Method for dry forming a cellulose product from a cellulose blank structure in a product forming unit - Patents.com

Abstract

A method for dry forming a cellulose product (1) from a cellulose blank structure (2) in a product forming unit. The product forming unit comprises a blank dry forming module (4) and a press module (6). The cellulose blank structure (2) is air formed on a forming wire (4c) in the blank dry forming module (4). The press module (6) comprises one or more forming dies (3) for forming the cellulose product (1) from the cellulose blank structure in a pressing operation. The method includes the step of placing the forming wire in a stationary mode during the pressing operation.

Description

[Technical field]

[0001] The present disclosure relates to a method for dry forming a cellulose product from a cellulose blank structure in a product forming unit, the product forming unit having a blank dry forming module and a press module, the cellulose blank structure is air formed in the blank dry forming module, the press module having one or more molds for forming a cellulose product from the cellulose blank structure, the disclosure further relates to a product forming unit.

[0002] Background technology Cellulosic fibers are often used as raw materials 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, hangers, and packaging materials.

[0003] 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.

[0004] 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.

[0005] Product forming units are used in dry forming cellulose products and generally use a press module with a forming mould, to which other modules and components are arranged, such as a feed module and a blank dry forming module. Product forming units generally use high-capacity press modules, such as vertical hydraulic press units, which are used to form other materials, such as steel sheets, since it is usually necessary to establish a high product forming pressure in the mould. Blank dry forming modules are generally sourced from the hygiene industry, such as forming modules in diaper production units. The product forming units used take up a large amount of space in the production facility, due to the type of standard modules used and the large number of modules and components involved.

[0006] One drawback of using standard modules developed for other purposes is the engineering work required to integrate various modules from different industries into a product-forming unit for producing cellulose products from air-formed cellulose blank structures. Such projects typically take 6-12 months and may involve several man-years for each individual product-forming unit, and usually end up as custom-made industrial lines with low value for replication and scale-up. The integration of various modules into one product-forming unit consisting of separately purchased modules is a hurdle for many converters to move to dry forming. Therefore, there is a strong demand for a complete product-forming unit, all integrated and standardized, ready to buy, ship, install, and operate.

[0007] Therefore, there is a need for an improved method for producing cellulosic products from air-formed cellulosic blank structures in a product forming unit with a more compact layout and structure.

[0008] overview The object of the present disclosure is to provide a method and a product-forming unit for dry-forming a cellulose product from a cellulose blank structure in a product-forming unit, which avoids the above-mentioned problems. This object is at least partially achieved by the features of the independent claims. The dependent claims contain further developments of the method for dry-forming a cellulose product from a cellulose blank structure in a product-forming unit.

[0009] The present disclosure relates to a method for dry forming a cellulose product from a cellulose blank structure in a product forming unit, the product forming unit having a blank dry forming module and a press module, the cellulose blank structure being air formed on a forming wire in the blank dry forming module, the press module having one or more forming dies for forming a cellulose product from the cellulose blank structure in a press operation, the method including placing the forming wire in a stationary mode during the press operation.

[0010] The advantage of these features is that due to the modular structure of the product forming unit, a compact layout can be achieved. The stationary mode provides an efficient operation of the product forming unit and allows for a very compact layout since there is no need to buffer the cellulose blank structures between the blank dry forming module and the press module. In conventional configurations, a buffer module is used to feed the continuously formed cellulose blank structures from the blank dry forming module to the intermittently operating press module. The buffer module occupies a large amount of space in the product forming unit and the design with the stationary mode during the press operation allows the buffer module to be omitted. The blank dry forming module allows the cellulose blank structures to be formed in close connection to the press module without the need to pre-manufacture the cellulose blank structures. Furthermore, the operation of the product forming unit is more efficient due to the cellulose feedstock used as input material for the in-line production of the cellulose blank structures. During the press operation, one or more forming dies are operated to form the cellulose products from the cellulose blank structures. The press operation is initiated when one or more forming dies are moved from a stationary position. In the rest position, one or more cooperating mold parts are arranged at a distance from each other so that the cellulose blank structure can be fed into one or more molds at a forming position between the mold parts. The mold parts are then moved towards each other to apply a forming pressure to the cellulose blank structure and then moved away from each other back to the rest position. When the mold parts reach the rest position again, the pressing operation is completed. A pressing operation is therefore defined as a pressing cycle during which the cellulose blank structure is subjected to a forming pressure, and the duration of the pressing operation is calculated from the moment when one or more mold parts start moving from the rest position until they reach the rest position again.

[0011] In one embodiment, in such a stationary mode, the forming wire is brought to a standstill. The duration of the standstill is synchronized with the duration of the pressing operation, such that the standstill occurs during the pressing operation. The forming wire may be brought to a standstill at any time during the pressing operation, and the duration of the standstill may be only a portion of the duration of the pressing operation, or alternatively may be the entire duration of the pressing operation.

[0012] In one embodiment, the stationary mode is followed by a conveying mode in which the forming wire is placed in motion. The method further includes moving the air-formed cellulose blank structure away from the blank dry-forming module by the forming wire in motion. The motion is synchronized with the feeding of the air-formed cellulose blank structure to the press module for efficient intermittent conveying operation of the cellulose blank structure from the blank dry-forming module to the press module.

[0013] In one embodiment, the state of motion occurs at least partially between two successive pressing operations, thus, for efficient operation of the product-forming unit, the state of motion occurs at least partially when one or more molds are in a stationary position.

[0014] In one embodiment, the cellulose blank structure is air-formed in a dry-forming module into discrete cellulose blanks, or the cellulose blank structure is air-formed in a dry-forming module into a continuous cellulose blank.

[0015] In one embodiment, the method further comprises forming a cellulose product from the cellulose blank structure in one or more molds by heating the cellulose blank structure to a forming temperature and pressing the cellulose blank structure at a forming pressure in a pressing operation.

[0016] In one embodiment, the forming temperature T Fis in the range of 100 to 300°C, preferably in the range of 100 to 200°C, and the molding pressure P F is in the range of 1 to 100 MPa, preferably in the range of 4 to 20 MPa. These parameters provide efficient shaping of the cellulose product with strong hydrogen bonds formed.

[0017] In one embodiment, the pressing operation is a single pressing operation, which means that the cellulosic product is formed from the cellulosic blank structure in one single pressing step in the press module, and in a single pressing operation, the cellulosic blank structure is not subjected to forming pressure and forming temperature in two or more repeated or consecutive pressing steps.

[0018] In one embodiment, the method further comprises the step of conveying the air-formed cellulosic blank structure from the blank dry-forming module to the press module. Any suitable conveying means, such as a conveying belt or a conveying roller, may be used for efficient conveying.

[0019] In one embodiment, the cellulosic blank structure is intermittently transferred from the blank dry forming module to the press module. The intermittent feeding ensures efficient transfer of the cellulosic blank structure into the intermittently operating press module.

