METHOD FOR PRODUCING CELLULOSE PRODUCTS AND PRODUCT-FORMING UNIT FOR PRODUCING

Abstract

A method for producing a non-flat cellulose product from an air-formed cellulose blank structure in a product forming unit, the product forming unit having a buffer module and a press module with one or more forming dies. The method includes the steps of: providing a cellulose blank structure and feeding the cellulose blank structure to the buffer module; buffering the cellulose blank structure in the buffer module and feeding the cellulose blank structure from the buffer module to the press module; forming a cellulose product from the cellulose blank structure in the one or more forming dies by heating the cellulose blank structure to a forming temperature and pressing the cellulose blank structure with a forming pressure. The cellulose blank structure is continuously fed to the buffer module in a first feed direction and intermittently fed from the buffer module in a second feed direction, the second feed direction being different from the first feed direction.

Description

[Technical field]

[0001] The present disclosure relates to a method for producing a cellulose product from an air-formed cellulose blank structure in a product forming unit, the product forming unit having a buffer module and a press module, the press module having one or more molds for forming a cellulose product from the cellulose blank structure. The cellulose product is formed from the cellulose blank structure in the one or more molds by heating the cellulose blank structure to a forming temperature and pressing the cellulose blank structure with a forming pressure. The present disclosure further relates to a product forming unit for producing a cellulose product from the air-formed cellulose blank structure.

[0002] 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.

[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 the dry forming of cellulose products and generally use a press module with a forming mould. In the product-forming unit, other modules and components are arranged connected to the press module, such as, for example, a feed module, a buffer module and a blank dry-forming module. Product-forming units generally use high-capacity press modules, such as vertical hydraulic press units, which are generally used for forming other materials, such as steel sheets, since it is usually necessary to establish a high product-forming pressure in the mould. Blank-forming modules are generally supplied 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 dry molded 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 molding. Therefore, there is a strong demand for a complete product forming unit, all integrated and standardized, ready to buy, ship, install, and operate.

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

[0008] overview The object of the present disclosure is to provide a method for producing a non-flat cellulose product from an air-formed cellulose blank structure in a product-forming unit and a product-forming unit for producing a non-flat cellulose product from an air-formed cellulose blank structure, 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 producing a non-flat cellulose product from an air-formed cellulose blank structure in a product-forming unit and of the product-forming unit for producing a non-flat cellulose product from an air-formed cellulose blank structure.

[0009] The present disclosure relates to a method for producing a non-flat cellulose product from an air-formed cellulose blank structure in a product forming unit. The product forming unit includes a buffer module and a press module with one or more forming dies. The method includes the steps of: providing a cellulose blank structure and feeding the cellulose blank structure to the buffer module; buffering the cellulose blank structure in the buffer module and feeding the cellulose blank structure from the buffer module to a press module; forming a cellulose product from the cellulose blank structure in the one or more forming dies by heating the cellulose blank structure to a forming temperature and pressing the cellulose blank structure with a forming pressure. The cellulose blank structure is continuously fed to the buffer module in a first feeding direction and intermittently fed from the buffer module in a second feeding direction, the second feeding direction being different from the first feeding direction.

[0010] The advantage of these features is that the different feed directions allow multiple optimized modules to be integrated 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 little or no modular engineering skill required from 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-traditional 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 that of current units with individual modules that are purchased separately and aligned to become a custom-made industrial line. This solution also reduces the multiple investment costs for the converter, since the weight of the machine is generally related to the purchase price. The reduced investment costs allow for a quicker conversion to products made with cellulose feedstock instead of plastic materials.

[0011] According to one embodiment of the present disclosure, the first feed direction is opposite or substantially opposite to the second feed direction, which 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.

[0012] According to another aspect of the present disclosure, 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.

[0013] According to a further aspect of the present disclosure, the cellulose blank structures are intermittently fed from the buffer module to the press module, the intermittent feeding ensuring efficient transport of the cellulose blank structures into the intermittently operating press module.

[0014] According to one aspect of the present disclosure, the buffer module is configured to alternately operate in a buffer mode and a feed mode. The method further includes: feeding the cellulose blank structures to the buffer module at a continuous input rate in the buffer mode and in the feed mode; and feeding the cellulose blank structures from the buffer module in the buffer mode at an output rate lower than the output rate of the cellulose blank structures from the buffer module in the feed mode. The continuous input rate ensures a steady transport of the cellulose blank structures into the buffer module. The relatively low output rate in the buffer mode allows a buffer of the cellulose blank structures to be formed in the buffer module.

[0015] According to another aspect of the present disclosure, the output speed in the buffer mode is zero or the output speed in the buffer mode is substantially zero. These speed options ensure efficient intermittent feeding of the cellulosic blank structure to the press module.

[0016] According to a further aspect of the present disclosure, the buffer module has an inlet portion, an outlet portion, and a buffer portion between the inlet portion and the outlet portion. The cellulose blank structure has a buffer extension in the buffer portion between the inlet portion and the outlet portion. The method further includes: gradually increasing the buffer extension of the cellulose blank structure in the buffer portion during the buffer mode and gradually decreasing the buffer extension of the cellulose blank structure in the buffer portion during the feed mode. Such operation of the buffer module allows for smooth buffering of the cellulose blank structure as well as smooth release of the cellulose blank structure from the buffer module.

[0017] According to one aspect of the disclosure, the buffer portion has a guide member having a first arm section and a second arm section configured to intermittently vary the buffer extension in a buffer mode and a feed mode. The method includes: varying an angular relationship between the first arm section and the second arm section in the buffer mode and the feed mode to vary the buffer extension. The change in the angular relationship ensures an efficient and compact layout of the buffer module, and the arm sections are used to vary the buffer extension in the different modes.

[0018] According to another aspect of the disclosure, the method further includes the steps of: continuously feeding the cellulose blank structures to the inlet portion and intermittently feeding the cellulose blank structures from the outlet portion by operating the guide members, in a buffer mode, during operation of the guide members, a buffer of cellulose blank structures is formed in the buffer portion, and in a feed mode, during operation of the guide members, the buffer of cellulose blank structures is released from the buffer portion.

[0019] According to a further aspect of the present disclosure, the product forming unit further comprises a blank dry-forming module configured to provide a cellulose blank structure. The method includes the steps of: providing a cellulose raw material and feeding the cellulose raw material to the blank dry-forming module; dry-forming a cellulose blank structure from the cellulose raw material in the blank dry-forming module; and feeding the cellulose blank structure from the blank dry-forming module to a buffer 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 an input material for the in-line production of the cellulose blank structure.

[0020] According to one aspect of the present disclosure, the blank dry-forming module includes a mill, a forming chamber, and a forming wire disposed in connection with the forming chamber. The method further includes: separating fibers from a cellulose feedstock in the mill, and distributing the separated fibers on the forming wire in the forming chamber for forming a cellulose blank structure.

[0021] According to another aspect of the present disclosure, the forming wire has a forming section connected to and disposed at a forming chamber opening of the forming chamber, the method further comprising: forming the cellulosic blank structure onto the forming section.

[0022] According to a further aspect of the present disclosure, the forming section extends in an upward blank-forming direction. The method further includes forming the cellulose blank structure on the forming section and transporting the formed cellulose blank structure from the forming section in the upward blank-forming direction towards the buffer module. 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 the upward direction for direct transport to the buffer module.

