Cellulosic toggle press module and method for using same - Patents.com

Abstract

A product forming unit (U) for producing a non-flat cellulose product (1) from an air-formed cellulose blank structure (2). The product forming unit (U) comprises a blank dry-forming module (4) with a movable forming wire (4c), a toggle press module (6) with a toggle press (6a) and a forming die (3), and an electronic control system (6h) operatively connected to the forming wire (4c) and the toggle press (6a). The blank dry-forming module (4) is configured to air-form the cellulose blank structure (2) on the forming wire (4c). The toggle press (6a) comprises a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to the press member (6d), and a press actuator assembly (6f) drivingly connected to the toggle mechanism (6e). The forming die (3) comprises a movable first die part (3a) attached to the press member (6d) and a second die part (3b). The electronic control system (6h) is configured to control operation of the press actuator assembly (6f) to perform a pressing operation including driving the press member (6d) in a pressing direction by a toggle mechanism (6e) and thereby forming a non-flat cellulose product from the air-formed cellulose blank structure by forcing the first die part (3a) against the second die part (3b). The electronic control system (6h) is further configured to intermittently feed the forming wire (4c) between successive pressing operations.

Description

[Technical field]

[0001] The present disclosure relates to a cellulosic toggle press module for forming a non-planar cellulosic product from an air-formed cellulosic blank structure. The present disclosure further relates to a method for forming a non-planar cellulosic product from an air-formed cellulosic blank structure using a cellulosic toggle press module.

[0002] Although the cellulosic toggle press module according to the present disclosure will be primarily described with respect to an exemplary cellulosic product forming unit with an incorporated fiber separation module, cellulose blank air forming module, and the like, the cellulosic product toggle press module and associated methods for using the same are not limited to this particular example and may alternatively be implemented and used in many other types of cellulosic product manufacturing systems.

[0003] Background technology Cellulosic fibers are often used as a raw material to manufacture or create products. Products made from cellulose fibers can be used in many different situations where there is a need to have sustainable products. A wide range of products can be made from cellulose fibers, some examples are disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.

[0004] Molds are commonly used in producing cellulose products from cellulose fiber raw materials, and traditionally, cellulose products are wet-formed. A commonly used material for wet-forming cellulose fiber products is wet-formed pulp. Wet-formed pulp has the advantage of being considered as a sustainable packaging material, since it is produced from biomaterials and can be recycled after use. As a result, wet-formed pulp is rapidly gaining popularity for various applications. Wet-formed pulp articles are generally formed by immersing a suction mold into a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers, and when suction is applied, the pulp mass is formed into the shape of the desired product by fiber deposition into the mold. All wet-forming techniques require drying of the wet-formed product, which is a very time- and energy-consuming part of production. There is an increasing demand for aesthetic, chemical and mechanical properties of cellulose products, and the properties of wet-formed cellulose products impose limitations on mechanical strength, flexibility, material thickness latitude, and chemical properties. It is also difficult to precisely control the mechanical properties of the product in wet molding processes.

[0005] One development in the field of cellulosic product manufacturing is the molding of cellulose fibers in a dry molding process without using wet molding techniques. Instead of molding cellulosic products from liquid or semi-liquid pulp suspensions or slurries, air-formed cellulose blank structures are used. The air-formed cellulose blank structures are inserted into a mold, and during the molding of the cellulosic products, the cellulose blank structures are subjected to high molding pressures and high molding temperatures in the mold.

[0006] The production of cellulose products by compression moulding of air-formed cellulose blank structures may take place in a production line or in a product moulding unit. The production facility usually includes a press module with a mould. Other modules and components, such as a feed module and a blank dry moulding module, are connected and arranged to the press module. The press module is usually a high-capacity press module, such as a large hydraulic or servo-driven press machine, which is also sometimes used to mould other materials, such as steel sheets, as it is available as an independent off-the-shelf machine.

[0007] One drawback of using standard press modules developed for general purpose applications is the high costs typically associated with conventional high capacity hydraulic or servo driven press machines, as well as the problems caused by their large size and weight in terms of transportation, installation, maintenance and factory size.

[0008] Furthermore, because customers who invest in cellulosic product forming units, typically referred to as converters, typically have little or no engineering skills required to develop and integrate the modules required for a complete cellulosic product forming unit, converters require the ability to purchase fully integrated, standardized product forming units that can be easily transported, installed and operated.

[0009] Thus, there is a need for a low-cost, compact, and lightweight cellulosic product press module for forming non-planar cellulosic products from air-formed cellulosic blank structures, and a method for forming non-planar cellulosic products from air-formed cellulosic blank structures using such a cellulosic product press module. There is also a need for a cellulosic product press module that allows for the development and manufacture of a low-cost, compact, fully integrated, standardized cellulosic product forming unit that can be easily transported, installed, and operated.

[0010] overview The object of the present disclosure is to provide a cellulose product press module for forming a non-flat cellulose product from an air-formed cellulose blank structure, as well as an associated method for forming a non-flat cellulose product from an air-formed cellulose blank structure using such a press module, which avoids the above-mentioned problems. This object is at least partially achieved by the features of the independent claims.

[0011] According to a first aspect of the present disclosure, there is provided a product forming unit for producing a non-flat cellulose product from an air-formed cellulose blank structure, the product forming unit comprising: a blank dry-forming module with a movable forming wire; a toggle press module with a toggle press and a forming die; and an electronic control system operatively connected to the forming wire and the toggle press; the blank dry-forming module is configured to air-form a cellulose blank structure on the forming wire; the toggle press comprises a press member movably arranged in a press direction, a toggle mechanism drivingly connected to the press member, and a press actuator assembly drivingly connected to the toggle mechanism; the forming die comprises a first die part movable attached to the press member and a second die part; the electronic control system is configured to control operation of the press actuator assembly to perform a pressing operation including driving the press member in the press direction by the toggle mechanism, thereby forcing the first die part against the second die part to form a non-flat cellulose product from the air-formed cellulose blank structure; and the electronic control system is further configured to intermittently supply the forming wire between successive pressing operations.

[0012] According to a second aspect of the present disclosure, there is provided a method for forming a non-flat cellulosic product from an air-formed cellulosic blank structure in a product forming unit, the product forming unit having a blank dry forming module with a movable forming wire, a toggle press module with a toggle press and a forming die, and an electronic control system operatively connected to the forming wire and the toggle press module. The toggle press has a press member movably arranged in a pressing direction, a toggle mechanism drivingly connected to the press member, and a press actuator assembly drivingly connected to the toggle mechanism. The forming die has a movable first die portion attached to the press member and a second die portion. The method includes the steps of air-forming a cellulose blank structure onto a forming wire by a blank dry-forming module; feeding the air-formed cellulose blank structure into a press area defined by spaced apart first and second mold portions; controlling operation of a press actuator assembly by an electronic control system to perform a press operation including driving a press member in a press direction by a toggle mechanism, thereby forcing the first mold portion against the second mold portion to form a non-flat cellulose product from the air-formed cellulose blank structure; and controlling operation of the forming wire by the electronic control system to intermittently feed the forming wire between successive press operations.

[0013] Toggle mechanism clamps are well known in the art of injection molding, where, for example, a plastic material in its liquid phase is injected at high pressure into a cavity formed by a closed mold. In the art of injection molding, the purpose of a toggle mechanism clamp is to simply close the injection mold sections and provide sufficient clamping force to keep the mold sections from separating due to the internal injection pressure within the mold.

[0014] However, toggle mechanisms are generally less commonly used in compression molding applications where the pressure level is a critical parameter that must be controlled with a certain degree of precision, in part because control of the press force is more complicated due to the exponential amplification characteristic of toggle mechanisms, and in part because the resulting press force cannot be easily measured with good precision. For example, the press force generated by the press actuator assembly in a toggle mechanism approaches zero as the toggle mechanism approaches a force equilibrium position, which makes the press force of the press actuator assembly less useful for measuring the press force.

[0015] On the other hand, toggle presses have the advantage of being relatively compact and low cost due to the low input press force required compared to conventional high capacity hydraulic or servo presses. In other words, a relatively small capacity actuator, e.g. a small capacity hydraulic or pneumatic linear actuator, i.e. a cylinder-piston arrangement, or a low power electric motor driven ball screw linear actuator, may be sufficient to drive the toggle mechanism and thus generate a much larger press force.

[0016] Additionally, toggle presses also have inherent and highly advantageous speed-force characteristics that can significantly reduce cycle times for cellulosic product forming cycles as compared to conventional high capacity hydraulic or servo presses. In particular, the inherent force amplification characteristic of the toggle mechanism results in a relatively high speed of the press members during the initial cycle time starting from the standby position, while this speed is gradually reduced as the maximum stroke condition of the toggle mechanism is approached, with the benefit of an amplified maximum press force. This allows the initial movement of the press members to occur at a high speed and a low maximum press force, while the movement of the press members during the actual press operation occurs at a low speed and a high maximum press force.

[0017] Additionally, having an electronic control system configured to intermittently supply the forming wire between successive press operations eliminates the need for relatively large, complex and costly buffer devices located in the area between the blank dry forming module and the press module, thereby further helping to reduce the overall cost of the product forming unit.

[0018] Furthermore, the compact size and light weight of the toggle press allows for the development of extremely compact, fully integrated and standardized cellulosic product forming units that are easy to transport, install and operate, and the low cost for the toggle press helps to keep the overall cost of the cellulosic product forming unit at a low level.

[0019] Further advantages are achieved by implementing one or more of the features of the dependent claims. In some exemplary embodiments, which may be combined with any one or more of the above-mentioned embodiments, the aforementioned pressing operation includes driving the press member in the pressing direction by setting the toggle mechanism in a maximum extended operating position, i.e. by aligning the first and second link members of the toggle mechanism. This allows for easier control of the actuator assembly used to drive the toggle mechanism, since the control can be performed using, for example, the position of the press member, or a similarly easily detectable parameter, as a feedback signal. Furthermore, when operating in the operating region of aligned link members of a toggle press, the target pressing force is relatively easily and reliably achieved compared to working near the asymptotic operating region, which is associated, for example, with the operating region of misaligned link members of a toggle press.

[0020] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the toggle press is installed or arranged to be installed with a press direction of the press members arranged mainly horizontally, in particular with a press direction of the press members arranged within 20 degrees of the horizontal, more preferably with a press direction parallel to the horizontal. The mainly horizontal orientation of the toggle press allows a low construction height of the cellulose product forming unit and allows a non-linear material flow of the continuous air-formed cellulose blank structures from the blank dry forming module to the press module. The non-linear material flow, for example, feeding the air-formed cellulose blank structures in a first direction, for example upwards, and then in a second direction, for example downwards, generally allows the development and manufacture of a more compact cellulose product forming unit. The mainly horizontal orientation of the toggle press is typically associated with a mainly vertically arranged feed flow of the cellulose blank structures, since the web of cellulose fiber material is usually fed into the press module approximately perpendicular to the press direction of the press module. It is therefore evident that in developing a compact cellulose product forming unit having a non-linear material flow of the air-formed cellulose blank structure from the blank dry-forming module to the press module, a predominantly horizontal arrangement of the press module is highly advantageous.

[0021] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the electronic control system is configured to intermittently feed the forming wire between successive pressing operations such that the forming wire periodically operates at a relatively high speed during periods between successive pressing operations and at a relatively low or zero speed during periods corresponding to the pressing operations, thereby eliminating the need for a relatively large, complex and costly buffer device located in the area between the blank dry forming module and the press module, which further helps reduce the overall cost of the product forming unit.

[0022] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the electronic control system is configured to synchronize the operation of the forming wire and the toggle press such that the forming wire is operated or operated at a relatively high speed during the period when the toggle press is in a non-pressing state, and the forming wire is stopped or operated at a relatively low speed during the period when the toggle press is in a pressing state. As a result, the need for a relatively large, complex and costly buffer device located in the area between the blank dry-forming module and the press module is reduced, which further helps reduce the overall cost of the product forming unit.

[0023] In some exemplary embodiments, which may be combined with any one or more of the above-mentioned embodiments, the electronic control system is configured to control the operation of the forming wire and the toggle press such that the feed rate of the forming wire is equal, or at least substantially equal, to the feed rate of the air-formed cellulosic blank structure entering the mold, particularly throughout the press cycle, thereby eliminating the need for a relatively large, complex and costly buffer device located in the area between the blank dry-forming module and the press module, which further helps reduce the overall cost of the product forming unit.

[0024] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the product forming unit does not have a buffer module disposed between the blank dry-forming module and the press module. By eliminating the buffer module, a more cost-effective product forming unit is obtained.

[0025] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the toggle press further comprises: a press force indicating assembly; an adjustment mechanism capable of adjusting the distance between the first mold part and the second mold part in a pressing direction when the toggle mechanism is in a non-moving operating state; and an adjustment actuator assembly configured to drive the adjustment mechanism, wherein the electronic control system is operatively connected to the press force indicating assembly and configured to control the operation of the adjustment actuator assembly based on feedback information indicative of the press force received from the press force indicating assembly, thereby allowing the operating position of the toggle press to be adjusted to better suit and / or match the particular characteristics of the cellulose blank structure and the shape of the forming mold.

[0026] In some exemplary embodiments that may be combined with any one or more of the above-described embodiments, the electronic control system is configured to control operation of the adjustment actuator assembly to adjust the distance between the first and second mold parts during the period between successive press operations with the goal that the press members provide a compression force closer to a predetermined target press force during the next press cycle, thereby adjusting the operating position of the toggle press to better suit and / or match the particular characteristics of the cellulosic blank structure and the shape of the forming mold.

[0027] In some exemplary embodiments that may be combined with any one or more of the above-described embodiments, the press force indication assembly includes one or more of the following sensors: load cells, deformation sensors, or strain gauge force sensors located on or in the mold, on the toggle mechanism, between the toggle mechanism and the rear structure of the rigid frame structure of the toggle press, between the toggle mechanism and the mold, on the rigid frame structure of the toggle press, or on the tie bars of the intermediate linear guide assembly of the toggle press, such that a reliable and accurate assessment of the resulting press force can be measured.

[0028] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the toggle press further comprises a front structure and a rear structure, the toggle mechanism is connected to the rear structure, the second die part is attached to the front structure, and the mechanical adjustment mechanism can adjust the distance between the front structure and the rear structure in the press direction to allow adjustment of the distance between the first die part and the second die part when the toggle mechanism is in a non-moving operating state, thereby enabling a compact and cost-effective press module.

[0029] In some exemplary embodiments, which may be combined with any one or more of the above-mentioned embodiments, each of the first and second mold parts has a rigid plate-shaped main body with a surface configured to face the other mold part and at least one pressing surface defining one or more molding cavities for molding the cellulose products, with or without additional sub-components, such as spring-loaded cutting devices and / or mold alignment devices, in which the aforementioned surfaces of the rigid plate-shaped main bodies of the first and second mold parts are not in direct contact with each other during the pressing cycle, thereby allowing the mold to be used for pressing non-flat cellulose products at a given molding pressure without undesirable interference between the aforementioned surfaces.

