Pickup press device and method for manufacturing a 3D molded product from pulp slurry

Abstract

A pickup press apparatus for producing a 3D formed product from a pulp slurry includes a pickup press tool presenting a first product surface, a press tool presenting a second product surface, and a vacuum source connected to the pickup press tool. The pickup press tool and the press tool are positioned such that, at a first relative position of the press tool, the product surface receives a liquid pulp slurry layer against the product surface, and at a second relative position of the press tool, the product surfaces are pressed toward each other to press the pulp slurry layer. The apparatus includes a first transfer tool having a first forming surface portion configured to match a first portion of the porous first product surface, the forming gap defining a desired pulp slurry layer thickness, and a second forming surface portion configured to diverge from a second portion of the porous first product surface, the non-forming space having a thickness greater than the forming gap.

Description

Technical Field

[0001] This document relates to a pick-up press device for use in the process of forming products from pulp slurry. The present disclosure also relates to a method of forming products from pulp slurry.

Background Art

[0002] It is known to form products from pulp slurry by immersing a porous mold in the pulp slurry, then drying it, and optionally pressing the thus formed product. Examples of such products are egg cartons, shock-absorbing packaging inserts and paper trays, paper cups, drink carry trays, mushroom and berry boxes, and other forms of industrial, agricultural, and consumer packaging.

[0003] Regarding the formation of products from pulp, it is desirable to provide a mold that is durable and capable of being exposed to high temperatures. Further, a smooth surface structure, reduction of energy consumption, and improvement of quality control of the forming process are desirable.

[0004] In regard to these aspects, International Publication No. WO 2016 / 101976 discloses an improved tool or tool part for use in forming products from slurry, comprising a self-standing tool wall portion having a product face for contacting the product and a back face on the opposite side of the wall to the product face. The tool wall portion exhibits pores provided by a plurality of channels extending through the tool wall portion from the product face to the back face. Such a tool or tool part can also provide sufficient pick-up, transfer, or evaporation of the pulp used, or form the product, while requiring less energy for vacuum generation compared to other known tools.

[0005] However, it is desirable to further reduce the energy consumption.

[0006] International Publication No. WO 2016 / 101976 further discloses a method of forming a product from a pulp slurry by applying a slurry layer to a porous mold and removing water from the slurry by simultaneously heating and pressing the slurry layer while drawing a vacuum through a mold wall whose opposite side is in contact with the slurry layer. The forming process may be carried out in two or more consecutive pressing steps, which is advantageous as it reduces the cycle time compared to the process of a single pressing step and thus increases the throughput of the manufacturing process.

[0007] However, it is desirable to further increase the throughput.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Summary of the Invention

[0009] An object of the present disclosure is to provide an improved pulp forming apparatus for forming a product from a pulp slurry, and more specifically, to provide an apparatus that increases the throughput of the forming process compared to the prior art.

[0010] Providing an improved forming process, and more specifically, providing a method of forming a product from a pulp slurry with an increased throughput of the manufacturing process, is further included in the objects of the present disclosure.

[0011] The present invention is defined by the appended independent claims. Embodiments are specified in the appended dependent claims, as well as in the following description and drawings.

[0012] According to a first aspect, there is provided a pickup press apparatus for use in a process of manufacturing a 3D molded product from pulp slurry, comprising a pickup press tool presenting a porous first product surface, a press tool presenting a second product surface, and a vacuum source connected to the pickup press tool, wherein the pickup press tool and the press tool are movable relative to each other perpendicularly, and in a first relative position of the press tool, at least one of the product surfaces is arranged to receive a liquid pulp slurry layer against that product surface, and in a second relative position of the press tool, the product surfaces are pressed towards each other to press the pulp slurry layer. The apparatus further comprises a first transfer tool, the first transfer tool comprising a first forming surface portion configured to coincide with a first portion of the porous first product surface such that a forming gap is defined therebetween, the forming gap defining a desired pulp slurry layer thickness, and a second forming surface portion configured to branch from a second portion of the porous first product surface such that a non-forming space is defined by the second forming surface portion and a second portion of the porous first product surface, the non-forming space having a thickness greater than the forming gap.

[0013] For the purposes of the present disclosure, the term "pulp" should be construed to include materials comprising fibers such as cellulose, minerals and starch, or combinations of these materials. The pulp preferably has a liquid carrier which may comprise water.

[0014] "Product surface" means the surface of a tool adapted to contact a pulp slurry layer or a pulp product during the formation of such a pulp product.

[0015] The second product surface may be porous or non-porous. Alternatively, the second product surface may present a porous portion and a non-porous portion.

[0016] The vacuum source may be in the form of a vacuum chamber connected to a pressure regulator.

[0017] "Pickup" means attracting pulp fibers to the porous first product surface of the pickup press tool.

[0018] In a second relative position of the pickup press tool and the press tool, where the product surfaces are pressed against each other to press the pulp slurry, at least one of the tools can be adapted to supply heat to the product surface of the tool. Further, at least one of the tools having a porous product surface or presenting a porous portion can be connected to a vacuum source so that it can be evacuated through the porous product surface of the tool.

[0019] Since the pickup press tool is adapted for both picking up and pressing the pulp slurry layer, the need for an additional transfer tool for transferring the pulp layer from the pickup tool to the press tool is eliminated.

[0020] Furthermore, since the pickup press tool and the press tool can also move perpendicular to each other, an efficient process for picking up and pressing the pulp slurry layer can be achieved, thereby shortening the cycle time and increasing the throughput of the process.

[0021] The first transfer tool can be adapted to transfer the pulp slurry layer from the pickup press tool to the product surface of a second pair of press tools.

[0022] The first transfer tool may be connected to a pressure regulator, which can generate a vacuum or air pressure.

[0023] The first transfer tool may also be attached to a transfer tool holder.

[0024] Since the non-forming space is defined by the second forming surface portion and the second portion of the porous first product surface, at least a part of the pulp slurry layer may be free during said transfer.

[0025] The free portion of the pulp slurry layer can be formed when the pulp slurry layer is transferred from the first transfer tool to the product surface of the second pair of press tools, whereby it is possible to bring the free portion of the pulp slurry layer into contact with the second forming surface portion of the first transfer tool.

[0026] Furthermore, since the first transfer tool transfers the pulp slurry layer to the second pair of cooperating press tools and is adapted to form at least a part of the pulp slurry layer during the transfer, additional forming or pressing steps may be eliminated, and a shorter cycle time of the process and an increase in throughput can be achieved.

[0027] Furthermore, since the first transfer tool is adapted such that at least a part of the pulp slurry layer contacts the first forming surface portion of the first transfer tool during the transfer and at least a part is free, i.e., does not contact, a pulp slurry layer can be provided that exhibits different portions with different levels of water content.

[0028] The pickup press tool may be provided with at least one heating element adapted to supply heat to the porous first product surface of the pickup press tool. Alternatively, or additionally, the press tool may be provided with at least one heating element adapted to supply heat to the second product surface of the press tool.

[0029] In the second relative position of the press tools, the product surfaces may be pressed towards each other to press the pulp slurry layer, while heating the pulp slurry layer by means of at least one heating element and drawing a vacuum through at least one of the porous product surfaces of the tools.

[0030] The non-forming space can be configured to provide contact between only one pulp slurry layer surface and one of the second forming surface portion and the second portion of the porous first product surface.

[0031] The "pulp slurry layer surface" means the surface of the pulp slurry layer adapted to contact the product surface of a tool such as a pickup press tool, a press tool, or a transfer tool.

[0032] The non-forming space presents a space between the second forming surface portion and the second portion of the porous first product surface, which is more than 20 times, preferably more than 15 times, more than 10 times, or more than 5 times the thickness of the forming gap.

[0033] The non-forming space can be provided at the innermost part of the female mold and / or the distal part of the male mold when viewed in the pressing direction.

[0034] Alternatively, the non-forming space can be provided at the outermost part of the female mold and / or the distal part of the male mold when viewed in the pressing direction.

[0035] The female mold can be a pickup press tool or a press tool. The male mold can be a transfer tool.

[0036] The forming gap can have a thickness small enough such that both the first forming surface portion and the first portion of the porous first product surface contact their respective pulp slurry layer surfaces.

