Systems and methods for web-feed dry forming of fiber-based products

Abstract

Methods and systems for producing fiber-based plastic-free products are disclosed, said fiber-based plastic-free products being produced via a web-feed dry molding process. In some embodiments, a method for manufacturing paper-based packaging products includes: conditioning a paper web to optimize its moisture content and treating the paper web with at least one additive to form a conditioned paper web; and dry molding the conditioned paper web under one or both of heat and pressure to produce a plurality of finished paper-based packaging products.

Description

Cross-references to related applications

[0001] This patent document claims priority and benefit to U.S. Provisional Patent Application No. 63 / 609,922, filed December 14, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0002] This technology generally relates to the manufacture of plastic-free, fiber-based products, and more specifically to the design, chemical composition, and tools for dry molding of plastic-free, fiber-based products using substantially dry web or sheet forms. Background Technology

[0003] Molded fiber is a packaging material typically made from pulp from recycled cardboard and is considered an environmentally sustainable packaging option. In recent years, molded pulp manufacturing has become increasingly popular in a wide range of applications, including cups, bowls, and straws. Fiber-based packaging products are biodegradable, compostable, and unlike plastics, do not migrate into the ocean.

[0004] Molded fiber processing can generally be categorized as either “wet” or “dry.” The two most common types of “wet” molding pulp are classified as Type 1 and Type 2. Type 1 wet molding pulp manufacturing (also known as “wet web forming”) uses a fiber pulp made from milled newsprint, kraft paper, or other fibers dissolved in water. A die mounted on a press plate is dipped or submerged in the pulp, and a vacuum is applied to the generally convex back side. The vacuum pulls the pulp onto the die to form the shape of the package. While still under vacuum, the die is removed from the pulp tank, allowing water to drain from the pulp. Air is then blown through a tool to eject the molded fiber sheet. The parts are typically placed on a conveyor inside a drying oven.

[0005] Type 2 wet molding pulp manufacturing is typically used for packaging electronic devices, cell phones, and household goods in containers with specific wall dimensions. Type 2 molding pulp uses the same materials as Type 1 manufacturing and follows the same basic process until a vacuum draws the pulp onto a mold. After this step, the mold is transferred to a fiber packaging unit, and the resulting “wet part” is moved to a hot press, where the fibrous material is compressed and dried to increase density and provide a smooth outer surface finish.

[0006] Unlike wet-process molding pulp manufacturing, dry processing of molding pulp products does not use wet pulp. Instead, it employs substantially dry pulp material to form dry webs, which are then pressed to produce the molding product. For example, air-laid webs are produced by mixing fibers with air to form a uniform air-fiber mixture, which is then pressed or vacuum-drawn into a flat blank. Summary of the Invention

[0007] Methods and systems for producing fiber-based plastic-free products are disclosed, said fiber-based plastic-free products being produced via a web-feed dry forming process (also known as a "roll-feed" or "paper-feed" process). In some aspects, the disclosed web-feed dry forming process is configured to be carried out as a continuous process or a partially continuous process.

[0008] According to various embodiments, a method of manufacturing paper-based packaging products includes: conditioning a paper web to optimize the moisture content of the paper web and treating the paper web with at least one additive to form a conditioned paper web; and dry molding the conditioned paper web under one or both of heat and pressure to produce a plurality of finished paper-based packaging products.

[0009] According to various embodiments, a system for manufacturing paper-based packaging products includes: a conditioning device comprising one or more fluid distribution units and one or more heating units, the conditioning device being configured to condition a paper web fed into the conditioning device by optimizing the moisture content of the paper web and by treating the paper web with at least one additive to form a conditioned paper web; and a dry forming device comprising at least one slitting tool, at least one pressing tool, and at least one cutting tool, the dry forming device being configured to dry mold one or more portions of the conditioned paper web under one or both of heat and pressure to produce a plurality of finished paper-based packaging products.

[0010] According to various embodiments, a web-feed dry forming method includes: adjusting a first region of a continuously or partially continuously fed paper web to optimize moisture content and treating the paper web with at least one additive to form an adjusted web region (which can be done offline or online), wherein the additive may include one or more of reinforcing agents, oleophobic additives, wet steam, dry steam, and / or hydrophobic additives; perforating or pre-cutting the adjusted web region to form a perforated web region; pressing the perforated web region to form a pressed web region; cutting the pressed web region to form a finished product region; transporting the finished product to a storage area; and winding the remaining web region onto a second web roll.

[0011] Various features and characteristics will become apparent from the accompanying drawings and this background section, as well as from the following detailed description and appended claims. Attached Figure Description

[0012] Exemplary embodiments will now be described in conjunction with the accompanying drawings, wherein similar reference numerals denote similar elements, and: Figure 1AThis is a diagram depicting a web-feed dry forming manufacturing method for fiber-based packaging according to this technology.

[0013] Figure 1B This describes an embodiment of the present technology for implementation. Figure 1A A diagram of the system of the method shown.

[0014] Figure 1C This describes an embodiment of the present technology for implementation. Figure 1A The diagram illustrates a system of methods in which paper conditioning is performed "offline," or as a preparatory step for dry forming and transport.

[0015] Figure 1D This describes an embodiment of the present technology for implementation. Figure 1A The diagram illustrates a system of methods in which the conditioned paper web is cut and / or diced prior to the forming stage.

[0016] Figure 2 This is a diagram illustrating a regulating subsystem for performing a web-feed dry forming manufacturing method according to various embodiments of the present technology.

[0017] Figure 3A This is a diagram illustrating a molding subsystem for a web-feed dry forming manufacturing method according to various embodiments of the present technology.

[0018] Figure 3B This is a diagram illustrating a molding subsystem for a web feed dry forming manufacturing method comprising a series of two pressing steps, according to an embodiment of the present technology.

[0019] Figure 4 A portion of a web is shown after a perforation or “pre-splitting” process in a web-feed dry forming manufacturing method according to some embodiments of the present technology.

[0020] Figure 5 This is a flowchart depicting various embodiments of the dry molding process according to the present technology.

[0021] Figure 6 A block diagram of a data processing unit of a fiber-based packaging product manufacturing system configured according to the present technology is shown. Detailed Implementation

[0022] This technology generally relates to advanced systems and methods for web-feed dry forming of molded fiber products. In various embodiments, the disclosed fiber-based web-feed dry forming technology allows fiber webs to flow within a continuous processing chamber and utilizes heat and pressure to reshape the fiber webs to form molded fiber products. The disclosed technology and systems are capable of producing a wide variety of fiber-based products, including paper-based packaging products made from renewable resources such as recycled paper fibers and replanted trees. While the disclosed embodiments primarily relate to the production of paper-based packaging products, it should be understood that paper-based packaging products are used as examples, and the disclosed methods and systems can be implemented or adapted to produce other fiber-based products.

[0023] Unlike existing technologies that require paper pressing, this technology promises to reduce or eliminate creases, wrinkles, and folds in the final product (e.g., at flanges and / or sidewalls). The disclosed technology can be implemented in a wide variety of fiber-based products currently known or developed thereafter, including but not limited to fast-food restaurant (QSR) paper plates, trays, flip-top boxes, bowls, and cups; hot / cold drinking cups; packaging materials for frozen, refrigerated, microwave, and oven-heated food containers; dairy fiber packaging, etc.

[0024] Compared to current wet and dry molding technologies, this technology promises to improve efficiency. For example, wet web molding processes can be difficult to scale up, and therefore products must be produced in relatively small batches. Airflow web forming processes require multiple steps and contact points, which increases the complexity of the web forming process. Wet molding processes also require more time and energy (e.g., for drying) compared to roll-to-roll feeding processes typically used only in the plastics industry. In contrast, this technology promises to enable large-scale molding because the web feeding process can operate continuously or substantially continuously as the fiber web (e.g., paper web) moves through various processes to form large batches of molded products. It should be understood herein that "continuous" means a process or subprocess that is ongoing and has no planned interruption within a certain period or interval, and it should be understood that for continuous processes or subprocesses, interruptions or pauses may occur between periods and intervals. In some embodiments of this technology, the web feeding process can operate partially continuously as the fiber web (e.g., paper web) moves through various processes to form large batches of molded products. In this article, it should be understood that "partially continuous" refers to a process or subprocess that is ongoing but has one or more planned interruptions within a certain period or interval before resuming.