[0030] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the mold is configured to mold the cellulose product from the cellulose blank structure by heating the cellulose blank structure to a molding temperature in the range of 100-300° C. and pressing the cellulose blank structure at a molding pressure in the range of 1-100 MPa, preferably 4-20 MPa. These parameters provide efficient molding of the cellulose product with strong hydrogen bonds formed.

[0031] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the blank dry-forming module further includes a mill and a forming chamber, the forming wire is connected to and arranged in the forming chamber, the mill is configured to separate fibers from the cellulose raw material, and the forming chamber is configured to distribute the separated fibers onto the forming section of the forming wire for forming the cellulose blank structure. The mill and the forming chamber enable forming the cellulose blank structure without the need to pre-manufacture the cellulose blank structure, while being closely connected to the press module so that a compact layout is achieved, and the operation of the product forming unit is efficient due to the cellulose raw material used as an input material for the in-line production of the cellulose blank structure.

[0032] In some exemplary embodiments, which may be combined with any one or more of the above-mentioned embodiments, the forming sections of the forming wire extend in an upward blank forming direction, which allows the design of a more compact and shorter product forming unit, since the air-formed cellulose blank structure is at least initially fed upwards and is therefore not guided only in the horizontal direction.

[0033] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the blank dry-forming module is configured to air-form discrete cellulose blanks onto the forming wire, or the blank dry-forming module is configured to air-form a continuous cellulose blank structure onto the forming wire. Forming discrete cellulose blanks onto the forming wire may, in certain implementations, result in reduced levels of residual material after forming, thereby reducing raw material costs.

[0034] In some exemplary embodiments, which may be combined with any one or more of the above-described embodiments, the pressing action is a single pressing action.

[0035] In some exemplary embodiments, which may be combined with any one or more of the above-mentioned embodiments, the product forming unit is adapted to intermittently feed the cellulose blank structure from the blank dry forming module by the forming wire in a first feed direction and to intermittently feed the cellulose blank structure to the press module in a second feed direction, where the second feed direction is different from the first feed direction, in particular the second feed direction is reverse or substantially reverse to the first feed direction. The different feed directions allow the integration of multiple modules into one single unit or machine that can be shipped in a cargo container, placed on the converter's factory floor, connected and started production in a few months, without requiring any or little module engineering skills of the converter. A further advantage is that the different feed directions allow a more compact layout and structure of the product forming unit. Such a structure allows the modules to be positioned relative to each other in a non-conventional manner for an efficient and compact layout. Furthermore, the integrated modular design allows the weight of the product forming unit to be reduced to a fraction of the weight of current units with individual modules purchased separately and aligned into custom-made industrial lines. This solution also lowers multi-time investment costs for converters, as the weight of the machine is typically related to the purchase price. The reduced investment costs allow for a quicker conversion to products made from cellulose feedstocks instead of plastic materials.

[0036] In some exemplary embodiments, which may be combined with any one or more of the above-described embodiments, the first feed direction is an upward direction and the second feed direction is a downward direction, which allows for an elegant and efficient layout of the product forming units, which can be assembled vertically for a compact layout.

[0037] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the product forming unit further comprises a cellulose blank conveying device, in particular a conveyor belt and / or a set of feed rollers, configured to convey the air-formed cellulose blank structure from the forming wire of the blank dry-forming module to the forming mold of the toggle press module, in which the electronic control system is configured to provide a substantially synchronized operation of the forming wire and the conveying device, thereby eliminating the need for a costly cellulose blank buffer device.

[0038] In some exemplary embodiments that may be combined with any one or more of the above-described embodiments, the electronic control system is configured to operate the mill continuously; and is configured to continuously supply the cellulosic feedstock to the mill or to intermittently supply the cellulosic feedstock to the mill.

[0039] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the product forming unit further includes a blank recycling module configured to transport a remaining portion of the cellulose blank structure from the press module to the blank dry-forming module, whereby the transport of the remaining portion ensures that the unused portion of the cellulose blank structure can be reused.

[0040] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the blank recycle module includes a recycle compression unit configured to compress a remaining portion of the cellulose blank structure in the recycle compression unit when conveying the blank from the press module to the blank dry-forming module, whereby efficient operation of the mill is achieved by compressing the remaining portion.

[0041] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the method includes controlling operation of the forming wire by an electronic control system to intermittently supply the forming wire between successive pressing operations such that the forming wire periodically operates at a relatively high speed during periods between successive pressing operations and at a relatively low speed or zero speed during periods corresponding to the pressing operations.

[0042] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the method includes controlling the operation of the forming wire and press actuator assembly such that the forming wire and the toggle press have synchronized operation such that the forming wire is operated or operated at a relatively high speed during periods when the toggle press is in a non-pressing state, and the forming wire is stopped or operated at a relatively low speed during periods when the toggle press is in a pressing state.

[0043] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the method includes controlling the operation of the forming wire and the toggle press by an electronic control system so that the feed rate of the forming wire is equal, or at least substantially equal, to the feed rate of the air-formed cellulosic blank structure entering the forming mold.

[0044] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the method includes controlling operation of an adjustment actuator assembly to adjust a distance between the first and second mold parts during a period between successive press operations with the goal that the press members provide a compression force closer to a predetermined target press force during a next press cycle.

[0045] In some exemplary embodiments, which can be combined with any one or more of the above-mentioned embodiments, the step of air-molding a cellulose blank structure from the cellulose raw material in the blank dry-molding module includes the steps of separating fibers from the cellulose raw material in a mill, distributing the separated fibers onto a forming wire of the blank dry-molding module to form a cellulose blank structure, and conveying the formed cellulose blank structure in an upward blank-molding direction. The upward extension of the forming section, which is different from the conventional one, allows a compact layout of the product forming unit, since the cellulose blank structure can be formed in an upward direction and then redirected for conveyance to the press module.

[0046] In some exemplary embodiments that may be combined with any one or more of the above-described embodiments, the cellulose blank structure is air-formed in a dry forming module into separate cellulose flanks or the cellulose blank structure is air-formed in a dry forming module into a continuous cellulose blank.

[0047] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the cellulose blank structure is intermittently transported by the forming wire from the blank dry-forming module in a first feed direction and intermittently transported to the press module in a second feed direction, where the second feed direction is different from the first feed direction, in particular, the second feed direction is reverse or substantially reverse to the first feed direction.

[0048] In some exemplary embodiments that may be combined with any one or more of the above-described embodiments, the method further includes operating the mill continuously; and continuously feeding the cellulose feedstock to the mill, or feeding the cellulose feedstock to the mill intermittently, such that the composition of the resulting airlaid allows the cellulose blank structure to be altered and adapted to the particular environment.

[0049] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the forming wire has a forming section that is connected to and arranged at a forming chamber opening of the forming chamber, and the method further includes air forming the cellulosic blank structure onto the forming section, the forming section controls the forming of the cellulosic blank structure onto the forming wire, and the forming section can be used to shape the cellulosic blank structure into a suitable profile.

[0050] In some exemplary embodiments that may be combined with any one or more of the above-mentioned embodiments, the product forming unit further includes a blank recycling module, and the method further includes a step of transporting a remaining portion of the cellulose blank structure from the press module to a blank dry-forming module.

[0051] In some exemplary embodiments that can be combined with any one or more of the above-mentioned embodiments, the blank recycle module has a recycle compression unit, and the method further includes compressing a remaining portion of the cellulose blank structure in the recycle compression unit when conveying it from the press module to the blank dry-forming module.

[0052] The present disclosure further relates to a cellulosic product toggle press module for forming a non-planar cellulosic product from an air-formed cellulosic blank structure. The toggle press module has: a toggle press including a press member movably disposed in a press direction, a toggle mechanism drivingly connected to the press member, and a press actuator assembly drivingly connected to the toggle mechanism for controlling movement of the toggle mechanism between a retracted operating position and an extended operating position; a forming die including a movable first die part and a second die part attached to the press member; an adjustment mechanism capable of adjusting a distance between the first die part and the second die part in the press direction when the toggle mechanism is in a non-moving operating state, and an adjustment actuator assembly configured to drive the adjustment mechanism; a press force indication assembly; and an electronic control system operatively connected to the press force indication assembly, the press actuator assembly, and the adjustment actuator assembly; the electronic control system is configured to control operation of the press actuator assembly to drive the press member in the press direction by setting the toggle mechanism in the extended operating position, and thereby to form a non-flat cellulose product from the air-formed cellulose blank structure by forcing the first die part against the second die part, and the electronic control system is configured to control operation of the adjustment actuator assembly based on feedback information indicative of the press force received from the press force indication assembly.

[0053] The various aspects of the dependent claims mentioned above can of course also be combined with this cellulosic toggle press module.

[0054] The disclosure further relates to a method of forming a non-flat cellulosic product from an air-formed cellulosic blank structure in a toggle press module, the toggle press module having: a toggle press including a press member movably disposed in a press direction, a toggle mechanism drivingly connected to the press member, and a press actuator assembly drivingly connected to the toggle mechanism for controlling movement of the toggle mechanism between a retracted operating position and an extended operating position; a forming die including a movable first die part and a second die part attached to the press member; an adjustment mechanism capable of adjusting a distance between the first die part and the second die part in the press direction when the toggle mechanism is in a non-moving operating state, and an adjustment actuator assembly configured to drive the adjustment mechanism; a press force indication assembly; and an electronic control system operably connected to the press force indication assembly, the press actuator assembly, and the adjustment actuator assembly. The method includes the steps of: air-forming a cellulose blank structure onto a forming wire by a blank dry-forming module; feeding the air-formed cellulose blank structure into a press area defined by spaced apart first and second mold portions; controlling operation of a press actuator assembly to perform a press operation including driving a press member in a press direction by setting a toggle mechanism to an extended operating position, thereby forcing the first mold portion against the second mold portion to form a non-flat cellulose product from the air-formed cellulose blank structure; and controlling operation of an adjustment actuator assembly based on feedback information indicative of the press force received from a press force indication assembly.

[0055] The various above-mentioned aspects of the dependent claims can of course also be combined with this method of forming a non-flat cellulosic product.

[0056] Further features and advantages of the present invention will become apparent upon review of the appended claims and the following description. Those skilled in the art will recognize that different features of the present disclosure may be combined to form embodiments other than those explicitly described above and below without departing from the scope of the present disclosure.

[0057] The product forming unit and associated method for forming non-flat cellulose according to the present disclosure will now be described in detail with reference to the accompanying drawings. [Brief description of the drawings]

[0058] [Figure 1a] FIG. 2 is a schematic diagram illustrating the layout of a product forming unit according to the present disclosure. [Figure 1b] FIG. 1 is a perspective view showing a schematic diagram of a product forming unit according to the present disclosure. [Figure 1c] FIG. 1 is a perspective view showing a schematic diagram of a blank dry forming module according to the present disclosure. [Figure 1d] 2A-2C are schematic diagrams illustrating exemplary embodiments of paths for feeding cellulosic blank structures within a product forming unit according to the present disclosure; [Figure 1e] 2A-2C are schematic diagrams illustrating exemplary embodiments of paths for feeding cellulosic blank structures within a product forming unit according to the present disclosure; [Figure 2a] 4 is a timing diagram reflecting an alternative control scheme for operating a product forming unit according to the present disclosure. [Figure 2b] 4 is a timing diagram reflecting an alternative control scheme for operating a product forming unit according to the present disclosure. [Figure 3a] FIG. 1 is a perspective view illustrating a press module according to the present disclosure. [Figure 3b] 1 is a side view schematic of a cellulose molding process in a mold according to the present disclosure. FIG. [Figure 3c] 1 is a side view schematic of a cellulose molding process in a mold according to the present disclosure. FIG. [Figure 3d]1 is a side view schematic of a cellulose molding process in a mold according to the present disclosure. FIG. [Figure 3e] 1 is a side view schematic of a cellulose molding process in a mold according to the present disclosure. FIG. [Figure 4a] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 4b] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Diagram 5] FIG. 1 illustrates the main process steps of a press cycle. [Figure 6a] 11A-11C are side views illustrating schematic diagrams of alternative orientations of a press module according to the present disclosure. [Figure 6b] 11A-11C are side views illustrating schematic diagrams of alternative orientations of a press module according to the present disclosure. [Figure 7a] 1A-1C are side views that diagrammatically illustrate alternative designs of toggle mechanisms according to the present disclosure. [Figure 7b] 1A-1C are side views that diagrammatically illustrate alternative designs of toggle mechanisms according to the present disclosure. [Figure 8a] 1 is a side view diagrammatically illustrating selective operational settings of an adjustment mechanism of a press module according to the present disclosure; FIG. [Figure 8b] 1 is a side view diagrammatically illustrating selective operational settings of an adjustment mechanism of a press module according to the present disclosure; FIG. [Figure 8c] 1 is a side view diagrammatically illustrating selective operational settings of an adjustment mechanism of a press module according to the present disclosure; FIG. [Figure 9] FIG. [Figure 10a] FIG. 1 is a perspective view illustrating a schematic of a selective control system for a press module according to the present disclosure. [Figure 10b] FIG. 1 is a perspective view illustrating a schematic of a selective control system for a press module according to the present disclosure. [Figure 11] 13A-13C are schematic diagrams illustrating alternative layouts of product forming units according to the present disclosure; [Figure 12a]FIG. 13 is a side view schematic of a press module according to another exemplary embodiment of the present disclosure. [Figure 12b] FIG. 13 is a side view schematic of a press module according to another exemplary embodiment of the present disclosure. [Figure 13] FIG. 1 shows a schematic diagram of some basic steps of a method according to the present disclosure. [Figure 14] FIG. 2 shows a schematic diagram of some basic steps of another method according to the present disclosure.

[0059] Description of exemplary embodiments Various aspects of the present disclosure are described below with reference to the accompanying drawings, which are presented for purposes of illustration and not limitation of the present disclosure, where like designations refer to like elements, and variations of the described aspects are not limited to the specifically illustrated embodiments, but may be applicable to other variations of the present disclosure.

[0060] 1a and 1b show schematic diagrams of different schematic views of one exemplary embodiment of a product-forming unit U for producing a cellulose product 1 from an air-formed cellulose blank structure 2. FIG. 1a shows a schematic layout of the product-forming unit U, and FIG. 1b shows a perspective side view of the product-forming unit U. The product-forming unit U is arranged in a horizontal or planar D H and the vertical direction D V The product forming unit U comprises a blank dry forming module 4 and a press module 6, as will be further described below.

