Barrier former system and method for dry-molded structures

Abstract

A barrier forming system for dry-formed cellulosic fiber containers, the barrier forming system comprising: a support structure configured to support a dry-formed cellulosic fiber structure; a barrier material disposed proximal to the support structure; and a force generating mechanism configured to move at least one of the barrier material and the dry-formed cellulosic fiber structure into contact with one another.

Description

Cross-reference to related applications

[0001] This application claims the benefit of U.S. Application No. 63 / 637,503, filed April 23, 2024, the entire contents of which are incorporated herein by reference. Background Technology

[0002] This disclosure relates to dry-molded cellulose fiber structures, and more specifically to barrier molding systems and methods for dry-molded structures.

[0003] Molded fiber production, involving the use of cellulose fibers to produce products such as cardboard, cups, plates, bowls, bottles, and egg packaging, has existed for a long time. Traditionally, a process called wet molding involves dispersing cellulose fibers in an aqueous medium to form a pulp slurry, molding the pulp slurry, and drying the molded pulp slurry to form the product. Various chemical and / or mechanical processes may be involved to improve the wet molding process.

[0004] Recent advancements in molded fiber production have focused on dry molding fibers. Dry molding fibers are produced via a dry molding process that does not require dispersing cellulose fibers in an aqueous medium. Instead, dry molding involves placing an air-formed cellulose preform within a molding die and subjecting it to high temperatures and pressures to form the dry-molded product. The dry die can utilize a fluff pulp formed from, for example, cork fibers. For instance, dry-molded products can be formed at 600 PSI and temperatures ranging from 140°C to 200°C. During the dry molding process, hydrogen bonding and filament aggregation contribute to the formation of the dry-molded cellulose fiber structure.

[0005] Molded fiber production (including dry molding) transforms renewable plant fibers into sustainable packaging and products. Molded fiber production is a sustainable alternative to single-use plastics, offering acceptable speed, scalability, and cost. Dry molding processes offer advantages including reduced time and cost, as the drying step is eliminated, and products made using dry molding can exhibit superior strength and other mechanical properties compared to those made using wet molding. Summary of the Invention

[0006] According to a non-limiting example, a barrier molding system for a dry-molded cellulose fiber container includes: a support structure configured to support a dry-molded cellulose fiber structure; a barrier material disposed proximal to the support structure; and a force generating mechanism configured to move at least one of the barrier material and the dry-molded cellulose fiber structure into contact with each other.

[0007] In addition to one or more of the features described herein, the barrier material molding system also includes a vacuum system configured to extract gas between the barrier material and the dry-molded cellulose fiber structure, such that the barrier material adheres to the dry-molded cellulose fiber structure.

[0008] In addition to one or more of the features described herein, the supporting structure is a vacuum shell.

[0009] In addition to one or more of the features described herein, the vacuum housing is operable to be connected to a pump or blower of a vacuum system that extracts gas from the vacuum housing to force the gas between the barrier material and the dry-formed cellulose fiber structure through the dry-formed cellulose fiber structure.

[0010] In addition to one or more of the features described herein, the barrier molding system also includes a heater assembly configured to heat the barrier material before removing gas between the barrier material and the dry-molded cellulose fiber structure.

[0011] In addition to one or more of the features described herein, the heater assembly includes a heating element configured to radiate infrared wavelengths to heat the barrier material.

[0012] In addition to one or more of the features described herein, the force generating mechanism assembly includes a plunger assembly configured to either push a portion of the barrier material toward a dry-formed cellulose fiber structure or push the dry-formed cellulose fiber structure toward the barrier material.

[0013] In addition to one or more of the features described herein, the plunger assembly includes a plunger operably connected to an actuator configured to actuate the plunger toward a barrier material.

[0014] In addition to one or more of the features described herein, the plunger assembly includes a plunger having an insulating surface configured to contact a barrier material.

[0015] In addition to one or more of the features described herein, the plunger assembly includes a plunger having one or more air injection orifices formed therein.

[0016] In addition to one or more of the features described herein, the plunger assembly is operatively connected to a pump or blower configured to inject air toward the barrier material through one or more air injection ports.

[0017] In addition to one or more of the features described herein, the barrier material is a thermoplastic sheet or film.

[0018] According to a non-limiting example, a method for molding a dry-molded cellulose fiber container includes: placing a barrier material proximal to the dry-molded cellulose fiber structure; and conforming the barrier material to the dry-molded cellulose fiber structure.

[0019] In addition to one or more of the features described herein, the method also includes heating the barrier material via a heater assembly.

[0020] In addition to one or more of the features described herein, the method further includes: moving the barrier material toward the cellulose fiber structure via the plunger assembly, or moving the cellulose fiber structure toward the barrier material.

[0021] In addition to one or more of the features described herein, the method further includes: extracting gas between the barrier material and the dry-formed cellulose fiber structure through the dry-formed cellulose fiber structure.

[0022] In addition to one or more of the features described herein, the barrier material is heated to a predetermined temperature and held at that predetermined temperature for a predetermined period of time to reduce residual orientation stress.