[0025] This article references Figure 1A-6Specific details of several embodiments of the present technology have been described. However, the present technology may be practiced without some of these specific details. In some cases, well-known structures and techniques typically associated with fiber-based molding processes have not been shown in detail so as not to obscure the present technology. Although the terminology used in the description presented below is used in conjunction with the detailed description of certain specific embodiments of this disclosure, it is intended to be interpreted in its broadest and most reasonable manner. Some terms may even be emphasized below; however, any term intended to be interpreted in any limited manner will be so obviously and specifically defined in this Detailed Description section.

[0026] The accompanying drawings illustrate embodiments of the present technology and are not intended to limit its scope. The various depicted elements are not necessarily drawn to scale, and these various elements may be arbitrarily enlarged to improve readability. When component details are not necessary for a full understanding of how the present technology is manufactured and used, such details may be abstracted in the drawings to exclude details such as the position of components and certain precise connections between such components. Many details, dimensions, angles, and other features shown in the drawings are merely for illustrating specific embodiments of this disclosure. Therefore, other embodiments may have different details, dimensions, angles, and features without departing from the spirit or scope of the present technology.

[0027] Figure 1A and 1B A diagram is shown illustrating a web-feed dry molding method 100 for producing fiber-based packaging articles using a fiber-based packaging product manufacturing system 140, according to an example embodiment of the present technology. As discussed below, method 100 includes a first process 110 (“conditioning process”), a second process 120 (“dry molding process”), and optionally a third process 130 (“transport process”), which can be implemented by various embodiments of system 140. Figure 1B The diagram illustrates an embodiment of system 140 of an example embodiment of method 100, wherein a web of fibrous material 150 (e.g., “paper web”) is continuously fed through each of a first process 110, a second process 120, and (optionally) a third process 130 to produce a fiber-based finished packaged product 180.

[0028] Also refer to Figure 1A and 1BIn some embodiments, method 100 includes a first process 110 (“conditioning process”) in which the fibrous material web 150 (e.g., “paper web”) is conditioned with a predetermined moisture content (e.g., optimized moisture content) and / or with one or more additives as the paper web 150 is fed through a first section 141 of the fiber-based packaging product production system 140, thereby producing a conditioned paper web 170, which can then be molded to produce a final product. In some embodiments, for example, a moisture content (MC) optimization or enhancement process is performed to control the amount of water in the paper web 150. In some embodiments of conditioning process 110, the one or more additives may include one or more chemical compounds that can affect the properties and characteristics of the final product, such as increasing the strength of the finished paper-based packaging product and / or reducing its oil, water, or vapor permeability. The additives may be internally conditioned (e.g., intrinsically) in the paper web 150 and / or externally conditioned on the paper web 150 (e.g., by spraying or other deposition techniques) to improve the stiffness, barrier formation, and / or other functions of the conditioned paper web 170. These and other embodiments and implementations of the conditioning process 110 will be discussed in further detail below (in the “conditioning process” section).

[0029] Method 100 proceeds to a second process 120 (“dry molding process”) to dry mold the conditioned paper web 170 in a heat and pressure scheme in a second segment 142 of system 140 to form a fiber-based finished package product 180. Method 100 may further include a third process 130 (“transport process”) to transport the fiber-based finished package product 180 from a third segment 143 of system 140 for product handling, including but not limited to storage, further processing and / or distribution.

[0030] In some embodiments of method 100, the conditioning process 110 is continuous with the dry molding process 120 and the transport process 130. That is, the paper web 150 is continuously fed into a first section 141 for moisture content optimization and additive treatment to form a conditioned paper web 170, and the newly formed conditioned paper web 170 is continuously fed into a second section 142 for dry molding to produce a paper-based finished package product 180, which is then fed into a third section 143 for transport and processing. However, in some embodiments of method 100, the conditioning process 110 is a preliminary process in which the conditioned paper web 170 is stored (e.g., temporarily) and then undergoes the dry molding process 120 to produce the paper-based finished package product 180 and transported for processing.

[0031] like Figure 1BAs shown, in some embodiments of system 140, a substantially flat paper web 150 is continuously fed from a roll 101 configured to distribute paper material into a first section 141, through a second section 142 and a third section 143, and output to a roll 102 configured to be located outside the third section 143. In some example embodiments of system 140, rolls 101 and 102 may be arranged using suitable web feeders, for example, including blanks (e.g., reel structures) and roll feeding mechanisms, the roll feeding mechanism including a belt or line between the reel structures and a motor (not shown) for driving the belt or line movement. Furthermore, for example, system 140 may include a control system 147, which may include associated controller devices or systems, sensors, etc., which may be included in the first section 141 and / or the second section 142 ( Figure 1B (Not shown in the image) includes, for example, humidity sensors, temperature sensors, pressure sensors, pH sensors, etc., and actuator control systems, which are used to operate interconnected fluid distributors, heaters, vacuum and / or air pumps, etc., based on parameters detected by the sensors. The speed of the paper web 150 through the process can be selected based on the properties of the regulating process 110 and the dry molding process 120, as described in further detail below.

[0032] Although Figure 1B An embodiment of paper web adjustment performed "online" (i.e., substantially simultaneously with subsequent operations) is shown, but in other embodiments, Figure 1C This demonstrates that the paper roll can be adjusted "offline" via a separate adjustment process 160. The separate adjustment process 160 can be configured according to various example embodiments of the adjustment process 110. Such embodiments of the method 100, including the offline adjustment process 160, can be used in a fiber-based packaging product manufacturing system 140 (in... Figure 1C The example embodiment shown is implemented as system 145.

[0033] like Figure 1CAs shown, in some embodiments of the offline conditioning process 160, the paper web 150 is advanced from the roll 161 through the first section 141 of the system 149 to the roll 162, and is subsequently stored in a suitable climate-controlled storage facility 165 (also referred to as “storage vault 165”) of the system 140 prior to the implementation processes 120 and 130. In some embodiments, the storage facility 165 may have a humidity level or range between 50% and 99% (e.g., 50%–70%, 50%–94%) to maintain a desired level of moisture content in the paper roll 162. In some embodiments, the humidity of the storage facility 165 may be below 50% or up to 100%. The humidity may be selected in part based on the desired moisture content of the roll 162 during molding, the storage duration of the roll 162, the composition of the roll 162, the time between removal from the storage facility 165 and molding, the time allocated to the conditioning phase, the external environment, and / or other factors related to the roll 162 and / or the molding process. For example, when the roll 162 is stored for a short period of time, the humidity of the storage facility 165 can be higher because the shorter duration reduces the risk of mold growth, and the higher humidity keeps the roll 162 at or near the predetermined moisture content level for dry molding, thereby reducing the total conditioning time (e.g., reducing or eliminating the time required for rehydration). In some embodiments, the storage facility 165 can be controlled to maintain a specific temperature or temperature range, such as 55℉ (12.78°C) to 100℉ (37.78°C).

[0034] In addition, such as Figure 1C As shown, in some embodiments, method 100 includes an offline conditioning process 160 to condition the paper web 150 by altering (e.g., optimizing) its moisture content and treating it with one or more additives, thereby producing a conditioned paper web 170. The conditioned paper web 170 is then placed in a storage vault before the subsequent dry molding process 120 and (optionally) transport process 130 of method 100. In such embodiments, for example, the first segment 141 of system 140 implementing the offline conditioning process 160 may be physically separated from the second segment 142 and the third segment 143 of system 140. In such instances, rolls 161 and 162 (which feed the paper web 150 through the first segment 141 for the offline conditioning process 160) are not connected to rolls 101 and 102 (which feed the (previously stored) conditioned paper web 170 through segments 142 and 143 for the dry molding process 120 and the transport process 130).

[0035] Figure 1D The disclosed technology is shown. Figure 1B An example embodiment of a fiber-based packaging product manufacturing system 140 is described, wherein the system... Figure 1DThe diagram shows system 149, which is configured to partially or completely cut, slit, and / or divide the adjusted paper web 170 as a step prior to the dry forming process 120 of method 100. Figure 1D As shown, in some embodiments, method 100 includes an intermediate cutting process 119 following the conditioning process 110 to divide the conditioned paper web 170 into conditioned paper web portions 170'', such as referred to as "blanks" or "segments". The conditioned paper web segments 170 then continue with the subsequent dry molding process 120 of method 100 (and optionally a transport process 130). In such embodiments of system 149, for example, a cutting and / or slitting device 190 receives the conditioned paper web 170 (e.g., it may be a roll of conditioned paper web 170) and may cut the received conditioned paper web 170 into portions forming segments 170''. The size, shape, and other characteristics of the segments 170'' may be formed (e.g., cut and / or slit) based on predetermined dimensional parameters of the received conditioned paper web 170. For example, implementation of process 119 may configure the segments 170'' to have any desired size prior to the dry molding process 120.

