Area section made of fibrous material, method for producing an area section and method for producing three-dimensional molded parts from an area section

Abstract

A surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, a method for producing a surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, and a method for producing three-dimensional molded parts from a surface section made of fibrous material are described, wherein the degree of forming of surface sections can be significantly increased by means of a defined separation of the fibrous material before forming.

Description

Technical field

[0001] A surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, a method for producing a surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, and a method for producing three-dimensional molded parts from a surface section made of fibrous material are described.

[0002] Sections of fibrous material can be formed into three-dimensional parts, such as food packaging (e.g., trays, capsules, boxes, lids, etc.) and consumer goods (e.g., electronic devices, etc.), through a forming process under pressure and temperature. Everyday objects, such as disposable cutlery and tableware, can also be manufactured from fibrous material. Fibrous materials include natural and synthetic fibers, with an increasing use of materials containing or consisting of natural fibers. These can be derived, for example, from renewable resources or recycled paper. Sections of fibrous material can consist of at least one layer of paper, cardboard, nonwoven fabric, or a nonwoven-like layer, such as airlaid, fluff pulp, compressed airlaid, and others.Such materials have a relatively low moisture content of up to about 30 wt% water. background

[0003] The forming of the aforementioned materials in a so-called dry thermoforming process is subject to significant limitations regarding formability due to the material properties of natural fibers in their dry state. The maximum elongation, depending on the fibrous material used, is approximately 2-15% relative to the initial state. Furthermore, fibrous materials exhibit poor flow behavior. This severely restricts the range of possible product geometries (depth, ribs, undercuts, draft angles <10°, etc.) for products made from fibrous materials. Paper, in particular, can only be formed to a very limited extent, as it tends to tear easily when deformed.

[0004] The manufacture of products from a fibrous material is known, for example, from WO 2017 / 160218 A1.

[0005] When manufacturing molded parts using dry fiber thermoforming, it is often necessary to retract the material surrounding the mold, as the material's elasticity is usually insufficient. This applies to paper as well as airlaid, kraft paper, and similar natural fiber materials. Especially when multiple products or molded parts are to be formed simultaneously from a single sheet or web, they must first be cut / punched from the sheet or web (pre-cutting). However, this completely separates the cutout (blank), which is subsequently formed into the molded part, from the web or sheet. Consequently, the blank, and later the formed product, must be handled separately during further transport within the machine.

[0006] Separate handling, however, is very complex and expensive. Furthermore, individually removing molded parts increases production time, as individual removal cannot operate at the same speed as, for example, a continuous feed system (e.g., a roller feeder). Additionally, the handling system must be moved in and out of a molding station, resulting in a significant investment in a separate and more complicated transport system. Another disadvantage is that positioning individual blanks or products becomes more difficult, as the cutouts or products are no longer positioned by a track or sheet. Task

[0007] The task is therefore to provide a solution that overcomes the disadvantages of the prior art and enables the forming of surface sections made of fiber-containing material, whereby no singulation of blanks from a surface section is necessary and high mold heights can be achieved in production, so that there are essentially no restrictions regarding the mold depth and product geometry in the production of three-dimensional molded parts in a "dry fiber" processing process. Solution

[0008] The aforementioned problem is solved by a surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, wherein the surface section has at least one material layer, wherein the surface section has at least one forming area for forming to produce a three-dimensional molded part and at least one first area and at least one second area, wherein the at least one first area and the at least one second area extend circumferentially around at least a part of the at least one forming area, wherein the at least one first area has at least two sections in which the at least one material layer is completely separated, and the at least one second area has at least one section in which the at least one material layer is completely separated.and wherein the two sections of the at least one first region are separated from each other by a first connecting region, the first connecting region between the sections of the at least one first region being located relative to the section of the at least one second region.

[0009] A surface section can be provided by an endless material web or a sheet of material. The at least one forming area within the surface section can remain with the rest of the surface section, e.g., in an endless material web or sheet of material, and be transported via the sections of the at least one first area and the at least one second area, even during and after forming. This eliminates the need for separate transport of individual blanks or molded parts and ensures that the position of the blanks or molded parts formed in the forming area is maintained along the transport path.

