System and method for making fiber board

Abstract

A system and method for forming a fiber board. The system in some configurations includes an extruder, a forming press, an output handling assembly, a carrier transfer assembly, a collector assembly, a heater press, a post formation press removal assembly, a carrier decoupling assembly and an acclimating assembly. In some configurations, the foregoing are positioned sequentially to form a continuous, or batch operated system. In some configurations, an extruder, a forming press and a heater press are contemplated, as well as a system for directing an initially shaped mat from a forming press to a heater press and from a heater press.

Description

TITLESYSTEM AND METHOD FOR MAKING FIBER BOARDCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is related to, but do not claim priority from, Netherlands Patent Application No. 2033117 filed 23 September 2022 as well as Netherlands Patent Application No. 2033678 filed 06 December 2022, both of which are incorporated by reference in their entirety herein.BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure

[0002] The disclosure relates in general to fiber boards, and more particularly, to a system and method for making fiber boards. While not limited thereto, the present system and method described herein is well suited for the formation of fiber boards that are typically free from formaldehyde, formaldehyde derivatives and / or adhesives, including, but not limited to petroleum based adhesives.2. Background Art

[0003] The formation of fiber boards is known in the art. Typically, fiber boards are formed by providing cellulose based fibers along with adhesives or other formaldehyde based materials and then utilizing heat and pressure to form a fiber board. Problematically, such fiber boards are difficult to recycle and include constituents that can be harmful.

[0004] There has been a desire to provide fiber boards that are free of adhesives, formaldehyde and formaldehyde derivatives. Difficulties have been encountered in the formation of fiber boards having such properties with any consistency and throughput. Additionally, it has proven difficult to form fiber boards with such properties on a continuous or batch basis.SUMMARY OF THE DISCLOSURE

[0005] The disclosure is directed to a system and method for forming a fiber board. The system in some configurations includes an extruder, a forming press, an output handling assembly, a carrier transfer assembly, a collector assembly, a heater press, a post formationpress removal assembly, a carrier decoupling assembly and an acclimating assembly. In some configurations, the foregoing are positioned sequentially to form a continuous, or batch operated system.

[0006] The extruder has an inlet and an outlet. The outlet of the extruder feeds pulp into an inlet of the forming press. At an outlet of the forming press, a dimensionally stable initially shaped mat is directed therefrom. The initially shaped mat is directed onto a receiving table of the output handling assembly. At such time, the initially shaped mat can be cut to the desired dimensions utilizing a plurality of saws.

[0007] The initially shaped mat is then transferred onto a carrier transfer assembly so as to be positioned onto a carrier. The carrier comprises a base having a plurality of openings therethrough and a plurality of passageways formed into a lower surface thereof. A mesh is positioned on the upper surface of the base, upon which the initially shaped mat is positioned.

[0008] A plurality of carriers, each having an initially shaped mat positioned thereon, are positioned on adjacent shelves on a collector assembly. Once the collector assembly has received the desired number of carriers with initially shaped mats, the carriers are transferred into the heater press.

[0009] In the heater press, the initially shaped mats are pressed between the respective carrier and the lower surface of the respective shelf of the heater press for a predetermined period of time, under predetermined pressure and temperature conditions. Preferably, the initially shaped mats are simultaneously pressed within the heater press.

[0010] After a predetermined period of time, the carriers, now having a pressed fiber board (which was created through the pressing of the initially shaped mat) are removed by the post formation press removal assembly, then transferred sequentially to the carrier decoupling wherein the pressed fiber board is separated from the carrier. The pressed fiber board is then placed onto the shelves of the ferris wheel of the acclimating assembly so as to acclimate to the ambient conditions. Upon acclimating, the pressed fiber board can be trimmed and further processed.

[0011] It is contemplated that the system operates continuously, and that the heater press is configured for heating and pressing multiple initially shaped mats simultaneously, forexample ten initially shaped mats while greater and lesser number of mats is likewise contemplated.

[0012] Variations to the system are contemplated, including, variations in the formation of the initially shaped mats, as well as the heating press and the method associated with the same. It is further contemplated that variations may be formed in the transfer from the forming press to the heater press as well as the transfer from the heater press to the acclimating assembly. Further variations to the acclimating assembly are contemplated.

