part of a single dry press, and each station moves synchronously with the dry press between a die-open position and a die-closed position. In the illustrated example, the number of dry pressing stations is equal to the number of wet pressing stations. In some embodiments, the number of dry pressing stations may be greater than the number of wet pressing stations. In the illustrated embodiment, the wet pressing subsystem 4 has two wet pressing stations 30a, 30b, and the dry pressing subsystem 8 includes two dry pressing stations 46a, 46b. In the illustrated example, a first dry pressing station 46a is associated with a first wet pressing station 30a, i.e., the first dry pressing station 46a is used to process a first fiber mat formed using the first wet pressing station 30a. A second dry pressing station 46b is associated with a second wet pressing station 30b, i.e., the second dry pressing station 46b is used to process a second fiber mat formed using the second wet pressing station 30b.

[0079] Each dry pressing station 46a, 46b is disposed between opposing pressure plate surfaces of the dry press. In the illustrated example, the dry press is configured as a horizontally stacking die machine, having a base supporting a fixed pressure plate, a moving pressure plate, and a central pressure plate disposed between the fixed pressure plate and the moving pressure plate. The first dry pressing station 46a is disposed between opposing surfaces 48a, 48a of the fixed pressure plate and the central pressure plate. The second dry pressing station is disposed between opposing surfaces 48b, 48b of the moving pressure plate and the central pressure plate.

[0080] Each dry-press platen surface 48a, 48b has a dry-press die component 50 mounted thereto, the die component being complementary in shape to the fiber pad formed by the wet-press subsystem 4. In embodiments, one or all dry-press plates may be attached to or integrated with a heat source (e.g., an electric heating element), or define conduits for heating the flow of a fluid (e.g., hot oil or steam) to heat the dry-press die component 50. In the embodiment shown in the figures, the dry-press plates have vertically oriented faces to which the die may be attached. In the illustrated example, the inner dry-press die components 50 (i.e., those mounted to the central platen) are cavity-side die components, while the outer dry-press die components 50 (i.e., those mounted to the stationary and moving plates) are core-side die components.

[0081] Each dry pressing station 46a, 46b can be actuated between a dry pressing open configuration and a dry pressing closed configuration. In the dry pressing open configuration, the dry pressing plates 48 are spaced apart to allow the product to enter between the dry pressing plates 48. In the dry pressing closed configuration, the dry pressing plates 48 are positioned to compress the product between them. Figures 9 to 13 The dry press platen 48 is shown in the dry press open configuration. The dry press can be closed to simultaneously close the first and second dry press stations, thereby producing dry-pressed first and second fiber mats in a single cycle of the dry press.

[0082] To help understand the operation of a dry press configured for stacking dies in two stations, references were also made to... Figure 23A and Figure 23BThe press 52 shown is further described in U.S. Patent Application Publication No. US2016 / 0303785 A1 (Segal; 2016-10-20), the entire contents of which are incorporated herein by reference where permitted. Press 52 has two press stations 53a and 53b. For the first press station 53a, a die assembly 54 is mounted on a stationary pressure plate 56, and a die assembly 58 is mounted on the adjacent side of a central pressure plate 60. For the second press, a die assembly 61 is mounted on a moving pressure plate 62, and a die assembly 64 is mounted on the adjacent side of a central portion 60. The die portions are mounted on and translate along a tie rod 66. The linkage mechanism 68 includes a central link member 70 pivotally connected to a central portion 60; a first link arm 72 pivotally connected at one end to the central link member 70 and at the other end to a fixed pressure plate 56; and a second link arm 74 pivotally connected at one end to the central link member 70 and at the other end to a moving pressure plate 62. A drive device (not shown), such as a hydraulic cylinder or rotary actuator, can be used to drive the press from the open configuration (…). Figure 23A Move to closed configuration () Figure 23B It should be understood that... Figures 9 to 13 The dry press 46 shown can be operated in a similar manner.

[0083] wet to dry transfer system Figure 8 This illustrates an embodiment combining the wet pressure subsystem 4 and the wet-to-dry transfer subsystem 6. Figure 9 and Figure 10 Different views show the combination of wet-to-dry transfer subsystem 6 and dry pressure subsystem 8.