[0023] According to one aspect of the present disclosure, the product forming unit includes a blank recycling module, and the method further includes: feeding a residual portion of the cellulosic blank structure from the press module to a blank dry-forming module, where the feeding of the residual portion ensures that the unused portion of the cellulosic blank structure can be reused.

[0024] According to another aspect of the present disclosure, the product forming unit includes a barrier application module disposed upstream of the buffer module, and the method further includes the step of: applying a barrier composition onto the cellulosic blank structure in the barrier application module, the barrier composition being used to modify the hydrophobic properties of the cellulosic product.

[0025] According to a further aspect of the present disclosure, the method further comprises the steps of: forming a cellulose product from the cellulose blank structure in one or more molds by heating the cellulose blank structure to a forming temperature in the range of 100-300° C. and pressing the cellulose blank structure at a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa. These parameters provide efficient forming of the cellulose product with strong hydrogen bonds formed.

[0026] According to one aspect of the disclosure, the press module is a cellulosic toggle press module for forming a non-planar 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 molds, the toggle press having 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, each of the one or more molds having a movable first mold part attached to the press member and a stationary second mold 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, more specifically to have a press direction parallel to the horizontal; feeding a cellulose blank structure into a press area defined by the spaced apart first and second mold 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 pressing each first mold part against the stationary second mold 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.It is therefore clear that a primarily horizontally oriented press module is extremely beneficial when developing a compact cellulose product forming unit for efficient production of cellulose products having press members primarily oriented horizontally, specifically having a press direction of the press members oriented within 20 degrees of the horizontal, and more specifically having a press direction parallel to the horizontal.

[0027] The present disclosure further relates to a product forming unit for producing a non-flat cellulose product from an air-formed cellulose blank structure. The product forming unit includes a buffer module and a press module with one or more molds. The product forming unit is adapted to feed the cellulose blank structure to the buffer module, buffer the cellulose blank structure in the buffer module, and feed the cellulose blank structure from the buffer module to the press module. The product forming unit is further adapted to form a cellulose product from the cellulose blank structure in the one or more molds by heating the cellulose blank structure to a forming temperature and pressing the cellulose blank structure with a forming pressure. The buffer module includes a blank feeding system configured to continuously feed the cellulose blank structure to the buffer module in a first feeding direction and intermittently feed the cellulose blank structure from the buffer module in a second feeding direction, where the second feeding direction is different from the first feeding direction.

[0028] The advantage of these features is that the different feed directions allow for a more compact layout and construction of the product forming unit, whereby the modules can be positioned relative to each other in a non-traditional manner for an efficient and compact layout.

[0029] According to one embodiment of the present disclosure, the buffer module has an inlet portion, an outlet portion, and a buffer portion between the inlet portion and the outlet portion. The cellulose blank structure is disposed with a buffer extension in the buffer portion between the inlet portion and the outlet portion. The buffer portion is configured to gradually increase the buffer extension of the cellulose blank structure during a buffer mode and to gradually decrease the buffer extension of the cellulose blank structure during a feed mode. Such a configuration of the buffer module allows for smooth buffering of the cellulose blank structure as well as smooth release of the cellulose blank structure from the buffer module.

[0030] According to another aspect of the disclosure, the buffer portion includes a guide member having a first arm section and a second arm section configured to intermittently vary the buffer extension in a buffer mode and a feed mode. The buffer portion is configured to vary an angular relationship between the first arm section and the second arm section in the buffer mode and the feed mode to vary the buffer extension. The change in the angular relationship ensures an efficient and compact layout of the buffer module, and the arm sections are used to vary the buffer extension in the different modes.

[0031] According to a further aspect of the present disclosure, the blank feed system comprises at least one blank feed roller connected to or arranged upstream of the inlet section and / or connected to or arranged downstream of the outlet section, the blank feed roller being used to ensure a desired transport of the cellulose blank structure into and away from the buffer module.

[0032] According to one embodiment of the present disclosure, the buffer module has a first blank deflection device located upstream of the inlet section and / or a second blank deflection device located downstream of the outlet section. The deflection devices are used to change the direction of the cellulosic blank structure within the buffer module, which may be required depending on the design and construction of the buffer module.

[0033] According to another aspect of the present disclosure, the blank feeding system is configured to continuously feed the cellulose blank structures to the inlet portion and intermittently feed the cellulose blank structures from the outlet portion by actuation of the guide members, in a buffer mode, during actuation of the guide members, a buffer of the cellulose blank structures is formed in the buffer portion, and in a feed mode, during actuation of the guide members, the buffer of the cellulose blank structures is released from the buffer portion.

[0034] According to a further aspect of the present disclosure, the product forming unit further comprises a blank dry forming module configured to provide a cellulose blank structure. 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.

[0035] According to one aspect of the disclosure, a blank dry forming module includes a mill, a forming chamber, and a forming wire disposed in connection with the forming chamber. The mill is configured to separate fibers from a cellulose feedstock. The forming chamber is configured to distribute the separated fibers onto a forming section of the forming wire for forming a cellulose blank structure.

[0036] According to another aspect of the present disclosure, the forming section extends in an upward blank forming direction. The non-conventional upward extension of the forming section allows a compact layout of the product forming unit since the cellulose blank structures can be formed in an upward direction for direct transfer to the buffer module.

[0037] According to a further aspect of the present disclosure, the product forming unit includes a blank recycling module configured to feed a remaining portion of the cellulosic blank structure from the press module to the blank dry forming module, the recycling module ensuring that the remaining portion of the cellulosic blank structure can be reused.

[0038] According to one aspect of the present disclosure, the product forming unit includes a barrier application module disposed upstream of the buffer module, the barrier application module configured to apply a barrier composition onto the cellulosic blank structure, the barrier application module effectively applying the barrier composition onto the cellulosic blank structure to alter hydrophobic properties of the cellulosic product.

[0039] According to another aspect of the present disclosure, the one or more molds are configured to mold a 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.

[0040] According to a further aspect of the disclosure, the press module is a cellulosic product toggle press module for forming a non-flat cellulosic product from a cellulosic blank structure. The press module includes: a toggle press with a press member movably arranged in a press direction, a toggle mechanism drivingly connected to the press member, a press actuator assembly drivingly connected to the toggle mechanism, and an electronic control system operably connected to the press actuator assembly, and one or more molds each having a movable first mold part and a stationary second mold part attached to the press member. The electronic control system is configured to control the operation of the press actuator assembly to drive the press member in the press direction using the toggle mechanism to press the first mold part against the stationary second mold part to form a non-flat cellulosic product from the air-formed cellulosic blank structure. The toggle press is installed or arranged to be installed 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, more specifically to have a press direction parallel to the horizontal. The predominantly horizontal orientation of the toggle press allows for a low construction 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. The non-linear material flow, where the air-formed cellulosic blank structures are fed in a first direction, e.g., upwards, and then in a second direction, e.g., downwards, generally allows for the development and manufacture of a more compact cellulosic product forming unit. The predominantly horizontal orientation of the toggle press is typically associated with a predominantly vertically arranged feed flow of the continuous cellulosic blank structures, since the continuous web of cellulosic fiber material is typically fed into the press module approximately perpendicular to the press direction of the press module.It is therefore evident that a primarily horizontally oriented press module is extremely beneficial when developing a compact cellulose product forming unit having a non-linear material flow of the cellulose blank structure from the blank dry-forming module to the press module.