[0013] It will be understood that the pressed fiber boards may be further treated in any number of different manners, including cutting, laminating, sanding, painting, among other processes.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The disclosure will now be described with reference to the drawings wherein:

[0015] Figure 1 of the drawings is an image of the extruder and the forming press of the present system for forming a fiber board, showing, in particular, pulp proceeding into the inlet and out the outlet of the extruder into the forming press, along with the upper and lower belts of the forming press, and the first side wall thereof;

[0016] Figure 2 of the drawings is an image of the extruder and the forming press of the present system for forming a fiber board, showing, in particular, the inlet, the upper and lower belts, including the upper and lower belt surfaces as well as the first side wall (with the second side wall being a mirror image thereof;

[0017] Figure 3 of the drawings is an image of the outlet of the forming press along with the output handling and a portion of the carrier transfer assembly, showing, in particular, the receiving table and the dimensioning assembly, as well as the belt assembly and portions of the carrier movement assembly;

[0018] Figure 4 of the drawings is an image of the outlet of the forming press along with the output handling and apportion of the carrier transfer assembly, showing, in particular, the movable portion of the receiving table, as well as the dimensioning assembly;

[0019] Figure 5 of the drawings is an image of a portion of the output handling assembly and the carrier transfer assembly, showing, in particular, the transfer of the initiallyshaped mat onto a carrier, along with the application of a mold release onto the upper surface of the initially shaped mat;

[0020] Figure 6 of the drawings is an image of a portion of an example of the carrier showing the upper surface and the mesh thereof;

[0021] Figure 7 of the drawings is an image of a portion of an example of the carrier showing the lower surface thereof, along with the openings, the outer perimeter and the lower surface configuration, including the pathways, the peaks and the valleys thereof;

[0022] Figure 8 of the drawings is an image of the collector assembly, and a portion of the carrier movement assembly, showing, in particular, the filling of the lowermost shelf with a carrier having an initially shaped mat thereon, with the remaining shelves each filled with a carrier having an initially shaped mat thereon. Figure 8 also shows a portion of the carrier movement assembly, along with the heater press, showing, in particular, the transfer of a plurality of carriers, each having an initially shaped mat thereon, from the collector assembly to the heater press;

[0023] Figure 9 of the drawings is an image of the heater press having each shelf thereof filled with a carrier having an initially shaped mat thereon. Figure 9 also shows an embodiment of the heater press wherein the shelves have been moved into a pressed configuration applying pressure and temperature to the initially shaped mats that are on the carriers, with steam and water exiting through the passageways defined by the cooperation of the carrier with the shelves. The image of the heater press shows, in particular, one of the screens in position, and the collector assembly moved by the actuator into a position wherein the uppermost shelf is aligned with the carrier movement assembly. Figure 9 of the drawings is an image of the heater press and the post formation press removal assembly, showing, in particular, the side and back screens in the deployed orientation, with the post formation press removal awaiting receipt of the carriers having a pressed fiber board thereon by way of the articulating arm of the post formation press removal assembly;

[0024] Figure 10 of the drawings is an image of the post formation press removal assembly having the shelves thereof filled with carriers, each having a pressed fiber board thereon, showing, in particular, the removal of a lowermost carrier with pressed fiber board for placement on the carrier decoupling assembly. Figure 10 of the drawings is an image of the carrier decoupling assembly, showing, in particular, the separation of the pressed fiberboard from a carrier by the lifting tool, with the carrier being removed by the carrier removal member; and

[0025] Figure 11 of the drawings is an image of the acclimating assembly, showing, in particular, a plurality of pressed fiber boards mounted on shelves of the ferris wheel, whereupon acclimating, the pressed fiber boards can be removed for further post processing as set forth herein.DETAILED DESCRIPTION OF THE DISCLOSURE

[0026] While this disclosure is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment(s) with the understanding that the present disclosure is to be considered as an exemplification and is not intended to be limited to the embodiment(s) illustrated.

[0027] It will be understood that like or analogous elements and / or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

[0028] Referring now to the drawings and in particular to the Figures as a whole, the system is shown as including extruder 11 , forming press 12, output handling assembly 13, carrier transfer assembly 14, collector assembly 15, heater press 16, post formation press removal assembly 17, carrier decoupling assembly 18 and acclimating assembly 19. As will be understood, the configuration of the system is shown for the formation of fiber board having a generally rectangular configuration having dimensions of approximately 3050 mm by 1220 mm and a thickness of between 0,5 mm and 50 mm. Of course, it will be understood that a number of different configurations and dimensions are contemplated, and the dimensions set forth are solely exemplary. The other dimensions may be both larger or smaller and can be varied without limitation.

[0029] Referring to Figures 1 and 2, the extruder 11 is shown as comprising inlet 26 and outlet 28. The extruder 11 is configured to direct pulp 200 into the forming press. The pulp 200 may be of the type set forth in the two patent applications filed in the Netherlands which are incorporated by reference herein, and which are set forth hereinabove. The watercontent of the pulp can be varied so that the extruder can adequately supply pulp to the forming press to sufficiently fill the press volume. The extruder of the present configuration includes an auger (not shown) which directs pulp through the outlet at a predetermined flow rate. The supply of pulp 200 can come from any number of different sources, some of which are pumped under pressure, whereas other rely on gravity or combinations thereof.