[0020] In one embodiment, the cellulosic blank structures are intermittently transported from the blank dry-forming module by the forming wire in a first feed direction and intermittently transported to the press module in a second feed direction, the second feed direction being different from the first feed direction, the different feed directions allowing a compact layout of the product forming unit.

[0021] In one embodiment, the first feed direction is opposite or substantially opposite to the second feed direction. This allows for efficient feeding of the cellulose blank structure, where the cellulose blank structure is redirected from the first feed direction to the second feed direction, which directions are opposite or substantially opposite to each other. The different feed directions allow for 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 matter of months, with no or little modular engineering skills required from the converter. A further advantage is that the different feed directions allow for 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-traditional manner for an efficient and compact layout. Furthermore, the integrated modular design allows for the weight of the product forming unit to be reduced to a fraction of the current units with individual modules purchased separately and aligned to become a custom-made industrial line. This solution also lowers the multiple investment costs for the converter, since the weight of the machine is generally related to the purchase price. The reduced investment costs will allow for a quicker conversion to products made from cellulosic raw materials instead of plastic materials.

[0022] In one embodiment, 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.

[0023] In one embodiment, the method further comprises the steps of providing a cellulose raw material and feeding the cellulose raw material to a blank dry-forming module; and air-forming a cellulose blank structure from the cellulose raw material on a forming wire in the blank dry-forming module. The blank dry-forming module allows the cellulose blank structure to be formed in close connection with the press module without the need to pre-manufacture the cellulose blank structure. Due to the modular structure of the product forming unit, a compact layout can be achieved. Furthermore, the operation of the product forming unit is efficient due to the cellulose raw material used as input material for the in-line production of the cellulose blank structure.

[0024] In one embodiment, the blank dry-forming module further comprises a mill and a forming chamber. The forming wire is arranged in connection with the forming chamber. The method further comprises the steps of separating cellulose fibers from the cellulose feedstock in the mill and distributing the separated cellulose fibers onto the forming wire in the forming chamber for air-forming the cellulose blank structure. The mill is configured to separate the cellulose fibers from the cellulose feedstock and the forming chamber is configured to efficiently distribute the separated cellulose fibers onto the forming wire for air-forming the cellulose blank structure.

[0025] In one embodiment, the method further comprises the steps of operating the mill continuously; and continuously supplying the cellulosic feedstock to the mill, or intermittently supplying the cellulosic feedstock to the mill.

[0026] In one embodiment, the forming wire has a forming section connected to and positioned at the forming chamber opening of the forming chamber, the method further comprising air forming the cellulosic blank structure onto the forming section, the forming section controlling 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.

[0027] In one embodiment, the forming section extends in an upward blank-forming direction. The method further includes the steps of air-forming the cellulose blank structure on the forming section and conveying the formed cellulose blank structure in the upward blank-forming direction by a forming wire. The non-conventional upward extension of the forming section allows a compact layout of the product forming unit since the cellulose blank structure can be formed in an upward direction for direct conveyance to the press module.

[0028] In one embodiment, the forming section extends in a horizontal blank-forming direction. The method further includes air forming the cellulose blank structure on the forming section and conveying the formed cellulose blank structure in the horizontal blank-forming direction by a forming wire. Such a conventional orientation provides an alternative to an efficient forming process.

[0029] In one embodiment, the forming wire has a first side facing the forming chamber and a second side facing a vacuum box arranged in connection with the forming chamber. The vacuum box is configured to control air flow in the forming chamber to distribute the separated cellulose fibers onto the forming wire. The method further includes the steps of air forming the cellulose blank structure onto the first side of the forming wire; applying a negative pressure to the second side to ensure adhesion of the cellulose fibers to the first side.

[0030] In one embodiment, the product forming unit includes a blank recycling module. The method further includes a step of conveying a remaining portion of the cellulose blank structure from the press module to a blank dry forming module. The conveying of the remaining portion ensures that the unused portion of the cellulose blank structure can be reused.

[0031] In one embodiment, the blank recycle module includes a recycle compression unit. The method further includes compressing the remaining portion of the cellulosic blank structure in the recycle compression unit when conveying from the press module to the blank dry-forming module. By compressing the remaining portion, efficient operation of the mill is achieved.

[0032] In one embodiment, the press module is a cellulosic toggle press module for forming a cellulosic product from a cellulosic blank structure. The method further includes the steps of providing a cellulose product toggle press module having a toggle press and one or more forming dies, where the toggle press has a press member movably arranged in a press direction, a toggle mechanism connected to the press member, a press actuator assembly connected to the toggle mechanism, and an electronic control system operably connected to the press actuator assembly, where each of the one or more forming dies has a movable first die part attached to the press member and a stationary second die part; installing the toggle press to have a press direction of the press member arranged primarily horizontally, specifically to have a press direction of the press member arranged within 20 degrees of the horizontal direction, more specifically to have a press direction parallel to the horizontal direction; feeding a cellulose blank structure into a press area defined by the spaced apart first and second die parts; and controlling operation of the press actuator assembly by the electronic control system to drive the press member in the press direction using the toggle mechanism and to form a cellulose product from the cellulose blank structure by forcing each first die part against the stationary second die part. The predominantly horizontal orientation of the toggle press allows for a low build height of the cellulosic product forming unit and allows for a non-linear material flow of the cellulosic blank structures from the blank dry-forming module to the press module. Because a continuous web of cellulosic fibrous material is typically fed into the press module approximately perpendicular to the press direction of the press module, the predominantly horizontal orientation of the toggle press is typically associated with a predominantly vertically disposed feed flow of the continuous cellulosic blank structures.Therefore, if one is to develop a compact cellulose product forming unit for efficient production of cellulose products having press members arranged primarily horizontally, specifically having a press direction of the press members arranged within 20 degrees of the horizontal, more specifically having a press direction parallel to the horizontal, it is clear that a primarily horizontally arranged press module would be extremely beneficial.

[0033] The present disclosure further relates to a product forming unit for dry forming a cellulose product from a cellulose blank structure. The product forming unit includes a blank dry forming module and a press module. The cellulose blank structure is air-formed on a forming wire in the blank dry forming module. The press module includes one or more forming dies configured to form a cellulose product from the cellulose blank structure in a press operation. The blank dry forming module is configured to place the forming wire in a stationary mode during the press operation. The stationary mode provides an efficient operation of the product forming unit and allows for a very compact layout since there is no need to buffer the cellulose blank structure between the blank dry forming module and the press module. The blank dry forming module allows for forming the cellulose blank structure in close connection to the press module without the need to pre-manufacture the cellulose blank structure. Furthermore, the operation of the product forming unit is more efficient due to the cellulose feedstock used as input material for the in-line production of the cellulose blank structure.