[0061] The cellulose product 1 is formed from the cellulose blank structure 2 in a product forming unit U. The press module 6 has one or more forming dies 3 for forming the cellulose product 1 from the air-formed cellulose blank structure 2 in a pressing operation. The cellulose blank structure 2 is air-formed on a forming wire 4c in a blank dry-forming module 4 and fed to one or more forming dies 3 of the press module 6. Thus, the forming of the cellulose product 1 takes place in the press module 6. The cellulose product 1 is non-flat. By non-flat product is meant a product that has a three-dimensional extent different from flat products such as blanks or sheets.

[0062] The air-formed cellulose blank structure 2 refers to a substantially air-formed fibrous web structure made from cellulose fibers. The cellulose fibers may be derived from a suitable cellulose raw material R, for example, a pulp material. Suitable pulp materials are, for example, fluff pulp, paper structures, or other cellulose fiber-containing structures. The air-formed cellulose blank structure 2 refers to forming the cellulose blank structure in a dry forming process in which the cellulose fibers are air-formed to produce the cellulose blank structure 2. When the cellulose blank structure 2 is air-formed in the air forming process, the cellulose fibers are conveyed by air as a conveying medium to be formed into the fibrous blank structure 2. This is different from the normal papermaking process or the conventional wet forming process in which water is used as a conveying medium for the cellulose fibers when forming the paper or fibrous structure.

[0063] In the air-molding process, small amounts of water or other substances may be added to the cellulose fibers as necessary to change the properties of the cellulose product, but air is still used as a transport medium in the molding process. The cellulose blank structure 2 may have a dryness that corresponds primarily to the ambient humidity in the atmosphere surrounding the air-molded cellulose blank structure 2, if appropriate. Alternatively, the dryness of the cellulose blank structure 2 can be controlled to have a suitable dryness level when molding the cellulose product 1.

[0064] The blank dry-forming module 4 of the embodiment shown in Fig. 1a and 1b is shown separately in Fig. 1c, which has a horizontal distribution direction of the cellulose fibres F from the mill 4a through the forming chamber 4b to the forming wire 4c. Thus, a horizontal flow of air feeds the cellulose fibres F from the mill 4a to the forming section 4d, which is different from conventional dry-forming systems using a vertical flow of air. The length of the fibre transport distance by the air flow inside the forming chamber 4b must be long enough to minimise turbulence and / or to create a uniform flow of the cellulose fibres F. The length of the blank-forming module 4 is therefore dependent on the fibre transport distance by the air flow.

[0065] Upward blank forming direction D U allows for a compact construction and layout of the product forming unit U, reducing the length of the product forming unit U compared to conventional solutions. Furthermore, the location of the blank dry forming unit 4 at factory floor level allows access for maintenance of the mill 4a from the factory floor level without the need for additional floor structures or platforms that increase the height. This arrangement, together with the horizontal air flow, allows for a reduced height of the product forming unit U compared to conventional solutions using vertical air flow.

[0066] The cellulose blank structure 2 can be air-formed in the dry-forming module 4 into separate cellulose blanks. The separate cellulose blanks are formed as separate pieces of material separated from one another and can be shaped, for example, to a suitable contour to avoid material residues after forming, thereby minimizing the amount of cellulose material used. Alternatively, the cellulose blank structure 2 can be air-formed in the dry-forming module 4 into a continuous cellulose blank 2b. Depending on the air-forming process, the basis weight of the air-formed cellulose blank structure 2 can be uniform or variable.

[0067] 1a-1c, the blank dry-forming module 4 comprises a mill 4a, a forming chamber 4b, and a forming wire 4c arranged in connection with the forming chamber 4b. Fibers F of the cellulose raw material R are separated from the cellulose raw material R in the mill 4a, and the separated fibers F are distributed in the forming chamber 4b onto the forming wire 4c for forming the cellulose blank structure 2. The mill 4a is configured to separate the cellulose fibers F from the cellulose raw material R, and the forming chamber 4b is configured to distribute the separated fibers F onto a forming section 4d of the forming wire 4c for forming the cellulose blank structure 2. The forming section 4d is arranged in connection with a forming chamber opening 4e of the forming chamber 4b. In the illustrated embodiment, the forming section 4d is arranged in a direction parallel to the blank forming direction D, which is upward. U The cellulose blank structure 2 is formed on the forming section 4d and is pulled from the forming section 4d by the forming wire 4c in an upward blank forming direction D. U and then further towards the press module 6. U are used for a compact construction and layout of the product-forming unit U and allow efficient positioning of the various modules of the product-forming unit U relative to one another.

[0068] The pulp structure 20 used may be, for example, a bale, sheet or roll of fluff pulp, a paper structure or other suitable cellulose fiber-containing structure, which is fed to the mill 4a, which may be of any conventional type, such as, for example, a hammer mill, a sawtooth mill or other type of pulp fiberizer. The pulp structure 20 is fed into the mill 4a through an inlet opening and the separated fibers F are distributed into the forming chamber 4b through an outlet opening of the mill 4a, which is arranged in connection with the forming chamber 4b.

[0069] The forming chamber 4b is arranged to distribute the separated fibers onto the forming wire 4c for air forming the cellulose blank structure 2. The forming chamber 4b is arranged as a hood structure or compartment connected to the forming wire 4c. The forming chamber 4b encloses a volume in which the separated fibers F are distributed from the mill 4a to the forming wire 4c. The cellulose fibers F are distributed by an air flow generated by the mill 4a, which carries the fibers in the forming chamber 4b from the mill 4a to the forming wire 4c.

[0070] The forming wire 4c may be of any suitable conventional type and may be formed as an endless belt structure, as shown in Figures 1a-1b. A vacuum box 4f may be arranged connected to the forming wire 4c and the forming chamber 4b in order to control the air flow in the forming chamber 4c and to distribute the separated fibres F onto the forming wire 4c. The forming wire 4c has a first side S1 facing the forming chamber 4b and a second side S2 facing the vacuum box 4f. A negative pressure P is applied to the second side S2 to ensure the adhesion of the cellulose fibres F to the first side S1. NEG While applying pressure, the cellulose blank structure 2 is thus air molded onto the first side S1 of the forming wire 4c.

[0071] The blank dry-forming module 4 is arranged upstream of the press module 6, as shown for example in Fig. 1a-1c. The press module 6 comprises a toggle press 6a with a mould 3 mounted in the press module. The toggle press 6a operates by a reciprocating motion having two main phases, namely an opening phase, during which the cellulose blank structure 2 can be fed into the mould, and a pressing phase, during which the cellulose blank structure 2 in the mould is immobile. The cellulose blank structure 2 must therefore be intermittently transported to the mould 3 of the press module 6.

[0072] According to the present disclosure, the intermittent supply of the cellulose blank structure 2 to the forming mold 3 of the press module 6 is solved by operating the forming wire 4a of the blank dry forming module 4 also intermittently and in synchronization with the press module 6.

[0073] In the exemplary embodiment of Fig. 1a, the product-forming unit U additionally comprises an intermediate feeder 16 arranged between the blank dry-forming module 4 and the press module 6. The intermediate conveying or intermediate feeder 16, which may be a set of conveyor belts and / or feed rollers or the like, may in this case also be arranged to operate intermittently and synchronously with the press module 6.

[0074] In other words, the product forming unit U may further comprise a cellulose blank conveying device 16, in particular a conveyor belt, a set of feed rollers, a vacuum belt, an elongated tractor belt feeder or the like, configured for conveying the air-formed cellulose blank structure 2 from the forming wire 4c of the blank dry-forming module 4 to the forming mould 3 of the toggle press module 6, in which the electronic control system 6h is configured to provide a substantially synchronous operation of the forming wire 4c and the conveying device, so that the forming wire 4c and the conveying device are operating at almost the same conveying speed at all times.

[0075] As a result, the intermittent transport of the cellulose blank structure 2 to the press module 6 is, in the exemplary embodiment of FIG. 1 a, partly by the forming wire 4 a and partly by a suitable feeding device 16 that is intermittently controlled to feed the cellulose blank structure 2 to the press module 6. The press module 6 applies a forming pressure P F When operated to apply a force, the cellulose blank structure 2 is in a non-moving state, or at least in a slow moving state.

[0076] In other words, the cellulose blank structure 2 is fed to the molding position between one or more first mold parts 3a and one or more second mold parts 3b when the mold parts are in an open state, so that the cellulose blank structure 2 can be safely positioned between the one or more first mold parts 3a and the one or more second mold parts 3b without any disruptive interaction with the mold parts.

[0077] Accordingly, the present disclosure relates to a product forming unit U for producing a non-flat cellulose product 1 from an air-formed cellulose blank structure 2, the product forming unit U comprising a blank dry-forming module 4 with a movable forming wire 4c, a toggle press module 6 with a toggle press 6a and a forming die 3, and an electronic control system 6h operatively connected to the forming wire 4c and the toggle press 6a. The blank dry-forming module 4 is configured to air-form the cellulose blank structure 2 onto the forming wire 4c. Furthermore, the toggle press 6a is adapted to move in a pressing direction D. P The mold 3 further comprises a press member 6d movably arranged in a direction parallel to the pressing axis 6c, a toggle mechanism 6e drivingly connected to the press member 6d, and a press actuator assembly 6f drivingly connected to the toggle mechanism 6e. The mold 3 further comprises a movable first mold part 3a and a second mold part 3b attached to the press member 6d. The electronic control system 6h controls the pressing direction D by the toggle mechanism 6e. PThe electronic control system 6h is further configured to control operation of the press actuator assembly 6f to perform pressing operations including driving the press member 6d with the press actuator 6f and thereby forming a non-flat cellulose product from the air-formed cellulose blank structure by forcing the first mold part 3a against the second mold part 3b. Additionally, the electronic control system 6h is further configured to intermittently feed the forming wire 4c between successive pressing operations.

[0078] The movable forming wire 4c is, for example, an air-permeable conveyor belt.

[0079] The air-formed cellulosic blank structure 2 is, for example, an air-formed fibrous web structure made from cellulosic fibers.

[0080] In the exemplary embodiment of FIG. 1a, an electronic control system 6h is operatively connected to the drive motor 5 of the forming wire 4c and to the press actuator assembly 6f of the toggle press 6a.

[0081] After the pressing operation, the electronic control system 6h changes the pressing direction D to open the mold 3. P The press actuator assembly 6f is configured to control the operation of the press actuator assembly 6f to drive the press member 6d in the opposite direction to the pressing force.

[0082] A first embodiment for operating the product-forming unit U is explained in more detail with reference to Fig. 2a, which shows the operating speed V of the forming wire 4c over time. W (solid line) and the operating speed of the press member over time V P 1 shows a timing diagram of a short operating sequence of the product forming unit U, including (dashed lines).

[0083] During the first period t1, the mould 3 is in an open state and the moulding wire 4c is temporarily operated to feed a new section of the cellulose blank structure 2 into the mould 3. During the first period t1, the operating speed V WFrom zero, the cellulose blank structure 2 moves to a predefined target speed V1 and then returns to a speed of zero. Since no buffer device or the like is disposed between the forming wire 4c and the forming die 3, in this case, the cellulose blank structure 2 moves at the operating speed V of the forming wire 4c. W may be considered to have the same feed rate into the mold as

[0084] In the illustrated exemplary embodiment, during a second period t2 subsequent to the first period t1 but slightly overlapping the end of the first period t1, the press member 6d is controlled to move forward towards the mold 3 for closing and to initiate the fiber forming event. During the second period t2, the operating speed V P The motion speed V of the forming wire 4c goes from zero to a predefined target speed and then back to zero. W is zero at least during the end extent of the second period t2 such that there is no feeding of the cellulose blank structure 2 towards the closed mould 3.

[0085] During a subsequent third period t3, following the second period t2, the forming wire 4c and the press members 6d are controlled to temporarily hold their operating positions, i.e. to remain in a non-moving state. During the third period, the mold 3 is closed and the toggle press 6a applies a full compressive force to the mold. In other words, the third period t3 corresponds to a fiber forming event of the cellulose blank structure 2 located in the mold 3.

[0086] During a fourth period t4 following the third period t3, the press member 6d is controlled to move backward to open the mold 3. During the fourth period t4, the operation speed V P goes from zero to a predefined target speed and then back to a speed of zero. The return speed is illustrated here as negative to indicate the direction of movement of the press member 6d, i.e., backwards.

[0087] At or after the end of the fourth period t4, the operating speed V of the forming wire 4c Wagain goes from zero to the predefined target speed, and thus the cyclic sequence t5 is repeated. Thus, the total period t5 consisting of the accumulation periods t1 to t4 represents the repeated cyclic operation sequence of the product forming unit U.

[0088] The timing diagram of FIG. 2a shows the motion speed V of the forming wire 4c. W is clearly not constant, but rather varies periodically over a total period t5, clearly indicating that the electronic control system 6h is arranged to intermittently supply the forming wire 4c.

[0089] Furthermore, the timing diagram of FIG. 2a clearly shows that the electronic control system 6h is configured to supply the forming wire 4c between successive pressing operations, i.e. before and after the third period t3.

[0090] FIG. 2a shows that the electronic control system 6h is configured to intermittently supply the forming wire 4c between successive press operations such that the forming wire 4c operates cyclically at a relatively high speed V1 during periods t1 between successive press operations t3 and at zero speed during periods t3 coinciding with the press operations.

[0091] A second embodiment for operating the product-forming unit U is explained in more detail with reference to Fig. 2b, which shows the operating speed V of the forming wire 4c over time. W (solid line) and the operating speed of the press member over time V P 1 shows a timing diagram of a short operating sequence of the product forming unit U, including (dashed lines).

[0092] In this exemplary embodiment, the operation sequence of the press member 6d and the operation speed V P 2a, but this exemplary embodiment differs in that the forming wire 4c is moved at a particular motion speed V during a period t3 that coincides with the pressing motion. W4c, which may be considered advantageous in certain applications, for example, to provide a smoother and less variable thickness of the resulting cellulose blank structure 2. On the other hand, such motion control of the forming wire 4c usually requires a certain level of buffering of the cellulose blank structure 2 during transport from the blank dry forming module 4 to the toggle press module 6.

[0093] The operating speed V of the forming wire 4c W may be relatively low during the aforementioned period t3, which coincides with the pressing operation. W may be partially zero and partially above zero during the period t3 that coincides with the pressing operation. As a result, the buffer requirement is kept relatively low and can be implemented, for example, by a variable length suspended section of the cellulose blank structure 2, or a variable length curved section of the cellulose blank structure 2, or a relatively small capacity type buffer device, etc.

[0094] 2b, during a first period t1, the mould 3 is in an open state and the moulding wire 4c is controlled to feed a new section of the cellulose blank structure 2 into the mould 3. During the first period t1, the movement speed V W The relatively low speed V2 goes from a relatively high target speed V1 that is predefined, and then goes back to the relatively low speed V2. The relatively low speed V2 may be, for example, about 1 to 30% of the relatively high speed V1.