[0023] In addition to one or more of the features described herein, the heater assembly heats the barrier material via infrared wavelength radiation.

[0024] In addition to one or more of the features described herein, air is injected toward the barrier material via one or more air injection holes formed in the plunger assembly.

[0025] In addition to one or more of the features described herein, the barrier material is a thermoplastic sheet or film.

[0026] In addition to one or more of the features described herein, the method further includes: heating a barrier material via a heater assembly; moving the barrier material heated by the heater assembly toward a cellulose fiber structure, or moving the cellulose fiber structure toward the barrier material heated by the heater assembly; extracting gas between the barrier material and the dry-formed cellulose fiber structure through the dry-formed cellulose fiber structure; and cooling the barrier material such that the barrier material adheres to the cellulose fiber structure.

[0027] According to a non-limiting example, a dry-formed cellulose fiber container is formed by a method comprising the following steps: placing a barrier material near the dry-formed cellulose fiber structure; and conforming the barrier material to the dry-formed cellulose fiber structure.

[0028] In addition to one or more of the features described herein, the barrier molding system is configured to adhere barrier materials to a dry-molded cellulose fiber structure.

[0029] In addition to one or more of the features described herein, the barrier molding system is configured to place an adhesive on a dry-molded cellulose fiber structure to adhere the barrier material to the dry-molded cellulose fiber structure.

[0030] In addition to one or more of the features described herein, the barrier forming system also includes a clamping structure configured to hold the periphery of the barrier material in place.

[0031] In addition to one or more of the features described herein, the clamping structure forms a seal around the barrier material.

[0032] In addition to one or more of the features described herein, openings are formed in the dry-formed cellulose fiber structure to transmit vacuum through the dry-formed cellulose fiber structure.

[0033] In addition to one or more of the features described herein, the force generating mechanism includes a pressure generating mechanism that generates positive pressure on the barrier material to push the barrier material toward the dry-formed cellulose fiber structure.

[0034] In addition to one or more of the features described herein, the barrier molding system also includes a cooling assembly configured to cool the barrier material.

[0035] The above-described features and advantages of this disclosure, as well as other features and advantages, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. Attached Figure Description

[0036] Figure 1 A schematic diagram of a barrier molding system according to one or more embodiments is shown;

[0037] Figure 2 A barrier molding assembly according to one or more embodiments is shown;

[0038] Figure 3 A barrier molding assembly according to one or more embodiments is shown;

[0039] Figure 4 A barrier molding assembly according to one or more embodiments is shown;

[0040] Figure 5 A barrier molding assembly according to one or more embodiments is shown;

[0041] Figure 6 A barrier molding assembly according to one or more embodiments is shown;

[0042] Figure 7 A barrier molding assembly according to one or more embodiments is shown;

[0043] Figure 8 A barrier molding assembly according to one or more embodiments is shown;

[0044] Figures 9A to 9C The steps of a barrier molding process according to one or more embodiments are shown;

[0045] Figures 10A to 10F illustrate the steps of the barrier molding process according to one or more embodiments;

[0046] Figure 11 A barrier molding assembly according to one or more embodiments is shown; and

[0047] Figure 12 A barrier molding assembly according to one or more embodiments is shown. Detailed Implementation

[0048] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0049] The wet molding process allows for the addition of chemicals to the pulp slurry to enhance desired properties in the wet-molded cellulosic fiber products. For example, additives can be included in the pulp slurry, and when the slurry dries, these additives can impart water-resistant or waterproof properties to the wet-molded cellulosic fiber products. Examples of additives include waxes, polyamide epichlorohydrin, and cationic starch. Therefore, wet-molded cellulosic fiber products can be used in applications where they contain (or at least come into contact with) liquids.

[0050] While omitting wet molding steps, such as dispersing cellulose fibers in an aqueous medium and drying the pulp slurry, offers advantages including reduced time, energy, and cost, omitting these steps also eliminates the opportunity to add one or more additives that can impart water-resistant or waterproof properties to molded cellulose fiber products. Without such additives, dry-molded cellulose fiber structures are porous and lack barrier properties. For example, dry-molded cellulose fiber structures are liquid / air permeable, offering virtually no protection against the environment and / or moisture, as well as liquids, fluids, or wet products that may be found within the dry-molded cellulose fiber structure.

[0051] In addition to the cardboard, cups, plates, bowls, bottles, and egg packaging mentioned above, dry molding can be beneficial for a wide range of goods, including dairy products (such as cheese and spreadable cheeses including cream cheese), beauty and cosmetic products, refrigerated foods, dried foods, coffee, frozen foods, personal care products, medical devices, tobacco, and other food and non-food consumer goods. Dry-molded cellulose fiber structures can be used in packaging forms such as buckets and lids, blister packs, and trays. However, for many of these applications, the dry-molded cellulose fiber structure must have low moisture and / or oxygen permeability to be practical for the contained product. To impart the desired low moisture and / or oxygen permeability, a low moisture and / or oxygen permeability layer can be formed on the dry-molded cellulose fiber structure.