[0034] The present disclosure will now be described in detail with reference to the accompanying drawings. [Brief description of the drawings]

[0035] [Figure 1] FIG. 2 is a side view showing a schematic diagram of a product forming unit according to the present disclosure. [Diagram 2] FIG. 1 is a perspective view showing a schematic diagram of a blank dry forming module according to the present disclosure. [Figure 3a]FIG. 1 is a perspective view illustrating a press module according to the present disclosure. [Figure 3b] FIG. 1 is a side view diagrammatically illustrating a press module according to the present disclosure. [Figure 3c] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 3d] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 3e] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 4a] FIG. 2 is a schematic side view of a press module according to an alternative embodiment of the present disclosure. [Figure 4b] FIG. 2 is a schematic side view of a press module according to an alternative embodiment of the present disclosure. [Figure 5a] 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 5b] 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 6] FIG. 2 is a side view showing a schematic diagram of a product forming unit according to an alternative embodiment of the present disclosure.

[0036] 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.

[0037] Those skilled in the art will appreciate that the steps, services, and functions described herein may be performed using discrete hardware circuits, using software working in conjunction with a programmed microprocessor or general-purpose computer, using one or more application specific integrated circuits (ASICs), and / or using one or more digital signal processors (DSPs). Also, where the present disclosure is described in terms of a method, it will be understood that the present disclosure may be embodied in one or more processors and one or more memories coupled to the one or more processors, where the one or more memories store one or more programs that, when executed by the one or more processors, perform the steps, services, and functions disclosed herein.

[0038] FIG. 1 shows diagrammatically a product-forming unit U for dry-forming a cellulose product 1 from an air-formed cellulose blank structure 2. 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 described further below. The cellulose product 1 is dry-formed from the cellulose blank structure 2 in the product forming unit U. The press module 6 presses the cellulose product 1 from the cellulose blank structure 2 in a pressing operation O. P The blank dry forming module 4 has one or more forming dies 3 for forming the cellulose blank structure 2 in a press module 6. The cellulose blank structure 2 is air-formed on a forming wire 4c in the blank dry forming module 4 and fed to one or more forming dies 3 in the press module 6. The shaping of the cellulose product 1 thus takes place in the press module 6. The cellulose product 1 is preferably 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.

[0039] 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 the formation of 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. In the air-forming process, a small amount 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 conveying medium in the forming process. The cellulose blank structure 2 may have a dryness that, if appropriate, mainly corresponds to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2. Alternatively, the dryness of the cellulosic blank structure 2 can be controlled to have an appropriate dryness level when forming the cellulosic product 1 .

[0040] The air-formed cellulose blank structure 2 is formed from cellulose fibers in a blank dry forming module 4 as shown in Figures 1 and 2 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 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 cellulose fibers or manufactured cellulose fibers. The cellulose blank structure 2 may specifically comprise at least 95% cellulose fibers, or more specifically at least 99% cellulose fibers. However, the cellulose blank structure 2 may have another suitable structure and amount of cellulose fibers.

[0041] 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.

[0042] One or more reinforcing layers comprising cellulose fibers may be added to the cellulose blank structure 2. The one or more reinforcing layers may be arranged as a support layer for the cellulose blank structure 2. The reinforcing layers may have a higher tensile strength than 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 layers having a higher tensile strength thus act as a support structure for the cellulose blank structure 2. The reinforcing layers may be of a different composition than the cellulose blank structure 2, for example a tissue layer comprising cellulose fibers, an air-laid structure with cellulose fibers, or any other suitable layer structure. Thus, the reinforcing layers do not need to be air-formed.

[0043] 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.

[0044] 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.

[0045] The press module 6, as shown in Figures 1, 3a-3e and 6, has one or more moulds 3, each of which has a first mould part 3a and a second mould part 3b. The corresponding first and second mould parts are arranged to perform a pressing operation O during the moulding of the cellulose product 1 in the press module 6. P Each first mold part 3a and the corresponding second mold part 3b are arranged to be movable relative to each other, and the first mold part 3a and the second mold part 3b cooperate with each other in a pressing direction D. P The actuators are configured to move relative to each other.

[0046] In the embodiment shown in Figures 1, 3a to 3e and 6, the second mould part 3b is stationary and the first mould part 3a is pressed by a pressing operation O. P Middle, press direction D P As shown by the double-headed arrow in Figures 3a-3b, the first mould part 3a is arranged to be movable relative to the second mould part 3b in a pressing direction D. P The second mould part 3b is adapted to move in both directions towards and also away from the second mould part 3b with a linear movement along an axis extending in the direction

[0047] In an alternative embodiment, the pressing action O P wherein 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.

[0048] 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, as shown in FIG. 6. A multi-cavity press module has two or more molds 3 with cooperating first and second mold parts, respectively. In the embodiment shown in FIG. 1 and FIG. 3a, the press module 6 is arranged as a multi-cavity press module with a plurality of molds 3 with first and second mold parts, the movement of the mold parts being preferably synchronized for simultaneous molding operations. The portion of the press module 6 shown in FIG. 3b-FIG. 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.

[0049] 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.

[0050] Press operation P The term "pressing" refers to the action of the mold parts to form a cellulosic product from a cellulosic blank structure. P The one or more first mold parts 3a and / or the one or more second mold parts are in a stationary position P SIn the rest position, the one or more first mould parts 3a and the one or more second mould parts 3b are arranged at a distance from each other, such that the cellulose blank structure 2 can be provided in the mould 3 at a moulding position between the one or more first mould parts 3a and the one or more second mould parts 3b. The one or more first mould parts 3a and / or the one or more second mould parts 3b are then moved towards each other to apply a moulding pressure to the cellulose blank structure 2 and then moved away from each other to the rest position P S The mold part is again returned to the rest position P S When it reaches the position, press the button P Therefore, the press operation O P is defined as the pressing cycle in which the cellulose blank structure is subjected to a molding pressure, and the pressing operation O P The duration of the stationary position P S From the time when the one or more first mold parts 3a and / or the one or more second mold parts 3b start to move from S is calculated until it reaches

[0051] The molding pressure is the pressing motion O P It should be understood that the forming pressure may be applied to the cellulose blank structure 2 in only one pressing step during the pressing operation O. Alternatively, the forming pressure may be applied in the same manner as in the pressing operation O. P Two or more repeated pressing steps may be applied during the molding process, such that the mold sections repeatedly apply a molding pressure to the cellulosic blank structure.

[0052] Preferably, the pressing operation O P The molding pressure is the pressing operation O P A single pressing operation is applied to the cellulose blank structure 2 in only one pressing step during SP That is, single press operation SP means that the cellulose product 1 is formed from the cellulose blank structure 2 in one single pressing operation in the press module 6. This single pressing operation O SPIn a single press operation, one or more first mold parts 3a and one or more second mold parts 3b interact with each other to establish a forming pressure and a forming temperature during a single operative engagement step. In a single press operation, the forming pressure and forming temperature are not applied to the cellulosic blank structure 2 in two or more repeated or successive pressing steps.

[0053] To form a cellulose product 1 from the air-formed cellulose blank structure 2 in the product forming unit U, the cellulose blank structure 2 is air-formed from cellulose fibers in a blank dry-forming module 4 of the product forming unit U and fed directly to the press module 6.