[0095] In the illustrated exemplary embodiment, during a second period t2 subsequent to the first period t1 but slightly overlapping the end of the first period t1, the press member 6d is controlled to move forward towards the mold 3 for closing and to initiate the fiber forming event. During the second period t2, the operating speed V P The motion speed V of the forming wire 4c goes from zero to a predefined target speed and then back to zero. Wremains at a relatively low speed V1 in this exemplary embodiment. As soon as the mould 3 is closed, the cellulose blank structure 2 starts to accumulate in the buffer.

[0096] Following the second period t2, during a subsequent third period t3, both the forming wire 4c and the pressing members 6d are controlled to temporarily hold their operating positions, i.e. remain in a non-moving state, i.e. corresponding to a fibre forming event of the cellulose blank structure 2 located in the mould 3.

[0097] During a fourth period t4 following the third period t3, the press member 6d is controlled to move backward to open the mold 3. During the fourth period t4, the operation speed V P goes from zero to a predefined target speed and then back to a speed of zero. The return speed is illustrated here as negative to indicate the direction of movement of the press member 6d, i.e., backwards.

[0098] Once the mould 3 is opened, the cellulose blank structure 2 in the buffer may be fed into the mould 3 .

[0099] At the end of the fourth period t4, the operation sequence starts again from period t1.

[0100] The timing diagram of FIG. 2b shows the motion speed V of the forming wire 4c. W is clearly not constant, but rather varies periodically over the total period t5, clearly indicating that the electronic control system 6h may be configured to supply the shaping wire 4c intermittently.

[0101] Furthermore, the timing diagram of FIG. 2b clearly shows that the electronic control system 6h is configured to supply the forming wire 4c between successive pressing operations, i.e. before and after the third period t3.

[0102] Furthermore, Figure 2b shows that the electronic control system 6h may be configured to intermittently supply the forming wire 4c between successive press operations such that the forming wire 4c periodically operates at a relatively high speed V1 during periods t1 between successive press operations t3 and at a relatively low speed V1 during periods t3 corresponding to the press operations.

[0103] In other words, the drive motor 5 of the forming wire 4c operates according to a cyclic sequence that includes a first period of relatively high speed followed by a second period of relatively low speed or no speed.

[0104] Thus, according to some exemplary embodiments, the electronic control system 6h is configured to synchronize operation of the forming wire 4c and the toggle press 6a such that during periods when the toggle press 6a is in a non-pressing state, the forming wire 4c is operated or operated at a relatively high speed V2, and during periods when the toggle press 6a is in a pressing state, the forming wire 4c is stopped or operated at a relatively low speed V2.

[0105] In other words, the electronic control system 6h may be configured to control the operation of the forming wire 4c and the toggle press 6a so that the feed rate of the forming wire is equal, or at least substantially equal, to the feed rate of the air-formed cellulose blank structure 2 entering the forming mould 3, particularly over the entire press cycle t5.

[0106] Furthermore, the product-forming unit U may not have a buffer module arranged between the blank dry-forming module 4 and the press module 6. This relates in particular to the product-forming unit U described with reference to figure 2a.

[0107] Since the forming unit U may be arranged without any buffer module or similar device, or at least with only a relatively small buffer capacity, the intermittent transport of the cellulose blank structure to the press module must be synchronized with the air forming of the cellulose blank structure 2 in the blank dry forming module 4.

[0108] It will be appreciated that the forming pressure may be applied to the cellulosic blank structure 2 in just one pressing step during the pressing operation, as described above with reference to Figures 2a-b, or alternatively, the forming pressure may be applied in two or more repeated pressing steps during the pressing operation, in this manner the mould parts repeatedly apply forming pressure to the cellulosic blank structure.

[0109] Preferably, the pressing operation is a single pressing operation, in which the forming pressure is applied to the cellulose blank structure 2 in only one pressing step during the pressing operation. That is, a single pressing operation means that the cellulose product 1 is formed from the cellulose blank structure 2 in one single pressing step in the press module 6. In this single pressing operation, one or more first mould parts 3a and one or more second mould parts 3b interact with each other to establish a forming pressure and a forming temperature during a single operating engagement step. In a single pressing operation, the forming pressure and the forming temperature are not applied to the cellulose blank structure 2 in two or more repeated or successive pressing operations.

[0110] Thus, as described above, the product forming unit U includes an electronic control system 6h arranged to control the operation of both the blank dry-forming module 4 and the toggle press module 6, in particular to control the operation of one or more drive motors used to drive the forming wire 4c of the blank dry-forming module 4, and to control the operation of the press actuator assembly 6f used to drive the toggle press module 6.

[0111] The mill 4a may be operated in various ways depending on the configuration of the cellulose blank structure 2 being air-formed in the dry-forming module 4. The mill 4a preferably operates continuously. In one embodiment, the cellulose feedstock R is continuously fed to the mill 4a. In an alternative embodiment, the cellulose feedstock R is instead intermittently fed to the mill 4a.

[0112] The air-formed cellulose blank structure 2 may be formed from cellulose fibers in a conventional air-forming process or in a blank dry-forming module 4 as shown in Fig. 1a-1b and may be constructed in various ways. For example, the cellulose blank structure 2 may have a composition in which the fibers are of the same origin or alternatively include a mixture of two or more types of cellulose fibers, depending on the desired properties of the cellulose product 1. The cellulose fibers used in the cellulose blank structure 2 are strongly bonded to each other by hydrogen bonds during the forming process of the cellulose product 1. As will be further described below, the cellulose fibers may be mixed with other substances or compounds up to a certain amount. By cellulose fibers is meant any type of cellulose fiber, such as natural or manufactured cellulose fibers. The cellulose blank structure 2 may specifically include at least 95% cellulose fibers, or more specifically include at least 99% cellulose fibers.

[0113] The air-formed cellulose blank structure 2 may have a single layer or a multi-layer structure. A cellulose blank structure 2 having a single layer structure refers to a structure formed from one layer containing cellulose fibers. A cellulose blank structure 2 having a multi-layer structure refers to a structure formed from two or more layers containing cellulose fibers, where these layers may have the same or different compositions or structures.

[0114] The cellulose blank structure 2 may have a reinforcing layer comprising cellulose fibers, which may be arranged as a support layer for one or more other layers of the cellulose blank structure 2. The reinforcing layer may have a higher tensile strength than the other layers of the cellulose blank structure 2. This is effective to avoid the cellulose blank structure 2 being destroyed during the formation of the cellulose product 1 when one or more air-formed layers of the cellulose blank structure 2 have a composition with a lower tensile strength. The reinforcing layer having a higher tensile strength thus serves as a support structure for the other layers of the cellulose blank structure 2. The reinforcing layer may be of a different composition than the other layers of the cellulose blank structure, for example a tissue layer comprising cellulose fibers, an air-laid structure with cellulose fibers, or any other suitable layer structure. Thus, the reinforcing layer does not have to be air-formed. The cellulose blank structure 2 may have two or more reinforcing layers, if appropriate.

[0115] The cellulose blank structure 2 may further include or be disposed in connection with one or more barrier layers that provide the cellulose product with the ability to retain or withstand liquids, for example, when the cellulose product 1 is used in contact with beverages, foods, and other wet substances. The one or more barrier layers may be of a different composition, e.g., barrier structure organization, than the other layers of the cellulose blank structure 2.

[0116] The one or more air-formed layers of the cellulosic blank structure 2 are a fluffy, air-like structure in which the cellulose fibers forming the structure are relatively loosely arranged relative to one another. The fluffy cellulosic blank structure 2 is used for efficient forming of the cellulosic product 1, allowing the cellulose fibers to efficiently form the cellulosic product 1 during the forming process.

[0117] The product forming unit U may further comprise a barrier application module arranged upstream of the press module 6. The barrier application module is configured to apply a barrier composition to the cellulose blank structure 2 prior to forming the cellulose product 1 in one or more molds 3.

[0118] One preferred property of the cellulose product 1 is its ability to retain or resist liquid, such as when the cellulose product is used in contact with beverages, foods, and other water-containing materials. The barrier composition may be one or more additives used in producing the cellulose product, such as AKD or latex, or other suitable barrier compositions. Another suitable barrier composition is a combination of AKD and latex, where tests have shown that unique product properties can be achieved by the combination of AKD and latex added to the air-formed cellulose blank structure 2 when forming the cellulose product 1. When using a combination of AKD and latex, a high level of hydrophobicity can be achieved, resulting in a cellulose product 1 with a high ability to resist liquids such as water without adversely affecting the mechanical properties of the cellulose product 1.

[0119] The barrier application module may be arranged connected to the cellulose blank structure 2 as a hood structure, which has a spray nozzle for continuously or intermittently spraying the barrier composition onto the cellulose blank structure 2. In this way, the barrier composition is applied to the cellulose blank structure 2 in the barrier application module. The barrier composition may be applied only to one side of the cellulose blank structure, or alternatively to both sides. The barrier composition may further be applied over the entire surface of the cellulose blank structure 2, or only to a portion or some sections of the surface of the cellulose blank structure 2. The hood structure of the barrier application module prevents the barrier composition from splashing into the surrounding environment. Other application techniques for applying the barrier structure may include, for example, slot coating and / or screen printing.

[0120] The product forming unit U further heats the cellulose blank structure 2 at a forming temperature T F The one or more forming dies 3 are adapted to form a non-flat cellulose product 1 from the cellulose blank structure 2 in one or more forming dies 3 by heating the cellulose blank structure 2 to a forming temperature T in the range of 100 to 300° C. and pressing the cellulose blank structure 2 under a forming pressure. F and pressing the cellulose blank structure 2 at a molding pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa, to form a non-flat cellulose product 1 from the cellulose blank structure 2.

[0121] First feed direction D F1 and the second feed direction D F2 The difference allows for a compact construction and layout of the product-forming unit U and allows for an efficient and compact positioning of the various modules of the product-forming unit U relative to one another.

[0122] The product forming unit is adapted to intermittently feed the cellulose blank structure from the blank dry forming module by the forming wire in a first feed direction and to intermittently feed the cellulose blank structure to the press module in a second feed direction, in which case the second feed direction D F2 is the first feed direction D F1 The first feed direction D F1 and the second feed direction D F2 The difference allows for a compact construction and layout of the product-forming unit U and allows for an efficient and compact positioning of the various modules of the product-forming unit U relative to one another.

[0123] In some exemplary embodiments, the second feed direction D F2 is the first feed direction D F1 The opposite, or substantially the opposite, of

[0124] First feed direction D F1 A second feed direction D arranged substantially opposite to F2 means that the first supply direction D F1 The second supply direction D F2 This means that the difference between the angles is less than 45 degrees, particularly less than 30 degrees.

[0125] In the illustrated embodiment, the first feed direction D F1 is the upward direction, and the second feed direction D F2 oriented downwards, which allows for a compact and efficient construction of the product forming unit U.

[0126] For clarity, the feed path and feed direction of the cellulose blank structure 2 of the exemplary embodiment of Figures 1a-1b are shown diagrammatically in Figure 1d, and the compact configuration and layout of the product forming unit U made possible by feeding the cellulose blank structure 2 first primarily upward, then primarily horizontally, and then primarily downward, when compared to the conventional straight horizontal path of the cellulose product compression molding process, can be clearly understood.

[0127] Alternatively, as shown diagrammatically in Fig. 1e, the blank dry-forming module 4 may be arranged with a mainly horizontally oriented feed path and feed direction of the cellulose blank structure 2, i.e. with a mainly horizontally oriented forming wire 4c in the region of the forming chamber opening 4e, before feeding the cellulose blank structure 2 upwards, then mainly horizontally and then mainly downwards into the press module 6. Such a layout of the product forming unit U may also be utilized to provide a compact product forming unit U.

[0128] 1d-e, the blank dry-form module 4 typically forms the beginning of the feed path and the press module 6 typically forms the end of the feed path, not considering the blank recycle module 7. Other modules, such as a barrier coating module, may be located in any suitable position between the dry-form module 4 and the press module 6, i.e. downstream of the dry-form module 4 and upstream of the press module 6, and not necessarily in the exemplary positions of the embodiment of FIGS.

[0129] Feeding the cellulose blank structure primarily downwards while passing through the press module 6 is beneficial in terms of easy feeding of the cellulose blank structure 2 and easy removal of the cellulose product 1 after the forming process is completed, i.e. when it leaves the press module 6.

[0130] In particular, high speed intermittent feeding of the cellulose blank structure 2 from the dry forming module 4 to the press module 6 can be difficult to implement due to damage to the cellulose blank structure 2 or changes in the properties of the cellulose blank structure 2, e.g. the thickness of the cellulose blank structure 2. However, the toggle press is mainly used for the horizontal D H By arranging the air-formed cellulose blank structure 2 in a generally downward direction and feeding the cellulose blank structure 2 primarily downwards into the press module 6, gravity assists this feeding process, which requires less force to be applied by the feeding device 16 to feed the air-formed cellulose blank structure 2 into the press area 15 of the press module 6, thereby reducing the risk of damage and / or changes in the properties of the cellulose blank structure 2.

[0131] Furthermore, removal of the finished, discharged cellulose product 1 after the moulding process is complete may also be simplified by the predominantly vertical feeding of the cellulose blank structure 2 through the mould 3, as gravity again may assist and facilitate removal of the finished, discharged cellulose product 1 from the mould 3 and subsequent transport to a storage chamber or conveyor belt or the like.

[0132] The press module 6, as shown in Figs. 1a-1b and 3a, comprises one or more moulds 3, each of which comprises a first mould part 3a and a second mould part 3b. The corresponding first and second mould parts cooperate with each other during the moulding of the non-flat cellulose product 1 in the press module 6. Each first mould part 3a and the corresponding second mould part 3b are arranged to be movable relative to each other, and the first mould part 3a and the second mould part 3b are arranged to be movable relative to each other in a pressing direction D. P The actuators are configured to move relative to each other.

[0133] In the embodiment shown in Figures 1a-1b and 3a-3e, the second mould part 3b is stationary and the first mould part 3a is pressed in the pressing direction D P As shown by the double-headed arrow in FIG. 3b, the first mold part 3a is arranged to be movable relative to the second mold part 3b in the pressing direction D. P The second mould section 3b is adapted to move in both directions towards and away from the second mould section 3b with linear movement along an axis extending in the x direction.

[0134] In alternative embodiments, the first mold part 3a may be stationary and the second mold part 3b may be movably arranged relative to the first mold part 3a, or both the first mold part 3a and the second mold part 3b may be movably arranged relative to each other.

[0135] The press module 6 may be of single-cavity construction or alternatively of multi-cavity construction. A single-cavity press module has only one mold 3 with first and second mold parts. A multi-cavity press module has two or more molds 3 with cooperating first and second mold parts, respectively. In the embodiment shown in Figs. 1a-1b and 3a, the press module 6 is arranged as a multi-cavity press module with multiple molds 3 with first and second mold parts, the movements of the mold parts being appropriately synchronized for simultaneous molding operations. The portion of the press module 6 shown in Figs. 3b-3e shows a section with one mold 3 of single-cavity construction or alternatively of multi-cavity construction. In the following, the press module 6 is described with respect to a multi-cavity press module, but the present disclosure is equally applicable to a single-cavity press module.