[0052] Figure 1 The diagram illustrates a barrier molding system 10 for adding such a layer according to a non-limiting example. The barrier molding system 10 includes a barrier molding assembly 100, which can be operatively connected to one or more of a vacuum housing 50, a force generating mechanism assembly 60, a heater assembly 70, and a cooling assembly 90.

[0053] Vacuum housing 50 can be connected to pump 20 via vacuum line 53. Pump 20 can be operated to remove gas from vacuum housing 50 via vacuum line 53. Vacuum reservoir 30 can be positioned between vacuum housing 50 and pump 20, and a first pressure gauge 35 can be operably connected to vacuum reservoir 30 to monitor the pressure within vacuum reservoir 30. Vacuum valve 40 can be positioned between vacuum housing 50 and pump 20. When pump 20 is operating, vacuum valve 40 can open to remove gas from vacuum housing 50 and can close to seal vacuum housing 50. Vacuum valve 40 can be positioned between vacuum reservoir 30 and vacuum housing 50. Pump 20 can create a vacuum in vacuum reservoir 30, and vacuum reservoir 30 can provide rapid evacuation of vacuum housing 50. A second pressure gauge can be connected to vacuum line 53 between vacuum valve 40 and vacuum housing 50 to monitor the pressure in vacuum line 53 directly upstream of vacuum valve 40. A third pressure gauge 55 can be operatively connected to the vacuum housing 50 to monitor the pressure within the vacuum housing 50. According to one or more embodiments, a blower can be used instead of the pump 20. Figure 1 Only a single pump 20 is shown; the barrier forming system 10 may include multiple pumps 20.

[0054] Force generating mechanism assembly 60 can be connected to actuator 61. Actuator 61 is operable to cause force generating mechanism assembly 60 and may include, for example, a motor, gear system, and / or pressure generating pump. Wherein force generating mechanism assembly 60 is used to blow mold barrier material 110 onto a dry-molded cellulose fiber structure 120 in a barrier molding system 10 (see Figures 10A-10F), force generating mechanism assembly 60 can be connected to pump 20 or another pump to receive air from it. Air valve 63 can be positioned between pump 20 and force generating mechanism assembly 60. Air valve 63 can open when pump 20 is operating to allow airflow into force generating mechanism assembly 60 and can close to stop airflow into force generating mechanism assembly 60. Pump 20 may include a single pump or multiple pumps. Pump 20 may include multiple pumps located in a single location or multiple locations. Pump 20 may include multiple pumps operable to simultaneously provide pressure and vacuum forces.

[0055] According to one or more embodiments, the barrier forming system 10 may include a force generating mechanism assembly 60 having a pressure building mechanism 67 that generates positive pressure over the barrier material 110 (see [link]). Figure 12 The force generating mechanism assembly 60 can be operatively connected to the pump 20, which can generate pressure within the pressure building mechanism 67. Alternatively or otherwise, the pressure building mechanism 67 may include its own pump, blower, or fan for generating pressure.

[0056] The barrier forming system 10 may also include a controller 80. The controller 80 may include processing circuitry, which may include application-specific integrated circuits (ASICs), electronic circuitry, a processor (shared, dedicated, or grouped), and memory storing and / or executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components providing the described functions. The controller 80 may be operatively connected to the pump 20 to control and / or operate the pump 20. The controller 80 may be operatively connected to the vacuum valve 40 and / or the air valve 63 to control and / or operate the vacuum valve 40 and / or the air valve 63. For example, the controller 80 may be operable to open and close the vacuum valve 40 and / or the air valve 63. The controller 80 may be operatively connected to a first pressure gauge 35, a second pressure gauge 45, and a third pressure gauge 55, and may be configured to receive data indicating pressure at one or more locations of the first pressure gauge 35, the second pressure gauge 45, and the third pressure gauge 55. Pressure data received from the first pressure gauge 35, the second pressure gauge 45, and / or the third pressure gauge 55 can be used to control the pump 20 and / or the vacuum valve 40. The controller 80 can be operatively connected to the actuator 61 to control and / or operate the actuator 61. The controller 80 can be operatively connected to the heater assembly 70 to control and / or operate the heater assembly 70. The controller 80 can be operatively connected to the cooling assembly 90 to control and / or operate the cooling assembly 90. Although not shown, the pump 20 can also be connected to the heater assembly 70 and / or the cooling assembly 90 to provide airflow.