[0054] The cellulose product 1 is molded by molding the cellulose blank structure 2 at a temperature T F 2. Pressing the Cellulose Blank Structure 2 by Heating P At the molding pressure P F The cellulose blank structure 2 is molded in one or more molds 3 by pressing at a molding temperature T F is in the range of 100 to 300°C, preferably in the range of 100 to 200°C, and the molding pressure P F is in the range of 1 to 100 MPa, preferably in the range of 4 to 20 MPa. The first mould parts 3a are arranged to mould the cellulose product 1 by interaction with the corresponding second mould parts 3b as illustrated in Figures 3b to 3e. During the moulding of the cellulose product 1, the cellulose blank structure 2 is subjected in each mould 3 to a moulding pressure P in the range of 1 to 100 MPa, preferably in the range of 4 to 20 MPa. F and a molding temperature T in the range of 100 to 300 ° C., preferably in the range of 100 to 200 ° C. F Therefore, the cellulose blank structure 2 is exposed to a molding temperature T F and the cellulose blank structure 2 is subjected to a molding pressure P in the range of 1 to 100 MPa, preferably in the range of 4 to 20 MPa. FA 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 pressing with a pressure of 1000 MPa. When forming 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 forming process, for example by suitable sensors arranged in or connected to the cellulose fibres in the cellulose blank structure 2.

[0055] 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.

[0056] In FIG. 3b, the first mold part 3a and the second mold part 3b are in a rest position P S From this rest position the first mould part 3a is moved in a pressing motion O P When the cellulose blank structure 2 is placed in the molding position between the first mould part 3a and the second mould part 3b as shown in Fig. 3b, the first mould part 3a can be moved in the pressing direction D as shown 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 to apply a molding pressure P F and molding temperature T FThe cellulose blank structure 2 is increasingly compressed between the mould parts until it reaches a product moulding position where a moulding pressure P is applied. During moulding of the cellulose product 1, as each first mould part 3a is pressed towards a corresponding second mould part 3b with the cellulose blank structure 2 being located between said mould parts, a moulding cavity C for moulding the cellulose product 1 is formed between each first mould part 3a and the second mould part 3b. F and molding temperature T F is applied to the cellulose blank structure 2 in each forming cavity C. The forming 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 on the cellulose product 1 and the cellulose product 1 is separated from the cellulose blank structure 2 during the forming of the cellulose product 1. The mould parts may be arranged for such operations, for example with an edge forming device and a cutting or separating device, or alternatively the edge may be formed with a cutting or separating operation of the product. Once the cellulose product 1 has been formed in the press module 6, 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. The first mould part 3a is moved away from the second mould part 3b, as shown in Fig. 3b, in a stationary position P S When the pressing operation returns to , the pressing operation is completed.

[0057] A pressure distribution 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 Fig. 3b-3e, the pressure distribution element E is attached to the first mould part 3a. The pressure distribution element E deforms when pressure is applied and by arranging the pressure distribution element E in connection with one of the mould parts, the molding pressure P F can be formed as an equalized forming pressure, in which case the pressure in the forming tool 3 is efficiently distributed in various directions. The pressure distribution element E is P As well as the press direction D PFor example, the pressing direction D P and press direction D P The equalized molding pressure may include an isotropic molding pressure.

[0058] The first mould part 3a and / or the second mould part 3b may comprise a pressure distribution element E, which distributes a moulding pressure P to the cellulose blank structure 2 in the moulding cavity C during the moulding of the cellulose product 1. F The pressure distribution 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 moulding of the cellulose product 1, the pressure distribution element E applies a moulding pressure P to the cellulose blank structure 2 in the moulding cavity C. F The pressure distribution element E is deformed to apply a pressure P to the cellulose blank structure 2, and the deformation of the pressure distribution element E achieves an equalized pressure distribution even if the cellulose product 1 has a complex three-dimensional shape or the cellulose blank structure 2 has a variable thickness. F In order to apply a force or pressure, the pressure distribution element E is made of a material that can be deformed when a force or pressure is applied, and the pressure distribution element E is preferably made of an elastic material that can recover its size and shape after deformation. The pressure distribution element E furthermore supports the high molding pressure P used during molding of the cellulose product 1. F and molding temperature T F It may be made of a material having suitable properties to withstand the levels.

[0059] Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the pressure distribution elements E are made of such materials or combined with such materials, an equalized pressure distribution can be achieved in the molding process. Each pressure distribution element E may be made of a suitable structure of elastic material, and by way of example, the pressure distribution elements E may be made of a structure of gel material, silicone rubber, polyurethane, polychloroprene, rubber, or a combination of different suitable materials.

[0060] As mentioned above, the product forming unit U further comprises a blank dry forming module 4 configured to air-form the cellulose blank structure 2 from the cellulose raw material R, as shown in Fig. 1, Fig. 2 and Fig. 6. The cellulose raw material R is provided from a suitable source, and the cellulose raw material R is fed to the blank dry forming module 4. The cellulose blank structure 2 is dry-formed from the cellulose raw material R onto a forming wire 4c in the blank dry forming module 4, and then the air-formed cellulose blank structure 2 is conveyed from the blank dry forming module 4 to the press module 6. The cellulose blank structure 2 can be air-formed in the dry forming module 4 into separate cellulose blanks 2a, as shown in Fig. 2. The separate cellulose blanks 2a are formed as separate pieces of material separated from each other, and can be shaped, for example, into a suitable profile to avoid material residue 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, as shown in Fig. 2 and Fig. 6. Depending on the air forming process, the basis weight of the air formed cellulosic blank structure 2 may be uniform or variable.

[0061] As shown in Figures 1 and 2, 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. The fibers F of the cellulose raw material R are separated from the cellulose raw material R in the mill 4a, and the separated cellulose fibers F are distributed in the forming chamber 4b onto the forming wire 4c for air-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 cellulose fibers F onto the forming section 4d of the forming wire 4c for air-forming the cellulose blank structure 2. The forming section 4d is arranged in connection with the 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 air-formed onto the forming section 4d and is pulled upward from the forming section 4d in a blank forming direction D by the forming wire 4c. U The blank is transported in the upward blank forming direction D. U is used for a compact structure and layout of the product forming unit U and allows efficient positioning of the various modules of the product forming unit U relative to one another. After the cellulose blank structure 2 is formed on the forming section 4d, the formed cellulose blank structure 2 is moved upward from the forming section 4d in a blank forming direction D U and then further towards the press module 6.

[0062] The mill 4a separates cellulose fibers F from the cellulose raw material R and distributes the separated cellulose fibers F into the forming chamber 4b. The cellulose raw material R used may be, for example, a bale, sheet or roll of fluff pulp, a paper structure or any other suitable cellulose fiber-containing structure, which is fed into the mill 4a. The mill 4a may be of any conventional type, for example a hammer mill, a disk mill, a sawtooth mill or any other type of pulp defibrator. The cellulose raw material R is fed into the mill 4a through an inlet opening, and the separated cellulose 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.