[0037] The forming gap can be configured to provide a pressure higher than the ambient pressure on the pulp slurry layer.

[0038] The first forming surface portion can present a contact surface area corresponding to 10 - 99.9%, preferably 25 - 95% of the total surface area of the porous first product surface.

[0039] The first transfer tool can present a porous product surface having a porosity of 10 to 90%.

[0040] For the purposes of the present disclosure, the term "porosity" is defined as the pore opening area relative to the total product surface area (including pore openings) of a given product surface portion.

[0041] The porous product surface of the first transfer tool can present pores having a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[0042] The porous first product surface of the pickup press tool can have a porosity of 10 to 90%.

[0043] The porous first product surface of the pickup press tool can present pores having a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[0044] The pickup press tool can be provided with at least one heating element adapted to supply heat to the porous first product surface of the pickup press tool.

[0045] The heating element may be an electric heating element, a hot air or liquid heating element, or an induction heating element. The heating element can be controlled by a controller.

[0046] The press tool can be provided with at least one heating element adapted to supply heat to the second product surface of the press tool.

[0047] The heating element may be an electric heating element, a hot air or liquid heating element, or an induction heating element. The heating element can be controlled by a controller.

[0048] According to a second aspect of the present invention, a method for manufacturing a 3D molded product from a pulp slurry, the method comprising: applying a liquid pulp slurry layer to a porous first product surface of a pickup press tool of a first mold; in a first forming step, heating the pulp slurry layer and pressing the pulp slurry layer on the porous first product surface of the pickup press tool against a second product surface of a cooperating press tool of the first mold while drawing a vacuum through at least one porous product surface of the tool; transferring the pulp slurry layer to a porous product surface of a first press tool of a second mold; and in a second subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against a second product surface of a second press tool of the second mold while drawing a vacuum through at least one porous product surface of the first and second press tools of the second mold, wherein at least a portion of the pulp slurry layer is formed during transfer to the first press tool of the second mold.

[0049] Optionally, a cleaning step of the pulp slurry layer may be performed before the second forming step.

[0050] The pickup press tool and the cooperating press tool of the first mold, and / or the first and second press tools of the second mold may form part of a pickup press apparatus according to the above description.

[0051] The transfer of the pulp slurry layer from the first mold to the second mold can be carried out by a first transfer tool, the first transfer tool comprising a first forming surface portion and a second forming surface portion, during the transfer of the pulp slurry layer from the first mold to the first transfer tool, the first forming surface portion coincides with a first portion of the porous first product surface of the first mold such that a forming gap is defined therebetween, the forming gap defining a desired pulp slurry layer thickness, the second forming surface portion branches off from a second portion of the porous first product surface of the first mold such that a non-forming space is defined by the second forming surface portion and the second portion of the porous first product surface of the first mold, the non-forming space having a thickness greater than the forming gap.

[0052] The first transfer tool can be porous.

[0053] The first transfer tool can form part of a pick-up press device according to the above.

[0054] During the transfer of the pulp slurry layer from the first mold to the first transfer tool, the forming gap can provide a pressure on the pulp slurry layer that is higher than the ambient pressure.

[0055] During the movement of the first transfer tool from the first mold to the second mold, the first forming surface portion can contact the pulp slurry layer and the second forming surface portion can be free.

[0056] During the transfer of the pulp slurry layer from the first mold to the second mold, it is possible to evacuate through the first transfer tool so that at least some water is discharged from the pulp slurry layer.

[0057] The vacuum can be applied when the pulp slurry layer is received by the first transfer tool, i.e., when transferred from the first mold to the first transfer tool, and / or during the movement of the transfer tool from the first mold to the second mold.

[0058] The pulp slurry layer transferred to the second mold can exhibit a first pulp slurry layer portion and a second pulp slurry layer portion, the first and second pulp slurry layer portions are juxtaposed, and the first pulp slurry layer portion has a water content level higher or lower than that of the second pulp slurry layer portion.

[0059] The pickup of the pulp slurry layer can be achieved by immersing the porous first product surface of the pickup press tool into the liquid tank containing the pulp slurry while pulling a vacuum through the porous first product surface of the pickup press tool so that the pulp slurry layer is applied to the product surface.

[0060] The pickup press tool can move vertically upward from the liquid tank so as to come into contact with the cooperating press tool.

[0061] Alternatively, the pulp slurry layer can be applied to the porous first product surface of the pickup press tool by spraying or injection.

[0062] The first pressure on the back side of the porous first product surface during the pickup of the pulp slurry layer can be 300 - 700 mbarA, preferably 400 - 600 mbarA.

[0063] In the first forming step, the second pressure on the back side of the porous product surface of the first mold can be lower than the third pressure on the back side of the porous product surface of the second mold in the second forming step.

[0064] The second pressure can be 1 - 99% of the third pressure, preferably 50 - 99%, or 90 - 99%.

[0065] The second pressure can be 200 - 900 mbarA, preferably 300 - 800 mbarA.

[0066] In the first forming step, the second product surface of the cooperating press tool of the first mold can be heated to about 150 to 400 °C, preferably 200 to 300 °C.

[0067] In the first forming step, the porous first product surface of the pick-up press tool of the first mold can be heated to about 100 to 150 °C.

[0068] The porous first product surface of the pick-up press tool may be heated in the first forming step for the purpose of additional drying effect of the pulp slurry layer or for maintaining the warmth of the fibers for formability.

[0069] In the first forming step, the pulp slurry layer can be pressed against the second product surface of the first mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa.

[0070] In the first forming step, the pulp slurry layer can be pressed against the second product surface of the first mold during a first pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds.

[0071] In the first forming step, the initial water content of the pulp slurry layer can be 70 to 90% by weight, and the final water content can be 45 to 65% by weight, preferably about 50 to 60% by weight.

[0072] The third pressure can be 200 to 900 mbarA, preferably 300 to 800 mbarA.

[0073] In the second forming step, at least one of the product surfaces of the second mold can be heated to about 110 to 400 °C, preferably 200 to 300 °C.

[0074] In the second forming step, the pulp slurry layer can be pressed against the second product surface of the second mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa.

[0075] In the second forming step, the pulp slurry layer can be pressed against the second product surface of the second mold for a second pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds.

[0076] In the second forming step, the initial water content of the pulp slurry layer can be about 45 to 65% by weight, preferably about 50 to 60% by weight, and the final water content can be about 25 to 40% by weight, preferably about 30 to 35% by weight.

[0077] The method can further comprise transferring the pulp slurry layer to the porous product surface of the first pressing tool of the third mold and, in a third subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against the second product surface of the second pressing tool of the third mold while pulling a vacuum through at least one of the porous product surfaces of the first and second pressing tools of the third mold.

[0078] Optionally, the cleaning step of the pulp slurry layer can be performed before the third forming step.

[0079] The transfer of the pulp slurry layer can be performed by a second transfer tool.

[0080] The third pressure on the back side of the porous product surface of the second mold can be made lower than the fourth pressure on the back side of the porous product surface of the third mold.

[0081] The fourth pressure can be 200 to 900 mbarA, preferably 300 to 800 mbarA.

[0082] In the third forming step, at least one of the product surfaces of the third mold can be heated to about 100 to 300 °C, preferably 200 to 280 °C.

[0083] In the third forming step, the pulp slurry layer can be pressed against the second product surface of the third mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa.

[0084] In the third forming step, the pulp slurry layer can be pressed against the second product surface of the third mold for a third pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds.

[0085] In the third forming step, the initial water content of the pulp slurry layer can be about 25 to 45 wt% or 25 to 40 wt%, preferably about 30 to 40 wt% or 30 to 35 wt%, and the final water content can be less than about 5 wt%, preferably less than about 1 wt%.

[0086] According to a third aspect of the present invention, a method of forming a receptacle is provided in accordance with the above, and a non-forming space is provided in each part of the pressing tool and the transfer tool corresponding to the opening portion of the receptacle.

[0087] The receptacle can be a container, cup, jar, can, bottle, etc. adapted to contain solid, liquid, and / or gaseous contents. This can be used as a container for various products such as, for example, personal care products, home care products, food or beverages.