[0036] In some embodiments, for example, the cutting and / or slitting device 190 may include a transverse cutter device comprising one or more blades or other sharp surfaces capable of transversely cutting the adjusted paper web portion 170 into adjusted paper web segments 170''. In some embodiments, for example, the cutting and / or slitting device 190 may include a conveyor unit, for example comprising a feed belt or line between a start point 191 and an end point 129, the feed belt or line being coupled to or integrated with the conveyor unit of the equipment implementing the adjustment process 110 and the dry forming process 120 of system 149. For example, in some embodiments of system 149, process 110 can be implemented by adjusting the roll-to-roll continuous feeding embodiment of process 110, i.e., the adjusted paper web 170 is passed to the conveyor unit (e.g., feed belt or line) of the cutting and / or slitting device 190 to perform intermediate cutting process 119 and to provide the adjusted paper web segment 170'' to the second segment 142 of system 149 (to perform dry forming process 120) along the same or different conveyor units (e.g., feed belt or line) of the second segment 142. In some embodiments, cutting or slitting the continuous paper web 170 into segments 170'' can occur at other stages of method 100, such as before and / or during the adjustment step.

[0037] Choose the characteristics of the paper web The paper web 150 can be produced using a variety of constituent materials and can be supplied in a wide range of weights and thicknesses. Suitable fiber types include, for example, (1) cellulose fibers, such as fluff webs or pulp webs; (2) biological or agricultural waste, such as chitosan flakes, rice husks, wheat or other grain straw, bagasse, etc.; and (3) virgin and recycled fibers, such as kraft paper, cardboard, poster board, etc. The materials can be woven or nonwoven and can be selected from a variety of virgin and recycled materials.

[0038] The basis weight of the 150mm paper width, measured in gsm (grams per square meter), can also be selected depending on the specific application. Generally, unlike conventional pressed paper, high “flowability” can be advantageous, allowing it to withstand the forces applied during the forming process. In some embodiments, the paper basis weight can be between 100 and 1000 gsm (e.g., preferably between 300 and 800 gsm for some embodiments, and about 750 gsm ± 1% for some embodiments). The paper thickness can also vary, but in many embodiments, the paper thickness (caliper measurement) is between 0.2 and 3.0 mm (e.g., preferably 0.4 to 1.3 mm for some embodiments, and about 1.4 mm ± 1% for some embodiments).

[0039] The web itself can be formed using various techniques, such as air-laid, dry-laid, or wet-laid fibrous materials, and can be processed using multiple materials in different proportions or any single material. In some example embodiments, the fiber type includes cellulose fibers, such as fluff web cellulose fibers, pulp web cellulose fibers, or cork cellulose fibers. In some embodiments, the web can be made from other nonwoven materials, recycled materials, virgin materials, and / or combinations thereof.

[0040] Regarding the physical properties of the paper web 150, higher bursting strength, bursting index, and larger tensile elongation are preferred (for conditioning process 110) because conditioning the paper web 150 with such properties can improve the overall yield and product performance characteristics of the paper-based finished packaging product 180. In some embodiments, for example, the paper web 150 may be selected and / or configured with a bursting index between 0.6 and 2.4 kPa / gsm (e.g., preferably between 1.2 and 1.9 kPa / gsm for some embodiments).

[0041] Implementation examples of the selected regulation process In some embodiments of conditioning process 110, for example, the moisture content of the initially fed paper web 150 is altered (e.g., optimized) to a predetermined level to control the amount of water in the paper web 150 prior to the dry molding stage. MC conditioning or optimization can occur before, during, and / or after additive treatment. For example, excessive moisture can have detrimental effects, such as excessive steam causing paper material delamination and / or additive degassing; while insufficient moisture can cause the paper web 150 to break and tear during molding. In some embodiments, MC optimization is performed, for example, based on a specific additive. MC optimization may include adding water and / or moisture to the paper web 150; and / or MC optimization may include applying heat to dry the paper web 150 (partially) to obtain the desired moisture content of the initially fed paper web 150, the paper web 150 during additive treatment, and / or the conditioned paper web 170. The moisture content (MC) of the web 150 can be detected using one or more moisture meters (e.g., infrared sensors) positioned in a straight line with the moving roll to detect the MC of the web 150 before, during, and / or after the conditioning process 110. In such embodiments, the moisture meters may be positioned above and / or below the unfolded web 150 to detect the MC in a first and / or second surface of the web 150. In some embodiments, the MC is determined based on a known dry weight and a measured current weight. For example, the MC detection or determination may be performed before the hydration process to calibrate hydration process parameters based on the current MC of the web 150, and / or as a quality check to confirm that the web 150 is at the appropriate MC for molding. In some embodiments, the MC of the web 150 is known, and parameters for the MC optimization process are selected based on the confirmed MC.

[0042] The conditioning process 110 may include incorporating one or more additives into the paper web 150. For example, to enhance structural stiffness, strength additives may be incorporated into the paper web 150, placed on the surface of the paper web, or otherwise carried by the paper web. Strength additives may include liquid starch, available as Topcat® L98 cationic additive or Hercobond® commercially, ranging from 0.1% to 5%, preferably 0.5% to 2.5% for some embodiments and about 2.0% ± 1% for some embodiments. Alternatively or additionally, liquid starch may be combined with low-charge liquid cationic starches (such as those available as Penbond® cationic additive and PAF 9137 BR cationic additive) to achieve a range of 0.1% to 5%, preferably 0.5% to 2.0% for some embodiments. To increase dry strength, other starches may be used to condition the paper web 150. Examples include polyamide-epidochlorohydrin (PAE) resins such as Kymene 920A, Kymene 1500, or other wet strength additives to achieve a range of 0.1% to 5%, for example, preferably a range of 0.5% to 2.0% for some embodiments.

[0043] The conditioning process 110 may include incorporating one or more additives that enhance the barrier properties of the paper web 150, such as water-repellent agents, hydrophobic additives, oleophobic additives, water vapor barrier agents, and / or oxygen barrier agents. The barrier additives may include stearates, such as zinc stearate and / or magnesium stearate, which have been found to increase the hydrophobicity and oleophobicity of the paper web 150. The stearate additives are dispensed to achieve an internal / external stearate chemical composition between 1.0% and 20.0%. For example, zinc stearate and / or magnesium stearate are dispensed to achieve a stearate chemical composition between 5% and 20% internally or on the surface. For optimal performance, for example, the stearate additives are dispensed to achieve approximately 10%-15% stearate internally or externally.

[0044] In some embodiments, such as for non-disposable products, the paper web 150 may be conditioned with additives having hydrophobic properties. For example, alkyl ketene dimers (AKD) and / or long-chain diene ketones, alkyl succinic anhydrides (ASA), and / or some waxes may be included as additional moisture / water barrier agents. These additives are dispensed to achieve approximately 1%-10% internally or externally, for example, preferably 2%-4% for some embodiments, and approximately 2.3% ± 1% for some embodiments.

[0045] One or more hydrophobic and / or oleophobic additives may also or alternatively include polysaccharides, such as NCC, pectin, and alginate, which have been found to increase the hydrophobic and / or oleophobic properties, as well as water vapor and oxygen barrier properties, of the paper web 150. In some embodiments, the polysaccharide is dispensed to achieve an internal or external chemical composition between 5% and 25%. In selected embodiments, for example, the polysaccharide additive is dispensed to achieve approximately 10% to 15% polysaccharide internally or externally. In some embodiments, crosslinking agents such as citric acid or malic acid may be added to obtain better barrier properties. In some embodiments, plasticizers such as xylitol and polyglycerol may also be added to obtain additional flexibility.

[0046] One or more additives may include one or more proteins or combinations of polysaccharides and proteins, which have been found to increase the hydrophobicity and / or oleophobicity of the paper web 150, as well as its water vapor and oxygen barrier properties. For example, one or more additives may include casein, zein, etc., which are sprayed or otherwise deposited on areas of the web 150 to provide a widely distributed water vapor barrier and / or oxygen barrier. In some embodiments, the protein or protein combination is dispensed to achieve approximately 1%-20% internally or externally, for example, preferably 5%-15% for some embodiments.