[0057] Figures 2 to 6 A barrier molding process according to one or more embodiments is shown. For example... Figure 2 As shown, the barrier molding assembly 100 includes a barrier material 110 positioned on top of a dry-molded cellulose fiber structure 120. As a non-limiting example, the barrier material 110 may be a thermoplastic material in sheet or film form. A clamping structure 130 may be positioned on the barrier material 110 around the periphery of the dry-molded cellulose fiber structure 120. The clamping structure 130 may clamp the barrier material 110 such that the periphery of the barrier material 110 is stationary and / or sealed. The clamping structure 130 may clamp the barrier material 110 to a top wall 58. According to one or more embodiments, an adhesive may be applied to the upper surface and / or upper flange of the dry-molded cellulose fiber structure 120 such that the barrier material 110 adheres to the upper surface or upper flange of the dry-molded cellulose fiber structure 120. The dry-molded cellulose fiber structure 120 defines a space 121 therein. Figure 2In the initial configuration shown, the barrier material 110 can be positioned above the space 121. The dry-molded cellulose fiber structure 120 can be supported by a vacuum housing 50. The vacuum housing 50 may include a bottom wall 56, a plurality of side walls 57, and a top wall 58. According to one or more embodiments, the vacuum housing 50 may have a single annular side wall 57 instead of a side wall 57. The bottom wall 56, side walls 57, and top wall 58 together define a vacuum chamber 51 with the outer surface of the dry-molded cellulose fiber structure 120. The top wall 58 includes an opening through which the dry-molded cellulose fiber structure 120 is inserted into the vacuum housing 50. The bottom wall 56 may include an opening coupled to a vacuum line 53. Alternatively or additionally, the side walls 57 may include openings coupled to a vacuum line 53. According to one or more embodiments, the opening is formed in the bottom wall 56 at its lowest point.

[0058] like Figure 2 As shown, a heater assembly 70 is positioned above a barrier material 110. The heater assembly 70 may include a heater 71 having a heating element 72. The heater 71 may heat the barrier material 110 via radiation. According to one or more embodiments, the heater assembly 70 may include a fan 73 configured to blow heated air 75 from the heater 71 onto the barrier material 110. The heater assembly 70 heats the barrier material 110 for a period of time, causing the barrier material 110 to soften. The barrier material 110 may be heated for a period of time until it softens and becomes pliable. Once heated for this period of time, the barrier material 110 may sag and then tighten due to orientation stress. The period of time for heating the barrier material 110 may include a predetermined period of time during which the barrier material 110 remains heated to reduce residual orientation stress. As a non-limiting example, the predetermined period of time may be 15 to 20 seconds. As a non-limiting example, depending on the type and shape of the barrier material 110, the barrier material 110 may be heated to a temperature in the range of 285℉ to 375℉. Some barrier materials 110 may benefit from being heated to temperatures outside this range. If the barrier material 110 is thermoplastic, the temperature may be raised to or slightly above its melt temperature. The heater assembly 70 may heat the barrier material 110 via conduction, convection, or radiation. According to one or more embodiments, the heater assembly 70 may include a heat source that emits infrared wavelengths to heat the barrier material 110 via radiation.

[0059] The force generating mechanism assembly 60 may include various force generating mechanisms. For example, the force generating mechanism of the force generating mechanism assembly 60 may include a plunger and / or a blower mechanism such as a fan, blower, or pump. Figure 12As shown, the force generating mechanism of the force generating mechanism assembly 60 can be a pressure establishing mechanism 67, which is used to establish positive pressure above the barrier material 110, such that the pressure difference between the top and bottom of the barrier material 110 (which may be subjected to vacuum force) presses the barrier material 110 downward onto the dry-molded cellulose fiber structure 120. The pressure generating mechanism 67 may include a pressure chamber, a fan, a blower, or a pressure generating pump.

[0060] like Figure 3 As shown, the force generating mechanism assembly 60 can be moved to a position above the barrier material 110 softened by the heater assembly 70, or the barrier material 110 softened by the heater assembly 70 can be moved to a position below the force generating mechanism assembly 60. The force generating mechanism assembly 60 may include a plunger 65, and a thermally insulating layer 67, a non-stick coating, and / or a low-friction coefficient coating may be formed on a portion of the plunger 65, which is configured to contact the barrier material 110 such that the barrier material is not prematurely cooled by the plunger 65, does not stick to the plunger 65, and / or can easily slide along the plunger 65. Actuator 61 (see...) Figure 1 The plunger 65 can be moved from... Figure 3 The raised position shown actuated to Figure 4 The lowered position is shown. As the plunger 65 lowers, the barrier material 110 can be pushed and deformed by the plunger 65 into the space 121 defined by the dry-molded cellulose fiber structure 120. The barrier material 110 can be stretched by the plunger 65 to... Figure 4 The configuration shown. The clamping structure 130 can clamp the periphery of the barrier material 110, so that the peripheral portion of the barrier material 110 does not move when the plunger 65 stretches the barrier material 110. Although Figure 4 The illustration shows plunger 65 partially inserted into space 121, but according to one or more embodiments, plunger 65 can be fully inserted into space 121 such that barrier material 110 deforms through plunger 65 and contacts the inner surface of dry-molded cellulose fiber structure 120. For example, plunger 65 can correspond to the shape of dry-molded cellulose fiber structure 120, such that plunger 65 is inserted until barrier material 110 contacts dry-molded cellulose fiber structure 120. That is, the outer surface of plunger 65 matches the shape of the inner surface of dry-molded cellulose fiber structure 120. In this case, the outer surface of dry-molded cellulose fiber structure 120 can be, for example, made of… Figure 7 The porous support structure 52 shown is supported.