[0088] The opening portion may present the rim of the receptacle.

[0089] According to a fourth aspect of the present invention, a system for manufacturing a 3D molded product from a pulp slurry is provided, the system comprising a pick-up press device according to the above and a second pair of cooperating press tools.

[0090] The second pair of cooperating press tools may each be attached to respective tool holders. At least one of the tools of the second pair of cooperating press tools may present a porous product surface. At least one of the tools may be connectable to a vacuum source.

[0091] The system may further comprise a second transfer tool and a third pair of cooperating press tools.

[0092] The second transfer tool can be adapted to transfer a pulp slurry layer from the product surface of the second pair of press tools to the product surface of the third pair of press tools.

[0093] The second transfer tool may be connected to a pressure regulator, which can generate a vacuum or a pneumatic pressure.

[0094] The second transfer tool may also be attached to a transfer tool holder.

[0095] The third pair of cooperating press tools may each be attached to respective tool holders. At least one of the tools of the third pair of cooperating press tools may present a porous product surface. At least one of the tools may be connectable to a vacuum source.

Brief Description of the Drawings

[0096]

Figure 1a

Figure 1b

Figure 1c

Figure 1d

Figure 2a

Figure 2b

Figure 2c

Figure 2d

Figure 2e

Figure 2f

Figure 2g

Figure 3

Mode for Carrying Out the Invention

[0097] FIG. 1a schematically shows a pickup press tool 10, a cooperating press tool 20, and a container 1 having a pulp slurry 2.

[0098] The pickup press tool 10 is adapted for both picking up a pulp slurry layer 3 from the pulp slurry 2 and pressing the pulp slurry layer 3 in a first pressing step.

[0099] The pickup press tool 10 is attached to a tool holder 11, which together with the pickup press tool defines a vacuum chamber 12 connected to a pressure regulator P1. The pressure regulator may have the ability to selectively generate at least a partial vacuum (i.e., an air pressure lower than the ambient air pressure) and / or an air pressure higher than the ambient air pressure.

[0100] The pickup press tool can be self - supporting, which means that the tool wall portion of the tool is sufficiently rigid and has a sufficiently high melting point so as not to require a support structure for maintaining its shape during operation.

[0101] The pickup press tool 10 presents a porous first product surface, i.e., a porous surface of the tool adapted to contact a pulp slurry layer or a pulp product during the formation of such a pulp product. The porosity of the porous first product surface can be between 10% and 90%.

[0102] The porous first product surface may further present pores having a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[0103] As shown in Figure 1a, the press tool 20 can also be attached to a tool holder 21. The tool holder 21 can define a vacuum chamber 12 together with the press tool 20. The vacuum chamber 12 can be connected to a pressure regulator P2. The pressure regulator can have the ability to selectively generate at least a partial vacuum (i.e., an air pressure lower than the ambient air pressure) and / or an air pressure higher than the ambient air pressure.

[0104] The press tool 20 presents a second product surface. The second product surface can be porous or non-porous. Alternatively, the second product surface can present porous and non-porous portions.

[0105] The pickup press tool 10 and the press tool 20 are movable perpendicular to each other.

[0106] In a first relative position of the press tools 10, 20, at least one of the product surfaces is arranged to receive a pulp slurry layer 3, which can be in a liquid state, on its product surface. See Figure 1a.

[0107] In a second relative position of the press tools 10, 20, the product surfaces are pressed towards each other to press the pulp slurry layer. See Figure 1d.

[0108] As a result, the pickup press tool 10 can maintain its orientation with respect to the press tool 20 from the pickup of the pulp slurry layer to the pressing of the pulp slurry layer.

[0109] Furthermore, the pickup press tool 10 can move in the direction Y1 to initiate the step of picking up the pulp slurry layer 3 from the container 1 having the pulp slurry 2. See FIG. 1a.

[0110] Furthermore, the pickup press tool 10 can move in the direction Y2 to initiate the step of pressing the pulp slurry layer 3 in the first pressing step. See FIG. 1c.

[0111] Alternatively, or additionally, the press tool 20 may move in the direction Y1 to initiate the first pressing step.

[0112] FIG. 1b schematically shows the pickup press tool 10 immersed in the container 1 holding the pulp slurry 2. While the pickup press tool is immersed in the pulp slurry 2, the pressure regulator P1 may generate a vacuum and draw the pulp fibers 3 towards the product surface of the pickup press tool 10.

[0113] FIG. 1c schematically shows the pickup press tool 10 moving the pulp fibers 3 towards the press tool 20, i.e., initiating the first pressing step.

[0114] During the movement, the pressure regulator P1 may generate a vacuum and attach the pulp fibers 3 to the product surface of the pickup press tool 10.

[0115] FIG. 1d schematically shows the pickup press tool 10 and the press tool 20 in the pressing position. As a result, the pickup press tool 10 and the press tool 20 can form a press configuration adapted to perform the first pressing step of the pulp slurry layer 3.

[0116] The pickup press tool 10 and the press tool 20, as well as their associated tool holders 11, 21, are movable relative to each other between an open position and a press position. In the press position, as shown in FIG. 1d, the tools 10, 20 are pressed against each other, thus pressing a pulp slurry layer between the product surfaces of the respective tools 10, 20 so that a pulp product 3' is formed.

[0117] As shown in FIG. 1d, one or both of the pickup press tool and the press tool may be supplied with heating elements 13, 23. The heating elements are adapted to supply heat to the product surfaces of the tools.

[0118] The heating elements can be supplied with energy by energy sources E1, E2. Further, the heating elements can be controlled by a controller C.

[0119] The heating elements may be electric heating elements, hot air or liquid heating elements, or induction heating elements.

[0120] When in the press position, heat can be supplied by one or both of the heating elements 13, 23.

[0121] During the pressing of the pulp product 3', one or both of the pressure regulators P1, P2 can provide a vacuum to assist in the discharge of water vapor from the pulp product 3'.

[0122] Alternatively, one of the pressure regulators P1, P2 can provide a vacuum and the other can provide a pressure higher than the ambient air pressure.

[0123] Optionally, hot air or steam may be introduced through the tools during the pressing process (FIG. 1d).

[0124] Instead of immersing the pickup press in the pulp slurry, the pulp slurry can be applied by a coating operation such as spray coating or injection. Optionally, during the coating operation, the pressure regulator P1 can generate a vacuum and draw the pulp fibers 3 towards the product surface of the pickup press tool 10.

[0125] It should also be noted that two or more consecutive press steps can be used to gradually form all or part of the products 3', 3'', 3''' and / or to apply additional features such as coating, decoration, etc. to the products.

[0126] Figures 2a to 2d show a first transfer tool 30 that can be used to transfer the product 3' from the first press tools 10, 20 to the second pair of press tools 40, 50. See Figures 2a to 2e.

[0127] The first transfer tool 30 may be connected to a third pressure regulator P3, which can generate a vacuum or air pressure. The transfer tool 30 may also be attached to the transfer tool holder 31 so as to define a vacuum chamber 32 connected to the third pressure regulator P3.

[0128] During the transfer of the pulp fibers, an air pressure higher than the ambient pressure can be generated by the first pressure regulator P1 to release the pulp fibers from the pickup press tool 10.

[0129] Alternatively, or in addition, a vacuum can be generated by the third pressure regulator P3 so that the pulp fibers are received by the transfer tool 30.

[0130] The first transfer tool may be supplied with a heating element (not shown). The heating element is adapted to supply heat to the product surface of the first transfer tool. The heating element can be supplied with energy by an energy source. Further, the heating element can be controlled by a controller C.

[0131] The heating element may be an electric heating element, a hot air or liquid heating element, or an induction heating element.

[0132] As shown in FIGS. 2a to 2d, the first transfer tool 30 is adapted to form part of the product 3'.

[0133] The first transfer tool 30 can present a porous product surface.

[0134] The porous product surface of the first transfer tool 30 can have a porosity of 10 - 90%.

[0135] The porous product surface of the first transfer tool 30 can present pores with a pore size of 0.1 - 0.7 mm, preferably 0.25 - 0.6 mm.

[0136] As shown in FIGS. 2a and 2b, the first transfer tool 30 can comprise a first forming surface portion 34 and a second forming surface portion 35.