[0063] The forming chamber 4b is arranged to distribute the separated cellulose fibres 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 cellulose fibres F are distributed from the mill 4a to the forming wire 4c. The cellulose fibres F are distributed by an air flow generated by the mill 4a, which carries the fibres in the forming chamber 4b from the mill 4a to the forming wire 4c.

[0064] The forming wire 4c may be of any suitable conventional type and may be formed as an endless belt structure, as can be seen from Figures 1, 2 and 6. 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 4b and distribute the separated cellulose 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.

[0065] The blank dry-forming module 4 of the embodiment shown in Figures 1 and 2 has a horizontal distribution direction of the cellulose fibers F, from the mill 4a through the forming chamber 4b to the forming wire 4c. A horizontal flow of air therefore feeds the cellulose fibers F from the mill 4a to the forming section 4d, which differs from conventional dry-forming systems using a vertical flow of air. The length of the fiber transport distance by the air flow inside the forming chamber 4b must be long enough to minimize turbulence and / or to create a uniform flow of the cellulose fibers F. The length of the blank-forming module 4 is therefore dependent on the fiber transport distance by the air flow. The 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 and the horizontal air flow also allows for a reduced height of the product forming unit U compared to conventional solutions using vertical air flows.

[0066] The blank dry-forming module 4 is arranged upstream of the press module 6, as shown for example in Figures 1 and 6, and has the purpose of air-forming a cellulose blank structure 2 from cellulose fibers F derived from a cellulose raw material R. Due to the intermittent operation of the press module 6, the cellulose blank structure 2 has to be conveyed to the press module 6 intermittently.

[0067] The intermittent transport of the cellulose blank structure 2 to the press module 6 is performed by a suitable feeding device, such as a conveyor belt or feeding rollers, which are intermittently controlled to feed the cellulose blank structure 2 to the press module 6. The press module 6 applies a forming pressure P FThe cellulose blank structure 2 is in a non-moving state when the forming unit U is operated to apply the forming wire 4c to the pressing operation O. In other words, the feeding of the cellulose blank structure 2 to the forming position between the one or more first mold parts 3a and the one or more second mold parts 3b is performed when the mold parts are in an at least partially open state. The at least partially open state allows the cellulose blank structure 2 to be safely placed between the one or more first mold parts 3a and the one or more second mold parts 3b without any disturbing interaction with the mold parts. Since the forming unit U is arranged without any buffer module or similar device, the intermittent transport of the cellulose blank structure to the pressing module must be synchronized with the air forming of the cellulose blank structure 2 in the blank dry forming module 4. Such synchronization is realized according to the present disclosure by the forming wire 4c being moved in the direction of the pressing operation O. P In static mode M ST This is achieved by placing the stationary mode M ST In this case, the forming wire 4c is in the stopped state S ST The stop state S ST The duration of the stop state S ST Press the button to operate P Press the button to make sure it is pressed properly. P The forming wire 4c is synchronized with the duration of the pressing operation O P At any point during the stop state S ST may be placed in a stop state S ST The duration of the press operation P or alternatively, the pressing operation O P It may be the entire period.

[0068] Stationary mode M of the formed wire 4c ST 2, Transport mode M TR Continued. Transport mode M TR Then, the forming wire 4c is in the motion state S MO The air-formed cellulose blank structure 2 is placed in a motion state S MOThe blank is separated from the dry-forming module 4 by the forming wire 4c at . The one or more first mould parts 3a and / or the one or more second mould parts are moved to the rest position P S When two consecutive presses are P Between the motion state S MO occurs at least partially. MO is synchronized with the feeding of the air-formed cellulose blank structures 2 to the press module 6, so as to provide an effective intermittent conveying operation of the cellulose blank structures 2 from the blank dry-forming module 4 to the press module 6. The cellulose blank structures 6 are preferably transferred from the forming wire 4c to a feeding device which further conveys the cellulose blank structures 2 to the press module 6.

[0069] The various modes and states of the forming wire 4c are suitably controlled by the control unit for efficient operation of the product forming unit U.

[0070] 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.

[0071] In the embodiment shown in FIG. 1, the cellulose blank structure 2 is fed in a first feed direction D F1 The blanks are intermittently conveyed from the dry forming module 4 by the forming wire 4c in the second feeding direction D F2 to the press module 6 in 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 F2The 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.

[0072] In a particular embodiment, the first feed direction D F1 is the second feed direction D F2 In the embodiment shown in FIG. 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.

[0073] In an alternative embodiment shown in FIG. 6, the forming section 4d of the forming wire 4c is aligned in a horizontal blank forming direction D HF The cellulose blank structure 2 is in this embodiment air-formed onto the forming section 4d and is pulled by the forming wire 4c from the forming section 4d in a horizontal blank forming direction D. HF The blank is transported in the horizontal direction D. HF is used for the conventional construction and layout of the product forming unit U and allows efficient positioning of the various modules of the product forming unit U relative to each other. After the cellulose blank structure 2 is formed on the forming section 4d, the formed cellulose blank structure 2 is moved from the forming section 4d in a horizontal blank forming direction D HF , and is then transported further towards the press module 6.

[0074] The blank dry-forming module 4 of the embodiment shown in Fig. 6 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.

[0075] The press module 6 may have any suitable configuration, such as, for example, a hydraulic press module or a toggle press module.

[0076] One embodiment of a press module 6 is shown in Figure 3a. In the illustrated embodiment, the press module 6 is a cellulosic toggle press module for forming a cellulosic product 1 from a cellulosic blank structure 2. The cellulosic toggle press module, as shown in Figures 1 and 3a-3e, includes one or more forming dies 3, each having a first die portion 3a and a second die portion 3b.

[0077] The press module 6 includes a toggle press 6a and one or more molds 3. The toggle press 6a includes a front structure 6b, a rear structure 6c, and a pressing direction D. P The press actuator assembly 6f is drivingly connected to the toggle mechanism 6e, and an electronic control system 6h is operatively connected to the press actuator assembly 6f and to the one or more mold dies 3. The one or more mold dies 3 have a movable first mold portion 3a and a stationary second mold portion 3b attached to the press member 6d. The electronic control system 6h controls the pressing direction D using the toggle mechanism 6e as described above. P The toggle press 6a is configured to control the operation of the press actuator assembly 6f to drive the press member 6d at a constant speed and to press the first die part 3a against the stationary second die part 3b to form the cellulose product 1 from the cellulose blank structure 2. The toggle press 6a is configured to rotate in a primarily horizontal direction D H The pressing direction D of the pressing member 6d arranged in P Specifically, in the horizontal direction D H The pressing direction D of the pressing member 6d arranged within 20 degrees from P More specifically, the horizontal direction D H Press direction D parallel to Pis installed or arranged to be installed so as to have

[0078] The press member 6d is disposed between the front structure 6b and the rear structure 6c. The toggle mechanism 6e is connected to the rear structure 6c and the press member 6d. The press actuator assembly 6f is connected to the toggle mechanism 6e, and the press actuator assembly 6f uses the toggle mechanism 6e to move the press member 6d in the pressing direction D. P The press actuator assembly 6f is further configured to drive the press member 6d away from the front structure 6b using a toggle mechanism 6e when the cellulose product 1 is formed in the one or more forming dies 3. The toggle press 6a further includes a press force indicating assembly 6g and an electronic control system 6h operably connected to the press actuator assembly 6f and the press force indicating assembly 6g. The electronic control system 6h is configured to control the operation of the press member 6d. Each of the one or more forming dies 3 includes a first die part 3a attached to the press member 6d and a second die part 3b attached to the front structure 6b. The first and second die parts 3a, 3b are configured to together form the cellulose product 1 from the cellulose blank structure 2 when pressed together.