[0030] With reference to Figures 1 through 4, the forming press comprises a dual belt press having an upper belt 30 and a lower belt 32. The belts, together with first side wall 34 and second side wall 36 define a volume 37 within which the pulp is distributed and dewatered. The dual belt press operates in a continuous operation and includes inlet 38 and outlet 39. As will be understood, the press belts can be stretched to a desired tension through, for example, pneumatic cylinders, and the belts can be biased through, for example pneumatic cylinders toward each other. Furthermore, the belts comprise a porous substrate which has openings sufficiently large to allow for the passage of water therethrough, while substantially precluding the passage of fibers from the pulp therethrough.

[0031] As will be explained below, the extruder delivers pulp to the inlet of the forming press, wherein the forming press dimensions the pulp and removes, through pressing, a desired quantity of water from the pulp.

[0032] With reference to Figures 3 and 4, at the outlet 39 of the forming press, the pulp comprises a dimensionally stable mat having an unstressed thickness of, for example, 1 to 120 mm, with a water content of approximately 20 to 80 %. Of course, other thicknesses are contemplated, as are other water content percentages.

[0033] Positioned at the outlet 39 of the forming press is the output handling assembly 13, which includes receiving table 40 and dimensioning assembly 60. The receiving table 40 includes rollers 42, first end 44, second end 46 and movable portion 48. The receiving table 40 in the configuration shown, is inclined in a downward direction and comprises a plurality of spaced apart, parallel rollers that extend from the first end to the second end.

[0034] The movable portion 48 is positioned proximate the second end 46 of the receiving table 40. The movable portion 48 includes pivot axle 50 and actuator 52. The movable portion 48 covers a lower opening 54. It will be understood that the movable portion 48 can be actuated by the actuator 52 so as to rotate about the pivot axle 50 to selectivelyopen and close the lower opening 54. In particular, when opened, output from the outlet of the forming press can be directed through the lower opening. When closed, the output from the outlet of the forming press passes over the movable portion 48. Below the lower opening, an auger can be suppled, which can be coupled to a bin for storing any output that is directed through the lower opening. As it is contemplated that the output is free of formaldehyde, adhesives, and / or formaldehyde derivatives, any output that is directed into the auger and the storage bin can be recycled directly into the pulp forming equipment, without further processing.

[0035] In the configuration shown, the dimensioning assembly 60 is configured to provide an initial trimming and dimensioning of the output from the forming press. In the configuration shown, a first side saw 62 is positioned on a first side, and a second side saw 64 is positioned on a second side, opposite the first side. The first and second side saws generally provide an initial dimensioning that corresponds to the width of the initial output. In the configuration shown, outboard and below the saws is a trough that is likewise directed to the auger that is positioned below the lower opening, so as to facilitate the recycling of the trimmed portions. Additionally, the cross cut saw 66 spans across the receiving table 40. As the process is contemplated to be continuous, and it is contemplated that the cross cut saw is actuated while the output is moving along and across the rollers, the cross cut saw traverses across the surface of the receiving table oblique to the rollers 42 and oblique to the direction of travel of the initial output. The angle at which the cross cut saw 66 is positioned and the speed of the cross cut saw can be varied depending on the speed of the initial output across the receiving table. It is contemplated that the dimensioning assembly sequentially cuts the initial output into initially shaped mats having a generally similar dimension. As will be understood that initial output has the dimensional stability sufficient so as to be cut by the first and second side saws and the cross cut saw.

[0036] Carrier transfer assembly 14 is shown in Figures 3, 4, 5 and 8, as comprising belt assembly 70 and carrier movement assembly 80. The belt assembly 70 comprises one or more belts 71 which extends between an initial roller 72 and a final roller 74. The belt assembly 70 defines a first end 75 proximate the second end of the receiving table 40 and a second end 76 space distally therefrom. The upper surface 78 of the belts 71 define the surface upon which the initially shaped mats are prepared for transfer to the carriers 150. Inthe configuration shown, the upper surface 78 of the belts 71 is generally oblique to the receiving table and is generally substantially horizontal. In the configuration shown, a pair of belts are positioned in an end to end configurations, whereas in other configurations, a single belt or more than three belts may be utilized, without limitation. In an embodiment several initially shaped mats are laid on carrier 150 before it is directed onto a shelf of collector assembly 15. In an embodiment carrier transfer assembly 14 comprises several belts assembly 70 on which each single initially shaped mat can be laid and provides the opportunity to continue further on with one or more initially shaped matts on carrier 150.