[0084] The purpose of the wet-to-dry transfer subsystem 6 is to transfer the product formed by the wet pressing subsystem 4 to the dry pressing subsystem 8. The wet-to-dry transfer subsystem 6 includes a wet-to-dry transfer support frame 76 and a plurality of wet-to-dry carriers 78a, 78b (collectively referred to as 78). The number of wet-to-dry carriers 78 is at least equal to the number of wet pressing plates 30. In the embodiment shown in the figures, the wet pressing subsystem 4 has two wet pressing plates 30, therefore the wet-to-dry transfer subsystem 6 includes two wet-to-dry carriers 78. The first wet-to-dry carrier 78a is associated with the first wet pressing plate 30a and the first dry press 46a, i.e., the first wet-to-dry carrier 78a is used to transfer a first product produced using the first wet pressing plate 30a to the first dry press 46a; the second wet-to-dry carrier 78b is associated with the second wet pressing plate 30b and the second dry press 46b, i.e., the second wet-to-dry carrier 78b is used to transfer a second product produced using the second wet pressing plate 30b to the second dry press 46b.

[0085] Each wet-to-dry carrier 78 is shaped to hold the product and is movably attached to the wet-to-dry transfer support frame 76 to move between a pick-up position and a drop-off position. In the pick-up position, the wet-to-dry carrier 78 is positioned to receive the product from an associated one of the wet press plates 30 in a transfer orientation. In the drop-off position, the wet-to-dry carrier is positioned to place the product onto an associated one of the dry presses 46. The releasable holding of the product on the wet-to-dry carrier 78 can be assisted by a vacuum.

[0086] At least one wet-to-dry actuator 80 ( Figure 6 A motor is coupled to each wet-to-dry carrier 78 to drive the wet-to-dry carrier 78 to move relative to the wet-to-dry transfer support frame 76 between a pick-up position and a drop-down position. In the embodiment shown in the figures, each wet-to-dry carrier 78 is in the form of a core-side mold component. A motor is coupled to the wet-to-dry carrier 78 to drive its translational movement along an elongated cantilever 82a or 82b (collectively referred to as 82) extending in the longitudinal direction. The cantilever 82 is movably attached to a gantry 84 extending upward from the wet-to-dry transfer support frame 76. A chain drive mechanism drives the movement of the cantilever 82 relative to the gantry 84 in the vertical, longitudinal, and lateral directions. The motor and chain drive mechanism can be considered as embodiments of at least one wet-to-dry actuator 78. For example, Figure 8 A first wet-to-dry carrier 78a in a pick-up position is shown for receiving a first product from a first wet pressure plate 30a in a transfer orientation. This is achieved by moving a first cantilever 82a to its final position relative to the gantry 84 and moving the first wet-to-dry carrier 78a along the first cantilever 82a to its final position. For example, Figure 9 The second wet-to-dry carrier 78b in the lowered position is shown, used to place the second product into the second dry press 46b by placing the second product onto the inner dry press plate 48b of the second dry press 46b. This is achieved by moving the second cantilever 82b to its foremost position relative to the gantry 84 and moving the second wet-to-dry carrier 78b along the second cantilever 82b to its foremost position.

[0087] The wet-to-dry transfer subsystem 6 also includes Figure 6The controller 18 shown in the functional block diagram (which may be referred to as the wet-to-dry controller in the context of controlling the wet-to-dry transfer subsystem 6) is described. The memory 44 stores instructions executable by the processor 42 to control the wet-to-dry actuator 80, thereby moving each wet-to-dry carrier 82 to a pick-up position when the associated wet press platen 30 is in the transfer position and loaded with products, and moving each wet-to-dry carrier 82 to a drop-off position when the associated dry press 46 is in a dry press open configuration to place products into the associated dry press 46. In an embodiment, the first and second wet-to-dry carriers 78 can simultaneously move from their respective pick-up positions to their respective drop-off positions, such that the first and second products are simultaneously loaded into the first and second dry presses 46. Therefore, a single wet press subsystem 4 can simultaneously serve multiple dry presses 46 to improve productivity for the time spent dry pressing products.

[0088] Trimming and Pressing Subsystem Figures 18 to 22 Different views of the trimming and pressing subsystem 12 are shown.

[0089] The purpose of the trimming pressing subsystem 12 is to cut off excess parts (e.g., molding burrs on the periphery of the product) from the product formed by the wet pressing subsystem 4 and dried by the dry pressing subsystem 8.