[0041] The present disclosure will now be described in detail with reference to the accompanying drawings. [Brief description of the drawings]

[0042] [Figure 1a] FIG. 2 is a side view showing a schematic diagram 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 product forming unit 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; [Diagram 2] FIG. 1 is a perspective view showing a schematic diagram of a blank dry forming module according to the present disclosure. [Diagram 3] FIG. 1 is a perspective view illustrating a buffer module according to the present disclosure. [Figure 4a] FIG. 2 is a side view diagrammatically illustrating a buffer module according to the present disclosure. [Figure 4b] FIG. 2 is a side view diagrammatically illustrating a buffer module according to the present disclosure. [Figure 4c] FIG. 2 is a side view diagrammatically illustrating a buffer module according to the present disclosure. [Figure 4d] FIG. 2 is a side view diagrammatically illustrating a buffer module according to the present disclosure. [Figure 5a] FIG. 13 is a side view diagrammatically illustrating a buffer module according to an alternative embodiment of the present disclosure. [Figure 5b]FIG. 13 is a side view diagrammatically illustrating a buffer module according to an alternative embodiment of the present disclosure. [Figure 5c] FIG. 13 is a side view diagrammatically illustrating a buffer module according to an alternative embodiment of the present disclosure. [Figure 5d] FIG. 13 is a side view diagrammatically illustrating a buffer module according to an alternative embodiment of the present disclosure. [Figure 5e] FIG. 13 is a side view diagrammatically illustrating a buffer module according to an alternative embodiment of the present disclosure. [Figure 6a] FIG. 1 is a perspective view illustrating a press module according to the present disclosure. [Figure 6b] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 6c] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 6d] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 6e] FIG. 1 is a side view illustrating a schematic diagram of a press module according to the present disclosure. [Figure 7a] FIG. 13 is a side view diagrammatically illustrating a press module according to an alternative embodiment of the present disclosure. [Figure 7b] FIG. 13 is a side view diagrammatically illustrating a press module according to an alternative embodiment of the present disclosure.

[0043] 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.

[0044] 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.

[0045] 1a-1c show diagrammatically 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 is configured to form a horizontal or planar D H and the vertical direction D V The product forming unit U comprises a buffer module 5 and a press module 6, as will be further described below. The cellulose product 1 is produced from a cellulose blank structure 2 in the product forming unit U. The cellulose blank structure 2 is provided from a suitable source and fed to the buffer module 5 and the press module 6. The shaping of the cellulose product 1 takes place in the press module 6. By non-flat product is meant a product having a three-dimensional extent which differs from flat products such as blanks or sheets.

[0046] The air-formed cellulose blank structure 2 according to the present disclosure 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 forming the cellulose blank structure 2 in the air-formed 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-formed 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 corresponds mainly to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2, if appropriate. Alternatively, the dryness of the cellulosic blank structure 2 can be controlled to have an appropriate dryness level when forming the cellulosic product 1 .

[0047] 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 Figs. 1a-1c 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 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.

[0048] 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.

[0049] 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 an air-formed layer. The cellulose blank structure 2 may have two or more reinforcing layers, if appropriate.

[0050] The cellulose blank structure 2 may further include 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 barrier layers may be of a different composition, e.g., barrier structure organization, than the other layers of the cellulose blank structure 2.

[0051] 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.

[0052] The press module 6, as shown in Figs. 1a-1b and 6a-6e, 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.

[0053] In the embodiment shown in Figures 1a to 1c and 6a to 6e, 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 Figs. 6a-6b, 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 at .

[0054] 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.

[0055] 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 6a, 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. 6b-6e 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.

[0056] 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.

[0057] 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 product forming unit U. Alternatively, the cellulose blank structure 2 may be air-formed from cellulose fibres in a blank dry-forming module 4 of the product forming unit U and fed directly to the press module 6 via a buffer module 5.

[0058] The cellulose product 1 is formed by subjecting the cellulose blank structure 2 to a molding temperature T F and the cellulose blank structure 2 is molded under a molding pressure P in the range of 1 to 100 MPa, preferably 4 to 20 MPa. F The cellulose blank structure 2 is formed in one or more forming dies 3 by pressing the cellulose blank structure 2 with a pressing pressure of 1 to 100 MPa, preferably 4 to 20 MPa. The first mould parts 3a are arranged to form the non-flat cellulose product 1 by interaction with the corresponding second mould parts 3b as illustrated in Figures 6b to 6e. During forming of the cellulose product 1, the cellulose blank structure 2 is pressed in each forming die 3 with a pressing pressure of 1 to 100 MPa, preferably 4 to 20 MPa. F and a molding 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 and the cellulose blank structure 2 is molded under a molding pressure P in the range of 1 to 100 MPa, preferably 4 to 20 MPa. 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 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.

[0059] 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 FThe 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.

[0060] As shown in FIG. 6b, 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. 6c. 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 F The 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 Fis applied to the cellulose blank structure 2 in each forming cavity C. The forming of the cellulose product 1 may further include 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. 6e, and the cellulose product 1 can be removed from the press module 6, for example, using an ejector rod or a similar device.

[0061] 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. 6b-6e, 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 is formed as an equalized forming pressure, in which 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 P For example, the pressing direction D P and press direction D P The equalized molding pressure may include an isotropic molding pressure.

[0062] 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. FThe 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 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 level.

[0063] 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.

[0064] The product forming unit U shown in Figs. 1a to 1c includes a buffer module 5 and a press module 6. The product forming unit U is adapted to supply the cellulose blank structure 2 to the buffer module 5, buffer the cellulose blank structure 2 in the buffer module 5, and supply the cellulose blank structure 2 from the buffer module 5 to the press module 6. The product forming unit U further supplies the cellulose blank structure 2 with a forming temperature T F and the cellulose blank structure 2 is heated to a molding pressure P F The one or more molds 3 are adapted to mold the cellulose blank structure 2 into a non-flat cellulose product 1 by pressing the cellulose blank structure 2 at a molding temperature T in the range of 100-300° C. As mentioned above, the one or more molds 3 press the cellulose blank structure 2 at a molding temperature T F and the cellulose blank structure 2 is molded under a molding pressure P in the range of 1 to 100 MPa, preferably 4 to 20 MPa. F The cellulosic blank structure 2 is configured to be pressed with a pressing machine to form a non-flat cellulosic product 1 from the cellulosic blank structure 2 .

[0065] The buffer module 5 is arranged, for example, as shown in FIG. 1, upstream of the press module 6, and has the purpose of converting the feeding mode of the cellulose blank structures 2 from a continuous feeding to an intermittent feeding. Due to the relatively fragile structural characteristics of the cellulose blank structures 2, a continuous feeding from a cellulose blank structure source is suitable. However, due to the intermittent operation of the press module 6, the continuous feeding has to be converted to an intermittent feeding without destroying the cellulose blank structures 2. To achieve this, as shown in FIG. 3, FIG. 4a-4d and FIG. 5a-5e, the buffer module 5 is provided with a blank feeding system S configured to continuously feed the cellulose blank structures 2 to the buffer module 5 and to intermittently feed the cellulose blank structures 2 from the buffer module 5. F It has a blank supply system S FFurther, the cellulose blank structure 2 is fed in a first feeding direction D F1 and the cellulose blank structure 2 is fed continuously into the buffer module 5 in a second feed direction D F2 , and in this case, the second supply 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 between the first and second feed directions D allows for a compact construction and layout of the product-forming unit U and allows for an effective and compact positioning of the various modules of the product-forming unit U relative to one another. During operation of the product-forming unit U, the cellulose blank structure 2 is buffered in the buffer module 5 and fed from there to the press module 6. The cellulose blank structure 2 is fed in a first feed direction D F1 into the buffer module 5 in a second feed direction D F2 The power is supplied intermittently from the buffer module 5.