[0037] The carrier movement assembly 80 generally extends below and beyond the belt assembly 70, extending from first end 82 to second end 84, and includes upper surface 86. In the configuration shown, the carrier movement assembly 80 and the belt assembly 70 are generally parallel to each other in a spaced apart configuration. The carrier movement assembly is configured for receipt of and movement of individual carriers, such as carrier 150.

[0038] With reference to Figures 6 and 7, carrier 150 is shown as comprising a base 152 having an upper surface 154 and a lower surface 156 opposite the upper surface 154. A plurality of openings 159 are formed in the base 152 extending from the upper surface 154 through the lower surface 156. For example, a multitude of openings may be positioned in a number of different spacings in every 25 mm2. While the upper surface 154 comprises, preferably, a planar surface free of surface variations, the lower surface 156 comprises a plurality of peaks 162 and valley 164, which collectively define a plurality of passageways 166 that can extend continuously to the outer perimeter 168 of the base 152. Indeed, preferably, the passageways 166 branch in different directions so as to provide multiple manners by which to reach the outer perimeter 168 of the base 152. The openings 159 in the base are positioned so that they generally correspond to valleys 164 which define the different passageways 166.

[0039] A mesh 158 extends over the upper surface 154. IN the configuration shown, the mesh 158 comprises a steel weave defined by a plurality of first parallel elements woven with a plurality of second parallel elements, wherein the first and second parallel elements are perpendicular to each other. The openings of the mesh may be generally uniform about the mesh or may be varied depending on the configuration. Other configurations, includingmeshes formed through chains or meshes formed from a single material are likewise contemplated.

[0040] Referring again to Figures 3, 4, 5, and 8, showing the carrier movement assembly, it will be understood, and explained below with respect to the method in greater detail, that the carrier movement assembly sequentially receives carriers (which may be delivered through additional conveyors or other structures, not shown) proximate the first end thereof, and generally below the belt assembly 70. The carriers are sequentially directed along the upper surface 86 from the first end 82 to the second end 84. The delivery of the carriers on the movement assembly is coordinated with the movement of the initially shaped mats so that the mats reach the final roller of the belt assembly as the carrier appears beyond the final roller, so that the initially shaped mats are delivered onto the mesh 158 positioned on the upper surface 154 of the base 152 of the carrier 150. The carrier 150 continues on the carrier movement assembly 80 to the second end thereof.

[0041] With reference to Figures 8 and 9, the collector assembly 15 includes frame 90 having a plurality of shelves 92 that are positioned in a spaced apart configuration therealong. An actuator 94 is coupled to the shelves so as to direct the shelves in a generally vertical configuration between a lower end and an upper end, and an articulating arm 96 which is configured to direct carriers placed on the shelves into the heater press 16. The shelves 92 comprise a pair of opposing flanges coupled to the frame, wherein the opposing flanges are sized and spaced apart from each other so as to be able to receive a carrier thereon.

[0042] The frame 90 is positioned so as to overlie a portion of the carrier movement assembly 80 proximate the second end thereof. And the actuator 94 is configured to sequentially place any one of the shelves 92 into alignment with the carrier movement assembly so that the carrier movement assembly can direct a carrier onto the desired shelf with which the carrier movement assembly is aligned.

[0043] As will be explained in greater detail with respect to the method, the frame is configured to sequentially receive carriers having an initially shaped mat positioned thereon, from an uppermost shelf to a lowermost shelf. In the configuration shown, a total of ten shelves are provided (although it is contemplated that a greater number of shelves, such as for example, twenty or more shelves, or fewer shelves, for example, as few as one or twoshelves). Thus, as the upper most shelf is filled with a carrier, the actuator can direct the frame upwardly to align the second upper most shelf with the carrier movement assembly so as to sequentially place another carrier upon the second upper most shelf. This can continue until all the shelves are filled. It is contemplated that, in certain configurations, it may be desirable to skip one or more shelves, and the disclosure is not limited to the filling of every shelf.

[0044] Positioned above the carrier movement assembly 80 a sufficient height so as to be free from interference is articulating arm 96. The articulating arm 96 is configured to push each of the carriers along the respective shelf 92 into the corresponding shelf of the heater press 16 when the heater press is in an open configuration. It will be explained in greater detail below that the frame is moved by the actuator so that each of the desired carriers on the respective one of the shelves are aligned with the corresponding shelf of the heater press.

[0045] With reference to Figures 8-9, the heater press 16 is shown as comprising frame 100, shelves 101 , actuator 104, screens 106 and heating elements 108. The heater press is positioned downstream from the collector assembly, and generally adjacent thereto. The shelves 101 are slidably attached to the frame 100, with the actuator configured to collectively drive the shelves 101 into abutment with each other (preferably simultaneously), and to apply a desired pressure between the shelves 101. The heating elements 108 are configured to heat the shelves to a desired temperature. Preferably, the heating elements provide substantially uniform heating to the shelves.