[0061] like Figure 5 As shown, during or after the descent of plunger 65, gas (e.g., air) within vacuum chamber 51 can be pumped through pump 20 (see...). Figure 1The gas is evacuated via vacuum line 53. A seal can be formed around the barrier material 110 held by clamping structure 130, sealing the space 121 between the barrier material 110 and the dry-molded cellulose fiber structure 120. If the dry-molded cellulose fiber structure 120 is sufficiently porous, when gas is evacuated from vacuum chamber 51, the gas between the barrier material 110 and the dry-molded cellulose fiber structure 120 can be forced through the porous dry-molded cellulose fiber structure 120 into vacuum chamber 51 by atmospheric pressure against the top surface of the barrier material 110, and then extracted via vacuum line 53. If the dry-molded cellulose fiber structure 120 is not sufficiently porous, such as... Figure 8 As shown, small openings 125 can be formed through the dry-molded cellulose fiber structure 120, forcing the gas between the barrier material 110 and the dry-molded cellulose fiber structure 120 into the vacuum chamber 51 through the openings 125 and then extracted via the vacuum line 53. By extracting the gas between the barrier material 110 and the dry-molded cellulose fiber structure 120, the barrier material 110 is pulled flush with the contour of the inner wall of the dry-molded cellulose fiber structure 120.

[0062] The barrier material 110 can then be actively cooled or allowed to cool, as discussed below. For example, a cooling airflow can be generated and / or directed onto the barrier material 110 via, for example, a fan, blower, or pump. As the barrier material 110 cools and hardens, the dry-molded cellulose fiber structure 120 partially or completely adheres to and / or is bonded to the inner wall of the dry-molded cellulose fiber structure 120.

[0063] like Figure 6 As shown, plunger 65 can be driven by actuator 61 (see...) Figure 1 The cooling assembly 90 can be positioned above the barrier material 110 and rise upwards. The cooling assembly 90 may include a cooler 91 having a heat exchanger 92. Although Figure 6The heat exchanger 92 is shown located within the cooler 91, but the heat exchanger 92 can be placed outside the cooler 91, and cool air can be supplied to the cooler 91 via ducting. Alternatively, the cooling assembly 90 can forgo the heat exchanger 92 and instead use air at ambient temperature. According to one or more embodiments, the cooling assembly 90 may also include a fan 93 configured to blow air 95 from the cooler 91 onto the barrier material 110. The cooling assembly 90 can actively cool the barrier material 110 on the dry-molded cellulose fiber structure 120 to cause the barrier material 110 to adhere to and / or be bonded to the dry-molded cellulose fiber structure 120. If an adhesive is placed between the barrier material and the dry-molded cellulose fiber structure 120, the cooling assembly can cool and harden the adhesive. Alternatively or additionally, cooling can be performed using a liquid (e.g., water) to quench the film and minimize shrinkage. When the barrier material 110 is cooled by the cooling assembly 90, the vacuum force on the barrier material 110 and / or the force on the barrier material 110 from the force generating mechanism assembly 60 can be maintained to maintain the shape of the barrier material 110 on the dry-molded cellulose fiber structure 120 until the barrier material 110 is fully cured and / or crystallized.

[0064] The dry-molded cellulose fiber structure 120 with the barrier material 110 adhered to and / or bonded thereto can then be removed from the vacuum housing 50. According to one or more embodiments, to facilitate removal of the dry-molded cellulose fiber structure 120 with the barrier material 110 from the vacuum housing 50, the pressure within the vacuum chamber 51 can be equalized by opening the vacuum chamber 51 or by allowing air to flow into the vacuum chamber 51 from the vacuum line 53. Any excess barrier material 110 can then be trimmed from the dry-molded cellulose fiber structure 120. Due to the barrier molding process, the barrier material 110 can be adhered to and / or bonded to the dry-molded cellulose fiber structure 120 thinner than before the barrier molding process.

[0065] According to one or more embodiments, the barrier molding process may include: loading barrier material 110 onto a dry-molded cellulose fiber structure 120; heating barrier material 110; bonding and / or adhering barrier material 110 to the dry-molded cellulose fiber structure 120; cooling barrier material 110; removing the dry-molded cellulose fiber structure 120 to which barrier material 110 is bonded and / or adhered; and / or trimming excess barrier material 110.

[0066] Figure 7A non-limiting example is shown, wherein the dry-molded cellulose fiber structure 120 is supported by a porous support structure 52 of a vacuum shell 50. According to one or more embodiments, the porous support structure 52 may be a mesh structure allowing air to pass through while supporting the dry-molded cellulose fiber structure 120. According to one or more embodiments, the porous support structure 52 may be shaped to correspond to the outer surface of the dry-molded cellulose fiber structure 120 to support the dry-molded cellulose fiber structure 120, such that the dry-molded cellulose fiber structure 120 is uniformly supported during the barrier molding process.

[0067] During the heating and molding processes described above, pump 20, vacuum valve 40, actuator 61, and heater assembly 70 may be controlled by controller 80 to prevent burn-through and pinhole formation of the barrier material 110. Additionally, heater assembly 70 may be controlled by controller 80 to release built-in stresses from the manufacturing process of barrier material 110, thereby achieving its low orientation. According to one or more embodiments, barrier material 110 may be a multilayer thermoplastic film or sheet to provide customized properties. According to one or more embodiments, barrier material 110 is placed as a colored thermoplastic film or sheet on a dry-molded cellulose fiber structure 120, because the barrier molding system 10 and method described above allow the use of colored thermoplastic films or sheets.