[0066] In certain embodiments, as shown, for example, in the embodiments of Figures 3, 4a-4d and 5a-5e, the first feed direction D F1 is the second feed direction D F2 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 the product forming unit U to be constructed compactly and efficiently.

[0067] The buffer module 5 has an inlet portion 5a, an outlet portion 5b, and a buffer portion 5c between the inlet portion 5a and the outlet portion 5b, as shown in Figures 3, 4a to 4d, and 5a to 5e. The cellulose blank structure 2 is provided with a buffer extension E in the buffer portion 5c between the inlet portion 5a and the outlet portion 5b. B The buffer extension E of the cellulose blank structure 2 is arranged. Bis measured as the extension length of the cellulose blank structure 2 between the inlet section 5a and the outlet section 5b. The buffer section 5c is a buffer mode M B Buffer extension of cellulose blank construct 2 during B gradually increases, and the supply mode M F Buffer extension of cellulose blank construct 2 during B is configured to decrease gradually.

[0068] In the embodiment shown in Figures 3, 4a-4d and 5a-5c, the buffer section 5c has a guide member 5d. The guide member 5d is arranged between the inlet section 5a and the outlet section 5b. As shown in more detail in Figure 3, the guide member 5d is arranged in the buffer mode M. B and supply mode M F In each case, the buffer extension E B A first arm section 5d configured to intermittently vary 1 and second arm segment 5d 2 The arm section or other part of the buffer module 5 may be arranged with a support plate, belt or other structure suitable for accurate positioning of the cellulose blank structure 2 during feeding, where the support plate, belt or structure may be arranged to move together with the arm section. 1 and second arm segment 5d 2 The actuator 10 is connected to the buffer extension E B To change the first arm section 5d 1 and second arm segment 5d 2 As can be seen from FIG. 3 and FIG. 4a to FIG. 4d, the buffer extension E B In order to change the 1 and second arm segment 5d 2 The angular relationship α between R , buffer mode M B and supply mode M FThe actuator may be of any suitable type, for example a hydraulic or pneumatic piston actuator, or an electric actuator.

[0069] In FIG. 4a, the buffer module 5 is in buffer mode M B From the start position in FIG. 4a, the actuator 10 moves the first arm section 5d 1 and second arm segment 5d 2 In FIG. 4b, the length of the cellulose blank structure 2 is increased by the first arm section 5d. 1 and second arm segment 5d 2 and therefore the buffer mode M B In the buffer extension E B increases. First arm section 5d 1 and second arm segment 5d 2 If the buffer is moved further, the buffer extension E B increases further up to the end position of the buffer module 5 shown in FIG. 1 and second arm segment 5d 2 When the first arm section 5d reaches its end position, the actuator 10 then 1 and second arm segment 5d 2 The downward displacement of the supply mode M F is started, and supply mode M F So, the buffer extension B In FIG. 4d, the length of the cellulose blank structure 2 decreases along the first arm section 5d. 1 and second arm segment 5d 2 Supply mode M F 1st Arm Division 5d 1 and second arm segment 5d 2 and ends when it returns to the position shown in FIG. 4a, where the buffer mode M B and supply mode M FThe buffer cycle, including up and down, can begin again as described above. Note that up and down in this context refer to the orientation of the buffer module 5 in the illustrated embodiment. In other embodiments, the orientation of the buffer module 5 may be different.

[0070] In the embodiment shown in FIG. 3 and FIG. 4a to FIG. 4d, the blank supply system S F The blank feed system S has a blank feed roller 9 arranged in connection with the inlet section 5a and a blank feed roller 9 arranged in connection with the outlet section 5b or downstream of the outlet section 5b. The blank feed roller 9 is used to feed the cellulose blank structure 2 into and away from the buffer module. The blank feed roller 9 arranged in connection with the inlet section 5a is preferably continuously driven by a drive source not shown, such as an electric motor or a similar device. The blank feed roller 9 arranged in connection with the outlet section 5b is intermittently driven by a suitable drive source, such as an electric motor or a similar device, and is controlled by the control system. The blank feed roller 9 is preferably arranged as a tractor feed roller that engages the cellulose blank structure 2. Other types of blank feed rollers may also be used. Thus, the blank feed system S F The buffer mode M is configured to continuously feed the cellulose blank structure 2 to the inlet portion 5a and to intermittently feed the cellulose blank structure 2 from the outlet portion 5b when the guide member 5d is actuated. As described above in relation to Figures 4a to 4d, the buffer mode M B During the operation of the guide member 5d, a buffer of the cellulose blank structure 2 is formed in the buffer portion 5c, and in the supply mode M F During the actuation of the guide member 5d, the buffer of the cellulose blank structure 2 is released from the buffer portion 5c. In the embodiment shown in Fig. 3 and Fig. 4a to 4d, as can be seen from the drawings, the cellulose blank structure 2 is fed in a first feeding direction D through an assembly with a feed roller 9. F15 and is connected directly to the buffer module 5 in a second supply direction D F2 The power supply 11 is directly connected to the buffer module 5 and is supplied intermittently from the buffer module 5.

[0071] The feed rollers 9 may each be arranged as a roller pair cooperating with the cellulose blank structure 2 disposed therebetween instead of as a single roller. In an alternative embodiment not shown, the blank feed rollers 9 may alternatively be arranged upstream of the inlet portion 5a and / or downstream of the outlet portion 5b.

[0072] For all embodiments, the cellulose blank structure 2 is intermittently fed from a buffer module 5 to a press module 6. The buffer module 5 is in a buffer mode M. B and supply mode M F The cellulose blank structure 2 is configured to operate alternately in the buffer mode M as shown in Figs. 4a to 4d. B and supply mode M F At a continuous input rate of V I The cellulose blank structure 2 is fed to the buffer module 5 in the buffer mode M B In this case, for intermittent supply operation, supply mode M F The output rate V of the cellulose blank structure 2 from the buffer module 5 at O Output speed V is lower than O The buffer module 5 is preferably in buffer mode M B Output speed V O is zero, or the buffer mode M B Output speed V O is effectively zero.

[0073] The buffer module 5 comprises a first blank deflection device 5e arranged upstream of the inlet section 5a. 1 and / or a second blank deflection device 5e arranged downstream of the outlet section 5b. 2The gypsum may further comprise:

[0074] In Fig. 5a an alternative embodiment of the buffer module 5 is shown, which is operated in a similar manner as described above in relation to the embodiment of Figs. 3 and 4a to 4d. 1 is disposed upstream of the inlet section 5a, and the second blank deflection device 5e 2 is arranged downstream of the outlet section 5b. Each deflection device is preferably arranged as a roller for changing the direction of the cellulose blank structure 2. According to the configuration of FIG. 5a, the cellulose blank structure 2 is fed in a first feed direction D F1 The blanks are continuously fed to the buffer module 5 by the first blank deflection device 5e 1 The cellulose blank structure 2 is deflected at the second blank deflection device 5e and fed to the feed rollers 9 at the inlet section 5a. 2 In the second feed direction D F2 The cellulose blank structure 2 is fed intermittently from the buffer module 5 to the second blank deflection device 5e from the feed rollers 9 at the exit section 5b. 2 where the cellulose blank structure is fed in a second feed direction D F2 As can be seen from the drawing, due to the compact structure of the product forming unit U, the second feed direction D F2 is the first feed direction D F1 The feed roller 9 is preferably driven in the same way as in the embodiment described above.