[0047] In various embodiments, one or more additives may include one or more fillers that add hydrophobicity and / or oleophobicity, as well as water vapor and oxygen barrier properties and strength properties to the web 150. These fillers may include, for example, clay, MFC, MCC, and / or CNF. In some embodiments, proteins are dispensed to achieve approximately 1%-20%, for example, preferably 2.5%-10%, internally or externally. Fillers may be impregnated or otherwise added to the interior of the web 150 itself to increase the density and porosity of the web 150. In some embodiments, fillers may be disposed (e.g., sprayed) on the surface of the web 150. In some embodiments, conditioning processes may include disposing of fillers and proteins such that they can work together to provide oxygen or water vapor barrier properties.

[0048] In various embodiments, one or more additives may comprise water-soluble polymers used as strength additives or stabilizers. These polymers may include polyvinyl alcohol (PVA), modified starch, carboxymethyl cellulose (CMC), with or without crosslinking agents and / or plasticizers. These polymers are dispensed to achieve approximately 1%-25% internally or externally, for example, preferably 2.5%-15% for some embodiments.

[0049] In some embodiments, one or more laminates (additional layers) may be bonded to the surface of the paper web 150 (e.g., the top and / or bottom sides) to provide selected properties that enhance the molding process and / or the finished product. For example, the laminated layers may include biopolymer films such as polylactic acid (PLA), thermoplastic starch, and cellulose acetate (CA) and polyhydroxybutyrate (PHB).

[0050] Figure 2 A diagram depicts a conditioning subsystem implemented in a first segment 141 of a fiber-based packaging product manufacturing system 140 for performing a conditioning process 110 according to various embodiments of method 100. In some embodiments, for example, the conditioning process 110 may include feeding a paper web 150 into a chamber 141C of the first segment 141, the chamber including a plurality of nozzles or other dispensers 201 and / or 202 respectively located above and / or below the feed belt or line 141F of the moving paper web 150. For example, when the paper web 150 moves laterally through the exemplary chamber 141C during the conditioning process 110, at least one upper nozzle 201a, 201b disposed above the feed belt or line 141F in the upper region of the chamber 141C may dispense one or more additives; and / or at least one lower nozzle 202a, 202b disposed below the feed belt or line 141F in the lower region of the chamber 141C may dispense one or more additives. The sample dispenser is configured to introduce one or more additives into the environment, either intrinsically or extrinsically. The additives can be provided online or offline, as described above. Figure 1B and Figure 1C As described. In some instances, conventional methods of applying liquids or solids can be used to chemically apply one or more additives to the paper web 150. Some examples include high-pressure or low-pressure spraying, aerosols, atomization, saturated high temperatures, dry steam, wet steam, etc. In some embodiments, only one side of the paper web 150 is treated; in other embodiments, both sides are treated. Both sides can be treated with the same additive or different combinations of additives.

[0051] Moisture content (MC) optimization may require paper web wetting or drying. This process can be implemented to provide a desired (necessary) moisture content parameter (MC%) as defined by product and process requirements (e.g., increased yield, strength, barrier properties, or others), which may be in the range of 0%-25%, or more preferably in the range of 6%-20%. For example, in some applications of the web-feed fiber material dry forming method 100, the moisture content parameter of the paper web 150 may be adjusted to be in the range of 10%-12% during conditioning process 110, for example, prior to the dry forming process 120.

[0052] In some embodiments of conditioning process 110, multiple nozzles or other dispensers 201 and / or 202 may be configured to spray water or provide steam at the paper web 150 to provide moisture while continuously feeding through chamber 141C, thereby obtaining a desired moisture content parameter (MC%). For example, for a paper web 150 with a lower MC% than desired, the preceding nozzles 201a, 201b may be used to provide water or steam to bring the paper web 150 to the desired MC% before the subsequent nozzles 201b, 202b. For example, one or more additives may be applied to the paper web 150 with the desired MC% using the subsequent nozzles for appropriate conditioning.

[0053] In some embodiments of the first section 141, for example, the first section 141 may include one or more heating units 203 (in Figure 2 The diagram shows heating units 203a above and 203b below the continuously fed paper web 150 during conditioning process 110. One or more heating units 203 may be used to provide heat to dry the paper web 150 to a desired moisture content and / or a desired temperature, for example, to apply additives and / or to prepare the conditioned paper web 170 for subsequent dry forming process 120.

[0054] In some embodiments, for example, one or more heating units 203 may be used to bring the surface of the conditioned (or unconditioned) paper web 150 to a desired temperature, for example, to cure, dry, or to allow additives to diffuse through the paper web 150, depending on the application. In some embodiments, for example, one or more heating units 203 may include induction heating devices or radiant heating devices. In some embodiments of the first segment 141 of system 140, other components (not shown) may be included, such as UV lamps, sensors, and / or fans or other mechanisms, to induce laminar or turbulent flow within the conditioning chamber 141C.

[0055] For example, in some embodiments, one or more heating units 203 (individually and / or in combination with multiple nozzles or other distributors 201 and / or 202) may be configured to produce a desired moisture content (e.g., 10%-12% MC%), for example, prior to the dry molding process 120, by treating the fiber web with wet steam or saturated dry steam at a temperature between 135°C and 150°C.

[0056] In some embodiments of the conditioning process 110, for example, MC% optimization may be performed in the pre-conditioning zone of the first section 141 prior to the additive deposition or integration zone of the first section 141.

[0057] In some embodiments, such as example system 145 (in Figure 1CAs shown in the embodiment illustrated in [illustration], the storage device 165 can be set to suitable temperature, pressure, and humidity to achieve a specified moisture content of the paper material (on the roll 162) after conditioning 160. Preferably, the environment is controlled to achieve a roll web moisture content between 0% and 25% prior to the dry molding process 120, for example, including a moisture content between 6% and 20% for some embodiments, and preferably, for some embodiments, 10% to 12% MC.

[0058] In some embodiments of conditioning process 110, multiple nozzles or other dispensers 201 and / or 202 include spray nozzles that, for example, spray additives onto the surface of the paper web as it is continuously fed in the first section 141. In some embodiments, for example, vapor deposition of the additive is achieved using a vapor (gase form). In some embodiments, for example, aerosols (suspended liquids and / or solids) are deployed in a chamber used in conjunction with conditioning 110. In some embodiments, for example, masking is used to selectively treat areas of the paper web 150 while leaving other areas untreated. Typically, the speed of the paper web 150 and the deposition rate of the additives are fine-tuned to achieve the desired internal chemical composition of the finished product.

[0059] The additives selected for process 110 may, among other things, depend on the structural properties and intended use of the finished product 180 obtained by method 100.

[0060] In some embodiments, the target pH range for the paper web 150 is 4.0 to 12.0, preferably 8.0 to 10.0 for some implementations. This pH will vary depending on the properties of the pulp material and the additives dispensed during conditioning. Note that the internal chemical composition, pH, and other inherent properties of the finished product can be correlated experimentally with process parameters used for nozzles 201 and 202, heater 203, etc.

[0061] Example of selecting a dry molding process Figure 3A and 3B An example embodiment of a dry molding process 120 for forming a paper-based finished packaging product 180 is shown. Figure 3A The process involving a single pressing step 122 is demonstrated, and Figure 3B The process involving two pressing steps is illustrated, namely, a first pressing process 122A and a second pressing process 122B, which can be carried out at different pressures / temperatures, as described below. Figure 3A In some embodiments of the single pressing step process shown, for example, the single pressing process 122 can be implemented by a flattener 322. Figure 3BIn some embodiments of the two-pressing-step process shown, for example, the first pressing process 122A can be implemented by a first flattener 322A, and the second pressing process 122B can be implemented by a second flattener 322B; while in some embodiments of the two-pressing-step process, for example, the first pressing process 122A and the second pressing process 122B can be implemented by a single press having multiple flatteners (e.g., the first flattener 322A and the second flattener 322B).

[0062] Now for reference Figure 3A In the illustrated embodiments, for example, the dry molding process 120 may include a series of three processes: a piercing (or pre-cutting) process 121, a pressing process 122, and a cutting process 123.