[0137] As shown in FIG. 2a, the first forming surface portion 34 can be configured to coincide with a first portion 14 of the porous first product surface such that a forming gap 80 is defined therebetween. The forming gap 80 can define the desired pulp slurry layer thickness.

[0138] The second forming surface portion 35 can be configured to branch from a second portion 15 of the porous first product surface such that a non - forming space 90 is defined by the second forming surface portion 35 and the second portion 15 of the porous first product surface. The non - forming space 90 can have a thickness greater than that of the forming gap 80.

[0139] The non - forming space 90 can be configured to provide contact between only one pulp slurry layer surface and one of the second forming surface portion 35 and the second portion 15 of the porous first product surface.

[0140] The non-forming space 90 presents a space between the second forming surface portion 35 and the second portion 15 of the porous first product surface, which is more than 20 times, preferably more than 15 times, more than 10 times, or more than 5 times the thickness of the forming gap 80.

[0141] The non-forming space 90 can be provided in the innermost part of the female mold and / or the distal part of the male mold when viewed in the pressing direction. See Fig. 2f.

[0142] Alternatively, the non-forming space 90 can be provided in the outermost part of the female mold and / or the distal part of the male mold when viewed in the pressing direction. See Fig. 2g.

[0143] The female mold can be a pickup press tool or a press tool. The male mold can be a transfer tool.

[0144] The forming gap 80 can have a thickness small enough for both the forming surface portion 34 and the first portion 14 of the porous first product surface to contact their respective pulp slurry layer surfaces.

[0145] The forming gap 80 can be configured to provide a pressure higher than the ambient pressure on the pulp product 3'.

[0146] As a result, since the pulp product 3' is transferred from the porous first product surface of the pickup press tool 10 to the first transfer tool 30 (see Fig. 2a), a pressure higher than the ambient pressure can be applied to the portion of the pulp product 3' that is in contact with both the forming surface portion 34 of the first transfer tool 30 and the first portion 14 of the porous first product surface.

[0147] The first forming surface portion 34 can be adapted to contact a part of the product 3' during the transfer of the product.

[0148] The first forming surface portion 34 can have a contact surface area sufficient to receive and hold the pulp product 3' with the first transfer tool during the movement of the first transfer tool.

[0149] The first forming surface portion 34 can exhibit a contact surface area corresponding to 10 to 99.9%, preferably 25 to 95%, of the total surface area of the porous first product surface.

[0150] As shown in FIG. 2b, at least a part of the pulp product 3' can be free during the movement of the first transfer tool from the first pressing tools 10, 20 to the second pair of pressing tools 40, 50.

[0151] As a result, during the movement of the first transfer tool that transfers the pulp product 3' from the first pair of pressing tools 10, 20 to the second pair of pressing tools 40, 50, the first forming surface portion 34 can contact the pulp slurry layer surface, and the second forming surface portion 35 can be free.

[0152] The shape of the porous product surface of the first transfer tool 30 can substantially match the shape of the product surface of the pressing tool among the second pair of pressing tools. See FIG. 2c.

[0153] As a result, since the pulp product 3' is transferred to the product surface of the pressing tool 40, at least one free portion of the pulp product 3' can be brought into contact with the second forming surface portion 35 of the first transfer tool 30. Thereby, at least one free portion of the pulp product 3' can be formed when the pulp product 3' is transferred from the first transfer tool 30 to the product surface of the pressing tool 40. See FIG. 2c.

[0154] The first transfer tool 30 can then be removed from the pressing tool 40 as shown in FIG. 2d. Next, as shown in FIG. 2e, the second pair of pressing tools 40, 50 can be used to press the pulp product 3'' in the second pressing step.

[0155] When the first transfer tool 30 transfers the product from the pickup press tool 10 (Fig. 2a), a vacuum is generated by the third pressure regulator P3, allowing the pulp fibers to be received by the transfer tool 30. Additionally, or alternatively, a vacuum may be generated during the movement of the first transfer tool 30 from the first pair of press tools 10, 20 to the second pair of press tools 40, 50. As a result, water can be discharged from the product during transfer.

[0156] The first transfer tool 30 is adapted such that at least a portion of the pulp product 3' can contact the porous product surface of the first transfer tool 30 during transfer and at least a portion of the pulp product 3' can be free, i.e., not in contact, so that different levels of water can be discharged from different parts of the pulp product 3'.

[0157] As a result, the pulp product 3' transferred to the second pair of press tools 40, 50 can exhibit a first pulp slurry layer portion and a second pulp slurry layer portion, the first and second pulp slurry layer portions being juxtaposed, and the first pulp slurry layer portion having a higher or lower water content level than the second pulp slurry layer portion.

[0158] A second transfer tool can be used to transfer the pulp product 3''' from the second pair of press tools 40, 50 to a third pair of press tools (not shown).

[0159] The second transfer tool may be designed essentially the same as the first transfer tool or may have a different design. As a result, the second transfer tool can be used to transfer the product from the second pair of press tools to the third pair of press tools or to perform both transfer and formation of a portion of the product.

[0160] According to the present invention, there is provided a pick-up press apparatus for use in a process for manufacturing a 3D molded product from pulp slurry, comprising a pick-up press tool, a press tool, a vacuum source connected to the pick-up press tool, and a first transfer tool, according to the content described with reference to FIGS. 1a to 1d and FIGS. 2a to 2e.

[0161] According to the present invention, there is also provided a method for manufacturing a 3D molded product from pulp slurry.

[0162] In one embodiment, steps are performed according to the content described with reference to FIGS. 1a to 1d and FIGS. 2a to 2c.

[0163] The 3D molded product can be a receptacle such as a container, cup, jar, can, bottle, etc. adapted to contain, for example, solid, liquid, and / or gaseous contents.

[0164] Next, a non-forming space 90 can be provided in each part of the press tool and the transfer tool corresponding to the opening of the receptacle. The opening may present the rim of the receptacle.

[0165] Here, referring to FIG. 3, the manufacturing process will be described.

[0166] In a first step 101, as described with reference to FIG. 1a for example, a pulp slurry layer is provided and the pulp slurry layer is applied to the porous first product surface of the first mold. This can be achieved by providing a first mold comprising a pick-up press tool presenting the porous first product surface and a press tool presenting a second product surface. The second product surface may be porous or non-porous. Alternatively, the second product surface may present a porous part and a non-porous part.

[0167] The pick-up press tool can be adapted to pick up the pulp slurry layer from the pulp slurry in the step of applying the pulp slurry layer to the porous first product surface.

[0168] The pickup of the pulp slurry layer can be carried out by immersing the porous pickup press tool of the first mold in the pulp slurry while applying a vacuum to the back side of the pickup press tool.

[0169] The first pressure on the back side of the porous first product surface during the pickup of the pulp slurry layer can be 300 to 700 mbarA (absolute millibar), preferably 400 to 600 mbarA.

[0170] The flow rate through the tool can be between 50 and 1000 m3 / h. Preferably, the flow rate can be between 1000 and 30000 m3 / h per square meter of the porous first product surface of the tool.

[0171] As a result, it is possible to evacuate through the porous first product surface of the pickup press tool so that the pulp slurry layer can be applied to the porous first product surface.

[0172] The porous first product surface of the pickup press tool can have a surface porosity of 10 to 90% with a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[0173] Alternatively, the pulp slurry may be applied to the pickup press tool by a coating operation such as spray coating or injection. Optionally, during the coating operation, a vacuum can be drawn through the porous first product surface of the pickup press tool to draw the pulp fibers towards the product surface of the pickup press tool.

[0174] In the second step 102, the pulp slurry layer is pressed within the first mold. As a result, the pickup press tool having the pulp slurry layer is lifted from the pulp slurry or its initial coating position, moved towards the press tool, whereby the pulp slurry layer is pressed against the second product surface of the press tool. This can be carried out in a single vertical movement such that the pickup press tool is lifted and directly moved to the press tool.

[0175] Alternatively, the pickup press tool may be lifted from the pulp slurry and the press tool may be moved towards the pickup press tool.

[0176] Alternatively, both the pickup press tool and the press tool may be moved vertically towards each other.