[0046] Each of the shelves 101 includes an upper surface configured to receive a carrier, and a lower surface 102 opposite the upper surface. In the configuration shown, the lower surface 102 is substantially planar so as to provide a flat engagement surface for the upper surface of the initially shaped mat which is positioned on the carrier immediately below the respective shelf.

[0047] A plurality of screens are provided which can be actuated upon placement of the carriers on the respective shelves of the heater press. The different screens include a front screen 106a positioned between the collector assembly 15 and the heater press 16, a side screen(s) 106b positioned on one or both sides of the heater press 16, and back screen 106c positioned. Due to the steam and water that is exiting from the heater press 16, thedifferent screens prevent inadvertent damage to the initially shaped mats that are in the collector assembly 15 as well as the pressed fiber boards positioned int eh post formation press removal assembly. The screens can be automated through the movement of the shelves within the heater press.

[0048] It will be understood that the shelves of the heater press can be moved between an open configuration wherein the shelves are separated from each other to a closed configuration wherein the shelves (having a carrier with an initially shaped mat positioned thereon) are pressed against each other to a desired pressure, temperature and for a desired duration. Sample pressures, temperatures and durations are disclosed in the incorporated by reference Netherlands patent applications. Of course, these are exemplary and other pressure, temperature and durations may be employed, without limitation.

[0049] The post formation press removal assembly 17 is shown in Figures 9 and 10 as comprising frame 110, shelves 112, actuator 114 and articulating arm 116. The post formation press removal assembly is positioned downstream of the heater press 16 and adjacent thereto. The frame 110 is configured to be movable in a vertical direction via actuators 114. Shelves 112 comprise opposing flange elements that extend from opposing sides of the frame 110 and which are configured to support a carrier (having a pressed fiber board positioned thereon). In the configuration shown, a total of ten shelves are positioned in a spaced apart configuration that generally corresponds to the orientation of the shelves 101 of the heater press in the open configuration.

[0050] The articulating arm 116 is configured to traverse across the post formation press removal assembly from a first position downstream of the frame 110 to a position proximate the heater press so as to engage the carriers positioned within the heater press. The articulating arm includes a carrier retainer clamp 117 structurally configured to releasably retain the carriers that are positionable on the shelves of the post formation press removal tool.

[0051] As will be described further with respect to the method, as the heater press completes a cycle and the actuator of the heater press returns to an initial position, the articulating arm traverses across the frame 110 and the shelves 112 so as to be adjacent the carriers within the heater press. Subsequently, the retainer clamp 117 engages the carriers and the articulating arm traverses back across the frame 112 pulling the carriers along andonto the respective shelves 112 of the post formation press removal assembly 17. Once positioned, the retainer clamp 117 releases leaving the carriers on the respective shelves.

[0052] With reference to Figure 10, the carrier decoupling assembly 18 is positioned downstream of the post formation press removal assembly and comprises conveyor 120, lifting tool 122, carrier removal member 124 and cutters 126. The conveyor 120 is positioned downstream of the post formation press removal assembly, and the conveyor includes upper surfacel 121 . The conveyor 121 is positioned in line with the shelves 112 of the post formation press removal assembly 17 so that the actuator 114 can sequentially align each one of the respective shelves 112 with the upper surface 121 of the conveyor 120.

[0053] When aligned, the conveyor can move the carrier having a pressed fiber board thereon from the respective one of the shelves 112 onto the upper surface 121 of the conveyor 120. The lifting tool 122 can couple to the pressed fiber board and lift the pressed fiber board from the surface of the conveyor. At such time, the carrier removal member 124 can direct the carrier away from the conveyor 120. In the configuration shown, the carrier is removed generally orthogonally from the direction of the conveyor 120. Once removed, the lifting tool can replace the pressed fiber board onto the upper surface 121 of the conveyor 120. In the configuration shown, the lifting tool 122 comprises a plurality of vacuum elements which through suction can be releasably coupled to the upper surface of the pressed fiber board.

[0054] As the pressed fiber board has been removed from the carrier, the pressed fiber board can be placed on to the accumulating assembly 19, shown in Figure 11 , which comprises ferris wheel 130 having a plurality of radial fiber board receiving shelves 132. The ferris wheel can be rotated so as to receive sequential and subsequent pressed fiber boards. As will be explained below, while on the ferris wheel, the pressed fiber boards are acclimated to the ambient conditions. That is, when placed on the ferris wheel, the pressed fiber boards tend to be substantially hotter than the ambient environment. This allows the pressed fiber boards to become acclimated gradually and so as to reach an equilibrium so as to preclude warping and the like. Cutters may be provided to further dimension the pressed fiber board into the desired outer dimensions. The fiber boards may then be stacked onto each other for further processing and / or shipping.