[0063] In some example embodiments, the perforation process 121 includes cutting, punching, and / or slicing the adjusted paper web 170 in a predetermined arrangement and cutting, punching, and / or slicing it to a predetermined depth to facilitate paper deformation during subsequent steps. For example, cutting elements (e.g., blades) may be patterned and / or moved to perforate the paper, thereby creating a pattern of cut lines along the web 150. The perforation process 121 may provide a form of stress relief that prevents or reduces the likelihood of paper tearing and folding during forming and allows for deeper stretching of the product and reduced trimming waste. This allows multiple individual molding tools to be positioned adjacent to each other, enabling the simultaneous formation of multiple different molded parts during a single forming operation (referred to as “cavitation”). For example, an optional slicing step in the perforation process 121 may help define and facilitate the formation of multiple cavities for the final product, such that the same multiple cavities formed at the perforation process 121 avoid interfering with the formation of adjacent cavities during dry molding steps. Therefore, the cavitation provided by the perforation process 121 improves the efficiency of the system while making optimal use of the web 150 (e.g., by reducing waste).

[0064] Figure 4 A diagram of an regulated paper web 470 for example web feed is shown, wherein a matrix of vertical and horizontal slits 400 is formed in the regulated paper web 470 near the periphery of the area to be compressed in a subsequent step of the dry forming process 120. It will be understood that... Figure 4 The examples shown are by no means limiting, and perforations or slits of any suitable shape, spacing, position, and depth can be used in any particular application.

[0065] Following the perforation process 121, which includes an optional pre-cutting step, the adjusted paper web 170 moves through the second section 142 to reach the pressing step 122. Figure 3A ) or pressing steps 122A, 122B ( Figure 3B (a sub-section of ). See reference. Figure 3A For example, thermoforming or cold forming is performed, in which the perforated paper web 170P is pressed between the upper and lower halves of flattener 322 (upper flattener 322U and lower flattener 322L), thereby producing a preliminary product structure 170PP. The force, speed, and surface characteristics of the upper and lower halves of flattener 322 can vary according to the desired properties, structure, and attributes of the final product 180.

[0066] refer to Figure 3B In the two-step pressing embodiment, the first pressing process 122A involves pressing the perforated paper web 170P to an optimized percentage (e.g., 5%-90%) prior to the final pressing process 122B. This final pressing process can pre-form the first-pressed paper structure 170PF to prepare for the preliminary product structure 170PP prior to the final patterning / cutting process 123, thereby producing the final product and increasing yield. This exemplary two-step pressing process 122A, 122B can also achieve undercut, snap-fit ​​features, and is particularly effective in forming certain types of caps, deeper drawn products, and low negative draft angles. Forming conditions can be low to high pressure (e.g., 20-4000 psi) and low to high temperature (e.g., standard room temperature to 500℉), depending on the application.

[0067] During the example second pressing process 122B, for example, hot pressing / forming can be performed within a specified moisture content range of about 0-25%. The pressing temperature is preferably in the range of 210°–500℉, for example, preferably between 260°–430℉ for some embodiments. The pressure required for dry forming of the paper fibers is in the range of 22-6,000 psi, for example, preferably between 200-4,000 psi (e.g., 350-750 psi) for some embodiments, depending on the product geometry and other factors known to those skilled in the art. For example, a pressure range of 200-4000 psi (e.g., 1.4-27.6 MPa) may be required to form the geometry and / or at least a portion of the area of ​​the first pressed paper structure 170PF in preparation for the preliminary product structure 170PP. The dwell time for applying forming pressure to either or both of the first and second pressings can be a duration of 0.1-3.0 seconds (e.g., 0.2-2 seconds).

[0068] refer to Figure 3A and Figure 3BBoth processes, following the pressing process 122, involve die-cutting the pressed area (i.e., the preliminary product structure 170PP) of the adjusted paper web 170 according to a predetermined pattern during the cutting process 123, for example, to separate the components into individual pieces. In some example embodiments, the preliminary product structure 170PP may be cut around the perimeter of each component, or smaller areas may remain attached prior to transport. Various finishing methods can be employed in this process 230, such as steel ruler punching, matching metal, laser cutting, etc.

[0069] In some implementations of the dry molding process, the molded final part (e.g., a lid for a container such as a margarine bucket) may be formed through the second section of system 140 using one or more of the following operating conditions: (i) a tool temperature of 150°C, (ii) a molding pressure in the range of 450-750 psi for structures with a wall thickness of about 0.8 mm and 700-800 gsm (e.g., for surface areas of a particular end product type, such as a lid), and / or (iii) a molding dwell time of 0.5 seconds at pressure.

[0070] Implementation examples of the transportation process After the adjusted paper web 170 (e.g., preliminary product structure 170PP) has been formed and die-cut to produce paper-based finished packaged products 180 (i.e., multiple individual paper-based packaged products), a transport process 130 is implemented to properly remove the finished product from the excess paper web portion after the cutting process 123 (e.g., before the remaining portion of the web is wound onto the web rewind roll 102). Removal of the finished product 180 can be accomplished by a pick-and-place robot or by any other electromechanical equipment configured to remove and stack the finished product 180. In some embodiments of the transport process 130, for example, the removed finished product 180 can be placed in a storage container (e.g., a transport and / or storage box) for various subsequent uses. In some embodiments of the transport process 130, process 130 may include popping and / or stacking the final product 180 for packaging or transfer to coating operations, printing operations, or others.

[0071] Figure 5A flowchart illustrating an example embodiment of a method 500 for producing a paper-based packaging article according to method 100 is shown. In some embodiments, for example, method 500 includes a paper conditioning process 501 according to an example embodiment of conditioning process 110. Method 500 includes a perforation process 502 according to an example embodiment of perforation process 121. Method 500 includes a pressing process 503 according to an example embodiment of a single pressing process 122 or a double pressing process 122A, 122B. Method 500 includes a die-cutting process 504 according to an example embodiment of a cutting / patterning process 123. Method 500 includes a transport process 505 according to a transport process 130. Additional processes and / or steps may also be included within the process flow of method 500, for example, depending on the application.

[0072] In some example embodiments of method 500, the final product 180 may be aggregated (e.g., recycled) after its applicable packaging use, such that the aggregated recycled packaging product is rewound in a skeleton and processed into fiber webs for use as raw material in another embodiment of method 100.

[0073] Figure 6 A fiber-based packaging product manufacturing system 140 is shown. Figure 1BThe diagram below shows a block diagram of an example embodiment of a data processing unit. System 140 may include one or more data processing units associated with segments of system 140 (such as first segment 141, second segment 142, and / or third segment 143). The data processing unit of system 140 includes at least one processor for processing data, at least one memory communicating with the processor for storing data, and / or input / output units (I / O) for interfacing the processor and / or memory with other segments, modules, units, or devices of system 140 or external devices. For example, the processor may include a central processing unit (CPU), a graphics processing unit (GPU), and / or a microcontroller unit (MCU). For example, the memory may include and store processor-executable code that, when executed by the processor, configures the data processing unit to perform various operations, such as receiving information, commands, and / or data, processing information and data, and transmitting or providing information / data to another device. In some implementations, the data processing unit can transmit raw or processed data to a computer system or communication network accessible via the Internet (referred to as the "cloud"), which includes one or more remote computing processing devices (e.g., servers in the cloud). To support the various functions of the data processing unit, memory can store information and data such as instructions, software, values, images, and other data processed or referenced by the processor. For example, the storage function of the memory unit can be implemented using various types of random access memory (RAM) devices, read-only memory (ROM) devices, flash memory devices, and other suitable storage media. The I / O of the data processing unit can interface the data processing unit with a wireless communication unit to utilize various types of wired or wireless interfaces compatible with typical data communication standards, for example, for communication between the data processing unit and other devices, such as wired or wireless communication devices (e.g., tablet computers, laptop computers, smartphones, or other computers or computing devices) communicating with the data processing unit of system 140. For example, the data processing unit can communicate wirelessly via a wireless transmitter / receiver (Tx / Rx) unit, including but not limited to Bluetooth, Bluetooth Low Energy (BLE), Zigbee, IEEE 802.11, Wireless Local Area Network (WLAN), Wireless Personal Area Network (WPAN), Wireless Wide Area Network (WWAN), WiMAX, IEEE 802.16 (Global Microwave Access Interoperability (WiMAX)), 3G / 4G / LTE / 5G / 6G cellular communication methods, NFC (Near Field Communication), and / or parallel interfaces or others. The I / O of the data processing unit can also interface with other external interfaces, data storage sources, and / or visual or audio display devices to retrieve and transmit data and information that can be processed by the processor, which is stored in a memory unit or displayed on the output unit of the system 140 or an external device.For example, the display unit of system 140 may be configured to communicate data with the data processing unit via I / O, for example, to provide visual displays, audio displays, and / or other sensory displays that generate user interfaces for software applications for health management using the disclosed techniques. In some instances, the display unit may include various types of screen displays, speakers, or printing interfaces, such as, but not limited to, light-emitting diode (LED) or liquid crystal display (LCD) monitors or screens, cathode ray tubes (CRTs) as visual displays; audio signal converters as audio displays; and / or toner, liquid inkjet, solid ink, dye sublimation, inkless (e.g., thermal or UV) printing equipment, etc.