[0177] In this first pressing step 102, a pressure lower than the surrounding ambient pressure is applied to the back side of the porous product surface of the first mold, thus creating a vacuum on the back side of the porous product surface and drawing in solvent vapors such as steam through the tool.

[0178] The pressure applied to the back side of the porous product surface can be a low or medium level of vacuum. That is, the first pressure can be 200 - 900 mbarA, preferably 300 - 800 mbarA.

[0179] The flow rate through the tool can be between 50 and 1000 m3 / h. Preferably, the flow rate can be between 1000 and 30000 m3 / h per square meter of the porous product surface of the tool.

[0180] The second product surface of the press tool of the first mold can be heated to about 150 - 500 °C, preferably 150 - 400 °C, 200 - 500 °C, 200 - 400 °C, or 200 - 300 °C, and in most cases 240 - 280 °C.

[0181] The porous first product surface of the pickup press tool of the first mold can be heated to about 100 - 150 °C.

[0182] The press pressure between the pickup press tool and the product surface of the press tool can be about 390 - 1570 kPa, and in most cases about 580 - 1170 kPa.

[0183] The press pressure can be applied during a first press time of 0.1 - 4.0 seconds, preferably 0.5 - 2.0 seconds. For most settings, a press time of about 0.5 - 1.5 seconds is sufficient, and in many cases 0.5 - 1.0 seconds may also be used.

[0184] Typically, in this first step, the initial water content of the pulp slurry layer is 70 - 90 wt%, and after the press step is carried out, the final water content can be 45 - 65 wt%, typically about 50 - 60 wt%.

[0185] After the first press step 102, the pulp slurry layer, now with a significant amount of its solvent removed, can be transferred 103 to the second press mold. The transfer can be carried out by a transfer tool as described above in connection with FIGS. 2a - 2e. As a result, at least a part of the pulp slurry layer can be formed during the transfer.

[0186] During the transfer step, a vacuum can be applied to the back side of the transfer tool wall so that the pulp slurry layer is held against the transfer tool wall. Instead, compressed air can be applied to the back side of the transfer tool wall to release the pulp slurry layer from the transfer tool wall.

[0187] Alternatively, or in addition, a vacuum can be applied to the back side of the porous product surface of the second mold to receive the pulp slurry layer by the second mold.

[0188] During the transfer, the product surface of the transfer tool can be heated to about 100 - 150 °C.

[0189] As a result, an additional drying effect of the pulp slurry layer can be achieved and / or the pulp slurry layer can maintain the warmth of the fibers for formability.

[0190] The second mold may comprise a pair of mating press tools, one of which may have a porous product surface that contacts the pulp slurry layer and through which vacuum can be applied.

[0191] The second mold may comprise a first press tool presenting a porous product surface and a second press tool presenting a second product surface. The second product surface may be porous or non-porous. Alternatively, the second product surface may present porous and non-porous portions.

[0192] Transfer 103 can be carried out by a transfer tool by transferring the pulp slurry layer from the first mold to the porous product surface of the first press tool of the second mold.

[0193] In the second pressing step 104, the pulp slurry layer can be pressed within the second mold. The pulp slurry layer can then be pressed against the second product surface of the second press tool of the second mold. In this second pressing step 104, a pressure lower than the surrounding ambient pressure is applied to the back side of the porous product surface of the mold, thus creating a vacuum on the back side of the porous product surface and drawing in solvent vapors such as steam through the tool.

[0194] The porous product surface of the second mold can have a porosity of 25 - 50% with a pore size of 0.1 - 1.2 mm, preferably 0.25 - 1.0 mm.

[0195] However, in the second pressing step 104, the pressure applied to the back surface of the porous product surface of the second mold may be higher than the pressure provided in the first pressing step 102.

[0196] Specifically, the pressure provided in the first pressing step 102 can be 1 to 99%, preferably 50 to 99%, 90 to 99%, 95 to 99%, or 99 to 99.9% of the pressure provided in the second pressing step 104.

[0197] In the second pressing step, the absolute pressure applied to the back side of the porous product surface of the second mold can be 200 to 900 mbarA, preferably 300 to 800 mbarA, but is always higher than in the case of the first pressing step.

[0198] The flow rate through the tool can be between 50 and 1000 m3 / h. Preferably, the flow rate can be between 1000 and 30000 m3 / h per square meter of the porous product surface of the tool.

[0199] At least one of the product surfaces of the second mold can be heated to about 110 to 500 °C, preferably 110 to 400 °C, 150 to 500 °C, 150 to 400 °C, 200 to 500 °C, 200 to 400 °C, or 200 to 300 °C, and in many cases to 240 to 280 °C. Typically, all product surfaces that make up the second mold and come into contact with the pulp slurry layer can be heated.

[0200] The pressing pressure between the product surfaces of the first and second pressing tools of the second mold can be about 390 to 1570 kPa, and in most cases about 580 to 1170 kPa.

[0201] The pressing pressure can be applied during a second pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds. For most settings, a pressing time of about 0.5 to 1.5 seconds is sufficient, and in many cases, 0.5 to 1.0 seconds may also be sufficient.

[0202] Typically, in this second pressing step, the initial water content of the pulp slurry layer can be about 45 to 65% by weight, typically about 50 to 60% by weight.

[0203] The final water content can be about 25 to 40% by weight, preferably about 30 to 35% by weight.

[0204] After the second pressing step 104, the pulp slurry layer, from which a substantial amount of the solvent has now been removed, can be transferred 105 to the third pressing mold. The transfer 106 can be carried out using similar equipment in the same manner as the transfer step 103. As a result, at least a part of the pulp slurry layer can be formed during the transfer.

[0205] Alternatively, the equipment may be different so that the pulp slurry layer is transferred without forming a second transfer tool.

[0206] The third pressing mold can be designed essentially as the second pressing mold.

[0207] The third mold may comprise a pair of mating pressing tools, one of which may have a porous product surface, which can contact the pulp slurry layer and draw a vacuum therethrough.

[0208] The third mold can comprise a first pressing tool presenting a porous product surface and a second pressing tool presenting a second product surface. The second product surface may be porous or non-porous. Alternatively, the second product surface may present porous and non-porous portions.

[0209] In the third pressing step 106, the pulp slurry layer can be pressed within the third mold. The pulp slurry layer can then be pressed against the second product surface of the second pressing tool of the third mold. In this third pressing step 106, a pressure lower than the surrounding ambient pressure is applied to the back side of the porous product surface, thus creating a vacuum on the back side of the porous product surface and drawing in solvent vapors such as steam through the tool.

[0210] The porous product surface of the third mold can have a porosity of 25 - 50% with a pore size of 0.1 - 1.2 mm, preferably 0.25 - 1.0 mm.

[0211] However, in the third pressing step 106, the pressure applied to the back surface of the porous product surface of the third mold may be higher than the pressure provided in the second pressing step 104.

[0212] Specifically, the pressure provided in the second pressing step 104 can be 1 to 99%, preferably 50 to 99%, 90 to 99%, 95 to 99%, or 99 to 99.9% of the pressure provided in the third pressing step 106.

[0213] In the third pressing step, the absolute pressure provided on the back side of the porous product surface of the third mold can be 200 to 900 mbarA, preferably 300 to 800 mbarA, but is always higher than in the case of the second pressing step.

[0214] The flow rate through the tool can be between 50 and 1000 m3 / h. Preferably, the flow rate can be between 1000 and 30000 m3 / h per square meter of the porous product surface of the tool.

[0215] At least one of the product surfaces of the third mold can be heated to about 100 to 400 °C, preferably 100 to 300 °C, 150 to 400 °C, 150 to 300 °C, 200 to 300 °C, or 200 to 280 °C, and in many cases 240 to 280 °C. Typically, all product surfaces that make up the third mold and contact the pulp slurry layer can be heated.

[0216] The pressing pressure between the product surfaces of the third mold can be about 390 to 1570 kPa, and in most cases about 580 to 1170 kPa.

[0217] The pressing pressure can be applied during a third pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds. In most settings, a pressing time of about 0.5 to 1.5 seconds is sufficient, and in many cases, 0.5 to 1.0 seconds may also be sufficient.