[0055] In operation, to form a fiber board utilizing the system of the present disclosure, as described above, pulp 200 is first provided. Once provided, the pulp is fed into the inlet 26 of the extruder 11 , wherein the extruder directs the pulp to the outlet 28 and into the forming press 12. As the pulp is directed into the forming press 12, the upper and lower belts are moving in a direction toward the outlet of the forming press, thereby squeezing the pulp between the upper belt surface 30 and the lower belt surface 32. As the belts are porous, water is pressed out of the pulp as the pulp proceeds from the inlet 38 to the outlet 39 of the forming press 12. Through the cooperation of the upper belt surface 30 and the lower belt surface 32, and the first and second side walls 34, 36, the pulp is directed into the volume formed thereby.

[0056] It will be understood that the upper and lower belts may be tensioned at different tensions within a wider range of tensions, so as to achieve the desired removal of water. Additionally, the upper belt and the lower belt can be biased relative to each other so as to exert a desired pressure onto the pulp that is placed within the volume defined by the forming press components. It will additionally be understood that the rate at which the extruder supplies pulp, along with the pulp formulation will also affect the properties of the initially shaped mat.

[0057] At the outlet 39, sufficient water has been removed so as to provide a dimensionally stable initially shaped mat. The shaped mat extends along the receiving table of the output handling assembly 40 toward the second end 46 thereof. During startup, or when there is a portion of an initially formed mat that is undesirable, the movable portion 48 can be actuated so that portions of the initially shaped mat are directed through the lower opening 54 to be recycled. Where the initially formed mat is of proper quality, the movable portion can be positioned so as to close the lower portion.

[0058] While traversing across the receiving table 40, the dimensioning assembly can trim the initially shaped mats into a desired initial dimension. That is, the opposing side saws 62, 64 can trim the opposing sides, while the cross cut saw can be intermittently operated so as to separate the material into mats of a desired length. As the output is continuous, the cross cut saw operates to make a transverse cut while the output is proceeding along the receiving table.

[0059] At the second end 46 of the receiving table the initially shaped mat is transferred to the belts 71 of the carrier transfer assembly. At the same time, a carrier 150 is directed onto the carrier movement assembly 80. The two are coordinated so that as the initially shaped mat reaches the second end of the belt assembly 70, a carrier 150 is there to meet the initially shaped mat so that continued movement places the initially shaped mat onto a carrier in the desired orientation.

[0060] The carrier having the initially shaped mat is next directed onto a shelf of the collector assembly 15 which is aligned with the carrier movement assembly. Once received, the actuator 94 of the carrier assembly moves the shelves so as to align a subsequent one of the shelves with the carrier assembly. Generally, the shelves are filled from the top shelf to the bottom shelf (which, in the configuration shown, comprises a total of ten shelves). The process is repeated until all of the desired shelves are filled with a carrier having an initially shaped mat thereon.

[0061] Once all of the shelves are filled, the actuator directs the shelves into an orientation wherein the shelves of the collector assembly 15 correspond to the shelves of the heater press 16. At such time, the articulating arm 96 of the collector assembly can direct the carriers having the initially shaped mats thereon from the shelves of the collector assembly 15 to the shelves of the heater press 16. It will be understood that a mold release spray can be applied to the upper surface of the initially shaped mat so as to preclude adhesion of the upper surface of the initially shaped mat to a lower surface of one of the shelves of the heater press 16.

[0062] It will be understood that the heater press 16 is preheated to the desired temperature so as to be ready to accept the carriers and the initially shaped mats. As the carriers with the initially shaped mats are received on each of the shelves of the heater press, the actuator is actuated so as to move the shelves toward and into contact with each other at the desired pressure and temperature. At the same time as the shelves are being moved (or prior thereto in some configurations), the screens can be lowered so as to minimize the expulsion of water and stream from the heater press.

[0063] While in the heater press, water from the initially shaped mats is directed from the initially shaped mats through the mesh of each of the carriers, through he openings in the base of the carriers, and then along the pathways that are formed into the lower surface ofthe each of the bases of the carriers. The water and steam is then directed to the outer perimeter and either exhausted as steam or through gravity directed toward a lower end of the heater press for collection and reuse. Advantageously, with the carrier configuration, water and steam is not trapped that is removed from the initially shaped mats is directed out of the heater press in a managed and expeditious manner, so as not to be captured within the heater press and so as not to damage the initially shaped mat that is being converted into pressed fiber board.