[0079] When forming the cellulose product 1, the press area A is defined by the first mold part 3a and the second mold part 3b when they are spaced apart as illustrated in FIG. P The cellulosic blank structure 2 is fed into the press actuator assembly 6f. The operation of the press actuator assembly 6f uses a toggle mechanism 6e to move the press member 6d in the pressing direction D. P 3. The first and second mould parts 3a, 3b are controlled by an electronic control system 6h to drive the first and second mould parts 3a, 3b towards the front structure 6b at the same speed. In this way, the first and second mould parts 3a, 3b respectively, when pressed together, together form the cellulose product 1 from the cellulose blank structure 2.

[0080] The press actuator assembly 6f may, for example, include a single or multiple hydraulic or pneumatic linear actuators, such as cylinder-piston actuators. Alternatively, a motor with a rotating output shaft, such as an electric motor, hydraulic motor or pneumatic motor, may be used to drive the mechanical actuator, or the press actuator assembly 6f may include a high torque electric motor drivingly connected to the toggle mechanism 6e via a rotary-to-linear converter.

[0081] The movable first mould part 3a may be attached directly or indirectly to the pressing member 6d. This means, for example, that there may be an intermediate member, such as a load cell for detecting the pressing force, arranged between the movable first mould part 3a and the pressing member 6d. The stationary second mould part 3b is typically stationary during the pressing operations, but nevertheless moves in the pressing direction D in the periods between successive pressing operations. P In the illustrated embodiment, 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 mould part 3b is attached to the front structure 6b. The stationary second mould part 3b may be attached directly or indirectly to the front structure 6b. This means that there may be, for example, 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.

[0082] The front structure 6b and the rear structure 6c represent two rigid structurally related parts that must be interconnected by some structurally rigid structure to ensure that the front and rear structures do not separate from each other during press operation. The front and rear structures may have many different shapes depending on the specific design of the press module 6. For example, the front and rear structures may have a plate-like shape, in particular a rectangular plate-like shape, which allows for cost-effective manufacturing and allows corner areas of the plate-shaped front and rear structures to be utilized for attachment to a common rigid frame structure defined by the front structure 6b, the rear structure 6c, and an intermediate frame structure connecting the front structure 6b to the rear structure 6c. In some exemplary embodiments, the toggle press 6a has a rigid frame structure defined by the front structure 6b, the rear structure 6c, and an intermediate linear guide assembly 6i connecting the front structure 6b to the rear structure 6c. The press members 6 are movably mounted on the linear guide assemblies 6i and are arranged to move in the pressing direction D. P A rigid frame structure may be disposed on the underlying support frame 6j to provide the desired height and angular inclination of the press module 6.

[0083] To allow a cost-effective and robust frame construction of the toggle press 6a, the intermediate linear guide assembly 6i may have four tie bars, which are arranged in the corner areas of the plate-shaped front structure 6b and the rear structure 6c. The tie bars may be, for example, cylindrical, and the corner areas of the plate-shaped front structure 6b and the rear structure 6c may be provided with corresponding cylindrical holes to accommodate said tie bars. The press member 6d may have any structural shape. However, in some exemplary embodiments, the press member also has an at least partially plate-like shape, in particular a rectangular plate-like shape, which allows for cost-effective manufacturing and makes it possible to utilize the corner areas of the plate-shaped press member 6d for attachment to the intermediate linear guide assembly 6i. Thus, in some exemplary embodiments, the toggle press 6a may be referred to as a three-plate press.

[0084] The toggle press 6a is mainly used for horizontal D H The pressing direction D of the pressing member 6d arranged in P Specifically, in the horizontal direction D H The pressing direction D of the pressing member 6d arranged within 20 degrees from P More specifically, the horizontal direction D H Press direction D parallel to P is installed or arranged to be installed so as to have

[0085] In the embodiment shown in FIG. 3a, the toggle press 6a is H The pressing direction D of the pressing member 6d arranged in P In the embodiment shown in Figures 4a-4b, the toggle press 6a is installed in a slightly inclined state, which allows an overall compact design of the product-forming unit U with a low construction height. In the embodiment shown in Figures 4a-4b, the toggle press 6a is installed in a slightly inclined state, which allows an overall compact design of the product-forming unit U with a low construction height. In the embodiment shown in Figures 4a-4b, the toggle press 6a is installed in a slightly inclined state, which allows an overall compact design of the product-forming unit U with a low construction height.P In this case, the above-mentioned installation angle α is set to have a value in the pressing direction D as shown in the figure. P and horizontal direction D H It is defined by:

[0086] In some exemplary embodiments, the toggle press 6a is configured to feed the feed material in a mainly vertical feed direction D F The press section 1 further includes a feeder 6k for feeding the cellulose blank structure 2 into one or more molds 3 at the press section A. The feeder 6k feeds the cellulose blank structure 2 into one or more molds 3 at the press section A. P Specifically, the cellulose blank structure 2 is fed in the vertical direction D V downward at a feed angle β of less than 20 degrees from press area A P More specifically, the air-formed cellulose blank structure is fed vertically downward into press area A. P The feed angle β is shown diagrammatically in Figures 4a-4b.

[0087] As stated above, primarily horizontal and primarily horizontally refer to orientations that are more horizontally oriented than vertically oriented, and primarily vertical and primarily vertically refer to orientations that are more vertically oriented than horizontally oriented.

[0088] 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.

[0089] Generally, with reference to the exemplary embodiment of FIG. 3a, the toggle mechanism 6e has a link member and the press actuator assembly 6f is directly or indirectly drivingly connected to the link member such that actuation of the press actuator assembly 6f results in movement of the press member 6d.

[0090] The use of a toggle press module to form a cellulose product from an air-formed cellulose blank structure has many advantages over the use of conventional bulky linear hydraulic presses, such as low cost, low weight, fast cycling, and compactness. Having an electronic control system 6h configured to control operation of the press actuator assembly 6f based on feedback information indicative of the press force received from a press force indication assembly 6g, the toggle press module is an advantageous alternative to conventional linear hydraulic presses.

[0091] The product forming unit U may further comprise a barrier application module (not shown) 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.

[0092] One preferred property of the cellulose product 1 is its ability to retain or resist liquids, 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.

[0093] 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.

[0094] For clarity, the feed path and feed direction of the cellulose blank structure 2 of the exemplary embodiment of Figure 1 is shown diagrammatically in Figure 5a, where 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, then primarily downward, when compared to the conventional straight horizontal path of the cellulose product compression molding process, can be clearly understood.