[0218] Typically, in this third pressing step, the initial water content of the pulp slurry layer can be about 25 - 45 wt% or 25 - 40 wt%, preferably about 30 - 40 wt% or 30 - 35 wt%, and the final water content can be less than about 5 wt%, preferably less than about 1 wt%.

[0219] After the third pressing step 106, the pulp slurry layer, now with most of its solvent removed, can be transferred 107 from the machine.

[0220] Optionally, additional steps such as surface treatment, cutting, or printing may be performed on the thus essentially dry product. The product can then be packaged, stored, and shipped.

[0221] Note that the third pressing step 106, and thus its associated transfer step 105, are also optional. Thus, the process may end after the second pressing step 104 immediately followed by the output step 107.

[0222] Thus, in the first pressing step, the initial water content of the pulp slurry layer can be 70 - 90 wt%, and the final water content can be 25 - 50 wt%, preferably about 30 - 35 wt%.

[0223] In the second pressing step, the initial water content of the pulp slurry layer can be about 25 - 50 wt%, preferably about 30 - 35 wt%, and the final water content can be less than about 5 wt%, preferably less than about 1 wt%.

[0224] Furthermore, the method may comprise at least one optional washing step of the pulp slurry layer. The washing step can be performed after the transfer step 103 and before the second pressing step 104, and / or after the transfer step 105 and before the third pressing step 106.

[0225] Furthermore, the method may comprise at least one step in which a laminate or coating is applied to the pulp slurry layer or the pulp product. The laminate or coating may be applied between the first and second pressing steps, or between the second and third pressing steps, or after the third pressing step.

[0226] Note that the vacuum source provided must be sized to provide a flow rate sufficient to discharge the amount of steam generated during the heating / pressing step and to contain the liquid water drawn out by the vacuum applied to each mold. The invention described in the original claims of the present application is appended below. [1] A pick-up press device for use in a process for manufacturing a 3D molded product from a pulp slurry, a pick-up press tool (10) presenting a porous first product surface, a press tool (20) presenting a second product surface, a vacuum source connected to the pick-up press tool (10) and comprising, the pick-up press tool (10) and the press tool (20) are movable perpendicular to each other, in a first relative position of the press tools (10, 20), at least one of the product surfaces is arranged to receive a liquid pulp slurry layer against that product surface, in a second relative position of the press tools (10, 20), the product surfaces are pressed towards each other to press the pulp slurry layer, the apparatus further comprises a first transfer tool (30), the first transfer tool (30) a first forming surface portion (34) configured to coincide with a first portion (14) of the porous first product surface such that a forming gap (80) is defined therebetween, the forming gap (80) defining a desired pulp slurry layer thickness, the first forming surface portion (34), a second forming surface portion (35) and a non-forming space (90) is defined by the second forming surface portion (35) configured to branch from the second portion (15) of the porous first product surface such that the non-forming space (90) has a greater thickness than the forming gap, the second forming surface portion (35) and comprising, a pick-up press device. [2] The pick-up press device according to [1], wherein the pick-up press tool (10) is provided with at least one heating element (13) adapted to supply heat to the porous first product surface of the pick-up press tool (10), and / or the press tool (20) is provided with at least one heating element (23) adapted to supply heat to the second product surface of the press tool (20). [3] In the second relative position of the press tools (10, 20), the product surfaces are pressed towards each other to press the pulp slurry layer, while heating the pulp slurry layer by the at least one heating element (13, 23) and drawing a vacuum through at least one porous product surface of the tools, the pickup press apparatus according to [2]. [4] The non-forming space (90) is configured to provide contact between only one pulp slurry layer surface and one of the second forming surface portion (35) and the second portion (15) of the porous first product surface, the pickup press apparatus according to any one of [1] to [3]. [5] The non-forming space (90) presents a space between the second forming surface portion (35) and the second portion (15) of the porous first product surface, which is more than 20 times, preferably more than 15 times, more than 10 times, or more than 5 times the thickness of the forming gap (80), the pickup press apparatus according to any one of [1] to [4]. [6] The non-forming space (90) is provided at the innermost part of the female mold and / or the distal part of the male mold when viewed in the press direction, the pickup press apparatus according to any one of [1] to [5]. [7] The non-forming space (90) is provided at the outermost part of the female mold and / or the distal part of the male mold when viewed in the press direction, the pickup press apparatus according to any one of [1] to [5]. [8] The forming gap (80) presents a thickness small enough for both the first forming surface portion (34) and the first portion (14) of the porous first product surface to contact their respective pulp slurry layer surfaces, the pickup press apparatus according to any one of [1] to [7]. [9] The forming gap (80) is configured to provide a pressure higher than the ambient pressure to the pulp slurry layer, the pickup press apparatus according to any one of [1] to [8].

[10] The first forming surface portion (34) presents a contact surface area corresponding to 10 to 99.9%, preferably 25 to 95% of the total surface area of the porous first product surface, the pickup press apparatus according to any one of [1] to [9].

[11] The first transfer tool (30) presents a porous product surface having a porosity of 10 to 90%, the pickup press apparatus according to any one of [1] to

[10] .

[12] The pick-up press device according to

[11] , wherein the porous product surface of the first transfer tool (30) exhibits pores having a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[13] The pick-up press device according to any one of [1] to

[12] , wherein the porous first product surface of the pick-up press tool (10) has a porosity of 10 to 90%.

[14] The pick-up press device according to any one of [1] to

[13] , wherein the porous first product surface of the pick-up press tool (10) exhibits pores having a pore size of 0.1 to 0.7 mm, preferably 0.25 to 0.6 mm.

[15] The pick-up press device according to any one of [1] to

[14] , wherein the pick-up press tool (10) is provided with at least one heating element (13) adapted to supply heat to the porous first product surface of the pick-up press tool.

[16] The pick-up press device according to any one of [1] to

[15] , wherein the press tool (20) is provided with at least one heating element (23) adapted to supply heat to the second product surface of the press tool.

[17] A method for manufacturing a 3D molded product from a pulp slurry, applying a liquid pulp slurry layer to the porous first product surface of the pick-up press tool (10) of the first mold; in a first forming step, heating the pulp slurry layer and pressing the pulp slurry layer on the porous first product surface of the pick-up press tool (10) against the second product surface of the cooperating press tool (20) of the first mold while drawing a vacuum through at least one of the porous product surfaces of the tools (10, 20); transferring the pulp slurry layer to the porous product surface of the first press tool of the second mold (40, 50); in a second subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against the second product surface of the second press tool of the second mold (40, 50) while drawing a vacuum through at least one of the porous product surfaces of the first and second press tools of the second mold (40, 50); comprising wherein at least a portion of the pulp slurry layer is formed during transfer of the pulp slurry layer to the first press tool of the second mold (40, 50).

[18] The transfer of the pulp slurry layer from the first mold (10, 20) to the second mold (40, 50) is carried out by a first transfer tool (30), and the first transfer tool includes a first forming surface portion (34) and a second forming surface portion (35). During the transfer of the pulp slurry layer from the first mold (10, 20) to the first transfer tool (30), the first forming surface portion (34) coincides with a first portion (14) of the porous first product surface of the first mold such that a forming gap (80) is defined therebetween, and the forming gap (80) defines a desired pulp slurry layer thickness. The second forming surface portion (35) branches from a second portion (15) of the porous first product surface of the first mold such that a non-forming space (90) is defined by the second forming surface portion (35) and the second portion (15) of the porous first product surface of the first mold, and the non-forming space (90) has a thickness greater than that of the forming gap, the method according to

[17] .

[19] During the transfer of the pulp slurry layer from the first mold (10, 20) to the first transfer tool (30), the forming gap (80) provides a pressure higher than the ambient pressure on the pulp slurry layer, the method according to

[18] .

[20] During the movement of the first transfer tool (30) from the first mold (10, 20) to the second mold (40, 50), the first forming surface portion (34) contacts the pulp slurry layer surface and the second forming surface portion (35) is free, the method according to

[18] or

[19] .

[21] During the transfer of the pulp slurry layer from the first mold (10, 20) to the second mold (40, 50), the first transfer tool (30) is evacuated so that at least some water is discharged from the pulp slurry layer, the method according to any one of

[18] to

[20] .