[0090] The trimming and pressing subsystem 12 includes a trimming press 86, which includes a pair of trimming and pressing plates 88a and 88b (collectively referred to as 88) suitable for trimming products. For example... Figures 18 to 22 A trimming press 86 is shown, having a lower trimming pressing plate 88a and an upper trimming pressing plate 88b. The trimming press 86 is actuable between a trimming press open configuration and a trimming press closed configuration. In the trimming press open configuration, the trimming pressing plates 88 are spaced apart to allow product to enter between the trimming pressing plates 88, such as... Figures 18 to 22 As shown. In the trimming press-close configuration, trimming press plates 88 are positioned to compress the product between them, thereby cutting off excess material from the product. In the illustrated embodiment, the trimming press-close configuration is achieved by lowering the upper trimming press plate relative to the lower trimming press plate. (Although the trimming press-close configuration is not shown in the figures, the operation of the trimming press 86 in this respect is conventional.) Dry to trimming transfer system Figures 14 to 16 Different views are shown of the combination of the dry pressing subsystem 8 and the dry-to-trimming transfer subsystem 10. Figure 17 The dry-to-trimming pressing subsystem 12 is shown in isolation. Figure 18 A view showing the dry-to-trimming pressing subsystem 12 combined with the trimming pressing subsystem 12 is displayed.

[0091] The purpose of the dry-to-trimming transfer subsystem 10 is to move products processed by the dry-pressing subsystem 8 to the trimming and pressing subsystem 12. The dry-to-trimming transfer subsystem 10 includes a dry-to-trimming transfer support frame 90 and a plurality of dry-to-trimming carriers 92a, 92b (collectively referred to as 92). The number of dry-to-trimming carriers 92 is at least equal to the number of dry presses 46. In the embodiment shown in the figures, the dry-pressing subsystem 8 has two dry presses 46, therefore the dry-to-trimming transfer subsystem 10 includes two dry-to-trimming carriers 92a, 92b. A first dry-to-trimming carrier 92a is associated with a first dry press 46a, i.e., the first dry-to-trimming carrier 92a is used to move a first product processed by the first dry press 46a to the trimming press 86; a second dry-to-trimming carrier 92b is associated with a second dry press 46b, i.e., the second dry-to-trimming carrier 92b is used to move a second product processed by the second dry press 46b to the trimming press 86.

[0092] Each dry-to-trimming carrier 92 is shaped to hold the product and is movably attached to the dry-to-trimming transfer support frame 90 to move between a pick-up position and a drop-off position. In the pick-up position, the dry-to-trimming carrier is positioned to receive the product from the associated dry press 46. In the drop-off position, the dry-to-trimming carrier 92 is positioned to place the product onto the trimming press 86. The releasable holding of the product on the dry-to-trimming carrier 92 can be vacuum-assisted.

[0093] At least one dry-to-trimming actuator 94 ( Figure 6 A motor is connected to each dry-to-trimming carrier 92 to drive the dry-to-trimming carrier 92 to move relative to the dry-to-trimming support frame between a pick-up position and a drop-off position. In the embodiment shown in the figures, each dry-to-trimming carrier 92 is in the form of a cavity-side mold component. A motor is connected to the dry-to-trimming carrier 92 to drive its translational movement along an elongated cantilever 96a or 96b (collectively referred to as 96) extending in the longitudinal direction. The cantilever 96 is movably attached to a gantry 98 extending upward from the dry-to-trimming transfer support frame 90. A chain drive mechanism drives the movement of the cantilever 96 relative to the gantry 98 in the vertical, longitudinal, and transverse directions. Furthermore, the motor drives the rotation of the cantilever 96 along its longitudinal axis, such that the dry-to-trimming carrier and the product it holds can be rotated from a vertical orientation to pick up the product from the dry press 46, and rotated to a horizontal orientation to place the product into the trimming press. The motor and chain drive mechanism can be considered as embodiments of at least one dry-to-trimming actuator 94. Reference Figure 14Positioning the dry-to-trimming carrier 92 in the pick-up position to receive products from the dry press is achieved by moving the cantilever 96 to its final position relative to the gantry 98 and moving the dry-to-trimming carrier 92 along the cantilever 96 to the final position so that it can pick up products from the outer dry press platen 48 of the dry press 46. Conversely, the lowering position is achieved by moving the cantilever 96 to its foremost position relative to the gantry 98 and moving the dry-to-trimming carrier along the cantilever 96 to the foremost position, rotating the cantilever 96 about its longitudinal axis to move the dry-to-trimming carrier 92 from a vertical orientation to a horizontal orientation, and moving the cantilever 96 laterally inward to the trimming press 86.