[0136] For all embodiments according to the present disclosure, the pressing direction D P The expression "movement in the press direction D" P It should be understood that this expression may also include both linear and non-linear motion of the mold parts, where the motion during molding results in a change in the press direction D P The mold parts are rearranged.

[0137] To form the non-flat cellulose product 1 from the air-formed cellulose blank structure 2 in the product forming unit U, first the cellulose blank structure 2 is provided from a suitable source. The cellulose blank structure 2 may be air-formed from cellulose fibres and arranged in rolls or in stacks. The rolls or stacks can then be connected and arranged in the mould system S. Alternatively, the cellulose blank structure 2 may be air-formed from cellulose fibres in the blank dry-forming module 4 of the product forming unit U and fed directly to the press module 6.

[0138] The cellulose product 1 is formed by subjecting the cellulose blank structure 2 to a molding temperature T F The cellulose blank structure 2 is formed in one or more forming moulds 3 by heating the cellulose blank structure 2 to a temperature within the range of 1 to 100 MPa, preferably 4 to 20 MPa, and pressing the cellulose blank structure 2 at a forming pressure within the range of 1 to 100 MPa, preferably 4 to 20 MPa. As illustrated in Fig. 3b to 3e, the first mould parts 3a are arranged to form the non-flat cellulose product 1 by interaction with the corresponding second mould parts 3b. During forming of the cellulose product 1, the cellulose blank structure 2 is subjected in each mould 3 to a forming pressure within the range of 1 to 100 MPa, preferably 4 to 20 MPa, and a forming temperature T in the range of 100 to 300°C. F Therefore, the cellulose blank structure 2 is exposed to a molding temperature T in the range of 100 to 300 ° C. F A cellulose product 1 is formed from the cellulose blank structure 2 between each first mould part 3a and a corresponding second mould part 3b by heating the cellulose blank structure 2 to a temperature of 1000 MPa and pressing the cellulose blank structure 2 at a moulding pressure in the range of 1-100 MPa, preferably 4-20 MPa. When moulding the cellulose product 1, strong hydrogen bonds are formed between the cellulose fibres in the cellulose blank structure 2 arranged between the first mould part 3a and the second mould part 3b. Temperature and pressure levels are measured in the cellulose blank structure 2 during the moulding process, for example by suitable sensors arranged in or connected to the cellulose fibres in the cellulose blank structure 2.

[0139] The press module 6 may further comprise a heating unit, which heats the cellulose blank structure 2 in each mold 3 to a forming temperature T F The heating unit may have any suitable structure. The heating unit may be integrated or cast into the first mould part 3a and / or the second mould part 3b, suitable heating devices being, for example, electric heaters such as resistor elements or fluid heaters. Another suitable heat source may also be used.

[0140] As shown in FIG. 3b, when the cellulose blank structure 2 is placed in a molding position between the first mold part 3a and the second mold part 3b, the first mold part 3a is pressed in a pressing direction D, as indicated by the arrow in FIG. 3c. P As the first mold part 3a is moved towards the second mold part 3b, the first mold part 3a is further moved towards the second mold part 3b, and the cellulose blank structure 2 is subjected to a molding pressure and a molding temperature T F The cellulose blank structure 2 is increasingly compressed between the press surfaces 3c, 3d of the mould parts until a product forming position as shown in Fig. 3d is reached, where a pressure of 0.1 MPa is applied. During forming of the cellulose product 1, a forming cavity C for forming the cellulose product 1 is formed between each first mould part 3a and the second mould part 3b, with the cellulose blank structure 2 being placed between them. The forming pressure and the forming temperature T F is applied to the cellulose blank structure 2 within each moulding cavity C.

[0141] The shaping of the cellulose product 1 may further comprise an edge forming operation and a cutting or separating operation in the press module 6, in which an edge is formed in the cellulose product 1 and the cellulose product 1 is separated from the cellulose blank structure 2 during the shaping of the cellulose product 1. The mould parts may be arranged with edge forming devices and cutting or separating devices for such operations, for example, or alternatively the edge may be formed in a cutting or separating operation of the product. Once the cellulose product 1 has been shaped in the mould system S, the first mould part 3a is moved away from the second mould part 3b, as shown in Fig. 3e, and the cellulose product 1 can be removed from the press module 6, for example, using an ejector rod or a similar device.

[0142] A deformation element E for establishing the molding pressure may be arranged connected to each first mould part 3a and / or second mould part 3b. In the embodiment shown in figures 3b-3e, the deformation element E is attached to the first mould part 3a. By using the deformation element E, the moulding pressure can be generated as an isotropic moulding pressure.

[0143] The first mould part 3a and / or the second mould part 3b may comprise a deformation element E, which is configured to apply a moulding pressure to the cellulose blank structure 2 in the moulding cavity C during the moulding of the cellulose product 1. The deformation element E may be attached to the first mould part 3a and / or the second mould part 3b by suitable attachment means, e.g. adhesive or mechanical fastening means. During the moulding of the cellulose product 1, the deformation element E is deformed to apply a moulding pressure to the cellulose blank structure 2 in the moulding cavity C, such that due to the deformation of the deformation element E, an even pressure distribution is achieved even if the cellulose product 1 has a complex three-dimensional shape or the cellulose blank structure 2 has a variable thickness. To apply the required moulding pressure to the cellulose blank structure 2, the deformation element E is made of a material that can be deformed when a force or pressure is applied, the deformation element E being preferably made of an elastic material that can recover its size and shape after deformation. The deformation element E is further adapted to withstand the high moulding pressure and moulding temperature T used during the moulding of the cellulose product 1. F It may be made of a material having suitable properties to withstand the levels.

[0144] Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the deformation elements E are made of such materials, an even pressure distribution can be achieved in the molding process, in which the pressure exerted by the deformation elements E on the cellulose blank structure 2 in the molding cavity C is equal or substantially equal in all directions between the mold parts. If each deformation element E is in a fluid-like state under pressure, a uniform fluid-like pressure distribution is achieved. The molding pressure is thus exerted by such materials on the cellulose blank structure 2 from all directions, and the deformation elements E thus exert an isotropic molding pressure on the cellulose blank structure 2 during the molding of the cellulose product 1. Each deformation element E may be made of a suitable structure of elastic material, and by way of example, the deformation elements E may be made of a solid or substantially solid structure of gel material, silicone rubber, polyurethane, polychloroprene or rubber with a hardness in the range of 20 to 90 Shore A.

[0145] Furthermore, in the embodiment shown in Fig. 1a-1b, the product forming unit U comprises a blank recycle module 7 for recycling cellulose fibers. The blank recycle module 7 is configured to feed the remaining part 2c of the cellulose blank structure 2 after forming of the cellulose product 1 from the press module 6 back to the blank dry forming module 4. The blank recycle module 7 is arranged to transport the remaining cellulose blank fiber material from the press module 6 to the mill 4a. After forming the cellulose product 1 in the forming mold 3, a remaining part 2c of the cellulose blank structure comprising cellulose blank fiber material may result. By means of the blank recycle module 7, the remaining or remaining cellulose fibers can be recycled and reused to form a new cellulose blank structure 2 together with fibers from the cellulose raw material. In Fig. 1a-1b, an exemplary embodiment of the blank recycle module 7 is shown in a schematic manner. The blank recycle module 7 comprises a feed structure 7a, such as a feed belt, a conveyor structure or other suitable means for conveying the remaining part 2c from the forming mold 3 to the mill 4a. The mill 4a may be arranged with a separate inlet opening for the residual material, through which the residual portion 2c of the cellulose blank structure 2 is fed into the mill 4a.

[0146] The blank recycle module 7 may include a recycle compression unit 7b that compresses the remaining portion 2c of the cellulose blank structure 2 as it is conveyed from the press module 6 to the blank dry-forming module 4. Preferably, the recycle compression unit 7b is arranged as a pair of cooperating rollers that compresses the remaining portion 2c of the cellulose blank structure 2 as shown in FIG.

[0147] In an embodiment not shown, instead of the above-mentioned configuration, the blank recycling module 7 may have a channel structure with an inlet portion arranged connected to the mould 3, into which the residual portion 2c of the cellulose blank structure may be sucked for further conveyance to the mill 4a. The channel structure may further be arranged with a suitably combined mill and fan unit, which is used to at least partially separate the residual material before further conveyance to an outlet portion connected to the mill 4a.

[0148] The blank recycling module 7 may further comprise a buffer assembly 51 having the purpose of converting the intermittent feeding movement of the residual portion 2c leaving the press module 6a into a continuous feeding movement before feeding the residual portion 2c to the mill 4a. This is particularly important when the residual portion 2c has the form of a continuous web structure. A continuous feeding of the residual portion 2c to the mill 4a may be advantageous in terms of a more uniform feeding rate of the residual portion 2c and therefore the formation of a cellulose blank structure 2 of more uniform thickness on the forming wire 4c. However, due to the intermittent operation of the press module 6, it is necessary to convert the intermittent feeding of the residual portion 2c from the press module 6 into a continuous feeding without breaking the web structure of the residual portion 2c. To achieve this, the buffer assembly 51 may comprise a residual portion 2c feeding system configured to feed the residual portion 2c intermittently to the buffer assembly 51 and to feed the residual portion 2c continuously from the buffer module 5a.

[0149] The buffer assembly 5 may be realized as a suspended section of a continuous structure forming the residual part 2c, in which the latter has no vertical support from a conveyor belt or the like and can therefore hang freely, in which case a buffer effect is achieved by suspending the residual part 2c more or less deeply in the suspended section. The buffer assembly 5 may alternatively be implemented in the form of a mechanical device having one or more moving parts controlled by actuators.

[0150] The above-mentioned modules allow a compact construction of the product forming unit U, which can be integrated into a single product forming unit U that can be transported in a freight container and easily located on the converter's factory floor. The different feeding directions allow a more compact layout and construction of the product forming unit U.

[0151] Some exemplary embodiments of the press module 6 will be described in more detail below with reference to the schematic illustrations in Figures 3a and 4a-4b, where Figure 4a shows a toggle press 6a in an open state and Figure 4b shows the same toggle press 6a during pressing operation.

[0152] The cellulosic toggle press module 6 is particularly suitable for forming a non-flat cellulose product 1 from an air-formed cellulose blank structure 2 because the continuous cellulose blank structure 2 allows for easy handling and feeding of the blank structure 2 to the toggle press 6a, and easy feeding of the remaining portion 2c of the cellulose blank structure 2 to the blank recycle module 7. However, the cellulosic toggle press module 6 is also suitable for forming a non-flat cellulose product 1 from a non-continuous air-formed cellulose blank structure 2, such as individual sheet pieces of air-formed cellulose blank structure 2.

[0153] The press actuator assembly 6f may include a single or multiple hydraulic or pneumatic linear actuators, such as, for example, cylinder-piston actuators. Alternatively, a motor with a rotating output shaft, such as, for example, an electric motor, a hydraulic motor, or a pneumatic motor, may be used to drive a mechanical actuator, particularly a linear mechanical actuator, such as a ball screw, a threaded rod actuator, or a rack and pinion actuator. Still alternatively, the press actuator assembly 6f may include a high torque electric motor drivingly connected to the toggle mechanism 6e via a rotary-linear transmission, such as an eccentric or crankshaft assembly. Still alternatively, the press actuator assembly 6f may include one or more high torque electric motors integrally attached to the toggle mechanism 6e and directly drivingly connected to a rotating member or pivot link of the toggle mechanism 6e.

[0154] The movable first mould part 3a may be directly or indirectly attached to the pressing member 6d, which means that there may for example be an intermediate member, such as for example a load cell for detecting the pressing force, arranged between the movable first mould part 3a and the pressing member 6d.

[0155] The stationary second mould part 3b is generally immobile during the pressing operations, but nevertheless moves in the pressing direction D during the periods between successive pressing operations, as will be described in more detail below. P It may be adjustable.

[0156] In some exemplary embodiments, the toggle press 6a has a front structure 6b and a rear structure 6c, the toggle mechanism 6e is also connected to the rear structure 6c, and the stationary second mold part 3b is attached to the front structure 6b.

[0157] The stationary second mould part 3b may be directly or indirectly attached to the front structure 6b, which means that there may for example be an intermediate member, such as a load cell for detecting the pressing force, arranged between the stationary second mould part 3b and the front structure 6b.

[0158] The front structure 6b and the rear structure 6c of the toggle press 6a represent two rigid structurally related parts that must be interconnected by some structurally rigid structure to ensure that the front structure 6a and the rear structure 6c do not separate from each other during press operation. The front structure 6b and the rear structure 6c may have many different shapes depending on the specific situation. For example, the front structure 6b and the rear structure 6c may have a plate-like shape, in particular a rectangular plate-like shape, which allows cost-effective manufacturing and allows the corner areas of the plate-shaped front structure 6b and the rear structure 6c to be used for attachment to a common rigid frame structure.

[0159] Indeed, the toggle press 6a typically has a rigid frame structure defined by a front structure 6b, a rear structure 6c and an intermediate frame structure connecting the front structure 6b to the rear structure 6c.

[0160] In some exemplary embodiments, the toggle press 6a has a rigid frame structure defined by a front structure 6b, a rear structure 6c, and an intermediate linear guide assembly 14 connecting the front structure 6b to the rear structure 6c, where the press member 6d is movably mounted to the linear guide assembly 14 and is movable in a pressing direction D. P A rigid frame structure may be disposed on the underlying support frame 38 to provide the desired height and angular inclination of the toggle press module 6.

[0161] In other words, the intermediate frame structure may be provided by an intermediate linear guide assembly 14 which has a dual function in that it provides structural strength and rigidity to the toggle press 6a and provides a rigid connection between the front structure 6b and the rear structure 6c, and additionally provides an intermediate linear guide assembly 14 for guiding the press members 6d.

[0162] To allow a cost-effective and robust frame construction of the toggle press 6a, the intermediate linear guide assembly 14 may have four tie bars 37, one of which is arranged in each corner area of ​​the plate-like front structure 6b and the rear structure 6c. The tie bars may, for example, be cylindrical, and corresponding cylindrical holes may be provided in the corner areas of the plate-like front structure 6b and the rear structure 6c to accommodate said tie bars.

[0163] The press member 6d may have any structural shape. However, in some exemplary embodiments, the press member may also have an at least partially plate-like shape, in particular a rectangular plate-like shape, which allows for cost-effective manufacturing and allows corner areas of the plate-shaped press member 6d to be used for attachment to the intermediate linear guide assembly 14. Thus, in some exemplary embodiments, the toggle press 6a may be referred to as a three-platen press.