[0010] Within the sections, the material of the surface area is separated, so that when the mold area is deformed, a "draw-in" of the fiber-containing material leads to a compensating movement by widening the sections. This results in a connection in the form of strips or the like between an edge of the mold area or the molded part and a portion of the surface area surrounding the first area. For example, at least two strips can be formed by deformation and the drawing in of material within the mold area, extending from at least one connection area between the sections of the first area to second connection areas on the mold area.

[0011] The relative arrangement of the first connection area between the sections of the at least one first area and the section of the at least one second area allows for compensation depending on the requirements and geometry of the molded part to be produced. For example, the sections of the first connection area can form strips of different lengths that share a common base in the connection area, so that the other ends of the strips connected to the mold area are displaced and positioned to varying degrees during forming.

[0012] In further embodiments, the first connection area between the sections of the at least one first area can be located essentially centrally to the section of the at least one second area, so that strips of essentially equal length are formed. Such embodiments can be used, for example, for the production of rotationally symmetrical molded parts.

[0013] In one embodiment, for example, a compensatory movement of the material can be achieved for only a portion of a mold area by separating the fiber-containing material into two areas, as described above. In further embodiments, the first and second areas can have multiple sections, so that there are several first connection areas in the first area and several second connection areas in the second area. This allows, for example, for compensation in the material during forming around the entire mold area, whereby the indentation in the mold area is essentially compensated for by an increase in size between the first and second areas, without deforming or indenting the portion of the surface section surrounding the first area, and whereby the position of the mold area or molded part is essentially maintained.

[0014] In further embodiments, at least one third area can also be provided, which is connected to the second area and the forming area according to the pattern described above, so that a deformation of the forming area is compensated by an equalization between the areas.

[0015] This makes it possible to achieve particularly large mold heights, since, depending on the design of the areas, a strong inward pull-in of material in the mold area can be achieved without the surface area outside the mold area and the first or second area being pulled in or deformed.

[0016] In further embodiments, the length of the section of at least one second area can be greater than the length of the sections of at least one first area. Such embodiments can, for example, accommodate a special forming process in the forming area, where a stronger forming is required locally compared to adjacent areas.

[0017] In further versions, the surface section can have an essentially flat extent. This allows the surface section to be easily transported and fed to different processing stations.

[0018] In further embodiments, the at least one first area and the at least one second area can run essentially parallel to each other. This allows defined strips or webs to be formed between the first area and the formed area after shaping by leveling.

[0019] In further embodiments, the at least one first area and the at least one second area can completely surround the mold area, taking into account material inward movement during forming in the mold area, and in which no inward movement occurs in the surface section, even with several mold areas, so that the position of the mold areas is maintained throughout the entire manufacturing process.

[0020] In further details, the length of the section of the at least one second area can be essentially 1.5 to 2.5 times the length of the sections of the at least one first area.

[0021] In further embodiments, the at least one first region can have circumferential sections, each separated from the other by a first connecting section, wherein the at least one second region has circumferential sections, each separated from the other by a second connecting section. This allows for compensation in every direction during forming.

[0022] In further embodiments, the first connection areas can be located essentially centrally to the sections of the at least one second area, and the second connection areas can be located essentially centrally to the sections of the at least one first area. This allows for compensation via the resulting "strips," whereby the load is distributed evenly within the fiber-containing material.

[0023] In further embodiments, the at least one forming area can have a three-dimensional forming part after forming, and an edge of the three-dimensional forming part can be connected via at least two strips to a material surrounding the at least one first area, wherein the strips are formed from the material which is located between the sections of the first area and the second area before forming.

[0024] In further embodiments, the at least one first region and the at least one second region can be oriented according to a degree of deformation during the forming process to create the three-dimensional molded part, wherein the at least one first region and the at least one second region can, for example, extend essentially circularly, ovally, or polygonally. In further embodiments, the distance of the at least one first region and / or the at least one second region to a center point of the molded surface can remain constant or vary.

[0025] The aforementioned problem is also solved by a method for producing a surface section made of fiber-containing material for processing into a three-dimensional molded part by a forming process, wherein the surface section has at least one material layer, comprising the following steps: Providing at least one surface section of fibrous material, and separating the fibrous material into at least one first area and at least one second area, wherein the at least one first area has at least two sections, and the at least one second area has at least one section, wherein the two sections of the at least one first area are separated from each other via a first connecting area.