[0094] exist Figures 14-18 In the diagram, cantilever arms 96a and 96b, dry-to-trimming support members 92a and 92b, and related elements are shown in orientations that are not necessarily the same as during operation. Those skilled in the art will understand, based on the description provided herein, the appropriate orientation these components will have during operation.

[0095] The dry-to-trimming transfer subsystem 10 also includes Figure 6 The controller 18 shown in the functional block diagram (which may be referred to as the dry-to-trimming controller in the context of controlling the dry-to-trimming transfer subsystem 10) is shown in the memory 44. The memory 44 stores instructions executable by the processor 42 to control the dry-to-trimming actuator 94 to move each dry-to-trimming carrier 92 to a pick-up position when the associated dry press 46 is in a dry-press open configuration, and to move each dry-to-trimming carrier 92 to a drop-off position when the trimming press 86 is in a trimming press open configuration. In one embodiment, the first and second dry-to-trimming carriers 92 may move sequentially from their respective pick-up positions to their respective drop-off positions, such that the first and second products are loaded into the trimming press 86 one at a time. In other embodiments, where the trimming press is large enough to accommodate two products simultaneously, the first and second dry-to-trimming carriers 92 may move simultaneously from their respective pick-up positions to their respective drop-off positions, such that the first and second products are loaded into the trimming press 86 simultaneously. In either case, a single trimming press 86 is used to serve multiple dry presses 46.

[0096] Conveyor Belt Subsystem Figures 18 to 22 Different views show the combination of the conveyor belt subsystem 16 and the trimming subsystem.

[0097] The purpose of the conveyor subsystem 16 is to remove products processed by the trimming press from the trimming press. The conveyor subsystem 16 includes a pair of electrically powered conveyor belts 100a and 100b (collectively referred to as 100). The first conveyor belt 100a is used to transport a first product processed by the trimming press, and the second conveyor belt 100b is used to remove a second product from the trimming press. Each of the first and second conveyor belts 100b has a first section of conveyor belt laterally adjacent to the trimming press and a second section of conveyor belt extending longitudinally forward from the first section. A stacking subsystem (not shown) is used to transfer and stack products from the first section of conveyor belt onto and on the second section of conveyor belt.

[0098] Trimming to Conveying Device Transfer Subsystem Figure 21 and Figure 22 Different views are shown of the combination of the trimming to conveyor transfer subsystem 14 with the trimming pressing subsystem 12 and the dry to trimming transfer subsystem 10.

[0099] The purpose of the trimming-to-conveyor transfer subsystem 14 is to move products processed by the trimming and pressing subsystem 12 to the conveyor belt 100. The trimming-to-conveyor transfer subsystem 14 includes a trimming-to-conveyor transfer support frame 102 and a plurality of trimming-to-conveyor carriers 104a and 104b (collectively referred to as 104). The number of trimming-to-conveyor carriers 104 is at least equal to the number of dry presses 46. In the embodiment shown in the figures, the dry press subsystem 8 has two dry presses 46, therefore the trimming-to-conveyor transfer subsystem 14 includes two trimming-to-conveyor carriers 104. The first trimming-to-conveyor carrier 104a is used to move a first product processed by the trimming press to the first conveyor belt 100a, and is associated with the first conveyor belt 100a in this sense; the second trimming-to-conveyor carrier 104b is used to move a second product produced by the trimming press to the second conveyor belt 100b, and is associated with the second conveyor belt 100b in this sense.

[0100] Each trimming-to-conveyor carrier 104 is shaped to hold a product and is movably attached to the trimming-to-conveyor transfer support frame 102 to move between a pick-up position and a drop-off position. In the pick-up position, the trimming-to-conveyor carrier 104 is positioned to receive a product from the trimming press. In the drop-off position, the trimming-to-conveyor carrier 104 is positioned to place the product onto the associated conveyor belt 100. The releasable holding of the product on the trimming-to-conveyor carrier 104 can be vacuum-assisted.