[0164] The toggle press 6a is mainly used for horizontal D H The pressing direction of the pressing member 6d is arranged or oriented in the horizontal direction D Hmeans in this case that the pressing direction is closer to the horizontal than to the vertical, i.e. less than 45 degrees. In particular, the toggle press 6a may be installed or arranged to be installed with the pressing direction of the pressing members 6d arranged within 20 degrees of the horizontal, more preferably with the pressing direction parallel to the horizontal.

[0165] The toggle press 6a is, for example, as shown in Figs. 1a-1b, 3a, and 4a-4b, arranged horizontally, with the pressing direction D of the pressing member 6d. P 6a-6b, however, a beneficial aspect is obtained in that, in some circumstances, even if the toggle press 6a is mounted in a slightly inclined state, it allows for an overall compact design of the cellulose product forming unit U having a low construction height. Thus, the beneficial aspect of the cellulose product toggle press module 6 is that it is mainly mounted in the horizontal direction D H The pressing direction D of the pressing member 6d arranged in P That is, by the toggle press 6a arranged so as to have a vertical direction D V More horizontal than D H The pressing direction D of the pressing member 6d arranged in P In other words, the toggle press 6a may be arranged to have a pressing direction DP of the press member 6d arranged to have an installation angle 13 in the range of 0 to 44 degrees, in particular in the range of 0 to 20 degrees, in which case the aforementioned installation angle is the pressing direction D P and horizontal direction D H It is defined by:

[0166] Moreover, as shown in Figures 6a-6b, the beneficial aspect of allowing an overall compact design and low construction height of the cellulose product forming unit U is obtained both when the rear structure 6c of the toggle press 6a is positioned higher than the front structure 6b of the toggle press, as shown in Figure 6a, and when the front structure 6b of the toggle press 6a is positioned higher than the rear structure 6c of the toggle press, as shown in Figure 6b. By way of example only, in Figure 6a, the power supply 39 for the press actuator assembly 6f is shown mounted below the support frame 38, and in Figure 6b, for example, the product removal assembly 48 is shown mounted below the support frame 38.

[0167] In some exemplary embodiments, the toggle press 6a further includes a feeder 16 for intermittently feeding the air-formed cellulose blank structure 2 into the press area 15 located between the first mold part 3a and the second mold part 3b, in which case the feeder 16 is arranged to feed the air-formed cellulose blank structure 2 primarily vertically downward into the press area 15, in particular to feed the air-formed cellulose blank structure 2 downward into the press area 15 at a feed angle 49 of less than 20 degrees from the vertical, and more preferably to feed the air-formed cellulose blank structure vertically downward into the press area 15.

[0168] As mentioned above, the expression mainly vertically means in this case feeding the blank structures in a direction that is more vertically disposed than horizontally. In other words, the linear portion of the feeding device 16 is oriented to define an angle 47 with the vertical in the range of 0 to 44 degrees, in particular 0 to 20 degrees. The feeding device 16 may therefore be considered to be mainly disposed above the mould 3.

[0169] Furthermore, the pressing direction D P But mainly horizontal D HAs a result of the horizontal arrangement of the press module 6, such that the press module 6 is oriented in the direction perpendicular to the axis of the press module 6, the plane defined by the interiors of the first and second mold parts 3a, 3b, typically substantially flat sides, is mainly oriented in the vertical direction D. V That is, in the vertical direction D V with respect to the pressing surface of the press cavity.

[0170] According to some exemplary embodiments, the feeding device 16 for feeding the air-formed cellulosic blank structure 2 into the press area 15 may include a motor-driven feed roller or a pair of motor-driven feed rollers, or an elongated vacuum belt feeder or an elongated tractor belt feeder, or the like, and is fed in a manner that is primarily directed in a vertical direction D V Especially in the vertical direction D V More preferably, the vertical direction D V 2 and 3. The feed direction is generally parallel to the feed direction of the feed nozzle 10.

[0171] The toggle mechanism 6e of the toggle press 6a may have a wide variety of designs and implementations. The basic requirement of the toggle mechanism 6e is to generate a press force amplification, which allows the use of a relatively low-cost and low-volume press actuator assembly 6f in terms of press force. The press force amplification is achieved by a corresponding reduction in the press speed of the press module. Thus, the toggle mechanism 6e amplifies the press force / decreases the press speed compared to the force / speed of the press actuator assembly 6f.

[0172] Generally, with reference to the exemplary embodiments of Figures 1a-1b, 3a and 4a-4b, the toggle mechanism 6e has a first link member 18 and a second link member 19, and the press actuator assembly 6f is drivingly connected, directly or indirectly, to the first or second link members 18, 19 such that actuation of the press actuator assembly 6f results in movement of the press member 6d.

[0173] More specifically, the toggle mechanism 6e, in some exemplary embodiments, may include a first link member 18 and a second link member 19 having first and second pivot connections 18a, 18b, 19a, 19b, respectively, where the first pivot connection 18a of the first link member 18 is pivotally connected to the rear structure 6c, the first pivot connection 19a of the second link member 19 is pivotally connected to the press member 6d, and the second pivot connection 18b of the first link member 18 is pivotally connected to the second pivot connection 19b of the second link member 19, and the press actuator assembly 6f is directly or indirectly drivingly connected to the first or second link member 18, 19 to adjust the alignment level between the first link member 18 and the second link member 19 such that the press member 6d is moved as a result of actuation of the press actuator assembly 5f.

[0174] The fact that the second pivot connection portion 18b of the first link member 18 is pivotally connected to the second pivot connection portion 19b of the second link member 19 means that the second pivot connection portion 18b of the first link member 18 is the same as the second pivot connection portion 19b of the second link member 19.

[0175] The effect of adjusting the alignment level between the first link member 18 and the second link member 19 is shown in Figures 4a-b. The alignment between the first link member 18 and the second link member 19 is determined by an alignment angle 22 defined by the longitudinal directions of the first and second link members 18, 19, as can be seen in the side views according to Figures 4a and 4b, where the longitudinal direction 18d of the first link member 18 is defined by a straight line passing through the first and second pivot connections 18a, 18b of the first link member 18 and the longitudinal direction 19d of the second link member 19 is defined by a straight line passing through the first and second pivot connections 19a, 19b of the second link member 19.

[0176] In FIG. 4b, the alignment angle 22 is 180 degrees, which corresponds to the alignment of the first link member 18 with respect to the second link member 19. Such an operating position of the toggle mechanism 6e may also be referred to as a force balance position. The force balance position is a position where all forces are in balance and the force actions cancel each other out. In other words, in the force balance position, the force required by the press actuator assembly 6f is equal to zero.

[0177] In some exemplary embodiments, depending on the particular design of the toggle mechanism 6e, the aforementioned pressing action includes controlling the press actuator assembly 6f to set the toggle mechanism 6e in the aforementioned force balanced position.

[0178] In some exemplary embodiments of toggle mechanism design, such as those shown in Figures 4a and 4b, the force equilibrium position corresponds to the maximum extended operating position of the toggle mechanism 6e.

[0179] The toggle mechanism 6e shown in the exemplary embodiment of Figures 4a-b can also be referred to as a five-point double toggle mechanism, meaning that there are provided two separate toggle mechanisms arranged side-by-side to provide a better press force distribution on the press member 6d, each of said two separate toggle mechanisms having five pivot points.

[0180] In particular, in the exemplary embodiment of Figures 4a-4b, the press actuator assembly 6f is drivingly connected to a single crosshead 20, and the crosshead link member 21 has a first connection portion 21a pivotally connected to the crosshead 20 and a second connection portion 21b pivotally connected to a third pivot connection portion 18c of the first link member 18.

[0181] In other words, the toggle mechanism 6e of the exemplary embodiment of Figures 4a-4b has a single crosshead that drives first and second separate toggle mechanisms arranged alongside one another, the first and second toggle mechanisms each comprising a first link member 18, a second link member 19 and a crosshead link member 21, where the first link member 18 is pivotally connected to the second link member 19 and the rear structure 6c, the second link member 19 is pivotally connected to the press member 6d and the crosshead link member 21 is pivotally connected to the first link member 18 and the crosshead 20.

[0182] Several alternative designs of the toggle mechanism 6e are possible within the scope of the present disclosure. For example, the crosshead link member 21 may be pivotally connected to the second link member 19 and the crosshead 20. Furthermore, the second and third pivot connections 18b, 18c of the first link member 18 may alternatively be a common pivot connection.

[0183] Additionally, as shown in FIG. 6a, the toggle mechanism 6e may be a three point single toggle mechanism having a first link member 18 pivotally connected to a second link member 19 which is also pivotally connected to the rear structure 6c and the second link member 19 is pivotally connected to the front structure 6d, and a press actuator assembly 6f is drivingly connected, directly or indirectly, to the first or second link members 18, 19 such that actuation of the press actuator assembly 6f results in movement of the press member 6d.

[0184] Moreover, a further exemplary design of the toggle mechanism 6e is shown diagrammatically in Fig. 7a, which shows a three-point double toggle mechanism, i.e. two three-point single toggle mechanisms as described with reference to Fig. 6a, comprising a press or pull actuator assembly 6f which is directly or indirectly drivingly connected to the first and / or second link members 18, 19 of both said single toggle mechanisms. Furthermore, in this exemplary embodiment, an electric servo motor is shown as the actuator assembly 6f.

[0185] According to a further exemplary embodiment, the toggle mechanism 6e as shown diagrammatically in FIG. 7b comprises a three-point double toggle mechanism, i.e. two three-point single toggle mechanisms as described with reference to FIG. 6a, but in this case the two single toggle mechanisms operate in opposite directions and are provided with an actuator assembly 6f between the two toggle mechanisms which is directly or indirectly drivingly connected to the first and / or second link members 18, 19 of both said single toggle mechanisms.

[0186] 3a and 4a-4b, in some exemplary embodiments, the toggle press 6a further comprises: a press force indication assembly 6g, an adjustment mechanism 23 capable of adjusting the distance between the first mold part 3a and the second mold part 3b in the press direction when the toggle mechanism 6e is in a non-movement operating state, and an adjustment actuator assembly 25 configured to drive the adjustment mechanism 23, where the electronic control system 6h is operably connected to the press force indication assembly 6g and configured to control the operation of the adjustment actuator assembly 25 based on feedback information indicative of the press force received from the press force indication assembly 6g.

[0187] For example, the mechanical adjustment mechanism 23 may have four gears 26a-26d, each having internal threads for threaded attachment to a corresponding threaded end of a tie bar of the linear guide assembly 14, and each gear 26a-26d having an external gear tooth arrangement so as to be driven by one or more motors of the adjustment actuator assembly 25.

[0188] For example, as shown in Figures 3a and 4a-b, each of the four aforementioned gears 26a-26d of the mechanical adjustment mechanism 23 may be connected to and driven by a single central gear 27 powered by a single motor of the adjustment actuator assembly 25.

[0189] The mechanical adjustment mechanism 23 changes the distance 24 between the front structure 6b and the rear structure 6c in the pressing direction in order to allow adjustment of the distance between the first and second mould parts 3a, 3b when the toggle mechanism 6e is in a non-moving operating state by the operation of the adjustment actuator assembly 25. This means that the adjustment of the aforementioned distance is not performed by the movement of the toggle mechanism, but rather by the change in the distance between the front structure 6b and the rear structure 6c.

[0190] In the exemplary embodiment of Figures 3a and 4a-4b, operation of the mechanical adjustment mechanism 23 displaces the rear structure 6c relative to the linear guide assembly 14 to change the distance 24 between the front structure 6b and the rear structure 6c.

[0191] Alternatively, operation of the mechanical adjustment mechanism 23 displaces the front structure 6b relative to the linear guide assembly 14 to vary the distance 24 between the front structure 6b and the rear structure 6c.

[0192] The electronic control system 6h is typically configured to control operation of the adjustment actuator assembly 25 to adjust the distance between the first and second die parts 3a, 3b during the period between successive press operations with the goal that the press member 6d provides a compression force closer to the predetermined target press force during the next press cycle.

[0193] Figure 5 shows diagrammatically the main process steps of the press module 6 during normal operation. The flowchart of the press operation usually starts with the press members at rest in a waiting position S associated with a retracted toggle mechanism and an open press mould 3, as shown diagrammatically in Figure 4a. Upon receipt of a command or instruction to start the press cycle, a second step F of the flowchart is performed, which comprises activating the press actuator assembly 6f to push the press member 6d forward F until the mould 3 is closed and a moulding pressure of about 1-100 MPa, in particular 4-20 MPa, is applied to the cellulose blank structure in a third step P of the main process. Thereafter, a fourth step R of the flowchart is performed, which comprises the initiation of a return movement of the press member 6d to the start position, i.e. to the waiting position S.

[0194] In case of high speed production, the process may skip step S, ie, skip returning completely to the waiting position S before starting again with the second step F of the flowchart.

[0195] As used herein, the term maximum stroke condition, also referred to as the "maximum extended operating position", refers herein to the maximum forward position obtained by the toggle mechanism when unobstructed by a mold, cellulosic blank structure or other part, for example, the alignment of the first and second link members 18, 19 as shown in FIG. 4b.

[0196] In some exemplary embodiments, each of the first and second mould parts 3a, 3b has a rigid plate-shaped main body with a typically substantially flat surface arranged to face the other mould part and at least one pressing surface 3c, 3d defining one or more moulding cavities C for moulding the cellulose products 1, with or without additional sub-components, such as spring-loaded cutting devices and / or mould alignment devices, in which case the aforementioned substantially flat surfaces of the rigid plate-shaped main bodies of the first and second mould parts 3a, 3b are not in direct contact with each other during the pressing cycle. Thus, the aforementioned surfaces of the rigid plate-shaped main bodies are not intended to come into contact with each other and are not intended to prevent further pressing movements of the first and second mould parts 3a, 3b. However, other parts of the first and second mold parts 3a, 3b that are not parts of the aforementioned surfaces of the first and second mold parts 3a, 3b, such as the spring-loaded cutting device and / or the mold alignment device, may still be in contact with each other during the pressing operation.

[0197] Figures 8a-8b show diagrammatically how the toggle press 6a can be adjusted using the mechanical adjustment mechanism 23 to obtain different levels of press force in the maximum extended working position, Figure 8c shows what occurs when the distance between the front structure 6b and the rear structure 6c is too small, and Figure 9 shows a schematic diagram of the press force resulting for each of these situations. The vertical axis in the graph of Figure 9 shows the press force provided by the toggle press 6a, and the horizontal axis in the graph of Figure 9 shows the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a. When the distance 24 between the front and rear structures 6b and the rear structure 6c is relatively short, the first and second link members of the toggle mechanism are still misaligned when the maximum pressing capacity of the toggle press 6a is reached, and when the distance 24 between the front and rear structures 6b and the rear structure 6c is relatively large, the first and second link members of the toggle mechanism easily reach an aligned position, but no large pressing force is generated at this position because a relatively large die gap 53 remains in the forming die 3.