[0074] In many cases, techniques related to additives, paper composition, etc., used in wet molding can be applied to dry molding according to this technology. In this regard, the above-described systems and methods are incorporated herein by reference in their entirety and for all purposes: U.S. Patent Publication No. 2020 / 0206984, “Methods, Apparatus, and Chemical Compositions for Selectively Coating Fiber-Based Food Containers”; US10428467, “Methods and Apparatus for Manufacturing Fiber-Based Meat Products”; US9988199, “Methods and Apparatus for Manufacturing Fiber-Based Microwavable Food Containers”; and US10036126, “Methods for Manufacturing Fiber-Based Beverage Caps”. US10124926 "Methods and Apparatus for Manufacturing Fiber-Based Collapsible Packaging Assemblies", and US10124926 "Methods and Apparatus for Manufacturing Fiber-Based Collapsible Packaging Assemblies".US9856608 "Methods for Manufacturing Fiber-Based Product Containers", US10087584 "Methods and Apparatus for Manufacturing Fiber-Based Meat Containers", US9869062 "Method for Manufacturing Microwavable Food Containers", US10377547 "Method and Apparatus for In-line Die Cutting of Vacuum Formed Molded Pulp Container", and US10240286 "Die Press Assembly for Drying and Cutting Molded Fiber Components" US10683611 “Method for Simultaneously Pressing and Cutting a Molded Fiber Part” and US10683611 “Method for Simultaneously Pressing and Cutting a Molded Fiber Part”.

[0075] Example In some embodiments of the present technology (Example A1), a method of manufacturing paper-based packaging products includes: conditioning a paper web to optimize the moisture content of the paper web and treating the paper web with at least one additive to form a conditioned paper web; and dry molding the conditioned paper web under one or both of heat and pressure to produce a plurality of finished paper-based packaging products.

[0076] Example A2 includes a method according to any one of Example A1 or Examples A1-A32, wherein the dry molding comprises: perforating a first region of the adjusted paper web to form a plurality of cavities in the first region; pressing the first region of the adjusted paper web to form a pressed web region; and cutting the pressed web region to form a cut product region, thereby producing the plurality of paper-based finished packaging products.

[0077] Example A3 includes the method according to any one of Example A2 or Examples A1-A32, wherein the perforation includes applying a plurality of slits in the first region, the plurality of slits forming a plurality of cavities for the dry molding to produce the paper-based finished package product.

[0078] Example A4 includes the method according to any one of Example A3 or Examples A1-A32, wherein the plurality of cavities provide stress relief during the pressing to prevent the regulated paper web from tearing and folding.

[0079] Example A5 includes the method according to any one of Examples A2 or A1-A32, wherein pressing the first region includes pressing a die structure on one or more portions of the first region of the adjusted paper web to a predetermined depth to facilitate deformation of the first region.

[0080] Example A6 includes the method according to any one of Example A2 or Examples A1-A32, wherein the pressing includes a first pressing operation and a second pressing operation, wherein at least one of pressure and temperature differs between the first pressing operation and the second pressing operation.

[0081] Example A7 includes the method according to any one of Example A2 or Examples A1-A32, wherein the pressing is performed at a molding tool temperature of 100°C to 150°C.

[0082] Example A8 includes the method according to any one of Example A2 or Examples A1-A32, wherein the pressing comprises applying a molding pressure of 350 psi to 750 psi.

[0083] Example A9 includes the method according to any one of Example A2 or Examples A1-A32, wherein the pressing includes a dwell time of applying molding pressure for a duration of 0.2 seconds to 2 seconds.

[0084] Example A10 includes the method according to any one of Examples A2 or A1-A32, wherein the cutting includes die-cutting at least a portion of the pressed web region in a predetermined pattern to divide the pressed web region into individual sheets corresponding to individual paper-based finished packaging products among the plurality of paper-based finished packaging products.

[0085] Example A11 includes the method according to any one of Example A1 or Examples A1-A32, wherein optimizing the moisture content includes applying wet or dry steam to the paper web prior to forming the conditioned paper web.

[0086] Example A12 includes the method according to any one of Example A11 or Examples A1-A32, wherein the application of the wet steam or the dry steam is carried out in a temperature range of 100°C to 150°C.

[0087] Example A13 includes the method according to any one of Example A1 or Examples A1-A32, wherein the moisture content of the conditioned paper web is in the range of 10% to 12% prior to the dry molding.

[0088] Example A14 includes the method according to any one of Example A1 or Examples A1-A32, wherein the moisture content of the conditioned paper web is at most 20% prior to the dry molding.

[0089] Example A15 includes the method according to any one of Example A1 or Examples A1-A32, wherein adjusting the paper web with at least one additive includes applying a variety of chemical compounds to enhance at least one property of the paper web.

[0090] Example A16 includes the method according to any one of Example A15 or Examples A1-A32, wherein at least one enhancing property includes increased strength, increased stiffness, and reduced permeability to oil, water, or vapor.

[0091] Example A17 includes the method according to any one of Examples A15 or A1-A32, wherein the plurality of chemical compounds include liquid starch or alkyl ketene dimer (AKD).

[0092] Example A18 includes the method according to any one of Example A17 or Examples A1-A32, wherein the liquid starch is in the range of 0.5% to 2.5%.

[0093] Example A19 includes the method according to any one of Example A17 or Examples A1-A32, wherein the liquid starch is in the range of 0.1% to 5.0%.

[0094] Example A20 includes the method according to any one of Example A17 or Examples A1-A32, wherein the AKD is in the range of 1.0% to 4.0%.

[0095] Example A21 includes the method according to any one of Example A17 or Examples A1-A32, wherein the AKD is in the range of 0.5% to 10.0%.

[0096] Example A22 includes the method according to any one of Example A21 or Examples A1-A32, the method further comprising transporting the paper-based finished packaged product for storage or subsequent operations.

[0097] Example A23 includes the method according to any one of Example A22 or Examples A1-A32, wherein the subsequent operation includes one or both of a coating operation and a printing operation.

[0098] Example A24 includes the method according to any one of Example A22 or Examples A1-A32, the method further comprising moving the remaining paper web to the final web roll.

[0099] Example A25 includes the method according to any one of Example A1 or Examples A1-A32, wherein the conditioning includes continuously feeding the paper web into a conditioning unit of the system such that the conditioned paper web formed by the conditioning is continuously fed into a dry molding unit of the system to undergo the dry molding and produce the paper-based finished packaging product.

[0100] Example A26 includes the method according to any one of Example A1 or Examples A1-A32, the method further comprising storing the conditioned paper web in a climate-controlled storage unit.

[0101] Example A27 includes the method according to any one of Example A1 or Examples A1-A32, the method further comprising dividing the adjusted paper web into a plurality of portions to form adjusted paper web segments.

[0102] Example A28 includes the method according to any one of Example A27 or Examples A1-A32, wherein the splitting includes cutting the adjusted paper web using a cross-cutting machine.

[0103] Example A29 includes the method according to any one of Example A27 or Examples A1-A32, wherein the segmentation includes cutting the adjusted paper web to form the adjusted paper web segments.

[0104] Example A30 includes the method according to any one of Example A1 or Examples A1-A32, wherein the paper web is provided from an initial web roll.

[0105] Example A31 includes the method according to any one of Example A1 or Examples A1-A32, wherein the paper web has one or both of a weight basis of 300 gsm to 800 gsm and a paper thickness of 0.2 mm to 3.0 mm.

[0106] Example A32 includes the method according to any one of Example A1 or Examples A1-A31, wherein the paper web has one or both of a weight basis of 100 gsm to 1,000 gsm.