[0101] At least one trimming to conveyor belt actuator 106 ( Figure 6A chain drive mechanism is connected to each trimming-to-conveyor carrier 104 to drive the trimming-to-conveyor carrier to move relative to the trimming-to-conveyor support frame between a pick-up position and a drop-off position. In the embodiment shown in the figures, each trimming-to-conveyor carrier 104 is in the form of a core-side mold component. The trimming-to-conveyor carrier 104 is attached to L-shaped arms 108a and 108b (collectively referred to as 108). A motor drives the trimming-to-conveyor carrier 104 to rotate relative to the arms 108 about a longitudinal axis. The arms 108 are attached to a gantry 110 extending upward from the trimming-to-conveyor support frame. A chain drive mechanism drives the arms 108 to move vertically and laterally relative to the gantry 110. The motor and chain drive mechanism can be considered as an embodiment of at least one trimming-to-conveyor actuator 106. Figure 21 The image shows a first trimmed conveyor belt carrier 104a in the lowered position, used to place a first product onto a first conveyor belt 100a. Figure 22 The second trimming conveyor belt carrier 104b is shown in the pick-up position for picking up the second product from the trimming press 86.

[0102] The trimming to conveyor transfer subsystem 14 also includes Figure 6 The controller 18 shown in the functional block diagram (which may be referred to as the trim-to-conveyor controller in the context of controlling the trim-to-conveyor subsystem 14) is shown in the memory 44. The memory 44 stores instructions executable by the processor 42 to control the trim-to-conveyor actuator 106 to move each trim-to-conveyor carrier 104 to a pick-up position and then to a drop-off position when the trim press is in a trim press-open configuration. In one embodiment, the first and second trim-to-conveyor carriers 104a and 104b move sequentially from their respective pick-up positions to their respective drop-off positions, such that the first and second products are unloaded from the trim press 86 onto the conveyor 100 one at a time. In other embodiments, where the trim press is large enough to accommodate two products simultaneously, the first and second trim-to-conveyor carriers 104a and 106 can move simultaneously from their respective pick-up positions to their respective drop-off positions, such that the first and second products are unloaded from the trim press 86 simultaneously.

[0103] System Operation Overview The subsystems of System 2 described above can be combined with each other to produce and process fiber-molded products. Specifically, the wet pressing subsystem 4 sequentially forms two products from the slurry. The wet-to-dry transfer subsystem 6 moves the formed products in parallel to the dry press 46 to dry them simultaneously. The dry-to-trimming transfer subsystem 10 moves the dried products to the trimming press 86 to trim them one by one. The trimming-to-conveyor transfer subsystem 14 moves the trimmed products one at a time from the trimming press 86 to the conveyor belt 100. The aforementioned sequence can be used as follows: Figure 6 It is executed under the control of the controller 18 shown.

[0104] Loading and unloading dry pressure subsystem refer to Figure 24 The dry pressing subsystem 8 is loaded and unloaded via the wet-to-dry transfer subsystem 6 and the dry-to-trimming transfer subsystem 10, respectively. In the illustrated example, the dry pressing subsystem 8 can be loaded and unloaded simultaneously, with each dry press 46 loading and unloading in parallel.

[0105] In the illustrated example, when the dry press 46 of the dry press subsystem 8 is in the dry press open configuration, the wet-to-dry carrier 78 is positioned within each dry press 46, and the dry-to-trimming carrier 92 is also positioned within each dry press 46. The wet-to-dry carrier 78 loads the molded product into each dry press 46 while the dry product is unloaded from each dry press 46 via the dry-to-trimming carrier 92.

[0106] By loading and unloading the dry press 46 of the dry press subsystem 8 simultaneously and in parallel, the overall throughput of the system and method described herein can be increased because less idle time is required when loading and unloading the dry press subsystem 8 while performing both operations simultaneously.

[0107] In some examples, the loading and unloading operations described herein can be modified to be performed partially concurrently, with at least a portion of the loading and unloading processes occurring simultaneously.

[0108] The foregoing description is intended to illustrate the teachings of this disclosure and not to limit the scope of the patent claims granted therefrom. The scope of these claims should be given the broadest interpretation consistent with the description as a whole.