[22] The pulp slurry layer transferred to the second mold (40, 50) exhibits a first pulp slurry layer portion and a second pulp slurry layer portion, the first and second pulp slurry layer portions are juxtaposed, and the first pulp slurry layer portion has a water content level higher or lower than that of the second pulp slurry layer portion, the method according to any one of

[17] to

[21] .

[23] The pickup of the pulp slurry layer is achieved by dipping the porous first product surface of the pickup press tool (10) into a liquid bath containing the pulp slurry while pulling a vacuum through the porous first product surface of the pickup press tool (10) so that the pulp slurry layer is applied to the product surface, according to any one of

[17] to

[22] .

[24] The pickup press tool (10) moves vertically upward from the liquid bath so as to contact the cooperating press tool (20), according to the method described in

[23] .

[25] The pulp slurry layer is applied to the porous first product surface of the pickup press tool (10) by spraying or injection, according to any one of

[17] to

[22] .

[26] The first pressure on the back side of the porous first product surface during the pickup of the pulp slurry layer is 300 to 700 mbarA, preferably 400 to 600 mbarA, according to any one of

[17] to

[25] .

[27] In the first forming step, the second pressure on the back side of the porous product surface of the first mold (10, 20) is lower than the third pressure on the back side of the porous product surface of the second mold (40, 50) in the second forming step, according to any one of

[17] to

[26] .

[28] The second pressure is 1 to 99% of the third pressure, preferably 50 to 99% or 90 to 99%, according to the method described in

[27] .

[29] The second pressure is 200 to 900 mbarA, preferably 300 to 800 mbarA, according to the method described in

[27] or

[28] .

[30] In the first forming step, the second product surface of the cooperating press tool (20) of the first mold is heated to about 150 to 400 °C, preferably 200 to 300 °C, according to any one of

[17] to

[29] .

[31] In the first forming step, the porous first product surface of the pickup press tool (10) of the first mold is heated to about 100 to 150 °C, according to any one of

[17] to

[30] .

[32] In the first forming step, the pulp slurry layer is pressed against the second product surface of the first mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa, according to any one of

[17] to

[31] .

[33] In the first forming step, the pulp slurry layer is pressed against the second product surface of the first mold for a first pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds, according to any one of

[17] to

[32] .

[34] In the first forming step, the initial water content of the pulp slurry layer is 70 to 90% by weight, and the final water content is 45 to 65% by weight, preferably about 50 to 60% by weight, according to any one of

[17] to

[33] .

[35] The third pressure is 200 to 900 mbarA, preferably 300 to 800 mbarA, according to any one of

[17] to

[34] .

[36] In the second forming step, at least one of the product surfaces of the second molds (40, 50) is heated to about 110 to 400 °C, preferably 200 to 300 °C, according to any one of

[17] to

[35] .

[37] In the second forming step, the pulp slurry layer is pressed against the second product surface of the second mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa, according to any one of

[17] to

[36] .

[38] In the second forming step, the pulp slurry layer is pressed against the second product surface of the second mold for a second pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds, according to any one of

[17] to

[37] .

[39] In the second forming step, the initial water content of the pulp slurry layer is about 45 to 65%, preferably about 50 to 60% by weight, and the final water content is about 25 to 40% by weight, preferably about 30 to 35% by weight, according to any one of

[17] to

[38] .

[40] Further comprising the step of transferring the pulp slurry layer to the porous product surface of the first pressing tool of the third mold, and in a third subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against the second product surface of the second pressing tool of the third mold while evacuating through at least one of the porous product surfaces of the first and second pressing tools of the third mold, according to any one of

[17] to

[39] .

[41] The third pressure on the back side of the porous product surface of the second mold is lower than the fourth pressure on the back side of the porous product surface of the third mold, according to the method described in

[40] .

[42] The method according to

[41] , wherein the fourth pressure is 200 to 900 mbarA, preferably 300 to 800 mbarA.

[43] The method according to any one of

[40] to

[42] , wherein in the third forming step, at least one of the product surfaces of the third mold is heated to about 100 to 300 °C, preferably 200 to 280 °C.

[44] The method according to any one of

[40] to

[43] , wherein in the third forming step, the pulp slurry layer is pressed against the second product surface of the third mold at a pressure of about 390 to 1570 kPa, preferably 580 to 1170 kPa.

[45] The method according to any one of

[40] to

[44] , wherein in the third forming step, the pulp slurry layer is pressed against the second product surface of the third mold for a third pressing time of 0.1 to 4.0 seconds, preferably 0.5 to 2.0 seconds.

[46] The method according to any one of

[40] to

[45] , wherein in the third forming step, the initial water content of the pulp slurry layer is about 25 to 45 wt% or 25 to 40 wt%, preferably about 30 to 40 wt% or 30 to 35 wt%, and the final water content is less than about 5 wt%, preferably less than about 1 wt%.

[47] A method for forming a receptacle, comprising the method according to any one of

[18] to

[46] , wherein the non-forming space (90) is provided in each part of the pressing tool and the transfer tool corresponding to the opening part of the receptacle.

[48] A system for manufacturing a 3D molded product from pulp slurry, a pick-up press device according to any one of [1] to

[16] , a second pair of cooperating press tools (40, 50) and a system comprising.

[49] a second transfer tool, a third pair of cooperating press tools and The system according to

[48] , further comprising.

Claims

Claim 1 A pick-up press device for use in a process for manufacturing a 3D molded product from a pulp slurry, a pick-up press tool (10) presenting a porous first product surface, a press tool (20) presenting a second product surface, a vacuum source connected to the pick-up press tool (10), comprising, the pick-up press tool (10) is provided with at least one heating element (13) adapted to supply heat to the porous first product surface of the pick-up press tool (10), and / or the press tool (20) is provided with at least one heating element (23) adapted to supply heat to the second product surface of the press tool (20), the pick-up press tool (10) and the press tool (20) are movable perpendicular to each other, in a first relative position of the press tools (10, 20), at least one of the product surfaces is arranged to receive a liquid pulp slurry layer against that product surface, in a second relative position of the press tools (10, 20), the product surfaces are pressed towards each other to press the pulp slurry layer, the apparatus further comprises a first transfer tool (30), the first transfer tool (30) comprising, a first forming surface portion (34) configured to coincide with a first portion (14) of the porous first product surface such that a forming gap (80) is defined therebetween, the forming gap (80) defining a desired pulp slurry layer thickness, a second forming surface portion (35) configured to branch from the second portion (15) of the porous first product surface such that a non-forming space (90) is defined by the second forming surface portion (35) and the second portion (15) of the porous first product surface, the non-forming space (90) having a greater thickness than the forming gap, a pick-up press device. Claim 2 In the second relative position of the press tools (10, 20), the product surfaces are pressed towards each other to press the pulp slurry layer, while heating the pulp slurry layer by the at least one heating element (13, 23) and drawing a vacuum through at least one porous product surface of the tools, the pickup press device according to claim 1.

3. The non-forming space (90) is configured to provide contact between only one pulp slurry layer surface and one of the second forming surface portion (35) and the second portion (15) of the porous first product surface, the pickup press device according to claim 1 or 2.

4. The non-forming space (90) presents a space between the second forming surface portion (35) and the second portion (15) of the porous first product surface, which is more than 20 times, more than 15 times, more than 10 times, or more than 5 times the thickness of the forming gap (80), the pickup press device according to any one of claims 1 to 3.

5. The non-forming space (90) is provided at the innermost part of the female mold and / or the distal part of the male mold when viewed in the press direction, the pickup press device according to any one of claims 1 to 4.

6. The non-forming space (90) is provided at the outermost part of the female mold and / or the distal part of the male mold when viewed in the press direction, the pickup press device according to any one of claims 1 to 4.

7. The forming gap (80) presents a thickness small enough for both the first forming surface portion (34) and the first portion (14) of the porous first product surface to contact their respective pulp slurry layer surfaces, the pickup press device according to any one of claims 1 to 6.

8. The forming gap (80) is configured to provide a pressure higher than the ambient pressure to the pulp slurry layer, the pickup press device according to any one of claims 1 to 7.