[0026] Separating the sections in the at least one first area and the at least one second area enables the formation of surface sections with preferably several forming areas, wherein the forming areas are separated from the remaining surface section in the at least one first area and at least one second area via the sections and remain connected after forming via webs or strips forming between them.

[0027] Separation can be achieved, for example, by punching with appropriate punching dies in a punching station located upstream of a forming station. In further embodiments, a station can have a combined punching and forming tool, where the tool is designed such that, during a closing movement, the sections are first punched, and during the subsequent movement, the forming process is initiated. This also facilitates the alignment of forming areas and parts, as the forming areas are no longer displaced relative to the tool after punching.

[0028] The process enables the formation of molded bodies with large mold depths (e.g., large mold heights) and simultaneously allows for easy transport of the surface section, whether as a track or arc, while also maintaining the positioning of mold areas, blanks, and formed molded parts across multiple stations and processing steps.

[0029] Furthermore, the advantages described above with regard to the surface section also apply in a corresponding manner to the method for producing such surface sections.

[0030] Furthermore, the aforementioned task is also solved by a method for producing three-dimensional molded parts from a surface section of fiber-containing material according to one of the embodiments described above, comprising the following steps: Providing a surface section made of fibrous material with at least one material layer, comprising at least one forming area and at least one first area and at least one second area, wherein the at least one first area and the at least one second area jointly extend circumferentially around at least a part of the at least one forming area, wherein the at least one first area has at least two sections in which the at least one material layer is completely separated, and the at least one second area has at least one section in which the at least one material layer is completely separated, and wherein the two sections of the at least one first area are separated from each other via a first joining area, and forming the forming area.wherein the fibrous material in the mold area is deformed at least locally in three dimensions from a substantially planar extent to form a molded part, wherein the distance between the at least two sections of the at least one first area and the at least one section of the at least one second area is increased and at least one clearance is created between the first connection area and an edge of the molded part.

[0031] The process for manufacturing three-dimensional molded parts allows for the formation of parts from a single surface section that exhibit no deviations from the specified form or from each other, because the position and orientation of the mold areas can be maintained and ensured throughout the entire manufacturing process. Furthermore, it is possible to form parts with more complex product geometries from a single surface section.

[0032] The foregoing statements regarding a surface section and a method for producing surface sections apply accordingly to the method for producing three-dimensional molded parts from a surface section.

[0033] Further features, designs and advantages will become apparent from the following presentation of exemplary embodiments with reference to the figures. Brief description of the characters

[0034] The drawings show: Fig. 1 a schematic representation of a surface section made of fibrous material for the production of three-dimensional molded parts after a stamping step; Fig. 2 a schematic representation of the surface section of Fig. 1after a forming step; Fig. 3 a schematic representation of a surface section made of fiber-containing material for the production of three-dimensional molded parts after a stamping step with a plurality of forming areas; Fig. 4 a schematic representation of the surface section of Fig. 3 after a forming step; Fig. 5 a schematic representation of a method for producing three-dimensional molded parts from a surface section of fibrous material; and Fig. 6 a schematic representation of a section of a forming tool during the forming of fibrous material. Detailed description of implementation examples

[0035] The following are exemplary embodiments of the technical teaching described herein, with reference to the figures. The same reference numerals are used in the figure descriptions for identical components, parts, and processes. Components, parts, and processes that are immaterial to the technical teaching disclosed herein or that are obvious to a person skilled in the art are not explicitly shown. Features given in the singular are also included in the plural unless explicitly stated otherwise. This applies in particular to terms such as "a" or "an".

[0036] Fig. 1Figure 1 shows a schematic representation of a surface section 10 made of fibrous material, which can be used as a starting material for the production of three-dimensional molded parts 40. The fibrous material is a relatively dry material consisting of fibers, the fibers preferably being of natural origin. This includes, but is not limited to, cellulose fibers. The moisture content of the fibrous material can be, for example, between 3 and 40% by weight, preferably between 5 and 30%, and more preferably between 7 and 20% by weight. The fibrous material, or the surface section 10, can have at least one layer of airlaid, paper (e.g., kraft paper, crepe paper, etc.), fluff pulp, or another essentially nonwoven-like layer.The surface section 10 or the fiber-containing material may have additives and / or a coating in further versions to achieve predefined properties (barrier, mechanical properties, coloring, etc.).