[0075] In Fig. 5b an alternative embodiment of the buffer module 5 is shown, which is operated in a similar manner as described above in relation to the embodiment of Figs. 3 and 4a to 4d. 2 is arranged downstream of the outlet section 5b. The deflection device is preferably arranged as a roller for changing the direction of the cellulose blank structure 2. According to the configuration of Fig. 5b, the cellulose blank structure 2 is fed in a first feed direction D to the feed roller 9 in the inlet section 5a.F1 The cellulose blank structure 2 is continuously fed to the buffer module 5 by a second blank deflection device 5e. 2 In the second feed direction D F2 The cellulose blank structure 2 is fed intermittently from the buffer module 5 to the second blank deflection device 5e from the feed rollers 9 at the exit section 5b. 2 where the cellulose blank structure is fed in a second feed direction D F2 As can be seen from the drawing, due to the compact structure of the product forming unit U, the second feed direction D F2 is the first feed direction D F1 The feed roller 9 is preferably driven in the same way as in the embodiment described above.

[0076] In Fig. 5c an alternative embodiment of the buffer module 5 is shown, which is operated in a similar manner as described above in relation to the embodiment of Figs. 3 and 4a to 4d. 1 is arranged upstream of the inlet section 5a. The deflection device is preferably arranged as a roller for changing the direction of the cellulose blank structure 2. According to the configuration of FIG. 5c, the cellulose blank structure 2 is fed in a first feeding direction D F1 The blanks are continuously fed to the buffer module 5 by the first blank deflection device 5e 1 and fed to feed rollers 9 in the inlet section 5a. The cellulose blank structures 2 are fed intermittently from the buffer module 5 at feed rollers 9 arranged in the outlet section 5b. As can be seen from the drawing, due to the compact structure of the product forming unit U, the second feed direction D F2 is the first feed direction D F1 The feed roller 9 is preferably driven in the same way as in the embodiment described above.

[0077] In Fig. 5d a further alternative embodiment of the buffer module 5 is shown. In this embodiment, the buffer module 5 is arranged without guide members. The buffer module 5 has an inlet section 5a, an outlet section 5b and a buffer section 5c between the inlet section 5a and the outlet section 5b. The cellulose blank structure 2 is connected to the buffer extension E in the buffer section 5c between the inlet section 5a and the outlet section 5b. B The buffer extension E of the cellulose blank structure 2 is arranged. B is measured as the extension length of the cellulose blank structure 2 between the inlet section 5a and the outlet section 5b. The buffer section 5c is a buffer mode M B Buffer extension of cellulose blank construct 2 during B gradually increases, and the supply mode M F Buffer extension of cellulose blank construct 2 during B The buffer module 5 is configured to continuously supply the cellulose blank structure 2 to the buffer module 5 and to intermittently supply the cellulose blank structure 2 from the buffer module 5. F As described above, the blank supply system S F Further, the cellulose blank structure 2 is fed in a first feeding direction D F1 and the cellulose blank structure 2 is fed continuously into the buffer module 5 in a second feed direction D F2 , and in this case, the second supply direction D F2 is the first feed direction D F1 It is configured to be different from.

[0078] In the embodiment shown in FIG. 5d, the blank supply system S FThe blank feed system S has a blank feed roller 9 arranged in connection with the inlet section 5a and a blank feed roller 9 arranged in connection with the outlet section 5b. The blank feed rollers 9 are used to feed the cellulose blank structure 2 into and away from the buffer module. The blank feed rollers 9 arranged in connection with the inlet section 5a are preferably driven continuously by a drive source not shown, such as an electric motor or a similar device. The blank feed rollers 9 arranged in connection with the outlet section 5b are driven intermittently by a suitable drive source, such as an electric motor or a similar device, and are controlled by the control system. Thus, the blank feed system S F is configured to continuously supply the cellulose blank structure 2 to the inlet portion 5a and to intermittently supply the cellulose blank structure 2 from the outlet portion 5b by the operation of the supply roller 9. B During the operation of the feed roller 9, a buffer of the cellulose blank structure 2 is formed in the buffer portion 5c, and in the feed mode M F During the actuation of the feed rollers 9, the buffer of the cellulose blank structure 2 is released from the buffer portion 5c. During the buffering, the cellulose blank structure 2 is allowed to hang down between the rollers, as can be seen from Fig. 5d. In the embodiment shown in Fig. 5d, the cellulose blank structure 2 is fed in a first feed direction D through the assembly with the feed rollers 9. F1 into the buffer module 5 in a second feed direction D F2 from the buffer module 5. The feed rollers 9 may alternatively each be arranged as a roller pair cooperating with the cellulose blank structure 2 arranged therebetween instead of as a single roller.

[0079] In Fig. 5e a further alternative embodiment of the buffer module 5 is shown. The buffer module 5 has an inlet section 5a, an outlet section 5b and a buffer section 5c between the inlet section 5a and the outlet section 5b. The cellulose blank structure 2 is provided with a buffer extension E in the buffer section 5c between the inlet section 5a and the outlet section 5b.B The buffer extension E of the cellulose blank structure 2 is arranged. B is measured as the extension length of the cellulose blank structure 2 between the inlet section 5a and the outlet section 5b. The buffer section 5c is a buffer mode M B Buffer extension of cellulose blank construct 2 during B gradually increases, and the supply mode M F Buffer extension of cellulose blank construct 2 during B The buffer module 5 is configured to continuously supply the cellulose blank structure 2 to the buffer module 5 and to intermittently supply the cellulose blank structure 2 from the buffer module 5. F As described above, the blank supply system S F Further, the cellulose blank structure 2 is fed in a first feeding direction D F1 and the cellulose blank structure 2 is fed continuously into the buffer module 5 in a second feed direction D F2 , and in this case, the second supply direction D F2 is the first feed direction D F1 It is configured to be different from.