9. The first forming surface portion (34) presents a contact surface area corresponding to 10 to 99.9% of the total surface area of the porous first product surface, the pickup press device according to any one of claims 1 to 8.

10. The pickup press device according to any one of claims 1 to 9, wherein the first transfer tool (30) presents a porous product surface having a porosity of 10 to 90%.

11. The pickup press device according to claim 10, wherein the porous product surface of the first transfer tool (30) presents pores having a pore size of 0.1 to 0.7 mm in diameter.

12. The pickup press device according to any one of claims 1 to 11, wherein the porous first product surface of the pickup press tool (10) has a porosity of 10 to 90%.

13. The pickup press device according to any one of claims 1 to 12, wherein the porous first product surface of the pickup press tool (10) presents pores having a pore size of 0.1 to 0.7 mm in diameter.

14. The pickup press device according to any one of claims 1 to 13, wherein the pickup press tool (10) is provided with at least one heating element (13) adapted to supply heat to the porous first product surface of the pickup press tool.

15. The pickup press device according to any one of claims 1 to 14, wherein the press tool (20) is provided with at least one heating element (23) adapted to supply heat to the second product surface of the press tool.

16. A method for manufacturing a 3D molded product from a pulp slurry, comprising: applying a liquid pulp slurry layer to the porous first product surface of the pickup press tool (10) of a first mold; in a first forming step, heating the pulp slurry layer and pressing the pulp slurry layer on the porous first product surface of the pickup press tool (10) against the second product surface of the cooperating press tool (20) of the first mold while drawing a vacuum through at least one of the porous product surfaces of the pickup press tool (10) and the press tool (20); transferring the pulp slurry layer to the porous product surface of a first press tool of a second mold (40, 50); In a second subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against a second product surface of a second press tool of the second mold (40, 50) while drawing a vacuum through at least one porous product surface of the first and second press tools of the second mold (40, 50). comprising at least a portion of the pulp slurry layer is formed during transfer to the first press tool of the second mold (40, 50), transfer of the pulp slurry layer from the first mold to the second mold (40, 50) is effected by a first transfer tool (30), the first transfer tool comprising a first forming surface portion (34) and a second forming surface portion (35), during transfer of the pulp slurry layer from the first mold to the first transfer tool (30), the first forming surface portion (34) coincides with a first portion (14) of the porous first product surface of the first mold such that a forming gap (80) is defined therebetween, the forming gap (80) defining a desired pulp slurry layer thickness, the second forming surface portion (35) branches from a second portion (15) of the porous first product surface of the first mold such that a non-forming space (90) is defined by the second forming surface portion (35) and the second portion (15) of the porous first product surface of the first mold, the non-forming space (90) having a greater thickness than the forming gap, a method.

17. The method according to claim 16, wherein during transfer of the pulp slurry layer from the first mold to the first transfer tool (30), the forming gap (80) provides a pressure on the pulp slurry layer that is higher than ambient pressure.

18. The method according to claim 16 or 17, wherein during movement of the first transfer tool (30) from the first mold to the second mold (40, 50), the first forming surface portion (34) is in contact with the pulp slurry layer surface and the second forming surface portion (35) is free.

19. The method according to any one of claims 16 to 18, wherein during transfer of the pulp slurry layer from the first mold to the second mold (40, 50), the first transfer tool (30) is evacuated such that at least some water is discharged from the pulp slurry layer.

20. The pulp slurry layer transferred to the second mold (40, 50) presents a first pulp slurry layer portion and a second pulp slurry layer portion, the first and second pulp slurry layer portions are juxtaposed, and the first pulp slurry layer portion has a water content level higher or lower than that of the second pulp slurry layer portion. The method according to any one of claims 16 to 19.

21. The pickup of the pulp slurry layer is achieved by immersing the porous first product surface of the pickup press tool (10) in a liquid tank containing the pulp slurry while drawing a vacuum through the porous first product surface of the pickup press tool (10) so that the pulp slurry layer is applied to the product surface. The method according to any one of claims 16 to 20.

22. The pickup press tool (10) moves vertically upward from the liquid tank so as to contact the cooperating press tool (20). The method according to claim 21.

23. The pulp slurry layer is applied to the porous first product surface of the pickup press tool (10) by spraying or injection. The method according to any one of claims 16 to 20.

24. The first pressure on the back side of the porous first product surface during the pickup of the pulp slurry layer is 300 to 700 mbarA. The method according to any one of claims 16 to 23.

25. In the first forming step, the second pressure on the back side of the porous product surface of the first mold is lower than the third pressure on the back side of the porous product surface of the second mold (40, 50) in the second forming step. The method according to any one of claims 16 to 24.

26. The second pressure is 1 to 99% of the third pressure. The method according to claim 25.

27. The second pressure is 200 to 900 mbarA. The method according to claim 25 or 26.

28. In the first forming step, the second product surface of the cooperating press tool (20) of the first mold is heated to about 150 to 400 °C. The method according to any one of claims 16 to 27.

29. The method according to any one of claims 16 to 28, wherein in the first forming step, the porous first product surface of the pickup press tool (10) of the first mold is heated to about 100 to 150 °C.

30. The method according to any one of claims 16 to 29, wherein in the first forming step, the pulp slurry layer is pressed against the second product surface of the first mold at a pressure of about 390 to 1570 kPa.

31. The method according to any one of claims 16 to 30, wherein in the first forming step, the pulp slurry layer is pressed against the second product surface of the first mold during a first pressing time of 0.1 to 4.0 seconds.

32. The method according to any one of claims 16 to 31, wherein in the first forming step, the initial water content of the pulp slurry layer is 70 to 90% by weight and the final water content is 45 to 65% by weight.

33. The method according to any one of claims 16 to 32, wherein the third pressure is 200 to 900 mbarA.

34. The method according to any one of claims 16 to 33, wherein in the second forming step, at least one of the product surfaces of the second molds (40, 50) is heated to about 110 to 400 °C.

35. The method according to any one of claims 16 to 34, wherein in the second forming step, the pulp slurry layer is pressed against the second product surface of the second mold at a pressure of about 390 to 1570 kPa.

36. The method according to any one of claims 16 to 35, wherein in the second forming step, the pulp slurry layer is pressed against the second product surface of the second mold during a second pressing time of 0.1 to 4.0 seconds.

37. The method according to any one of claims 16 to 36, wherein in the second forming step, the initial water content of the pulp slurry layer is about 45 to 65% by weight and the final water content is about 25 to 40% by weight.

38. transferring the pulp slurry layer to the porous product surface of the first press tool of the third mold; and, in a third subsequent forming step, heating the pulp slurry layer and pressing the pulp slurry layer against the second product surface of the second press tool of the third mold while drawing a vacuum through at least one of the porous product surfaces of the first and second press tools of the third mold, the method according to any one of claims 16 to 37.

39. The method according to claim 38, wherein the third pressure on the back side of the porous product surface of the second mold is lower than the fourth pressure on the back side of the porous product surface of the third mold.

40. The method according to claim 39, wherein the fourth pressure is 200 to 900 mbarA.

41. The method according to any one of claims 38 to 40, wherein in the third forming step, at least one of the product surfaces of the third mold is heated to about 100 to 300 °C.

42. The method according to any one of claims 38 to 41, wherein in the third forming step, the pulp slurry layer is pressed against the second product surface of the third mold at a pressure of about 390 to 1570 kPa.

43. The method according to any one of claims 38 to 42, wherein in the third forming step, the pulp slurry layer is pressed against the second product surface of the third mold for a third pressing time of 0.1 to 4.0 seconds.

44. The method according to any one of claims 38 to 43, wherein in the third forming step, the initial water content of the pulp slurry layer is about 25 to 45 wt% or 25 to 40 wt%, and the final water content is less than about 5 wt%.

45. A method of forming a receptacle, comprising the method according to any one of claims 16 to 44, wherein the non-forming space (90) is provided in each part of the press tool and the transfer tool corresponding to the opening of the receptacle.

46. A system for manufacturing a 3D molded product from pulp slurry, a pick-up press device according to any one of claims 1 to 15, a second pair of cooperating press tools (40, 50) and a system comprising.

47. a second transfer tool, a third pair of cooperating press tools and the system according to claim 46, further comprising.

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