[0107] In some embodiments of the present technology (Example A33), a system for manufacturing paper-based packaging products includes: a conditioning device comprising one or more fluid distribution units and one or more heating units, the conditioning device being configured to condition a paper web fed into the conditioning device by optimizing the moisture content of the paper web and by treating the paper web with at least one additive to form a conditioned paper web; and a dry forming device comprising at least one slitting tool, at least one pressing tool, and at least one cutting tool, the dry forming device being configured to dry mold one or more portions of the conditioned paper web under one or both of heat and pressure to produce a plurality of paper-based finished packaging products.

[0108] Example A34 includes a system according to any one of Example A33 or Examples A33-A35, wherein the system further comprises: a product transport device including pick-up and place means, the product transport device being configured to transport the plurality of paper-based finished packaged products for storage, distribution or subsequent operations.

[0109] Example A35 includes the system according to any one of Example A33 or Examples A33-A34, wherein the system is configured to implement the method according to any one of Examples A1-A32.

[0110] In some embodiments of the present technology (Example A36), a method of manufacturing a paper-based packaging product includes: providing a first web comprising a continuous paper web; conditioning the continuous paper web to optimize moisture content and treating the paper web with at least one additive to form a conditioned paper web; perforating a first region of the conditioned paper web to form a plurality of cavities in the first region; pressing the first region of the conditioned paper web to form a pressed web region; cutting the pressed web region to form a plurality of paper-based finished packaging products; transporting the paper-based finished packaging products to a storage area; and moving the remaining portion of the paper web to a second web.

[0111] Example A37 includes the method according to any one of Example A36 or Examples A36-A39, wherein the pressing step includes a first pressing operation and a second pressing operation, wherein at least one of pressure and temperature differs between the first pressing operation and the second pressing operation.

[0112] Example A38 includes the method according to any one of Example A36 or Examples A36-A39, wherein the at least one additive includes one or more of a reinforcing additive, an oleophobic additive, or a hydrophobic additive.

[0113] Example A39 includes the method according to any one of Example A36 or Examples A36-A38, wherein the method includes at least one feature of the method according to any one of Examples A1-A32.

[0114] In some embodiments of the present technology (Example A40), a system for manufacturing paper-based packaging products includes: a conditioning device comprising one or more fluid distribution units and one or more heating units, the conditioning device being configured to condition a paper web fed into the conditioning device by optimizing the moisture content of the paper web and by treating the paper web with at least one additive to form a conditioned paper web; a cutting device comprising one or more blades that cross-cut the conditioned paper web into conditioned paper web segments; and a dry forming device comprising at least one slitting tool, at least one pressing tool, and at least one cutting tool, the dry forming device being configured to dry mold one or more portions of the conditioned paper web segments under one or both of heat and pressure to produce a plurality of finished paper-based packaging products.

[0115] Example A41 includes a system according to any one of Example A40 or Examples A40-A49, wherein the conditioning device includes one or more sensors selected from the group consisting of a humidity sensor, a temperature sensor, a pressure sensor, and a pH sensor, the one or more sensors being operable to detect parameters associated with the moisture content of the paper web before and / or after the optimization or treatment performed by the conditioning device.

[0116] Example A42 includes a system according to any one of Examples A41 or A40-A49, wherein the regulating device includes one or more actuator devices that communicate with the one or more sensors and with one or more fluid distribution units and one or more heating units.

[0117] Example A43 includes a system according to any one of Examples A42 or A40-A49, wherein the one or more actuator devices are configured to control one or both of the fluid dispensing operations and heating operations performed by one or both of the one or more fluid dispensing units and the one or more heating units based at least in part on the parameters detected by the one or more sensors.

[0118] Example A44 includes a system according to any one of Examples A43 or A40-A49, the system further comprising a computing device including a processor and a memory, the computing device communicating with at least one of the regulating device, the cutting device, or the dry forming device, the computing device having a controller module communicating with the one or more sensors and the one or more actuator devices, and being configured to process signals associated with the moisture content converted by the one or more sensors and generate the parameters, and analyze the parameters relative to a predetermined moisture content parameter to determine control instructions to be provided to the actuator for controlling one or both of the fluid dispensing operation and the heating operation.

[0119] Example A45 includes a system according to any one of Example A40 or Examples A40-A49, wherein the cutting device includes a conveyor unit comprising a feed belt or line located between the start and end points of the conveyor unit.

[0120] Example A46 includes the system according to any one of Examples A45 or A40-A49, wherein the conveyor unit is coupled to or integrated with the conveyor unit of one or both of the regulating device and the dry forming device.

[0121] Example A47 includes a system according to any one of Example A40 or Examples A40-A49, the system further including a computing device including a processor and a memory, the computing device communicating with at least one of the regulating device, the cutting device or the dry forming device, the computing device having a controller module configured to control the operation of at least one of the regulating device, the cutting device or the dry forming device.

[0122] Example A48 includes the system according to any one of Example A40 or Examples A40-A49, the system further comprising: a product transport device including pick-up and place means, the product transport device being configured to transport the plurality of paper-based finished packaged products for storage, distribution or subsequent operations.

[0123] Example A49 includes the system according to any one of Example A40 or Examples A40-A48, wherein the system is configured to implement the method according to any one of Examples A1-A32.

[0124] in conclusion The embodiments of the subject matter and functional operation described in this patent document can be implemented in various systems, digital electronic circuit systems, or computer software, firmware, or hardware (including the structures disclosed in this specification and their structural equivalents) or combinations thereof. Embodiments of the subject matter described in this specification can be implemented as one or more computer program products, i.e., one or more computer program instruction modules encoded on a tangible and non-transitory computer-readable medium for execution by a data processing device or for controlling the operation of a data processing device. The computer-readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a combination of substances affecting machine-readable propagation signals, or combinations thereof. The terms "data processing unit" or "data processing device" encompass all devices, apparatuses, and machines for processing data, including, for example, programmable processors, computers, or multiple processors or computers. In addition to hardware, the device may include code that creates an execution environment for the computer program in question, such as code constituting processor firmware, a protocol stack, a database management system, an operating system, or combinations thereof.

[0125] Computer programs (also known as programs, software, software applications, scripts, or code) can be written in any programming language, including compiled or interpreted languages, and can be deployed in any form, including as standalone programs or as modules, components, subroutines, or other units suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored as part of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), as a single file dedicated to the program in question, or as multiple coordinating files (e.g., files storing portions of one or more modules, subroutines, or code). A computer program can be deployed to execute on a single computer or on multiple computers located at a single site or distributed across multiple sites and interconnected via a communication network.

[0126] The processes and logic flows described in this specification can be executed by one or more programmable processors, which execute one or more computer programs to perform functions by manipulating input data and producing outputs. The processes and logic flows can also be executed by a dedicated logic circuit system, and the device can also be implemented as a dedicated logic circuit system, such as an FPGA (Field-Programmable Gate Array) or an ASIC (Application-Specific Integrated Circuit).

[0127] For example, processors suitable for executing computer programs include both general-purpose microprocessors and special-purpose microprocessors, as well as any one or more processors in any type of digital computer. Typically, a processor receives instructions and data from read-only memory or random access memory, or both. The basic components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include, or be operatively coupled to, receiving data from or transferring data to one or more mass storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data, or both. However, a computer does not need to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, for example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices. The processor and memory may be supplemented by or incorporated into a special-purpose logic circuit system.

[0128] Although this patent document contains numerous details, these details should not be construed as limiting the scope of any invention or claimable content, but rather as a description of features specific to particular embodiments of a particular invention. Certain features described in this patent document in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although the features above may be described as operating in certain combinations and even initially stated so, in some cases one or more features of the claimed combination may be removed from the combination, and the claimed combination may refer to a sub-combination or a variation of the sub-combination.

[0129] Similarly, although the operations are depicted in a specific order in the accompanying drawings, this should not be construed as requiring these operations to be performed in the specific order shown or sequentially, or to perform all the shown operations to achieve the desired result. Furthermore, the separation of various system components in the embodiments described in this patent document should not be construed as requiring such separation in all embodiments.

[0130] Only a few implementation schemes and examples are described, and other implementation schemes, enhancements and variations can be made based on the content described and illustrated in this patent document.

Claims

1. A method for manufacturing a paper-based packaging product, the method comprising: Adjusting the paper web to optimize its moisture content and treating it with at least one additive to form an adjusted paper web; and The conditioned paper web is dry-molded under one or both of heat and pressure to produce multiple paper-based finished packaging products.