[0095] Alternatively, as shown diagrammatically in Fig. 5b, 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, with the forming wires mainly horizontally oriented in the region of the forming chamber opening, 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.

[0096] 5a-b, 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, are located at suitable positions between the dry-form module 4 and the press module 6, downstream of the dry-form module 4 and upstream of the press module 6.

[0097] 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 as it leaves the press module 6 after the forming process is completed.

[0098] In particular, high speed intermittent feeding of the cellulose blank structure 2 from the blank dry forming module 4 to the press module 6 can be difficult to implement without damaging the cellulose blank structure 2 or changing the properties of the cellulose blank structure 2, such as the thickness of the cellulose blank structure 2. However, the toggle press is primarily driven in the horizontal direction D H and feeding the cellulose blank structure 2 primarily downwards into the press module 6, whereby gravity assists this feeding process, thereby feeding the cellulose blank structure 2 into the press area A of the press module 6. P less force needs to be applied by the feeding device to feed the cellulose blank structure 2, thereby reducing the risk of damage and / or changes in the properties of the cellulose blank structure 2.

[0099] 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, conveyor belt or the like.

[0100] Furthermore, in the embodiment shown in Fig. 1 and Fig. 6, the product forming unit U has a blank recycle module 7 for recycling cellulose fibers. The blank recycle module 7 is configured to convey 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 convey 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 the 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. 1, an exemplary embodiment of the blank recycle module 7 is shown in a schematic manner. The blank recycle module 7 includes 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.

[0101] The blank recycle module 7 may include a recycle compression unit 7b for compressing 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 for compressing the remaining portion 2c of the cellulose blank structure 2 as shown in FIG.

[0102] 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 suitable combined mill and fan unit, which is used to at least partially separate the residual material before further conveyance to the outlet portion connected to the mill 4a.

[0103] The product forming unit U may further comprise a conveying or feeding device for intermittently feeding the cellulose blank structure 2 between different modes. The conveying device may be arranged as a conveyor belt, a vacuum belt, or a similar device for efficient conveying. According to some exemplary embodiments, the feeding device may include an elongated vacuum belt feeder, an elongated tractor belt feeder, or the like.

[0104] The above-mentioned modules allow a compact construction of the product-forming unit U, and several modules can be integrated into one 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.

[0105] The present disclosure has been presented above with respect to certain embodiments. However, other embodiments than those described above are possible and within the scope of the present disclosure. Method steps other than those described above, implementing the method by hardware or software, may be provided within the scope of the present disclosure. Thus, according to an exemplary embodiment, a non-transitory computer-readable storage medium storing one or more programs configured to be executed by one or more processors of a control system is provided, the one or more programs including instructions for performing a method according to any one of the above-mentioned embodiments. Alternatively, according to another exemplary embodiment, a cloud computing system may be configured to perform any of the aspects of the method presented herein. The cloud computing system may include distributed cloud computing resources that jointly perform aspects of the method presented herein under the control of one or more computer program products. Additionally, the processor may be connected to one or more communication interfaces and / or sensor interfaces for receiving and / or transmitting data to and from external entities, such as sensors, off-site servers, or cloud-based servers.

[0106] A processor associated with the control system may be or include any number of hardware components for performing data or signal processing or for executing computer code stored in memory. The system may have associated memory, which may be one or more devices for storing data and / or computer code for completing or facilitating various methods described herein. The memory may include volatile or non-volatile memory. The memory may include database components, object code components, script components, or any other type of information structure for supporting various activities herein. According to exemplary embodiments, any distributed or local memory device may be utilized with the systems and methods herein. According to exemplary embodiments, the memory is communicatively connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and includes computer code for performing one or more processes described herein.

[0107] It will be understood that the above description is merely exemplary in nature and is not intended to limit the application or use of the present disclosure. Although specific examples have been described in the specification and shown in the drawings, those skilled in the art will understand 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, 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 shown in the drawings and described in the specification as the best mode currently 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]

[0108] 1. Cellulose products 2. Cellulose blank structure 2a Separated cellulose blank 2b Consecutive cellulose blanks 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 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 6i Guide Assembly 6j Support Frame 7 Blank Recycle Module 7a Supply structure 7b Recycling Compression Unit C Molding Cavity D F Supply direction D F1 First feed direction D F2 Second feed direction D H horizontal direction D P Press Direction D HF Horizontal blank forming direction D U Upward blank forming direction D V vertical direction E Pressure Distribution Element F fiber O P Press action O SP Single press operation P F Molding Pressure P NEG Negative Molding Pressure P S rest position R Cellulose raw material S1 First Side S2 Second side T F Molding temperature U Product Forming Unit

Claims

1. A method for dry-forming a cellulose product (1) from a cellulose blank structure (2) in a product-forming unit (U), the product-forming unit (U) having a blank dry-forming module (4) and a press module (6), the cellulose blank structure (2) being air-formed on a forming wire (4c) in the blank dry-forming module (4), the blank dry-forming module (4) further having a mill (4a) and a forming chamber (4b), the forming wire (4c) being connected to and arranged in the forming chamber (4b), the press module (6) pressing the cellulose product (1) from the cellulose blank structure (2) in a pressing operation (O). Ｐ ) in one or more molds (3), the method comprising the steps of: providing a cellulose raw material (R) and feeding said cellulose raw material (R) into said blank dry-molding module (4); air-molding the cellulose blank structure (2) from the cellulose raw material (R) on the forming wire (4c) in the blank dry-molding module (4) by separating cellulose fibers (F) from the cellulose raw material (R) in the mill (4a) and distributing the separated cellulose fibers (F) on the forming wire (4c) in the forming chamber (4b) for air-molding the cellulose blank structure (2); and The forming wire (4c) is pressed by the pressing operation (O Ｐ ) in still mode (M ＳＴ ) Step A method comprising:

2. The stationary mode (M ＳＴ ), the forming wire (4c) is stopped (S ＳＴ ) and place it in the stopped state (S ＳＴ The duration of the stop state (S ＳＴ ) is the pressing operation (O Ｐ ) during the pressing operation (O Ｐ 2. The method of claim 1, further comprising synchronizing the duration of the first period of the first clock.

3. The stationary mode (M ＳＴ ) is the transport mode (M ＴＲ ) continues, and the transport mode (M ＴＲ ), the forming wire (4c) is moved in a moving state (S ＭＯ ), and the method further comprises placing the air-formed cellulose blank structure (2) in the motion state (S ＭＯ 3. The method according to claim 1 or 2, further comprising the step of moving the blank away from the dry forming module (4) by the forming wire (4c) located at the rear of the blank dry forming module (4).

4. The motion state (S ＭＯ ) is a combination of two successive press operations (O Ｐ 4. The method of claim 3, wherein the reaction occurs at least in part between

5. 3. The method according to claim 1 or 2, wherein the cellulose blank structure (2) is air-formed in the blank dry-forming module (4) into separate cellulose blanks (2a) or the cellulose blank structure (2) is air-formed in the blank dry-forming module (4) into a continuous cellulose blank (2b).