[0068] Pump 20, vacuum reservoir 30, first pressure gauge 35, vacuum valve 40, second pressure gauge, vacuum housing 50, vacuum chamber 51, porous support structure 52, vacuum pipeline 53, and third pressure gauge 55 can collectively define the vacuum system. One or more of the above components may be omitted from the vacuum system, as long as the vacuum system can generate a vacuum flow.

[0069] The barrier molding system 10 can move the heater 70, force generating mechanism assembly 60, and cooling assembly 90 to and from the stationary vacuum housing 50, barrier material 110, and dry-molded cellulose fiber structure 120, or move the vacuum housing 50, barrier material 110, and dry-molded cellulose fiber structure 120 to and from the stationary barrier molding system 10 and heater 70, or a combination thereof.

[0070] Figures 9A to 9C A barrier molding process according to one or more embodiments is shown. For example... Figure 9A As shown, barrier material 110 can be applied to the dry-molded cellulose fiber structure 120. For example... Figure 9BAs shown, heated air can be blown onto the top surface of the barrier material 110, thereby softening the barrier material 110. Then, pressure-forming air can be impacted onto the top surface of the barrier material 110, pushing the barrier material onto the dry-molded cellulose fiber structure 120. Similar to one or more embodiments described above, a vacuum can also be applied to the lower part of the dry-molded cellulose fiber structure 120 to pull the barrier material 110 onto the dry-molded cellulose fiber structure 120. Figure 9C As shown, excess portions of the barrier material 110 can be cut from the dry-molded cellulose fiber structure 120.

[0071] Figures 10A to 10F illustrate barrier molding processes according to one or more embodiments. As shown in Figure 10A, barrier material 110 can be formed into a preform. According to one or more embodiments, barrier material 110 can be preheated. Barrier material 110 is placed within a dry-molded cellulose fiber structure 120, which can be, but is not limited to, a bottle. Force generating mechanism assembly 60 can be a tension rod having one or more air injection holes formed therethrough and connected to pump 20 (see...). Figure 1 The force-generating mechanism assembly 60 longitudinally stretches the preform from the configuration shown in FIG. 10A to the configuration shown in FIG. 10B. As the force-generating mechanism assembly 60 further descends into the dry-molded cellulose fiber structure 120, air is blown into the barrier material 110 through air injection holes in the force-generating mechanism assembly 60 to apply internal pressure and circumferentially stretch the barrier material 110, as shown in FIG. 10C and FIG. 10E shows that air is continuously injected into the barrier material 110 through air injection holes in the force-generating mechanism assembly 60. Similar to one or more embodiments described above, a vacuum may also be applied to the lower part of the dry-molded cellulose fiber structure 120 to pull the barrier material 110 into the dry-molded cellulose fiber structure 120. As shown in FIG. 10F, the barrier material 110 may be adhered to and / or bonded to the inner surface of the dry-molded cellulose fiber structure 120. Then, the force generating mechanism component 60 is removed from the barrier material 110, and the barrier material 110 is actively cooled or allowed to cool, such that the barrier material 110 adheres to and / or is bonded to the dry-molded cellulose fiber structure 120.

[0072] Because the dry-molded cellulose fiber structure 120 can have a low thermal conductivity, i.e., it is an insulator, cooling air can be blown onto the barrier material 110 to aid the cooling process. For example, a fan, blower, or pump can generate a cooling airflow onto the barrier material 110. According to one or more embodiments, the barrier molding system 10 and the process can maintain molding force (e.g., evacuating the vacuum chamber 51 via a vacuum line 53) until the barrier material 110 adheres to and / or bonds to the dry-molded cellulose fiber structure 120, which can be particularly advantageous if the barrier material 110 is highly oriented.

[0073] During the manufacturing process of barrier material 110, the molecules of barrier material 110 can be oriented. When heated, the oriented molecules of barrier material 110 tend to revert to an unoriented state. Therefore, orientation can cause problems after molding. For example, barrier material 110 may shrink due to retained stress. Controller 80 can control the heating and cooling processes to reduce residual stress within barrier material 110. Furthermore, barrier material 110 can be heat-treated prior to the processes described above to reduce residual stress. According to one or more embodiments, barrier material 110 with low orientation, such as thermoplastic sheet, can be selected.