[0198] In Figure 8a, the distance 24 between the front structure 6b and the rear structure 6c is adjusted to be relatively long, which provides a relatively low press force when the press plate 6d reaches its maximum extended operating position. In this exemplary embodiment, the maximum extended operating position of the toggle mechanism 6e is achieved when the first and second link members 18, 19 are aligned. The resulting press force at this adjusted position of the mechanical adjustment mechanism 23 is shown in Figure 9 as point A.

[0199] In Figure 8b, the distance 24 between the front structure 6b and the rear structure 6c is reduced, thereby providing a relatively high press force when the press plate 6d reaches its maximum extended operating position. The resulting press force in this adjustment position of the mechanical adjustment mechanism 23 is shown in Figure 9 as point B.

[0200] If the distance 24 between the front structure 6b and the rear structure 6c is adjusted to be too short, the toggle mechanism 6e may be prevented from reaching a force equilibrium position, i.e., the first and second link members 18, 19 are in a misaligned position, as shown in Figure 8c. The resulting pressing force in this adjusted position of the mechanical adjustment mechanism 23 is shown in Figure 9 as point C.

[0201] The pressing action of the press module 6 may be performed in a variety of ways. For example, the toggle press 6a may be operated in an open loop manner, without feedback of parameters such as press force or press member position.

[0202] An exemplary embodiment of a control system 40 suitable for controlling the toggle press 6a in an open-loop manner is shown diagrammatically in FIG. 10a. In this exemplary embodiment, the press actuator assembly 6f is a hydraulic cylinder fluidly controlled by a variable displacement hydraulic pump 42 and a solenoid-operated directional control valve 41 fluidly connected to a fluid tank 43. Furthermore, a feed device 16, in this case in the form of an electric motor, is provided to control the movement of the forming wire 4c, and a press member position detection device 44 is provided to ensure that at each pressing event, the press member is operated to reach the maximum forward position of the toggle mechanism 6e. The operating state of the directional control valve 41 as well as the control of the speed of the feed device 16 may be controlled by an electronic control system 6h to provide the desired intermittent supply of the forming wire 4c between successive pressing operations of the toggle press 6a.

[0203] The press member position detection assembly may be, for example, a linear position encoder configured to detect the position of the press member 6d, or a position encoder for detecting the actuation position of the toggle mechanism 6e, or a position encoder for detecting the actuation position of the press actuator assembly 6f, etc.

[0204] According to an alternative control scheme, the control system 40 may be configured to control the toggle press 6a in a closed loop manner, as shown diagrammatically in FIG. 10b. According to such a control scheme, the press actuator assembly 6f may be controlled to simply displace the press member 6d to a maximum forward position, i.e., to a 180 degree alignment angle or maximum stroke state of the toggle mechanism 6e, and to pre-adjust the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a so that the resulting press force is equal to the target press force. The electronic control system 6h may be configured to control the press operation based on feedback data from the press force detection or indication assembly, and to adjust the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a between successive press operations so that the resulting press force is maintained at the target press force. Thus, variations in the process parameters may be better addressed to ensure an improved quality of the cellulose product 1.

[0205] In addition to the features described with reference to Fig. 10a, Fig. 10b shows an adjustment actuator assembly 25 configured to drive the mechanical adjustment mechanism 23. The adjustment actuator assembly 25 may be, for example, an electric or hydraulic motor. Furthermore, the system of Fig. 10b additionally shows a press force detection device 6g for providing feedback to the electronic control system 6h.

[0206] Thus, in some exemplary embodiments, the toggle press 6a further includes a press force indication assembly 6g, where the electronic control system 6h is operatively connected to the press force indication assembly 6g and configured to control operation of the press actuator assembly 6f based on feedback information indicative of the press force received from the press force indication assembly 6g.

[0207] The press force indicating assembly 6g typically includes some form of measurement device for measuring the level of the press force parameter. Thus, the feedback information indicative of the press force typically includes or is derived from a measured process variable of the toggle press 6a.

[0208] Operational control of the press actuator assembly 6f based on feedback information indicative of the press force received from the press force indication assembly 6g may include, for example, press force feedback control, position feedback control, or open loop control with automatic self-adjustment between successive press cycles.

[0209] The press force indicating assembly may correspond, for example, to one or more press force sensors of some type located at one or more suitable locations in the press module 6. For example, a load cell, such as a strain gauge force sensor, may be provided on or in the mold 3, or between the toggle mechanism 6e and the rear structure 6c, or between the toggle mechanism 6e and the mold 6.

[0210] Alternatively, or in combination with the above, the press force indicating assembly may correspond to a deformation sensor, for example a strain gauge sensor configured to detect deformation of one, two or all tie bars of the intermediate linear guide assembly 14. Alternatively, a deformation sensor such as a strain gauge sensor, a laser sensor or the like may be provided to detect deformation of the front structure 6b, or the rear structure 6c, or the press member 6d, or the toggle mechanism 6e.

[0211] The electronic control system may be configured in some embodiments to control the adjustment actuator assembly 25 to adjust, for example, the maximum press force of the toggle press for a particular cellulosic blank construction.

[0212] Thus, the toggle press may have a press force indication assembly 6g, and an electronic control system 6h may be operatively connected to the press force indication assembly 6g, the control system being configured to control operation of the adjustment actuator assembly based on feedback information indicative of the press force received from the press force indication assembly 6g to adjust the distance between the front structure and the rear structure in the press direction during periods between successive press operations. As a result, the electronic control system may adjust the maximum press force.

[0213] This may be done, for example, by receiving feedback information indicative of the press force from the press force indication assembly 6g during the first press cycle, determining whether adjustment of the current operating position of the toggle press, i.e. the distance 24 between the front structure 6b and the rear structure 6c, is appropriate, and if not, adjusting the distance 24 between the front structure 6b and the rear structure 6c by appropriate operation of the adjustment actuator assembly 25 such that the operating position and / or press force during the next press cycle more closely matches the target operating position and / or target press force. In other words, the electronic control system does not require active control and adjustment of the force input to the toggle mechanism 6e provided by the press actuator assembly 6f to adapt the press force of the press member 6d, but instead may rely solely on active control of the adjustment actuator assembly 25.

[0214] This control scheme may be implemented by adjusting the distance 24 between the front structure 6b and the rear structure 6c such that the toggle press module 6 reaches the target press force at the same time that the toggle mechanism 6e reaches the maximum stroke state. In other words, the electronic control system is configured to obtain information indicative of the press force from the press force display assembly 6g during the above-mentioned normal operation press operation of the toggle press 6a, and, for example, if the information indicative of the press force indicates that the press force PF continues to exceed the target press force over a series of press cycles, adjust the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a during the continued press operation such that the resulting press force is equal to the target press force.

[0215] According to alternative exemplary embodiments of the product forming unit U of the present disclosure, various aspects of the product forming unit U may have other designs, functionality, and / or layouts, as shown generally in FIG.

[0216] For example, the forming wire 4c may extend all the way to the press module 6, so that an intermediate conveying device 16 is effectively not required.

[0217] Furthermore, the forming section 4d of the forming wire 4c is H The cellulose blank structure 2 may be arranged to extend in a horizontal direction D from the forming section 4d by the forming wire 4c in this embodiment. H After the cellulose blank structure 2 is formed on the forming section 4d, the formed cellulose blank structure 2 is conveyed from the forming section 4d in the horizontal direction D H Then, it is transported further towards the press module 6.

[0218] Furthermore, the blank dry-forming module 4 of the embodiment shown in Fig. 11 has a vertical distribution direction of the cellulose fibers F from the mill 4a through the forming chamber 4b to the forming wire 4c. Thus, a vertical flow of air feeds the cellulose fibers F from the mill 4a to the forming section 4d.

[0219] Furthermore, the toggle press 6a is V The pressing direction D of the pressing member 6d arranged in P The sensor is set up so as to have

[0220] The use of a toggle press module to form non-flat cellulosic products from air-formed cellulosic blank structures has many advantages over the use of conventional high-volume hydraulic presses without toggles, such as low cost, low weight, fast cycling, and compactness. Thus, the toggle press module 6 may be a convenient alternative to conventional vertically mounted hydraulic presses in certain circumstances.

[0221] The toggle press module 6 shown diagrammatically in Figures 12a-b corresponds to the toggle press module 6 described above with reference to Figures 4a-b, and for details of the toggle press module 6 reference is made to the disclosure relating to Figures 4a-b, with the exception of the press actuator assembly 6f, which in this case is diagrammatically shown as a motorized ball screw linear actuator. The ball screw linear actuator may for example comprise a rod 50 with a helical track for holding a rolling ball which can circulate in a track in the crosshead 20, drivingly connected to an electric motor.

[0222] The basic steps of the method for forming a non-flat cellulose product from an air-formed cellulose blank structure in a product forming unit U are described below with reference to Fig. 13. The product forming unit U comprises a blank dry-forming module 4 with a movable forming wire 4c, a toggle press module 6 with a toggle press 6a and a forming die 3, and an electronic control system 6h operatively connected to the forming wire 4c and the toggle press module 6; the toggle press 6a comprises a press member 6d movably arranged in a pressing direction, a toggle mechanism 6e drivingly connected to the press member 6d, a press actuator assembly 6f drivingly connected to the toggle mechanism 6e; and in this case the forming die 3 comprises a movable first die part 3a attached to the press member 6d and a second die part 3b. The method comprises a first step S1 of air-forming a cellulose blank structure 2 on the forming wire 4c by the blank dry-forming module 4. The method further includes a second step S2 of feeding the air-formed cellulose blank structure 2 into a press area defined by the spaced apart first and second mould parts 3a, 3b. The method further includes a third step S3 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h to perform a pressing operation including driving the press member 6d in a pressing direction by a toggle mechanism 6e, thereby forcing the first mould part 3a against the second mould part 3b, thereby forming a non-flat cellulose product from the air-formed cellulose blank structure. Finally, the method includes a fourth step S4 of controlling the operation of the forming wire 4c by the electronic control system 6h to feed the forming wire 4c intermittently between successive pressing operations.

[0223] The aforementioned fourth step S4 of controlling the operation of the press actuator assembly 6f may be performed in a number of different ways while still solving the problem of forming a non-flat cellulose product from an air-formed cellulose blank structure using a low-cost, compact and low-weight cellulose product press module.

[0224] 14, according to some exemplary embodiments, the toggle press 6a further comprises a press force indication assembly 6g, an adjustment mechanism 23 capable of adjusting the distance between the first die part 3a and the second die part 3b in the press direction when the toggle mechanism 6e is in a non-movement operating state, and an adjustment actuator assembly 25 configured to drive the adjustment mechanism 23. In this case, in addition to steps S1 to S4 described with reference to FIG. 13, the method further comprises a fifth step S5 of controlling the operation of the adjustment actuator assembly 25 based on feedback information indicative of the press force received from the press force indication assembly 6g.

[0225] In particular, the fifth step S5 of controlling the operation of the adjustment actuator assembly 25 may include adjusting the distance between the first and second mold parts 3a, 3b during the period between successive press operations so as to target the press member 6d during the next press cycle to provide a compression force closer to the predetermined target press force.

[0226] The feedback controller 6h can be implemented in various alternative ways known to those skilled in the art, such as a P controller, a PI controller, a PID controller, optimal control such as a Linear Quadratic (LQ) controller, etc.

[0227] For example, a PID (Proportional-Integral-Derivative) controller is a control loop mechanism that uses feedback to provide a continuously modulated control of the process to be controlled. A feedback controller, such as a PID controller, continuously calculates an error value as the difference between a target set point (SP) and a measured process variable (PV) and applies a correction based on the proportional, integral and derivative terms of said error value. The set point (SP) may be, for example, a specific predefined compression force and the measured process variable (PV) may be, for example, measured as a press force detected by a strain gauge force sensor located on the tie bar 37 of the toggle press 6a.

[0228] The cellulosic toggle press module 6 according to the present disclosure can be extremely beneficial for forming a non-flat cellulosic product 1 from an air-formed cellulosic blank structure 2 even without the intermittent operating process of the forming wire 4c of the blank dry-forming module 4. Thus, in a cellulosic toggle press module having a buffer disposed between the blank dry-forming module 4 and the press module 6, where the blank dry-forming module 4 and the associated forming wire 4c operate continuously at a more or less constant operating speed, the cellulosic toggle press module according to the present disclosure can still provide various advantageous aspects such as compactness, cost-effectiveness, and rapid operating cycle.

[0229] This is provided, for example, by a cellulose product toggle press module 6 for forming a non-flat cellulose product 1 from an air-formed cellulose blank structure 2, the toggle press module 6 having a toggle press 6a including a press member 6d arranged movably in a press direction, a toggle mechanism 6e drivingly connected to the press member 6d, and a press actuator assembly 6f drivingly connected to the toggle mechanism 6e for controlling the movement of the toggle mechanism between a retracted operating position and an extended operating position. The toggle press module 6 further comprises a forming mold 3 including a movable first mold part 3a and a second mold part 3b attached to the press member 6d, as well as an adjustment mechanism 23 capable of adjusting the distance between the first mold part 3a and the second mold part 3b in the press direction when the toggle mechanism 6e is in a non-moving operating state, and an adjustment actuator assembly 25 configured to drive the adjustment mechanism 23. The toggle press module 6 further comprises a press force indication assembly 6g and an electronic control system 6h operably connected to the press force indication assembly 6g, the press actuator assembly 6f, and the adjustment actuator assembly 25. The electronic control system 6h is configured to control operation of the press actuator assembly 6f to drive the press member 6d in a press direction by setting the toggle mechanism 6e in an extended operating position, thereby forcing the first mold part 3a against the second mold part 3b to form a non-flat cellulose product from the air-formed cellulose blank structure, and the electronic control system is configured to control operation of the adjustment actuator assembly 25 based on feedback information indicative of the press force received from the press force indication assembly 6g.

[0230] The disclosure also includes a corresponding method for forming a non-flat cellulose product from an air-formed cellulose blank structure in a toggle press module 6. The toggle press module 6 has: a toggle press 6a including a press member 6d movably arranged in a press direction, a toggle mechanism 6e drivingly connected to the press member 6d, and a press actuator assembly 6f drivingly connected to the toggle mechanism 6e for controlling the movement of the toggle mechanism between a retracted operating position and an extended operating position; a mold 3 including a movable first mold part 3a and a second mold part 3b attached to the press member 6d; an adjustment mechanism 23 capable of adjusting the distance between the first mold part 3a and the second mold part 3b in the press direction when the toggle mechanism 6e is in a non-moving operating state; an adjustment actuator assembly 25 configured to drive the adjustment mechanism 23; a press force indication assembly 6g; and an electronic control system 6h operably connected to the press force indication assembly 6g, the press actuator assembly 6f, and the adjustment actuator assembly 25. The method includes the steps of: air-forming a cellulose blank structure 2 onto a forming wire 4c by a blank dry-forming module 4; feeding the air-formed cellulose blank structure 2 into a press area defined by spaced apart first and second mold parts 3a, 3b; controlling the operation of a press actuator assembly 6f to perform a pressing operation including driving a press member 6d in a pressing direction by setting a toggle mechanism 6e to an extended operating position, thereby forcing the first mold part 3a against the second mold part 3b, thereby forming a non-flat cellulose product from the air-formed cellulose blank structure; and controlling the operation of an adjustment actuator assembly 25 based on feedback information indicative of the pressing force received from a press force indication assembly 6g.