[0064] As set forth above, the particular temperature, pressure and duration of operation of the press can be varied depending on the configuration, and depending on the particular materials from which the fiber board is formed, the dimensions, the pulp constituents, among other factors. It will be understood that the heater press is configured for a plurality of pressures, temperatures and durations. Additionally, in the configuration shown, the shelves are moved in unison so that each of the initially shaped mats experience the same pressure, temperature, duration cycle. It will be understood that in other configurations, the shelves may be sequentially moved instead of in unison.

[0065] Once the heater press cycle is complete, the shelves of the heater press can return to an initial configuration wherein the shelves are separated from each other. Once separated, the articulating arm can be directed toward and into contact with the carriers, wherein the retainer clamp 117 can engage respective ones of the carriers. The articulating arm can then traverse the post formation press removal assembly pulling the carriers onto respective shelves 112 that are aligned with the shelves of the heater press when the heater press shelves are returned to then initial configuration. The articulating arm can then release the carriers.

[0066] It will be understood that at such time, the carriers each have a pressed fiber board positioned on an upper surface thereof. In the configuration shown, the lowermost shelf of the post formation press removal is aligned with the carrier decoupling assembly and a first carrier having a pressed fiber board positioned on an upper surface thereof is directed onto the conveyor of the carrier decoupling 18.

[0067] Once on the carrier, the lifting tool 122 engages the upper surface of the pressed fiber board and decouples the pressed fiber board from the underlying carrier. Next, the carrier removal member removes the carrier from the underlying conveyor of the carrierdecoupling assembly. The pressed fiber board is then released by the lifting tool onto the upper surface of the conveyor, and the conveyor directs the pressed fiber board onto the acclimating assembly 19. In particular, the pressed fiber board is directed onto a shelf of the ferris wheel 130.

[0068] This process is repeated for each of the pressed fiber boards that are removed from the heater press. For example, once the first carrier is removed, the actuator can align the subsequent one of the shelves 112 of the post formation press removal with the conveyor of the carrier decoupling and the process can be repeated to position each one of the pressed fiber boards onto the ferris wheel.

[0069] It will be understood that the pressed fiber board may have a thickness of between 0,5 and 50 mm and a density of between 300 and 1100 kg / m3, while other thicknesses and densities are likewise contemplated. Such configurations are further described in the incorporated by reference Netherlands patent applications.

[0070] It will be understood that after a certain period of time, which may vary depending on the formulations and properties of the pressed fiber board as well as the ambient conditions and the like, the pressed fiber board can be removed from the acclimating assembly and cut to the desired final dimensions, as well as further processed.

[0071] It will be understood that the system and method is configured for, preferably, continuous operation. For example, the extruder and the forming press operate continuously forming initially shaped mats for placement onto the collector assembly. By the time that the collector assembly has been filled, the heater press is ready for receipt of the batch of initially shaped mats from the collector assembly. Once the heater press cycle has completed and the pressed fiber boards are removed onto the post formation press removal assembly, the next set of initially shaped mats have been fully loaded on the collector assembly.Additionally, as the pressed fiber boards are removed from the post formation press removal assembly and onto the acclimating assembly, the heater press has completed another cycle. And the process continues in such a fashion so that the entire system operates in a continuous manner. It will be understood that variations can be made to make up for initially shaped mats that are directed out of the system through the movable portion of the receiving table or other issues. It is further contemplated that the system may operate in a fully batch process or other intermittent manners in some configurations. It is contemplated that thechanges can be made to the pulp configuration, to the dimensions of the initially shaped mats, to the parameters of the heater press on a continuous operating basis.

[0072] The foregoing description merely explains and illustrates the disclosure and the disclosure is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the disclosure.

Claims

CLAIMS1 . A system for forming a fibre board comprising: an extruder having an inlet for pulp and an outlet for directing the pulp into a forming press, a forming press provided with an upper belt and a lower belt for pressing water our of the pulp for obtaining an endless mat, a dimensioning assembly configured to provide an initial trimming and dimensioning of the output from the forming press for obtaining a dimensionally stable initially shaped mat, an output handling assembly for receiving the dimensionally stable initially shaped mat, a carrier movement assembly provided with a carrier for placing the dimensionally stable initially shaped mat onto a carrier in a desired orientation, a collector assembly for storing a carrier having a dimensionally stable initially shaped mat thereon, a heater press provided with shelves for accepting carriers having a dimensionally stable initially shaped mat thereon.

2. A system for forming a fibre board according to claim 1 , further comprising a post formation removal press removal assembly for releasing the carriers from the heater press, a carrier decoupling assembly for decoupling the pressed fiber board from the underlying carrier, an acclimating assembly for acclimating the pressed fiber board to the ambient conditions.

3. A system for forming a fibre board according to any one or more of the preceding claims further comprising a cutting assembly for cutting the pressed fiber board thus acclimatized to desired final dimensions.