[0037] The surface section 10 can be fed for later processing as an endless web from a roll or as a sheet, whereby the respective feeding and dimensions of the surface section 10 may depend on the geometry of the molded parts 40 to be produced and the properties of the material.

[0038] In the illustrated embodiment, surface section 10 has a substantially uniform thickness or material thickness. Depending on the number of layers and the material or design used, the material thickness can, for example, range between 0.2 and 10 mm.

[0039] In Fig. 1A surface section 10 is shown, which has a forming area 20 separated from the remaining material by a first area 22 and a second area 26. The first area 22 has uniform sections 24 around its perimeter. In the sections 24, the fibrous material is completely cut through. Between the sections 24, the fibrous material has webs 23, which serve as connection areas for the fibrous material between the forming area 20 and the remaining fibrous material. After forming, the webs 23 serve as connection points and must be designed and dimensioned according to the degree of forming, the material used, and the forces acting on the connection areas. The second area 26 has uniform sections 28 around its perimeter. In the sections 28, the fibrous material is completely cut through, as in the sections 24.Between sections 28, the fibrous material also has webs 27, which serve as connection areas for the fibrous material between the forming area 20 and the remaining fibrous material. After forming, the webs 27 serve as connection points and must be designed and dimensioned according to the degree of forming, the material used, and the forces acting on the connection areas.

[0040] Sections 24 and 28 are concentric with each other and, in the illustrated embodiment, are uniformly spaced apart. In further embodiments not shown, a first region 22 and a second region 26 can have sections that are not concentric with each other and / or only partially surround a molded area 20. In further embodiments, regions 22 and 26 can surround a molded area 20 with varying distances or not in a ring-like manner, with sections 24 and 28 also being oval or polygonal. Likewise, in further embodiments, molded areas 20 can have other planar extents, as shown in the figures.

[0041] The material of surface section 10, which surrounds the forming area 20 and especially the first area 22, is not required for the formation of formed parts 40 and defines a holding area 11. The holding area 11 serves, on the one hand, to transport surface section 10 during manufacturing and to feed it to processing stations. Furthermore, the holding area 11 enables the precise positioning of forming areas 20 for forming. In particular, when several forming areas 20 are formed simultaneously in one forming station, all forming areas 20 can assume a defined position and can also be transported together into and out of the forming station via a transport system. For example, several forming areas 20 can be precisely assigned to their corresponding cavities in a forming tool.

[0042] Sections 24 and 28 provide compensation during forming, enabling the forming area 20 to be transformed and transition from a planar extension to a three-dimensional extension, with a border 12 (see Fig. 2 ) in contrast, it is not displaced. This means that the deformation or reshaping of the forming area 20 has no effect on the holding area 11. This makes it possible to maintain the position of all parts of the surface section 10 with forming areas 20 even after forming, so that the forming areas 20 or forming parts 40 can be ejected together after forming and no individual removal is required. After forming, the surface section 10 with a large number of forming parts 40 can be removed from a forming tool together. The holding area 11 surrounding the forming parts 40 undergoes no or only negligible deformation.

[0043] Fig. 2shows a schematic representation of area section 10 of Fig. 1Following a forming step, the incorporation of fibrous material during forming creates tabs 30 that extend from connection areas at the webs 23 between sections 24 in the first area 22 to connection areas at the webs 27 between sections 28 in the second area 26. The offset arrangement of the webs 23 and 27 relative to each other enables a connection between the formed forming areas 20 or forming parts 40 and the holding area 11, whereby the position and orientation can be maintained because rotation of the forming areas 20 by the incorporation of fibrous material is prevented. One reason for this is that there are several connection points between the forming part 40 or forming area 20 and the holding area 11, so that displacement can only occur in one forming direction. In the illustrated embodiment, the material in the forming area 20 is drawn towards the center to form a cup or a bowl.Therefore, the material intake is uniform and is laterally limited by the tabs 30 formed between sections 24 and 18. The fiber-reinforced material of the tabs 30 can be stretched during further deformation. As a rule, the webs 23 and 27, and thus the length of sections 24 and 28, are positioned in areas 22 and 26 such that they are not subjected to high loads. The width of the webs 23 and 27, as well as the distance between sections 24 and 28, must also be determined according to the material used and the degree of deformation.