[0074] Although the above description involves adding barrier material 110 to the inner surface of the dry-molded cellulose fiber structure 120, such as Figure 11 As shown, however, a similar system and process can be used to add barrier material 110 to the outer surface of the dry-molded cellulose fiber structure 120. While having barrier material 110 on the inner surface of the dry-molded cellulose fiber structure 120 may be sufficient for the product housed within it, barrier material 110 on the outer surface of the dry-molded cellulose fiber structure 120 may be beneficial in protecting it from environmental impacts. The dry-molded cellulose fiber structure 120 can be supported on the vacuum housing 50 via a porous support structure 52. Barrier material 110 can be positioned above the outer surface of the dry-molded cellulose fiber structure 120, and the peripheral portion of barrier material 110 can be held by clamping structure 130. Similar to Figure 2In the illustrated embodiment, heater assembly 70 can heat barrier material 110. If the dry-molded cellulose fiber structure 120 does not have barrier material 110 on its inner surface, a vacuum can be applied to the inner surface of the dry-molded cellulose fiber structure 120 to pull barrier material 110 to the outer surface of the dry-molded cellulose fiber structure 120. For example, pump 20 can be operated to remove gas from the vacuum chamber 51 of vacuum housing 50 via vacuum line 53, thereby creating a vacuum in vacuum chamber 51 and space 121 within dry-molded cellulose fiber structure 120. Since dry-molded cellulose fiber structure 120 can be porous or perforated, the vacuum in space 121 pulls barrier material 110 toward the outer surface of dry-molded cellulose fiber structure 120, thereby causing barrier material 110 to adhere to and / or adhere to the outer surface of dry-molded cellulose fiber structure 120. A gap can be formed between the top wall 58 and the dry-molded cellulose fiber structure 120, allowing a vacuum to also be formed between the outer surface of the dry-molded cellulose fiber structure 120 and the inner surface of the barrier material 110. This helps to move the barrier material 110 toward the dry-molded cellulose fiber structure 120 and to allow the barrier material 110 to adhere to and / or be bonded to the dry-molded cellulose fiber structure 120. Similar to... Figure 6 In the embodiment shown, the barrier material 110 can then be cooled by the cooling assembly 90 to cause the barrier material 110 to adhere to and / or be bonded to the dry-molded cellulose fiber structure 120.

[0075] Alternatively, the dry-molded cellulose fiber structure 120 itself can be used as a plunger and actuated downwards onto the barrier material 110, which has been heated and stretched above the cavity. A vacuum can be applied to the dry-molded cellulose fiber structure 120 on the side opposite to the barrier material 110 to cause the barrier material 110 to adhere to and / or be bonded to the dry-molded cellulose fiber structure 120. For example, the dry-molded cellulose fiber structure 120 can be positioned on a plunger having one or more vacuum vents to evacuate gas between the dry-molded cellulose fiber structure 120 and the barrier material 110. Evacuation can be performed simultaneously with the insertion of the dry-molded cellulose fiber structure 120 into the barrier material 110.

[0076] According to one or more embodiments, a primer or adhesive may be applied to the dry-molded cellulose fiber structure 120 to help the barrier material 110 adhere to its surface.

[0077] While the barrier molding system 10 and process described above involve molding the barrier material 110 onto the dry-molded cellulose fiber structure 120 after molding, according to one or more embodiments, the barrier material 110 can be added to the cellulose fiber sheet during the molding of the dry-molded cellulose fiber structure 120. This can be done when the dry-molded cellulose fiber structure 120 has a shallow stretch, such as in board or shallow cardboard products. The barrier material 110 can be added by extrusion coating or lamination. This process may involve a mold cooling system.

[0078] Containers, such as those formed via a wet molding process, must be removed from a mold. Structures such as undercuts and diameters increasing towards the bottom of the container can prevent removal from the mold. In contrast, the barrier material 110 is not removed from the dry-molded cellulose fiber structure 120, and therefore the dry-molded cellulose fiber structure 120 with the barrier material 110 can have undercuts and diameters increasing towards the bottom of the container. The undercut can provide a mechanical lock between the barrier material 110 and the dry-molded cellulose fiber structure 120, further causing the barrier material 110 to adhere to and / or be bonded to the dry-molded cellulose fiber structure 120.

[0079] The barrier molding system 10 and barrier molding process described above can produce a dry-molded cellulose fiber structure 120 on which barrier material 110 is molded. Barrier material 110 can provide water-resistant or waterproof properties to the dry-molded cellulose fiber structure 120. In addition, barrier material 110 can improve the mechanical properties of the dry-molded cellulose fiber structure 120, such as its strength. The dry-molded cellulose fiber structure 120 with barrier material 110, molded according to the barrier molding system 10 and process described above, can be heat-sealable, recyclable, biodegradable, and compostable with biodegradable plastics, and can be made primarily from renewable resources. According to one or more embodiments, the dry-molded cellulose fiber structure 120 acts as a mold for the barrier material 110, eliminating the need for a separate mold for the barrier material 110. Since the dry-molded cellulose fiber structure 120 can be an insulator, the dry-molded cellulose fiber structure 120 on which the barrier material 110 is formed can be microwave-friendly.

[0080] The terms “an” and “a” do not imply a limitation on quantity, but rather indicate that at least one of the referenced items exists. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Reference throughout the specification to “an aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the various elements described can be combined in any suitable manner across various aspects.

[0081] When an element, such as a layer, film, region, or substrate, is referred to as being "on" another element, it can be directly on that other element, or there may be intermediate elements present. In contrast, when an element is referred to as being "directly on" another element, there are no intermediate elements present.