2. The method according to claim 1, wherein the dry molding comprises: The first region of the adjusted paper web is perforated to form a plurality of cavities in the first region; Pressing the first region of the adjusted paper web to form a pressed web region; and The pressed web area is cut to form a cut product area, thereby producing the plurality of paper-based finished packaging products.

3. The method of claim 2, wherein the perforation comprises applying a plurality of slits in the first region, the plurality of slits forming a plurality of cavities for the dry molding to produce the paper-based finished package product.

4. The method of claim 3, wherein the plurality of cavities provide stress relief during the pressing to prevent the regulated paper web from tearing and folding.

5. The method of claim 2, wherein pressing the first region comprises pressing a die structure on one or more portions of the first region of the adjusted paper web to a predetermined depth to facilitate deformation of the first region.

6. The method of claim 2, wherein the pressing includes a first pressing operation and a second pressing operation, wherein at least one of pressure and temperature differs between the first pressing operation and the second pressing operation.

7. The method of claim 2, wherein the pressing is performed at a molding tool temperature of 100°C to 150°C.

8. The method of claim 2, wherein the pressing comprises applying a molding pressure of 350 psi to 750 psi.

9. The method of claim 2, wherein the pressing comprises a dwell time of applying molding pressure for 0.2 seconds to 2 seconds.

10. The method of claim 2, wherein the cutting comprises die-cutting at least a portion of the pressed web region in a predetermined pattern to divide the pressed web region into individual sheets corresponding to individual paper-based finished packaging products among the plurality of paper-based finished packaging products.

11. The method of claim 1, wherein optimizing the moisture content includes applying wet or dry steam to the paper web prior to forming the conditioned paper web.

12. The method of claim 11, wherein the application of the wet steam or the dry steam is carried out in a temperature range of 100°C to 150°C.

13. The method of claim 1, wherein the moisture content of the conditioned paper web is in the range of 10% to 12% prior to the dry molding.

14. The method of claim 1, wherein the moisture content of the conditioned paper web is at most 20% prior to the dry molding.

15. The method of claim 1, wherein adjusting the paper web with at least one additive comprises applying a plurality of chemical compounds to enhance at least one property of the paper web.

16. The method of claim 15, wherein at least one enhancing property includes increased strength, increased stiffness, and reduced permeability to oil, water, or vapor.

17. The method of claim 15, wherein the plurality of chemical compounds comprises liquid starch or alkyl ketene dimer (AKD).

18. The method of claim 17, wherein the liquid starch is in the range of 0.5% to 2.5%.

19. The method of claim 17, wherein the liquid starch is in the range of 0.1% to 5.0%.

20. The method of claim 17, wherein the AKD is in the range of 1.0% to 4.0%.

21. The method of claim 17, wherein the AKD is in the range of 0.5% to 10.0%.

22. The method of claim 1, further comprising: The paper-based finished packaged products are transported for storage or subsequent operations.

23. The method of claim 22, wherein the subsequent operation includes one or both of a coating operation and a printing operation.

24. The method of claim 22, further comprising: Move the remaining paper webs to the final web roll.

25. The method of claim 1, wherein the conditioning includes continuously feeding the paper web into a conditioning unit of the system such that the conditioned paper web formed by the conditioning is continuously fed into a dry molding unit of the system to undergo the dry molding and produce the paper-based finished packaging product.

26. The method of claim 1, further comprising: The conditioned paper webs are stored in climate-controlled storage units.

27. The method of claim 1, further comprising: The adjusted paper web is divided into multiple parts to form adjusted paper web segments.

28. The method of claim 27, wherein the splitting comprises cutting the adjusted paper web using a cross-cutting machine.

29. The method of claim 27, wherein the segmentation comprises cutting the regulated paper web to form the regulated paper web segment.

30. The method of claim 1, wherein the paper web is provided from an initial web roll.

31. The method of claim 1, wherein the paper web has one or both of a weight basis of 300 gsm to 800 gsm and a paper thickness of 0.2 mm to 3.0 mm.

32. The method of claim 1, wherein the paper web has one or both of a weight basis of 100 gsm to 1,000 gsm.

33. A system for manufacturing paper-based packaging products, the system comprising: A conditioning device comprising one or more fluid distribution units and one or more heating units, the conditioning device being configured to condition a paper web fed into the conditioning device by optimizing the moisture content of the paper web and by treating the paper web with at least one additive to form a conditioned paper web; and A dry forming apparatus comprising at least one slitting tool, at least one pressing tool, and at least one cutting tool, the dry forming apparatus being configured to dry mold one or more portions of a conditioned paper web under one or both of heat and pressure to produce a plurality of paper-based finished packaging products.

34. The system of claim 33, further comprising: Product transport equipment, comprising pick-up and place devices, configured to transport the plurality of paper-based finished packaged products for storage, distribution or subsequent operations.

35. The system of claim 33, wherein the system is configured to implement the method of claim 1.

36. A method for manufacturing a paper-based packaging product, the method comprising: Provide the first sheet roll containing continuous paper webs; The continuous paper web is adjusted to optimize the moisture content and treated with at least one additive to form an adjusted paper web; The first region of the adjusted paper web is perforated to form a plurality of cavities in the first region; Press the first region of the adjusted paper web to form a pressed web region; Cut the pressed web area to form multiple paper-based finished packaging products; The paper-based finished packaging products are transported to the storage area; as well as The remaining portion of the paper web is moved to the second roll.

37. The method of claim 36, wherein the pressing step comprises a first pressing operation and a second pressing operation, wherein at least one of pressure and temperature differs between the first pressing operation and the second pressing operation.

38. The method of claim 36, wherein the at least one additive comprises one or more of a fortifying additive, an oleophobic additive, or a hydrophobic additive.

39. A system for manufacturing paper-based packaging products, the system comprising: A conditioning device comprising one or more fluid distribution units and one or more heating units, the conditioning device being configured to condition a paper web fed into the conditioning device by optimizing the moisture content of the paper web and by treating the paper web with at least one additive to form a conditioned paper web; A cutting device comprising one or more blades that cross-cut the adjusted paper web into adjusted paper web segments; as well as A dry forming apparatus comprising at least one slitting tool, at least one pressing tool, and at least one cutting tool, the dry forming apparatus being configured to dry mold one or more portions of a conditioned paper web segment under one or both of heat and pressure to produce a plurality of paper-based finished packaging products.

40. The system of claim 39, wherein the conditioning device comprises one or more sensors selected from the group consisting of a humidity sensor, a temperature sensor, a pressure sensor, and a pH sensor, the one or more sensors being operable to detect parameters associated with the moisture content of the paper web before and / or after the optimization or processing performed by the conditioning device.

41. The system of claim 40, wherein the regulating device includes one or more actuator devices that communicate with the one or more sensors and with one or both of the one or more fluid distribution units and the one or more heating units.

42. The system of claim 41, wherein the one or more actuator devices are configured to control one or both of the fluid dispensing operations and heating operations performed by one or both of the one or more fluid dispensing units and the one or more heating units based at least in part on the parameters detected by the one or more sensors.

43. The system of claim 42, further comprising: A computing device, comprising a processor and a memory, communicating with at least one of the regulating device, the cutting device, or the dry forming device, the computing device having a controller module communicating with the one or more sensors and the one or more actuator devices, and configured to process signals associated with the moisture content converted by the one or more sensors and generate the parameters, and analyze the parameters relative to a predetermined moisture content parameter to determine control instructions to be provided to the actuator for controlling one or both of the fluid dispensing operation and the heating operation.

44. The system of claim 39, wherein the cutting device includes a conveyor unit comprising a feed belt or line located between the start and end points of the conveyor unit.

45. The system of claim 44, wherein the conveyor unit is coupled to or integrated with the conveyor unit of one or both of the regulating device and the dry forming device.

46. ​​The system of claim 39, further comprising: A computing device including a processor and a memory, the computing device communicating with at least one of the adjusting device, the cutting device or the dry forming device, the computing device having a controller module configured to control the operation of at least one of the adjusting device, the cutting device or the dry forming device.

47. The system of claim 39, further comprising: Product transport equipment, comprising pick-up and place devices, configured to transport the plurality of paper-based finished packaged products for storage, distribution or subsequent operations.

48. The system of claim 39, wherein the system is configured to implement the method of claim 1.

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