[0044] For example, a fibrous material with a layer thickness of 0.2 to 10 mm, a forming area diameter 20 of 30 mm to 300 mm, and an inward displacement of an edge 21 of the forming area 20, i.e., a distance between the edge 21 and the edge 12 after forming, e.g., in the range of 2 to 50 mm, webs 23, 27 with a width of 1 to e.g. 100 mm and a width of the tabs 30 of 1 to 10 mm, can have fibrous material with a layer thickness of 0.2 to 10 mm, with a diameter of the forming area 20 from 30 mm to 300 mm.

[0045] Unlike what is shown in the figures, shape areas 20 can also have other planar dimensions (e.g. oval, rectangular) and the shape of areas 22, 26 and the length of sections 24, 28 can vary. This also applies in particular to the lengths of sections 24, 28 of an area 22, 26 relative to each other.

[0046] Fig. 3Figure 1 shows a schematic representation of a surface section 10 made of fibrous material for the production of three-dimensional molded parts 40 after a stamping step with a plurality of forming areas 20. The surface section 10 shown can represent an area that can be formed simultaneously in a mold. Such a mold has a tool table or tool plate with a corresponding number of cavities and a corresponding tool part that presses the fibrous material of the forming areas 20 into the cavities and thereby forms it.

[0047] The forming process is usually carried out under high pressure in the range of 100 N / cm² to 10,000 N / cm², e.g. in the range of 400 N / cm² to 800 N / cm², and temperatures from 80 °C to 300 °C, especially at temperatures in the range of 120 °C to 250 °C.

[0048] The pattern shown for the individual areas corresponds to the one in Fig. 1The embodiment shown may differ in other embodiments, particularly when other molded parts are to be manufactured. Furthermore, in other embodiments, surface sections 10 with multiple or fewer molded areas 20 can be formed.

[0049] The separation of sections 24 and 28 is generally carried out in a step preceding the forming process using a punching tool. In other configurations, a tool can include both punching blades for punching or cutting sections 24 and 28, as well as forming tools (e.g., a cavity and a forming die). When the tool closes, sections 24 and 28 can first be cut, followed by forming. For this purpose, the punching blades can, for example, extend from a tool surface so that they first come into contact with the fibrous material and cut through it in sections 24 and 28. Subsequently, the punching blades can retract mechanically, pneumatically, or electrically, allowing further movement of the tool halves to enable forming without the punching blades protruding into the forming area of ​​the tool.

[0050] Fig. 4shows a schematic representation of area section 10 of Fig. 3 after a forming step. Analogous to the representation of area section 10 of Fig. 3The position and spacing of the molded parts 40, as well as the distance between the edges 12 of the first areas 22, are shown in an exemplary embodiment. In other embodiments, the distance between the edges 12 can be significantly smaller, so that only one holding structure is provided. The distance to the edge areas of the surface section 10 can also differ from that shown in other embodiments. It is also possible to increase the distances, for example, to provide a sufficiently large holding area between the molded parts 40 or molded areas 20. The holding area allows the surface section 10 to be held away from the molded areas 20 during forming, so that no inward pull-in of the fiber-containing material is possible. Therefore, the fiber-containing material in the holding area 11 is not deformed.

[0051] Fig. 5Figure 1 shows a schematic representation of a process for producing three-dimensional molded parts 40 from a surface section 10 made of fiber-containing material.

[0052] In a first step, a surface section 51 made of fibrous material is provided. The surface section 10 can, for example, comprise kraft paper, airlaid, fluff pulp, crepe paper, nonwoven fiber material, or other fibrous material. The fibrous material can, in particular, comprise at least one layer of such material as described above. In further embodiments, a fibrous material can be formed by several layers. Preferably, the fibrous material can comprise cellulose fibers.

[0053] The provision of the surface section 10 can further include a step in the production of the surface section 10, whereby fibrous material is produced from a starting material (e.g., shredding and joining (e.g., airlaid)). The surface section 10 can be provided as a sheet of material or as a continuous web, e.g., on a roll.