Claims

1. A system for producing molded fiber articles, the system comprising: a) A wet pressing subsystem comprising a forming platen having a forming die mounting surface for carrying a single forming die, and a wet pressing platen assembly having a plurality of wet pressing stations for carrying respective wet pressing dies, wherein the plurality of wet pressing stations include at least a first wet pressing station and a second wet pressing station for carrying a first wet pressing die and a second wet pressing die, respectively, the wet pressing platen assembly being movable relative to the forming platen to alternately align the first wet pressing die and the second wet pressing die with the forming die in a continuous cycle of the wet pressing subsystem, thereby producing a first wet pressing fiber pad and a second wet pressing fiber pad respectively in the continuous cycle, wherein the first fiber pad and the second fiber pad correspond in size and shape to one or more of the molded fiber articles being produced; and b) A dry pressing subsystem comprising a dry press having a plurality of dry pressing stations equal in number to the plurality of wet pressing stations, and including at least a first dry pressing station and a second dry pressing station, the first dry pressing station and the second dry pressing station being configured to receive a first wet pressing pad and a second wet pressing pad, respectively, and the dry press being closable to simultaneously close the first dry pressing station and the second dry pressing station, thereby producing a dry-pressed first fiber pad and a dry-pressed second fiber pad.

2. The system of claim 1, further comprising a wet-to-dry transfer subsystem, the wet-to-dry transfer subsystem including a first wet-to-dry carrier alignable with the first wet pressing station to receive one of the first fiber mats therefrom, and a second wet-to-dry carrier alignable with the second wet pressing station to receive one of the second fiber mats therefrom, and the wet-to-dry transfer subsystem being configured to move each of the first wet-to-dry carrier and the second wet-to-dry carrier to the first dry press and the second dry press, respectively, and to load the first fiber mat and the second fiber mat into the first dry pressing station and the second dry pressing station, respectively.

3. A system for producing molded fiber articles, the system comprising: a) A wet pressing subsystem, the wet pressing subsystem comprising a single forming platen and a wet pressing platen assembly defining a plurality of wet pressing stations, the wet pressing subsystem being configured to produce a plurality of wet-pressed fiber mats, each wet pressing station producing a single wet-pressed fiber mat in a corresponding single cycle of the wet pressing subsystem; and b) A dry pressing subsystem comprising a plurality of dry pressing stations, each dry pressing station being configured to receive one of the wet-pressed fiber mats produced by a corresponding wet pressing station among the plurality of wet pressing stations, and simultaneously closing the dry pressing station to produce a plurality of corresponding dry fiber mats.

4. The system of claim 3, further comprising a wet-to-dry transfer subsystem, the wet-to-dry transfer subsystem comprising a plurality of wet-to-dry carriers, each wet-to-dry carrier corresponding to one of the plurality of wet pressing stations, the wet-to-dry transfer subsystem being configured to load a wet-pressed fiber pad from a corresponding wet pressing station into a corresponding wet-to-dry carrier, and to move each wet-to-dry carrier to a dry press and load the wet-pressed fiber pad into a corresponding one of the dry pressing stations.

5. A method of operating a fiber molding system to produce molded fiber articles, the method comprising: a) Turn on the dry press to simultaneously open the first dry pressing station and the second dry pressing station; b) Load the first wet fiber pad and the second wet fiber pad in parallel into the first dry pressing station and the second dry pressing station, respectively; and c) Unload the first dry fiber pad and the second dry fiber pad in parallel from the first dry pressing station and the second dry pressing station, respectively; Among them, a) and b) are at least partially carried out simultaneously.

6. The method according to claim 5, wherein, The first wet fiber pad and the second wet fiber pad are loaded into a first mold portion on one side of each dry pressing station, and the first dry fiber pad and the second dry fiber pad are unloaded from a second mold portion opposite to the first mold portion at each dry pressing station.

7. The method of claim 5, further comprising: The wet press upstream of the dry press is operated to produce the first wet fiber pad and the second wet fiber pad in an alternating continuous cycle of the wet press.

8. The method according to claim 7, wherein, Producing the first wet fiber mat includes engaging a first wet pressing mold with a molding mold, and producing the second fiber mat includes engaging a second wet pressing mold with the molding mold.

9. The method according to any one of claims 5 to 8, wherein, Loading the first wet fiber pad and the second wet fiber pad into the first dry pressing station and the second dry pressing station respectively includes moving the first carrier and the second carrier of the wet-to-dry transfer system into the first dry pressing station and the second dry pressing station respectively.

10. The method according to any one of claims 5 to 9, wherein, Unloading the first dry fiber pad and the second dry fiber pad from the first dry pressing station and the second dry pressing station respectively includes moving the first and second carriers of the dry to trimming transfer subsystem to the first dry pressing station and the second dry pressing station respectively.