4. A system for forming a fibre board according to any one or more of the preceding claims, wherein the extruder includes an auger which directs pulp through the outlet at a predetermined flow rate.

5. A system for forming a fibre board according to any one or more of the preceding claims, wherein the forming press comprises a dual belt press having an upper belt and a lower belt,wherein the belts, together with a first side wall and a second side wall define a volume within which the pulp is distributed and dewatered.

6. A system for forming a fibre board according to claim 5, wherein the dual belt press can be stretched to a desired tension through pneumatic cylinders, and the belts can be biased through pneumatic cylinders toward each other.

7. A system for forming a fibre board according to any one or more of the preceding claims, wherein the belts comprise a porous substrate which has openings sufficiently large to allow for the passage of water therethrough, while substantially precluding the passage of fibers from the pulp therethrough.

8. A system for forming a fibre board according to any one or more of the preceding claims, wherein the dimensioning assembly comprises a first side saw positioned on a first side, and a second side saw positioned on a second side, opposite the first side, wherein the first and second side saws provide an initial dimensioning that corresponds to the width of the initial output.

9. A system for forming a fibre board according to any one or more of the preceding claims, wherein the output handling assembly includes a receiving table including rollers, first end, second end and movable portion, wherein the receiving table is inclined in a downward direction and comprises a plurality of spaced apart, parallel rollers that extend from the first end to the second end.

10. A system for forming a fibre board according to claim 9, wherein the movable portion is positioned proximate the second end of the receiving table, wherein the movable portion covering a lower opening includes pivot axle and actuator, wherein the movable portion can be actuated by the actuator so as to rotate about the pivot axle to selectively open and close the lower opening.

11. A system for forming a fibre board according to any one or more of the preceding claims, wherein a carrier transfer assembly comprises a belt assembly and the carrier movement assembly, wherein belt assembly comprises one or more belts which extends between an initial roller and a final roller.

12. A system for forming a fibre board according to claim 11 , wherein the belt assembly defines a first end proximate a second end of a receiving table and a second end a spacedistally therefrom, wherein upper surface of the belts define the surface upon which the initially shaped mats are prepared for transfer to carriers.

13. A system for forming a fibre board according to any one or more of the preceding claims, wherein the carrier movement assembly is configured for receipt of and movement of individual carriers, and extends below and beyond the belt assembly, extending from first end to second end, and includes upper surface, wherein especially the carrier movement assembly and the belt assembly are parallel to each other in a spaced apart configuration.

14. A system for forming a fibre board according to any one or more of the preceding claims, wherein the collector assembly includes a frame having a plurality of shelves positioned in a spaced apart configuration there along, wherein the shelves comprise a pair of opposing flanges coupled to the frame, wherein the opposing flanges are sized and spaced apart from each other so as to be able to receive a carrier thereon.

15. A system for forming a fibre board according to claim 14, wherein an actuator is coupled to the shelves so as to direct the shelves in a vertical configuration between a lower end and an upper end, and an articulating arm which is configured to direct carriers placed on the shelves into the heater press.

16. A system for forming a fibre board according to any one or more of the preceding claims, wherein a heater press comprises a frame, shelves, an actuator, screens and heating elements configured to heat the shelves to a desired temperature, wherein the shelves are slidably attached to the frame, with the actuator configured to collectively drive the shelves into abutment with each other and to apply a desired pressure between the shelves.

17. A system for forming a fibre board according to any one or more of the preceding claims, wherein post formation press removal assembly comprises a frame, shelves, an actuator and an articulating arm, wherein the frame is configured to be movable in a vertical direction via the actuators and the shelves comprise opposing flange elements that extend from opposing sides of the frame and which are configured to support a carrier having a pressed fiber board positioned thereon.

18. A system for forming a fibre board according to claim 17, wherein the articulating arm includes an carrier retainer clamp structurally configured to releasably retain the carriers that are positionable on the shelves of the post formation press removal tool, wherein the articulating arm is further configured to traverse across the post formation press removalassembly from a first position downstream of the frame to a position proximate the heater press so as to engage the carriers positioned within the heater press.

19. A system for forming a fibre board according to any one or more of the preceding claims, wherein the carrier decoupling assembly comprises a conveyor, a lifting tool, a carrier removal member and cutters, wherein the conveyor is positioned downstream of the post formation press removal assembly.

20. A system for forming a fibre board according to claim 19, wherein the conveyor is positioned in line with the shelves of the post formation press removal assembly so that the actuator can sequentially align each one of the respective shelves with the upper surface of the conveyor.

21. A system for forming a fibre board according to any one or more of the preceding claims, wherein a carrier is configured for placing several dimensionally stable initially shaped mat onto a carrier in a desired orientation.

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