6. The method comprises subjecting the cellulose blank structure (2) to a forming temperature (T Ｆ ) and the cellulose blank structure (2) is pressed by the pressing operation (O Ｐ ) at molding pressure (P Ｆ 3. The method according to claim 1 or 2, further comprising the step of forming the cellulose product (1) from the cellulose blank structure (2) in the one or more forming dies (3) by pressing with a pressing machine.

7. The molding temperature (T Ｆ ) is in the range of 100 to 300° C., preferably in the range of 100 to 200° C., and the molding pressure (P Ｆ 7. The method of claim 6, wherein the pressure is in the range of 1 to 100 MPa, preferably in the range of 4 to 20 MPa.

8. The pressing operation (O Ｐ ) is a single press operation (O ＳＰ 3. The method according to claim 1 or 2, wherein

9. The method according to claim 1 or 2, further comprising the step of transporting the air-formed cellulosic blank structure (2) from the blank dry-forming module (4) to the press module (6).

10. 3. The method according to claim 1 or 2, characterized in that the cellulose blank structure (2) is conveyed intermittently from the blank dry-forming module (4) to the press module (6).

11. 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) in a second feeding direction (D Ｆ２ ) to the press module (6), in which the second feed direction (D Ｆ２ ) is the first supply direction (D Ｆ１ 11. The method of claim 10, wherein said first and second nucleotide sequences are different from each other.

12. The first supply direction (D Ｆ１ ) is the second supply direction (D Ｆ２ 12. The method of claim 11, wherein the reverse or substantially reverse of

13. The first supply direction (D Ｆ１ ) is an upward direction, and the second feed direction (D Ｆ２ 12. The method of claim 11, wherein the direction of the arrows is downward.

14. 2. The method of claim 1, further comprising the steps of: operating the mill (4a) continuously; and continuously supplying the cellulose raw material (R) to the mill (4a) or intermittently supplying the cellulose raw material (R) to the mill (4a).

15. 15. The method according to claim 1 or 14, wherein the forming wire (4c) has a forming section (4d) connected and arranged to a forming chamber opening (4e) of the forming chamber (4b), the method further comprising the step of air forming the cellulose blank structure (2) onto the forming section (4d).

16. The forming section (4d) is arranged in an upward blank forming direction (D Ｕ ), the method further comprising air forming the cellulose blank structure (2) on the forming section (4d) and moving the formed cellulose blank structure (2) by the forming wire (4c) in the upward blank forming direction (D Ｕ 20. The method of claim 15, further comprising the step of:

17. The forming section (4d) is aligned in the horizontal blank forming direction (D ＨＦ ), the method further comprising: pneumatically forming the cellulose blank structure (2) on the forming section (4d) and rotating the formed cellulose blank structure (2) by the forming wire (4c) in the horizontal blank forming direction (D ＨＦ 20. The method of claim 15, further comprising the step of:

18. The forming wire (4c) has a first side (S1) facing the forming chamber (4b) and a second side (S2) facing a vacuum box (4f) arranged in connection with the forming chamber (4b), the vacuum box (4f) being configured to control the air flow in the forming chamber (4b) and to distribute the separated cellulose fibers (F) onto the forming wire (4c), the method comprising the steps of: air forming the cellulose blank structure (2) onto the first side (S1) of the forming wire (4c); applying a negative pressure (P) onto the second side (S2) to ensure adhesion of the cellulose fibers (F) onto the first side (S1); ＮＥＧ 3. The method of claim 1, further comprising the step of:

19. 3. The method according to claim 1 or 2, wherein the product forming unit (U) comprises a blank recycling module (7), and the method further comprises a step of transporting a remaining portion (2c) of the cellulose blank structure (2) from the press module (6) to the blank dry-forming module (4).

20. 20. The method according to claim 19, wherein the blank recycle module comprises a recycle compression unit (7b), and the method further comprises compressing the remaining portion (2c) of the cellulose blank structure (2) in the recycle compression unit (7b) when transferring it from the press module (6) to the blank dry-forming module (4).

21. The press module (6) is a cellulosic product toggle press module for forming the cellulosic product (1) from the cellulosic blank structure (2), the method comprising: Providing the cellulose product toggle press module having a toggle press (6a) and the one or more molds (3), the toggle press (6a) being configured to have a pressing direction (D Ｐ a press member (6d) movably disposed on a press member (6d) and a toggle mechanism (6e) connected to said press member (6d), a press actuator assembly (6f) connected to said toggle mechanism (6e), and an electronic control system (6h) operably connected to said press actuator assembly (6f), wherein each of said one or more molds has a movable first mold portion (3a) attached to said press member (6d) and a stationary second mold portion (3b); The toggle press (6a) is mainly moved in the horizontal direction (D Ｈ ) of the pressing member (6d) disposed in the pressing direction (D Ｐ ) in particular in the horizontal direction (D Ｈ The pressing direction (D) of the pressing member (6d) is arranged within 20 degrees from Ｐ ), more preferably in the horizontal direction (D Ｈ ) parallel to the pressing direction (D Ｐ 4. The method of claim 1, further comprising: The cellulose blank structure (2) is pressed into a press area (A) defined by the spaced apart first and second mold parts (3a, 3b). Ｐ ) 。 The toggle mechanism (6e) is used to Ｐ controlling operation of said press actuator assembly (6f) by said electronic control system (6h) to drive said press members (6d) with said press actuators (6e) and to press each of said first mould parts (3a) against said stationary second mould parts (3b) to form said cellulose product (1) from said cellulose blank structure (2); The method of claim 1 or 2, further comprising:

22. A product forming unit (U) for dry forming a cellulose product (1) from a cellulose blank structure (2), the product forming unit (U) having a blank dry forming module (4) and a press module (6), the cellulose blank structure (2) being air-formed on a forming wire (4c) in the blank dry forming module (4), the blank dry forming module (4) further having a mill (4a) and a forming chamber (4b), the forming wire (4c) being connected to and arranged in the forming chamber (4b), the press module (6) pressing the cellulose product (1) from the cellulose blank structure (2) in a pressing operation (O). Ｐ ), the product forming unit (U) is configured to supply a cellulose raw material (R) to the blank dry-forming module (4), the blank dry-forming module (4) is configured to separate cellulose fibers (F) from the cellulose raw material (R) in the mill (4a) and distribute the separated cellulose fibers (F) onto the forming wire (4c) in the forming chamber (4b) to air-form the cellulose blank structure (2) from the cellulose raw material (R) in the blank dry-forming module (4), and the blank dry-forming module (4) is configured to air-form the cellulose blank structure (2) on the forming wire (4c) in the blank dry-forming module (4), the blank dry-forming module (4) feeding the forming wire (4c) to the blank dry-forming module (4) in the mill (4a). Ｐ ) in still mode (M ＳＴ ) a product forming unit (U).

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