[0080] In the embodiment shown in FIG. 5d, the blank supply system S F The blank feed system S has a blank feed roller 9 arranged in connection with the inlet section 5a and a blank feed roller 9 arranged in connection with the outlet section 5b. The blank feed rollers 9 are used to feed the cellulose blank structure 2 into and away from the buffer module. The blank feed rollers 9 arranged in connection with the inlet section 5a are preferably driven continuously by a drive source not shown, such as an electric motor or a similar device. The blank feed rollers 9 arranged in connection with the outlet section 5b are driven intermittently by a suitable drive source, such as an electric motor or a similar device, and are controlled by the control system. Thus, the blank feed system S Fis configured to continuously supply the cellulose blank structure 2 to the inlet portion 5a and to intermittently supply the cellulose blank structure 2 from the outlet portion 5b by the operation of the supply roller 9. B During the operation of the feed roller 9, a buffer of the cellulose blank structure 2 is formed in the buffer portion 5c, and in the feed mode M F During the actuation of the feed roller 9, the buffer of cellulose blank structures 2 is released from the buffer portion 5c. F further comprises intermediate rollers 11 configured to buffer the cellulose blank structure 2 in the buffer portion 5c. The two lower intermediate rollers 11 are arranged on a buffer actuator 12, which is arranged to be moved towards and away from the upper intermediate roller 11. During buffering, the buffer actuator 12 is moved away from the upper intermediate roller 11. When releasing the cellulose blank structure 2, the buffer actuator 12 is moved towards the upper intermediate roller 11. In this way, the buffer extension E B The buffer actuator may be displaced by a suitable displacement means, for example a linear actuator or a similar device. In the embodiment shown in FIG. 5d, the cellulose blank structure 2 is moved in a first feed direction D via an assembly comprising a feed roller 9 and an intermediate roller 11. F1 into the buffer module 5 in a second feed direction D F2 The cellulose blank structure 2 is intermittently fed from the buffer module 5 at 100° C. The feed roller 9 and the intermediate roller 11 may each alternatively be arranged as a roller pair cooperating with the cellulose blank structure 2 disposed therebetween instead of as a single roller. It should be noted that up and down in this context refers to the orientation of the buffer module 5 in the illustrated embodiment. In other embodiments the orientation of the buffer module 5 may be different.

[0081] In different embodiments, the buffer module 5 may further comprise a sensor and feedback system to measure and control the cellulose blank structure 2 in the buffer module. Stationary or movable support plates, belts or other suitable structures may be used in the buffer module 5 for accurate positioning of the cellulose blank structure 2 during feeding.

[0082] A press module 6 is shown, for example, in Figure 6a. In the illustrated embodiment, the press module 6 is a cellulosic toggle press module for forming a non-flat cellulosic product 1 from a cellulosic blank structure 2. The cellulosic toggle press module, as shown in Figures 1a-1b and 6a-6e, has one or more forming dies 3, each of which has a first die part 3a and a second die part 3b.

[0083] 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 molds 3. The one or more molds 3 have a moveable first mold part 3a and a stationary second mold part 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 movement of the press actuator assembly 6f to drive the press member 6d with a force of 1000 rpm to press the first mold part 3a against the stationary second mold part 3b, thereby forming the non-flat 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 DH 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

[0084] 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 once the cellulose product 1 has been 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 non-flat cellulose product 1 from the cellulose blank structure 2 when pressed together.

[0085] When forming the cellulose product 1, the press area A defined by the first mold part 3a and the second mold part 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. PThe first and second mold parts 3a, 3b are controlled by an electronic control system 6h to drive the first and second mold parts 3a, 3b towards the front structure 6b at the same speed. In this way, the first and second mold parts 3a, 3b respectively, when pressed together, together form a non-flat cellulose product 1 from the cellulose blank structure 2.

[0086] The press actuator assembly 6f may include, for example, a single or multiple hydraulic or pneumatic linear actuators, such as a cylinder-piston actuator. Alternatively, a motor with a rotating output shaft, for example 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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

[0091] In the embodiment shown in Figs. 1a to 1c and 6a, the toggle press 6a is H The pressing direction D of the pressing member 6d arranged in P In the embodiment shown in Figures 7a-7b, the toggle press 6a is installed in a slightly inclined state, which allows for an overall compact design of the product-forming unit U with a low construction height. In the embodiment shown in Figures 7a-7b, the toggle press 6a is installed in a slightly inclined state, which allows for an overall compact design of the product-forming unit U with a low construction height. In the embodiment shown in Figures 7a-7b, the toggle press 6a is installed in a slightly inclined state, which allows for 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:

[0092] 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 7a-7b.

[0093] As noted above, "predominantly horizontal" and "predominantly horizontally" refer to orientations that are more horizontally oriented than vertically oriented. "Predominantly vertical" and "predominantly vertically" refer to orientations that are more vertically oriented than horizontally oriented.

[0094] 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.

[0095] Generally, with reference to the exemplary embodiment of FIG. 6a, 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.

[0096] The use of a toggle press module to form a non-flat cellulosic product from an air-formed cellulosic 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.

[0097] The product forming unit U may further comprise a blank dry-forming module 4 configured to form a cellulose blank structure 2 from a cellulose raw material R, as shown in Figs. 1a-1c and 2. 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 in the blank dry-forming module 4, and then the cellulose blank structure 2 is fed from the blank dry-forming module 4 to a buffer module 5. 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 fibers F are distributed on the forming wire 4c in the forming chamber 4b for forming the cellulose blank structure 2. The mill 4a is configured for separating cellulose fibers F from the cellulose raw material R, and the forming chamber 4b is configured for distributing the separated fibers F onto a forming section 4d of a forming wire 4c for forming the cellulose blank structure 2. The forming section 4d is arranged connected to a forming chamber opening 4e of the forming chamber 4b. In the illustrated embodiment, the forming section 4d is arranged in an upward blank forming direction D. U The cellulose blank structure 2 is molded on the molding section 4d and extends from the molding section 4d in an upward blank molding direction D. U The blanks are transported toward the buffer module 5 in the upward blank forming direction D U serves for a compact 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 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 The paper is transported to the buffer module 5 by

[0098] The mill 4a separates the fibers F from the cellulose raw material R and distributes the separated fibers F into the forming chamber 4b. 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. The mill 4a may be of any conventional type, for example a hammer mill, a disk 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.

[0099] The forming chamber 4b is arranged to distribute the separated fibres onto the forming wire 4c for 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 fibres F are distributed from the mill 4a to the forming wire 4c. The fibres 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.

[0100] The forming wire 4c may be of any suitable conventional type and may be formed as an endless belt structure, as can be seen in Figure 2. A vacuum box 4f may be arranged connected to the forming wire 4c and the forming chamber 4b to control the air flow within the forming chamber 4b and distribute the separated fibers F onto the forming wire 4c.

[0101] The blank dry-forming module 4 of the embodiment shown in Fig. 1a-c and Fig. 2 has a horizontal distribution direction of the fibres, from the mill 4a through the forming chamber 4b to the forming wire 4c. Thus, a horizontal flow of air feeds the fibres 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 fibre transport distance by the air flow inside the forming chamber 4b must be long enough to minimise turbulence and / or to produce a uniform flow of cellulose fibres. The length of the blank-forming module 4 is therefore dependent on the fibre transport distance by the air flow. 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 allows for a reduced height of the product forming unit U compared to conventional solutions using vertical air flows.

[0102] For example, other suitable types of blank dry forming modules may be used, such as a web forming wheel.

[0103] The product forming unit U may further comprise a barrier application module 8 arranged upstream of the buffer module 5 as shown in Figures 1a-1b. The barrier application module 8 is configured to apply a barrier composition onto the cellulose blank structure 2 prior to forming the cellulose product 1 in one or more molds 3.

[0104] 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.

[0105] The barrier application module 8 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 8. 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 to 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.

[0106] For clarity, the feed path and feed direction of the cellulose blank structure 2 of the exemplary embodiment of Figures 1a-1c 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.

[0107] Alternatively, as shown diagrammatically in Fig. 1e, the blank dry-forming module 4 may be arranged with a mainly horizontally oriented forming wire 4c in the region of the forming chamber opening 4e, so as to have a mainly horizontally oriented feed path and feed direction of the cellulose blank structure 2 before feeding it 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.