[0082] Unless otherwise specified, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0083] Although the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted for its elements without departing from its scope. Furthermore, many modifications can be made to adapt a particular situation or substance to the teachings of this disclosure without departing from its essential scope. Therefore, this disclosure is not intended to be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A barrier molding system for dry-molded cellulose fiber containers, the barrier molding system comprising: A support structure configured to support a dry-formed cellulose fiber structure; A barrier material is placed near the support structure; as well as A force generating mechanism is configured to move at least one of the barrier material and the dry-formed cellulose fiber structure into contact with each other.

2. The barrier material molding system of claim 1, further comprising a vacuum system configured to extract gas between the barrier material and the dry-molded cellulose fiber structure, such that the barrier material adheres to the dry-molded cellulose fiber structure.

3. The barrier molding system according to claim 2, wherein the support structure is a vacuum shell.

4. The barrier molding system of claim 3, wherein the vacuum housing is operable to be connected to a pump or blower of the vacuum system, the pump or blower extracting gas from the vacuum housing to force the gas between the barrier material and the dry-molded cellulose fiber structure through the dry-molded cellulose fiber structure.

5. The barrier molding system of claim 1, further comprising a heater assembly configured to heat the barrier material prior to evacuating the gas between the barrier material and the dry-molded cellulose fiber structure.

6. The barrier molding system of claim 5, wherein the heater assembly includes a heating element configured to radiate infrared wavelengths to heat the barrier material.

7. The barrier molding system of claim 1, wherein the force generating mechanism assembly includes a plunger assembly configured to push a portion of the barrier material toward the dry-molded cellulose fiber structure or to push the dry-molded cellulose fiber structure toward the barrier material.

8. The barrier forming system of claim 7, wherein the plunger assembly includes a plunger operably connected to an actuator configured to actuate the plunger toward the barrier material.

9. The barrier forming system of claim 7, wherein the plunger assembly includes a plunger having an insulating surface configured to contact the barrier material.

10. The barrier forming system of claim 7, wherein the plunger assembly includes a plunger having one or more air injection holes formed therein.

11. The barrier forming system of claim 10, wherein the plunger assembly is operatively connected to a pump or blower configured to inject air toward the barrier material through the one or more air injection holes.

12. The barrier molding system according to claim 1, wherein the barrier material is a thermoplastic sheet or film.

13. A method for molding dry-molded cellulose fiber containers, the method comprising: The barrier material is placed near the dry-formed cellulose fiber structure; as well as The barrier material is adhered to the dry-formed cellulose fiber structure.

14. The method of claim 13, further comprising heating the barrier material via a heater assembly.

15. The method of claim 13, further comprising moving the barrier material toward the cellulose fiber structure via a plunger assembly, or moving the cellulose fiber structure toward the barrier material.

16. The method of claim 13, further comprising extracting gas between the barrier material and the dry-formed cellulose fiber structure through the dry-formed cellulose fiber structure.

17. The method of claim 14, wherein the barrier material is heated to a predetermined temperature and held at the predetermined temperature for a predetermined period of time to reduce residual orientation stress.

18. The method of claim 14, wherein the heater assembly heats the barrier material via infrared wavelength radiation.

19. The method of claim 15, wherein air is injected toward the barrier material via one or more air injection holes formed in the plunger of the plunger assembly.

20. The method of claim 13, wherein the barrier material is a thermoplastic sheet or film.

21. The method according to claim 13, further comprising: The barrier material is heated via a heater assembly; The barrier material being heated by the heater assembly moves toward the cellulose fiber structure, or the cellulose fiber structure moves toward the barrier material being heated by the heater assembly; The gas between the barrier material and the dry-formed cellulose fiber structure is extracted through the dry-formed cellulose fiber structure. as well as The barrier material is cooled so that it adheres to the cellulose fiber structure.

22. A dry-formed cellulose fiber container, said dry-formed cellulose fiber container being formed by a method comprising the following steps: The barrier material is placed near the dry-formed cellulose fiber structure; and The barrier material is adhered to the dry-formed cellulose fiber structure.

23. The barrier molding system of claim 1, wherein the barrier molding system is configured to adhere the barrier material to the dry-molded cellulose fiber structure.

24. The barrier molding system of claim 23, wherein the barrier molding system is configured to place an adhesive on the dry-molded cellulose fiber structure to adhere the barrier material to the dry-molded cellulose fiber structure.

25. The barrier forming system of claim 1, further comprising a clamping structure configured to clamp the periphery of the barrier material to keep it stationary.

26. The barrier forming system of claim 25, wherein the clamping structure forms a seal around the periphery of the barrier material.

27. The barrier molding system of claim 2, wherein openings are formed in the dry-molded cellulose fiber structure to transmit vacuum through the dry-molded cellulose fiber structure.

28. The barrier molding system of claim 1, wherein the force generating mechanism includes a pressure generating mechanism that generates positive pressure on the barrier material to push the barrier material toward the dry-molded cellulose fiber structure.

29. The barrier molding system of claim 1, further comprising a cooling assembly configured to cool the barrier material.

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