11. A method of operating a dry pressing subsystem to produce fiber pump molded products, the method comprising: a) Load multiple wet fiber pads into the corresponding multiple dry pressing stations in parallel; as well as b) Unload multiple dry fiber pads in parallel from the corresponding multiple dry pressing stations; Among them, a) and b) are at least partially carried out simultaneously.

12. The method according to claim 11, wherein, Loading the plurality of wet fiber pads into the plurality of dry pressing stations includes moving the corresponding upstream carriers of the wet-to-dry transfer system to the plurality of dry pressing stations.

13. The method according to any one of claims 10 to 13, wherein, Unloading the plurality of dry fiber pads from their respective dry pressing stations includes moving the corresponding downstream carriers of the dry-to-trimming transfer subsystem to the respective dry pressing stations.

14. A system for producing fiber-molded articles, the system comprising a wet pressing subsystem, the wet pressing subsystem comprising: a) An open container for holding fiber pulp; b) Wet pressure bracing frame; c) A forming plate having an attached forming die, the forming die being shaped to form the article; wherein the forming plate is rotatably attached to the wet pressing support frame to rotate between an immersion orientation and a pressing orientation, wherein in the immersion orientation the forming die is positioned to contact the fibrous pulp in the container, and in the pressing orientation the forming die is located outside the fibrous pulp in the container; d) A wet pressing platen assembly defining multiple wet pressing stations for holding a plurality of wet pressing dies, each wet pressing die being formed to mate with the forming die to form a fiber pad, the fiber pad corresponding in size and shape to one or more of the articles being produced; the wet pressing platen assembly being rotatable relative to the wet pressing support frame to individually rotate each of the plurality of wet pressing dies to a pressing orientation in which the wet pressing die is disposed opposite to the forming die in the pressing orientation; In this configuration, at least one of the forming platen or the plurality of wet pressing stations is movably attached to the wet pressing support frame to move between a wet pressing open configuration and a wet pressing closed configuration, wherein the forming platen and the plurality of wet pressing stations are spaced apart from each other, and wherein one of the forming platen in the pressing orientation and one of the wet pressing stations in the pressing orientation is positioned to compress the fiber pad between them.

15. The system according to claim 14, wherein, The wet pressure subsystem further includes: a) A forming plate actuator, the forming plate actuator being coupled to the forming plate to drive the forming plate assembly to rotate between the immersion orientation and the pressing orientation; b) A wet-pressing plate actuator, the wet-pressing plate actuator being coupled to the wet-pressing plate assembly to selectively position one of the wet-pressing plate stations in the pressing orientation; and c) A compression actuator coupled to at least one of the forming platen and the wet pressing platen assembly to drive at least one of the forming platen and the wet pressing platen assembly to move between the wet pressing open configuration and the wet pressing closed configuration; and d) A wet press controller including a processor operatively connected to the molding actuator, the wet press platen actuator, the compression actuator, and a memory, the memory including a non-transitory computer-readable medium storing instructions executable by the processor to: i) Control the molding actuator to rotate the molding platen between the immersion orientation and the pressing orientation; ii) the immersion orientation and the pressing orientation; iii) Controlling the wet pressing plate actuator to rotate each of the plurality of wet pressing plate stations to the pressing orientation; and iv) Control the compression actuator to move at least one of the forming platen and the plurality of wet pressing platen stations between the wet pressing open configuration and the wet pressing closed configuration.

16. The system of claim 14, further comprising: a) A trimming pressing subsystem including a trimming press having a pair of trimming pressing plates adapted to trim the fiber pad; wherein the trimming press is actuable between (i) a trimming press open configuration and (ii) a trimming press closed configuration, in which the trimming press open configuration the trimming pressing plates are spaced apart to allow the fiber pad to enter between the trimming pressing plates, and in the trimming press closed configuration the trimming pressing plates are positioned to compress the fiber pad between them; and b) A dry-to-trimming transfer subsystem comprising a dry-to-trimming transfer support frame and a plurality of dry-to-trimming carriers equal in number to the number of dry presses, wherein each of the dry-to-trimming carriers is associated with a different one of the dry presses; wherein each of the dry-to-trimming carriers is shaped to hold a product and is movably attached to the dry-to-trimming transfer support frame to move between a pick-up position for receiving a product from an associated one of the dry presses and a drop-off position for placing the product on the trimming press.

Images