[0108] 1d-1e, 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 the buffer module 5 and the barrier application module 8, are located in 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, and not necessarily in the exemplary positions of the embodiment of FIGS.

[0109] 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.

[0110] In particular, high speed intermittent feeding of the cellulose blank structure 2 from the buffer module 5 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, e.g. 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 continuous 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.

[0111] 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.

[0112] Furthermore, in the embodiment shown in Fig. 1a-1c, 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 residual part 2a of the cellulose blank structure 2 from the press module 6 back to the blank dry forming module 4 after forming the cellulose product 1. The blank recycle module 7 is arranged to convey the residual 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 residual part 2a of the cellulose blank structure comprising cellulose blank fiber material may result. By means of the blank recycle module 7, the residual 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-1c, 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 residual part 2a 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 2a of the cellulose blank structure 2 is fed into the mill 4a.

[0113] In an embodiment not shown, instead of the above-mentioned configuration, the blank recycling module 7 may have a channel structure with an inlet section 28 arranged connected to the mould 3, into which the residual part 2a 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 section connected to the mill 4a.

[0114] The product forming unit U may further comprise a conveying or feeding device for continuously or intermittently feeding the cellulose blank structures 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.

[0115] A product forming unit U having a buffer module 5, in which the cellulose blank structure 2 is fed in a first feed direction D F1 into the buffer module 5 in a second feed direction D F2 is intermittently supplied from the buffer module 5 in a first supply direction D F1 and the second feed direction D F2 The different feed directions allow for a compact construction of the product forming unit U. The different feed directions allow for multiple modules to 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 feed directions allow for a more compact layout and construction of the product forming unit, and the modules can be efficiently positioned relative to each other both horizontally and vertically, as can be seen from the drawings.

[0116] 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. Different method steps 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 an external entity, such as a sensor, an off-site server, or a cloud-based server.

[0117] 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.

[0118] 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]

[0119] 1. Cellulose products 2. Cellulose blank structure 2a 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 Buffer Module 5a Entrance section 5b Exit part 5c Buffer part 5d Guide member 5d 1 First Arm Section 5d 2 Second Arm Section 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 8 Barrier Coating Module 9 Blank supply roller 10 Actuator 11 Intermediate roller 12 Buffer Actuator C Molding Cavity D F Supply direction D F1First feed direction D F2 Second feed direction D H horizontal direction D P Press Direction D U Upward blank forming direction D V vertical direction E Pressure Distribution Element E B Buffer Extension F fiber M B Buffer Mode M F Supply Mode P F Molding Pressure R Cellulose raw material S F Blank Supply System T F Molding temperature U Product Forming Unit V I Input Speed V O Output Speed

Claims

1. A method for producing a non-flat cellulose product (1) from a cellulose blank structure (2) in a product-forming unit (U), the product-forming unit (U) comprising a buffer module (5) and a press module (6) with one or more forming dies (3), the product-forming unit (U) comprising a blank dry-forming module (4) configured to provide the cellulose blank structure (2), the blank dry-forming module (4) comprising a mill (4a), a forming chamber (4b) and a forming wire (4c) connected to and arranged in the forming chamber (4b), the forming wire (4c) having a forming section (4d) connected to and arranged in a forming chamber opening (4e) of the forming chamber (4b), the forming section (4d) extending in an upward blank-forming direction (D U ), The method comprises: providing a cellulose raw material (R), feeding the cellulose raw material (R) to the blank dry-forming module (4), separating fibers (F) from the cellulose raw material (R) in the mill (4a), and distributing the separated fibers (F) onto the forming section (4d) of the forming wire (4c) in the forming chamber (4b) for forming the cellulose blank structure (2), thereby dry-forming the cellulose blank structure (2) from the cellulose raw material (R) in the blank dry-forming module (4); feeding the formed cellulose blank structure (2) from the blank dry-forming module (4) to the buffer module (5) by conveying the formed cellulose blank structure (2) from the forming section (4d) towards the buffer module (5) in the upward blank forming direction (D U ); buffering the cellulose blank structure (2) in the buffer module (5) and feeding the cellulose blank structure (2) from the buffer module (5) to the press module (6); The cellulose blank structure (2) is molded at a molding temperature (T Ｆ ) and the cellulose blank structure (2) is heated to a molding pressure (P Ｆ forming said cellulose product (1) from said cellulose blank structure (2) in said one or more molds (3) by pressing with a pressing machine; Including, The cellulose blank structure (2) is fed in a first feeding direction (D Ｆ１ ) to the buffer module (5) in a second feeding direction (D Ｆ２ ) from the buffer module (5) in the second supply direction (D Ｆ２ ) is the first supply direction (D Ｆ１ ) is different from method.

2. The first supply direction (D Ｆ１ ) is the second supply direction (D Ｆ２ 2. The method of claim 1, wherein the process is the reverse or substantially the reverse of

3. The first supply direction (D Ｆ１ ) is an upward direction, and the second feed direction (D Ｆ２ 3. The method of claim 1, wherein the direction of the first and second electrodes is downward.

4. 4. The method according to claim 1, further comprising intermittently feeding the cellulose blank structure (2) from the buffer module (5) to the press module (6).

5. The buffer module (5) is in a buffer mode (M Ｂ ) and supply mode (M Ｆ ) and the method is configured to: alternately operate the cellulose blank structure (2) in the buffer mode (M Ｂ ) and the supply mode (M Ｆ ) at a continuous input rate (V Ｉ ) into the buffer module (5); and feeding the cellulose blank structure (2) into the buffer module (5) in the buffer mode (M Ｂ In the supply mode (M Ｆ The output speed (V) of the cellulose blank structure (2) from the buffer module (5) Ｏ ) lower output speed (V Ｏ 5. The method according to claim 1, further comprising the step of: feeding the buffer module (5) with

6. The buffer mode (M Ｂ ) at the output speed (V Ｏ ) is zero, or the buffer mode (M Ｂ ) at the output speed (V Ｏ 6. The method of claim 5, wherein: ##EQU1## is substantially zero.

7. The buffer module (5) has an inlet portion (5a), an outlet portion (5b) and a buffer portion (5c) between the inlet portion (5a) and the outlet portion (5b), and the cellulose blank structure (2) is provided with a buffer extension (E) in the buffer portion (5c) between the inlet portion (5a) and the outlet portion (5b). Ｂ ), the method comprising: Ｂ The buffer extension (E Ｂ ) is gradually increased, and the supply mode (M Ｆ The buffer extension (E Ｂ 7. The method of claim 5 or 6, further comprising the step of gradually decreasing

8. The buffer portion (5c) has a guide member (5d), and the guide member (5d) is Ｂ ) and the supply mode (M Ｆ In the buffer extension (E Ｂ The first arm section (5d) is configured to intermittently change １ ) and the second arm section (5d ２ ) , the method comprising: Ｂ In order to change the first arm section (5d １ ) and the second arm section (5d ２ ) and the angular relationship (α Ｒ ) to the buffer mode (M Ｂ ) and the supply mode (M Ｆ 8. The method of claim 7, further comprising the step of varying in

9. The method comprises: continuously feeding the cellulose blank structure (2) to the inlet portion (5a) and intermittently feeding the cellulose blank structure (2) from the outlet portion (5b) by operating the guide member (5d), wherein the buffer mode (M Ｂ In the feeding mode (M), during the operation of the guide member (5d), a buffer of the cellulose blank structure (2) is formed in the buffer portion (5c), Ｆ 9. The method according to claim 8, further comprising the step of: a) releasing the buffer of the cellulose blank structure (2) from the buffer portion (5c) during the actuation of the guide member (5d).