[0054] Subsequently, at least one surface section 10 is inserted 52 or continuously or discontinuously (e.g., in cycles) into a punching station, where punching 53 of the surface section 10 is performed. Punching patterns can be introduced into the fiber-containing material, as described above in various configurations. Punching patterns surround forming areas 20 for subsequent forming 54 over at least one first area 22 and at least one second area 26, each of which has sections 24, 28. After punching 53, at least one surface section 10 has completely severed sections 24, 28 in areas 22, 26. After punching 53, forming 54 takes place, whereby the previously punched surface section 10 is formed either in a combined punching and forming tool or in a forming tool downstream of the punching station.During forming process 54, forming areas 20 are transformed, whereby the fibrous material is transformed from its essentially planar extent into a three-dimensional shape by means of a forming tool 60. For this purpose, a compensating movement must be provided in the surface section 10 due to the slippage or pulling of the fibrous material during forming. This compensating movement is achieved by releasing the fibrous material previously separated in sections 24 and 28. The connection between a holding area 11 of the fibrous material in surface section 10 and the forming area 20, which is transformed into a molded part 40, remains only in connection areas or webs 23 and 27, which are connected to each other via tabs 30.The tabs 30 allow a displacement of the forming area 20 without causing compression, stretching or elongation of the fiber-containing material, particularly in the holding area 11, so that the position and orientation of all forming areas 20 in a forming tool for the simultaneous forming of several forming areas 20 in a surface section 10 remains unchanged.

[0055] During forming process 54, the fibrous material is only formed in the forming area 20 and compressed between the forming surfaces in a cavity of the forming tool under high pressure and temperature. Only the fibrous material in the forming area 20 can be partially compressed, stretched, and elongated.

[0056] Subsequently, the formed part 55 of the molded area 20 or the molded parts 40 are ejected, whereby the ejection 55 of molded parts 40 of a surface section 10 occurs simultaneously. Advantageously, the holding area 11 is not formed, compressed, or stretched, so that a feed mechanism for the forming process does not need to be taken into account. For example, a feed through the stations (at least punching, forming, etc.) of a molding system can be achieved via rollers, grippers, tongs, or clamps.

[0057] In further versions, after the dispensing 55 or the forming 54, further processing 56 can take place. Further processing 56 can include, for example, printing, filling, coating, etc.

[0058] Finally, the molded parts 40 are separated from the surface section 10 in a further punching station using a punching tool, whereby the connection via the tabs 30 between the molded parts 40 and the holding area 11 is severed. Preferably, the separation takes place in the connection areas of the webs 27, so that fiber material does not protrude from the finished product. In further embodiments, an edge of the molded parts 40 can be punched, whereby an outer circumferential edge area is completely separated.

[0059] Fig. 6Figure 1 shows a schematic representation of a section of a forming tool 60 during the forming of fibrous material. The forming tool 60 has a first lower tool part 62 with at least one cavity 64 and an upper second tool part 68 with a forming punch 69, wherein during forming 54 the fibrous material is compressed between the forming surfaces of the cavity 64 and the forming punch 69. At least the upper tool part 68 or the lower tool part 62 can be heated by a heating device (not shown) in order to achieve or support the bonding of the fibrous material during compression for forming.

[0060] A forming tool 60 can in particular have several cavities 64 and corresponding forming dies 69, so that several molded parts 40 can be produced simultaneously in a pressing operation.

[0061] In the exemplary illustration, the upper tool part 68 has clamping areas 67 which serve to hold the fibrous material in holding areas 11 when the forming tool 60 is closed, so that there is no displacement or deformation of the fibrous material there.

[0062] In the embodiment shown, the tabs 30 are located outside the cavity 64 when the forming tool 60 is closed and in the closed state. The tabs 30 are not clamped during forming and closing of the forming tool 60, allowing them to perform a compensating movement. In further embodiments, cavities 64 can have areas for the tabs 30, as shown by the dashed lines.

[0063] The mold 60 can, for example, be installed in a fiber molding system for the production of three-dimensional products from a fibrous material. The fiber molding system can produce products that are biodegradable and can themselves serve as raw material for the production of three-dimensional molded parts 40 from a fibrous material and can be composted, because they can generally be completely decomposed and do not contain any hazardous substances. Molded parts 40 can be designed, for example, as cups, lids, bowls, capsules, plates, and other molded and / or packaging parts (e.g., as holders / support structures for electronic or other devices). A fiber molding system can have additional stations and equipment. For example, a supply of fibrous material can be provided.In further embodiments, a mill can be provided for the comminution of a starting material and for the separation of fibers, which is then further processed as a surface section 10.