[0231] Adjusting the distance between the first and second mold parts 3a, 3b in the pressing direction when the toggle mechanism 6e is in a non-moving operating state means that this adjustment is not caused by the movement of the toggle mechanism but is achieved by some other means.

[0232] Additionally, the step of controlling operation of the press actuator assembly to drive the press members in the pressing direction by setting the toggle mechanism in an extended operating position generally includes setting the toggle mechanism in a maximum extended operating position.

[0233] It will be understood that the above description is merely exemplary in nature and is not intended to limit the application or uses of the present disclosure. While specific examples have been described in the specification and shown in the drawings, those skilled in the art will appreciate that various changes may be made and equivalents may be substituted for the elements without departing from the scope of the present disclosure as defined in the claims. In addition, features of the exemplary embodiments described herein may be combined with other exemplary embodiments described herein. Furthermore, modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its essential scope. Thus, the present disclosure is not limited to the specific examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but the scope of the present disclosure will include any embodiment that falls within the scope of the foregoing description and the appended claims. Reference signs in the claims should not be construed as limiting the scope of the subject matter protected by the claims, and their sole function is to facilitate comprehension of the claims. [Explanation of symbols]

[0234] 1. Cellulose products 2. Cellulose blank structure 2c remaining part 3 Molding mold 3a First mold part 3b Second mold part 4 Blank dry forming module 4a Mill 4b Molding chamber 4c Formed Wire 4d Molded Section 4e Molding chamber opening 5. Driving motor for forming wire 6 Press Module 6a Toggle Press 6b Front structure 6c Posterior structure 6d Press member 6e Toggle mechanism 6f Press Actuator Assembly 6g Press Force Display Assembly 6h Electronic Control System 7 Blank Recycle Module 7a Supply structure 9 Blank Supply Roll 10 Actuator 11 Intermediate roll 13 Toggle press installation angle 14 Linear Guide Assembly 15 Press Area 16 Feeding device 17 Extension direction of supply device 18 First link member 19 Second link member 20 Crosshead 21 Crosshead link member 22 Alignment angle 23 Mechanical Adjustment Mechanism 24 Distance between front and rear structure 25 Adjustment Actuator Assembly 26a~26d Gears 27 Single central gear 28 Maximum press force curve 29 Mold gap 30 Operational Window 31 Central press force vs. die gap curve 32 Right side press force vs die gap curve 33 Press force vs. die gap curve on the left 34 First Arrow 35 Asymptotic region 36 Second Arrow 37 Tie bar 38 Support frame 39 Power supply 40 Control System 41 Valve 42 Pump 43 Tank 44 Position detection device 46 First press force vs. die gap curve 47 Second press force vs die gap curve 48 Ejection Assembly 49 Feeding angle 50 Threaded Rod 51 Buffer Assembly 53 Mold gap 54a First individual toggle mechanism 54b Second individual toggle mechanism 55 Stepped decrease C Molding Cavity D F1 First feed direction D F2 Second feed direction D P Press Direction D U Upward blank forming direction D H horizontal direction D V vertical direction E Transformation Element F fiber M CONT Continuous Flow Mode M F Supply Mode M INT Intermittent Flow Mode N Example maximum pressing force PF Press Force PF T Target Press Force R Cellulose raw material T F Molding temperature U Product Forming Unit V I Input speed V O Output Speed

Claims

1. A product forming unit (U) for producing a non-flat cellulose product (1) from an air-formed cellulose blank structure (2), comprising: The product forming unit (U) comprises a blank dry forming module (4) with a movable forming wire (4c), a toggle press module (6) with a toggle press (6a) and a forming die (3), and an electronic control system (6h) operatively connected to the forming wire (4c) and the toggle press (6a); said blank dry forming module (4) configured to air form said cellulose blank structure (2) onto said forming wire (4c); The toggle press (6a) includes a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to the press member (6d), and a press actuator assembly (6f) drivingly connected to the toggle mechanism (6e); The mold (3) has a movable first mold part (3a) attached to the pressing member (6d) and a second mold part (3b); the electronic control system (6h) is configured to control operation of the press actuator assembly (6f) to perform a pressing operation including driving the press member (6d) in a pressing direction by the toggle mechanism (6e) and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by forcing the first die part (3a) against the second die part (3b); The electronic control system (6h) is further configured to intermittently feed the forming wire (4c) between successive pressing operations. Product forming unit (U).

2. 2. The product-forming unit (U) according to claim 1, wherein the toggle press (6a) is installed or arranged to be installed with a pressing direction of the press members (6d) arranged mainly horizontally.

3. Said toggle press (6a) further comprises: Press force display assembly (6g), an adjustment mechanism (23) capable of adjusting the distance between the first mould part (3a) and the second mould part (3b) in the pressing direction when the toggle mechanism (6e) is in a non-moving operating state; and an adjustment actuator assembly (25) configured to drive said adjustment mechanism (23); It has The electronic control system (6h) is operatively connected to the press force indication assembly (6g) and configured to control operation of the adjustment actuator assembly (25) based on feedback information indicative of the press force received from the press force indication assembly (6g). A product forming unit (U) according to claim 1 or 2.

4. 4. The product forming unit (U) of claim 3, wherein the electronic control system (6h) is configured to control operation of the adjustment actuator assembly (25) to adjust the distance between the first mould part (3a) and the second mould part (3b) during periods between successive press operations with the goal that the press members (6d) will provide a compression force closer to a predetermined target press force during a next press cycle.

5. 4. The product forming unit (U) according to claim 3, wherein the press force indication assembly (6g) comprises one or more of the following sensors: a load cell, a deformation sensor, or a strain gauge force sensor, the one or more sensors being arranged on or in the mold (3), on the toggle mechanism (6e), between the toggle mechanism (6e) and a rear structure (6c) of a rigid frame structure of the toggle press (6a), between the toggle mechanism (6e) and the mold (6), on the rigid frame structure of the toggle press (6a), or on a tie bar of an intermediate linear guide assembly (14) of the toggle press (6a).

6. 3. The product forming unit (U) according to claim 1 or 2, wherein the blank dry-forming module (4) further comprises a mill (4a) and a forming chamber (4b), the forming wire (4c) being connected and arranged to the forming chamber (4b), the mill (4a) being configured to separate fibers (F) from the cellulose raw material (R), and the forming chamber (4b) being configured to distribute the separated fibers (F) onto the forming section (4d) of the forming wire (4c) for forming the cellulose blank structure (2).

7. The product forming unit (U) according to claim 1 or 2, further comprising a cellulose blank supply device (16), in particular a conveyor belt and / or a set of supply rollers, configured to transport the air-formed cellulose blank structure (2) from the forming wire (4c) of the blank dry-forming module (4) to the forming mold (3) of the toggle press module (6), in which case the electronic control system (6h) is configured to provide substantially synchronized operation of the forming wire (4c) and the cellulose blank supply device (16).

8. The product forming unit (U) according to claim 1 or 2, wherein the forming mold (3) is configured to form the cellulose product (1) from the cellulose blank structure (2) by heating the cellulose blank structure (2) to a forming temperature in the range of 100 to 300°C and pressing the cellulose blank structure (2) at a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa.

9. 3. The product forming unit (U) according to claim 1 or 2, further comprising a blank recycling module (7) configured to transport a remaining portion of the cellulose blank structure from the toggle press module (6) to the blank dry-forming module (4).

10. 3. The product forming unit (U) according to claim 1 or 2, wherein the product forming unit (U) is adapted to intermittently feed the cellulose blank structure (2) from the blank dry-forming module (4) by the forming wire (4c) in a first feed direction and to intermittently feed the cellulose blank structure (2) to the toggle press module (6) in a second feed direction, wherein the second feed direction is different from the first feed direction, in particular the second feed direction is reverse or substantially reverse to the first feed direction.

11. 11. The product forming unit (U) of claim 10, wherein the first feed direction is an upward direction and the second feed direction is a downward direction.

12. A method for forming a non-flat cellulose product from an air-formed cellulose blank structure in a product forming unit (U), said product forming unit (U) having a blank dry-forming module (4) with a movable forming wire (4c), a toggle press module (6) with a toggle press (6a) and a forming die (3), and an electronic control system (6h) operatively connected to said forming wire (4c) and said toggle press module (6); The toggle press (6a) includes a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to the press member (6d), and a press actuator assembly (6f) drivingly connected to the toggle mechanism (6e); The mold (3) comprises a movable first mold part (3a) attached to the press member (6d) and a second mold part (3b). having The method comprises: air-forming a cellulose blank structure (2) onto said forming wire (4c) by said blank dry-forming module (4); feeding said air-formed cellulosic blank structure (2) into a press area defined by said spaced apart first and second mould parts (3a, 3b); controlling operation of the press actuator assembly (6f) by the electronic control system (6h) to perform a pressing operation including driving the press member (6d) in a pressing direction by the toggle mechanism (6e) and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by forcing the first mold part (3a) against the second mold part (3b); and controlling the movement of said forming wire (4c) by said electronic control system (6h) in order to feed said forming wire (4c) intermittently between successive pressing operations; A method comprising:

13. 13. The method of claim 12, further comprising controlling the movement of the forming wire (4c) by the electronic control system (6h) to intermittently feed the forming wire (4c) between successive pressing operations such that the forming wire (4c) operates periodically at a relatively high speed during periods between successive pressing operations and at a relatively low or zero speed during periods corresponding to the pressing operations.

14. 14. The method according to claim 12 or 13, wherein the toggle press (6a) further comprises a press force indication assembly (6g), an adjustment mechanism (23) capable of adjusting the distance between the first mould part (3a) and the second mould part (3b) in a pressing direction when the toggle mechanism (6e) is in a non-moving operating state, and an adjustment actuator assembly (25) configured to drive the adjustment mechanism (23), wherein the method further comprises the step of controlling an operation of the adjustment actuator assembly (25) based on feedback information indicative of the pressing force received from the press force indication assembly (6g).

15. 15. The method according to claim 14, further comprising the step of controlling operation of the adjustment actuator assembly (25) to adjust the distance between the first and second mould parts (3a, 3b) during the period between successive pressing operations with the aim that the press member (6d) will provide a compression force closer to a predetermined target press force during the next pressing cycle.

16. The step of air-molding the cellulose blank structure (2) from the cellulose raw material (R) in the blank dry-molding module (4) includes the steps of separating fibers (F) from the cellulose raw material (R) in a mill (4a), distributing the separated fibers (F) onto a forming wire (4c) of the blank dry-molding module (4) to form the cellulose blank structure (2), and feeding the formed cellulose blank structure (2) in an upward blank-molding direction (D). Ｕ 14. The method of claim 12 or 13, further comprising the step of:

17. The cellulose blank structure (2) is fed in a first feeding direction (D Ｆ１ ) by the forming wire (4c) from the blank dry forming module (4) and in a second feeding direction (D Ｆ２ ) to the toggle press module (6), in which the second feed direction (D Ｆ２ ) is the first supply direction (D Ｆ１ ) and in particular the second feed direction (D Ｆ２ ) is the first supply direction (D Ｆ１ 14. The method of claim 12 or 13, wherein the process is the reverse or substantially the reverse of

18. The method according to claim 12 or 13, wherein the step of forming the cellulose product (1) from the cellulose blank structure (2) in the forming mould (3) comprises heating the cellulose blank structure (2) to a forming temperature in the range of 100-300°C and pressing the cellulose blank structure (2) at a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.

19. A cellulosic product toggle press module (6) for forming a non-flat cellulosic product (1) from an air-formed cellulosic blank structure (2), the toggle press module (6) comprising: a toggle press (6a) including a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to said press member (6d), and a press actuator assembly (6f) drivingly connected to said toggle mechanism (6e) for controlling movement of said toggle mechanism between a retracted operating position and an extended operating position; a mold (3) including a movable first mold part (3a) attached to said pressing member (6d) and a second mold part (3b); an adjustment mechanism (23) capable of adjusting the distance between the first mould part (3a) and the second mould part (3b) in a pressing direction when the toggle mechanism (6e) is in a non-moving operating state, and an adjustment actuator assembly (25) configured to drive the adjustment mechanism (23); Press force display assembly (6g), an electronic control system (6h) operatively connected to said press force indication assembly (6g), said press actuator assembly (6f), and said adjustment actuator assembly (25); It has the electronic control system (6h) is configured to control operation of the press actuator assembly (6f) to drive the press member (6d) in a press direction by setting the toggle mechanism (6e) in the extended operating position, thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by forcing the first die part (3a) against the second die part (3b); and The electronic control system is configured to control the operation of the adjustment actuator assembly (25) based on feedback information indicative of the press force received from the press force indication assembly (6g). Cellulosic toggle press module (6).

20. 20. The cellulose toggle press module (6) of claim 19, wherein the electronic control system (6h) is configured to control operation of the adjustment actuator assembly (25) to adjust the distance between the first die part (3a) and the second die part (3b) during a period between successive press operations with the goal that the press members (6d) will provide a compression force closer to a predetermined target press force during a next press cycle.

21. 1. A method for forming a non-flat cellulosic product from an air-formed cellulosic blank structure in a toggle press module (6), comprising: a toggle press (6a) including a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to said press member (6d), and a press actuator assembly (6f) drivingly connected to said toggle mechanism (6e) for controlling movement of said toggle mechanism between a retracted operating position and an extended operating position; a mold (3) including a movable first mold part (3a) attached to said pressing member (6d) and a second mold part (3b); an adjustment mechanism (23) capable of adjusting the distance between the first mould part (3a) and the second mould part (3b) in a pressing direction when the toggle mechanism (6e) is in a non-moving operating state, and an adjustment actuator assembly (25) configured to drive the adjustment mechanism (23); Press force display assembly (6g), an electronic control system (6h) operatively connected to said press force indication assembly (6g), said press actuator assembly (6f), and said adjustment actuator assembly (25); It has The method comprises: pneumatically forming the cellulose blank structure (2) on a forming wire (4c) by a blank dry forming module (4); feeding said air-formed cellulosic blank structure (2) into a press area defined by said spaced apart first and second mould parts (3a, 3b); controlling operation of the press actuator assembly (6f) to perform a pressing operation including driving the press member (6d) in a pressing direction by setting the toggle mechanism (6e) in the extended operating position, thereby forcing the first mould part (3a) against the second mould part (3b) to form the non-flat cellulose product from the air-formed cellulose blank structure; controlling the operation of the adjustment actuator assembly (25) based on feedback information indicative of the pressing force received from the pressing force indication assembly (6g). A method comprising:

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