10. 10. The method according to any one of claims 1 to 9, wherein the product forming unit (U) comprises a blank recycling module (7), and the method further comprises the step of: feeding a remaining portion (2a) of the cellulose blank structure (2) from the press module (6) to the blank dry-forming module (4).

11. The method according to any one of claims 1 to 10, wherein the product forming unit (U) comprises a barrier application module (8) arranged upstream of the buffer module (5), and the method further comprises the step of: applying a barrier composition onto the cellulose blank structure (2) in the barrier application module (8).

12. The method comprises: subjecting the cellulose blank structure (2) to a forming temperature (T Ｆ ) and the cellulose blank structure (2) is molded under a molding pressure (P Ｆ The method according to any one of claims 1 to 11, 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.

13. The press module (6) is a cellulosic toggle press module for forming the non-flat cellulosic product (1) from the cellulosic blank structure (2), the method comprising: Providing the cellulose 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 ), specifically, in the horizontal direction (D Ｈ The pressing direction (D) of the pressing member (6d) is arranged within 20 degrees from Ｐ ), more specifically, 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 any one of claims 1 to 12, further comprising:

14. A product forming unit (U) for producing a non-flat cellulose product (1) from an air-formed cellulose blank structure (2), said product forming unit (U) comprising a blank dry-forming module (4) configured to provide said cellulose blank structure (2), a buffer module (5) and a press module (6) equipped with one or more forming dies (3), the blank dry-forming module (4) comprises a mill (4a), a forming chamber (4b) and a forming wire (4c) connected to and arranged in the forming chamber (4b), the mill (4a) being configured to separate fibers (F) from a cellulose raw material (R), the forming chamber (4b) being 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) extending in an upward blank forming direction (D U ); the product forming unit (U) is adapted to supply the cellulose blank structure (2) to the buffer module (5), buffer the cellulose blank structure (2) in the buffer module (5), and supply the cellulose blank structure (2) from the buffer module (5) to the press module (6); The product forming unit (U) further heats the cellulose blank structure (2) at a forming temperature (T Ｆ ) and the cellulose blank structure (2) is heated to a molding pressure (P Ｆ ) adapted to mold the cellulose product (1) from the cellulose blank structure (2) in the one or more molds (3), The buffer module (5) feeds the cellulose blank structure (2) in a first feed direction (D Ｆ１ ) into the buffer module (5) and the cellulose blank structure (2) is fed continuously in a second feeding direction (D Ｆ２ ) from the buffer module (5) in the second supply direction (D Ｆ２ ) is the first supply direction (D Ｆ１ ) is configured differently from the blank supply system (S Ｆ ).

15. The buffer module (5) has an inlet portion (5a), an outlet portion (5b) and a buffer portion (5c) between the inlet portion (5a) and the outlet portion (5b), and the cellulose blank structure (2) is provided with a buffer extension (E) in the buffer portion (5c) between the inlet portion (5a) and the outlet portion (5b). Ｂ ) and the buffer portion (5c) is arranged in a buffer mode (M Ｂ The buffer extension (E Ｂ ) and the supply mode (M Ｆ The buffer extension (E Ｂ 15. The product forming unit (U) according to claim 14, configured to gradually reduce the

16. The buffer portion (5c) has a guide member (5d), and the guide member (5d) is Ｂ ) and the supply mode (M Ｆ In the buffer extension (E Ｂ The first arm section (5d) is configured to intermittently change １ ) and the second arm section (5d ２ ), and the buffer portion (5c) has the buffer extension (E Ｂ In order to change the first arm section (5d １ ) and the second arm section (5d ２ ) and the angular relationship (α Ｒ ) to the buffer mode (M Ｂ ) and the supply mode (M Ｆ 16. The product forming unit (U) according to claim 15, configured to change in

17. The blank supply system (S Ｆ 17. The product forming unit (U) according to claim 15 or 16, wherein the blank feed roller (9) is connected to the inlet portion (5a) or arranged upstream of the inlet portion (5a) and / or connected to the outlet portion (5b) or arranged downstream of the outlet portion (5b).

18. The buffer module (5) comprises a first blank deflection device (5e) arranged upstream of the inlet section (5a). １ ) and / or a second blank deflection device (5e) arranged downstream of said outlet section (5b). ２ 18. The product-forming unit (U) according to any one of claims 15 to 17, further comprising a rotatable member (R).

19. The blank supply system (S Ｆ ) is configured to continuously supply the cellulose blank structure (2) to the inlet portion (5a) and intermittently supply the cellulose blank structure (2) from the outlet portion (5b) by the operation of a guide member (5d), in which case, the buffer mode (M Ｂ In the feeding mode (M), during the operation of the guide member (5d), a buffer of the cellulose blank structure (2) is formed in the buffer portion (5c), Ｆ 19. The product forming unit (U) according to any one of claims 15 to 18, wherein during operation of the guide member (5d) the buffer of the cellulose blank structure (2) is released from the buffer portion (5c).

20. The product forming unit (U) according to any one of claims 14 to 19, further comprising a blank recycling module (7) configured to supply a remaining portion (2a) of the cellulose blank structure (2) from the press module (6) to the blank dry-forming module (4).

21. The product forming unit (U) according to any one of claims 14 to 20, further comprising a barrier application module (8) arranged upstream of the buffer module (5), the barrier application module (8) being configured to apply a barrier composition onto the cellulose blank structure (2).

22. The one or more molds (3) are arranged to mold the cellulose blank structure (2) at a molding temperature (T Ｆ ) and the cellulose blank structure (2) is molded under a molding pressure (P Ｆ 22. The product forming unit (U) according to any one of claims 14 to 21, configured to form the cellulose product (1) from the cellulose blank structure (2) by pressing with a pressing member (14).

23. The press module (6) is a cellulose product toggle press module for forming the non-flat cellulose product (1) from the cellulose blank structure (2), and the press module (6) has: a press direction (D Ｐ a toggle press (6a) having a press member (6a) movably arranged in a pressing direction (D), a toggle mechanism (6e) drivingly connected to said press member (6d), a press actuator assembly (6f) drivingly connected to said toggle mechanism (6e), and an electronic control system (6h) operatively connected to said press actuator assembly (6f), and one or more molds (3) each having a movable first mold part (3a) and a stationary second mold part (3b) attached to said press member (6d), said electronic control system (6h) controlling said pressing direction (D) using said toggle mechanism (6e). Ｐ ) to drive the press member (6d) and press the first die part (3a) against the stationary second die part (3b) to form the non-flat cellulose product (1) from the air-formed cellulose blank structure (2), and the toggle press (6a) is configured to rotate in a primarily horizontal direction (D Ｈ ) of the pressing member (6d) disposed in the pressing direction (D Ｐ ), specifically in the horizontal direction (D Ｈ The pressing direction (D) of the pressing member (6d) is arranged within 20 degrees from Ｐ ), more specifically in the horizontal direction (D Ｈ ) parallel to the pressing direction (D Ｐ 23. The product-forming unit (U) according to any one of claims 14 to 22, which is installed or arranged to be installed so as to have a

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