[0064] The presented solution indicates how surface sections 10 can be pre-cut as a web or arc to allow virtually unimpeded material intake during forming, while at the same time blanks (forming area 20) or formed products (formed parts 40) can remain connected to the web or arc. Reference symbol list

[0065] 10 Surface section 11 Holding area 12 Edge 20 Forming area 21 Edge 22 First area 23 Web 24 Section 26 Second area 27 Web 28 Section 30 Tab 40 Molded part 50 Process 60 Molding tool 62 Tool part 64 Cavity 67 Clamping area 68 Tool part 69 Molding die 51-57 Process steps

Claims

1. Surface section made of fibrous material for processing into a three-dimensional molded part by a forming process, wherein the surface section has at least one material layer, comprising at least one forming area for forming to produce a three-dimensional molded part, and at least one first area and at least one second area, wherein the at least one first area and the at least one second area extend circumferentially around at least a part of the at least one forming area, wherein the at least one first area has at least two sections in which the at least one material layer is completely separated, and the at least one second area has at least one section in which the at least one material layer is completely separated, and wherein the two sections of the at least one first area are separated from each other by a first connecting area.wherein the first connecting area between the sections of the at least one first area is located relative to the section of the at least one second area.

2. Surface section according to claim 1, wherein a length of the section of the at least one second area is greater than a length of the sections of the at least one first area.

3. Surface section according to claim 1 or 2, wherein the surface section has a substantially planar extent.

4. Surface section according to one of claims 1 to 3, wherein the at least one first area and the at least one second area run substantially parallel to each other.

5. Surface section according to one of claims 1 to 4, wherein the at least one first area and the at least one second area completely surround the mold area.

6. Surface section according to one of claims 1 to 5, wherein a length of the section of the at least one second area is substantially 1.5 to 2.5 times a length of the sections of the at least one first area.

7. Surface section according to one of claims 1 to 6, wherein the at least one first area has circumferential sections which are each separated from each other by a first connecting area, wherein the at least one second area has circumferential sections which are each separated from each other by a second connecting area.

8. Surface section according to claim 7, wherein the first connection areas are located substantially centrally to the sections of the at least one second area and the second connection areas are located substantially centrally to the sections of the at least one first area.

9. Surface section according to one of claims 1 to 8, wherein the at least one forming area has a three-dimensional forming part after forming and an edge of the three-dimensional forming part is connected via at least two strips to a material surrounding the at least one first area, wherein the strips are formed from the material which is located between the sections of the first area and the second area before forming.

10. Surface section according to claim 9, wherein the at least one first area and the at least one second area are aligned according to a degree of forming during the forming process to form the three-dimensional molded part.

11. Method for producing a surface section of fibrous material for processing into a three-dimensional molded part by a forming process, wherein the surface section has at least one layer of material, comprising the following steps: - providing at least one surface section of fibrous material, and - separating the fibrous material into at least one first area and at least one second area, wherein the at least one first area has at least two sections, and the at least one second area has at least one section, wherein the two sections of the at least one first area are separated from each other by a first connecting area.

12. A method for producing three-dimensional molded parts from a surface section of fiber-containing material according to any one of claims 1 to 10, comprising the following steps: - Providing a surface section of fiber-containing material with at least one material layer, comprising at least one molded area and at least one first area and at least one second area, wherein the at least one first area and the at least one second area extend circumferentially around at least a part of the at least one molded area, wherein the at least one first area has at least two sections in which the at least one material layer is completely separated, and the at least one second area has at least one section in which the at least one material layer is completely separated.and wherein the two sections of the at least one first region are separated from each other by a first connection region, and - forming the molding region, wherein the fiber-containing material in the molding region is deformed at least locally in three dimensions from a substantially planar extent to form a molded part, wherein the distance between the at least two sections of the at least one first region and the at least one section of the at least one second region is increased and at least one clearance is created between the first connection region and an edge of the molded part.

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