A product forming unit having a cellulose product toggle press module and a method for using the same

Abstract

A cellulosic product toggle press module (6) for forming a non-flat cellulosic product (1) from an air-formed cellulosic blank structure (2). The toggle press module (6) has a toggle press (6a) including a press member (6d) movably arranged in a press direction, a toggle mechanism (6e) drivingly connected to the press member (6d), a press actuator assembly (6f) drivingly connected to the toggle mechanism (6e), and an electronic control system (6h) operably connected to the press actuator assembly (6f). The toggle press module (6) further has a mold (3) including a moveable first mold portion (3a) attached to the press member (6d) and a second mold portion (3b). The electronic control system (6h) is configured to control operation of the press actuator assembly (6f) to drive the press member (6d) in a pressing direction using the toggle mechanism (6e) and to press the first die part (3a) against the second die part (3b) to form a non-flat cellulose product from the air-formed cellulose blank structure. Further, the toggle press (6a) is installed or arranged to be installed to have a pressing direction of the press member (6d) disposed primarily horizontally, specifically to have a pressing direction of the press member (6d) disposed within 20 degrees of the horizontal, more specifically to have a pressing direction parallel to the horizontal.

Description

Technical Field

[0001] The present disclosure relates to a cellulose product toggle press module for forming non-flat cellulose products from air-formed cellulose blank structures. The present disclosure further relates to a method for forming non-flat cellulose products from air-formed cellulose blank structures using a cellulose product toggle press module.

[0002] The cellulose product toggle press module according to the present disclosure will be mainly described with respect to an exemplary cellulose product forming unit including an incorporated fiber separation module, a cellulose blank air forming module, etc. However, the cellulose product toggle press module and related methods for using it are not limited to this specific example and may alternatively be implemented and used in many other forms of cellulose product manufacturing systems.

[0003] Background Art Cellulose fibers are often used as raw materials for manufacturing products or for fabricating products. Products formed from cellulose fibers can be used in many different situations where there is a need for sustainable products. A wide range of products can be manufactured from cellulose fibers, and some examples are disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.

[0004] Forming molds are commonly used when manufacturing cellulose products from cellulose fiber raw materials. Conventionally, cellulose products are wet-formed. The material commonly used for the wet forming of cellulose fiber products is wet-forming pulp. Wet-forming pulp is manufactured from biomaterials and can be recycled after use. Therefore, wet-forming pulp has the advantage of being regarded as a sustainable packaging material. As a result, wet-forming pulp is rapidly gaining popularity for various applications. Wet-forming pulp articles are generally formed by immersing a suction forming mold in a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers. When suction is applied, a mass of pulp is formed into the shape of a desired product by fiber deposition on the forming mold. All wet-forming techniques require drying the wet-formed product, and such drying is an extremely time-consuming and energy-consuming part of production. The requirements for the aesthetics, chemical, and mechanical properties of cellulose products are increasing, and due to the properties of wet-formed cellulose products, there are limitations in mechanical strength, flexibility, freedom of material thickness, and chemical properties. Also, in the wet-forming process, it is difficult to precisely control the mechanical properties of the product.

[0005] One development in the field of manufacturing cellulose products is the forming of cellulose fibers in a dry-forming process without using wet-forming techniques. Instead of forming cellulose products from a liquid or semi-liquid pulp suspension or slurry, an air-formed cellulose blank structure is used. The air-formed cellulose blank structure is inserted into a forming mold, and during the forming of the cellulose product, a high forming pressure and a high forming temperature are applied to the cellulose blank structure in the forming mold.

[0006] The production of cellulose products by compression molding of air-formed cellulose blank structures may be carried out in a production line or a product molding unit. The manufacturing equipment usually includes a press module with a mold. Other modules and components, such as a supply module, a buffer module, and a blank dry forming module, are connected and arranged to the press module. Since the press module is available as an independent off-the-shelf machine, it is usually a high-capacity press module such as a large hydraulic or servo-driven press machine that may also be used to mold other materials such as steel plates.

[0007] One drawback of using standard press modules developed for general purposes is usually the high cost associated with conventional high-capacity hydraulic or servo-driven press machines, as well as the problems caused by their large size and weight with respect to transportation, installation, maintenance, and factory size.

[0008] Furthermore, customers who usually invest in cellulose product molding units are called converters and usually have little or no engineering skills required to develop and integrate the modules necessary for a complete cellulose product molding unit. Therefore, in converters, there is a need to be able to purchase a completely integrated and standardized product molding unit that can be easily transported, installed, and operated.

[0009] Accordingly, there is a need for a cellulose product press module for molding non-flat cellulose products from air-formed cellulose blank structures that is low-cost, compact, and lightweight, as well as a method for molding non-flat cellulose products from air-formed cellulose blank structures using such a cellulose product press module. There is also a need for a cellulose product press module that enables the development and manufacture of a low-cost, compact, completely integrated and standardized cellulose product molding unit that can be easily transported, installed, and operated.

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

[0011] According to a first aspect of the present disclosure, there is provided a cellulose product toggle press module for forming a non-flat cellulose product from an air-formed cellulose blank structure. The toggle press module has a toggle press comprising a press member movably arranged in the 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. The toggle press module further has a forming die including a movable first die part attached to the press member and a second die part. The electronic control system is configured to control the operation of the press actuator assembly so as to drive the press member in the press direction using the toggle mechanism and press the first die part against the second die part to form a non-flat cellulose product from the air-formed cellulose blank structure, and the toggle press is arranged or arranged to be arranged mainly in a horizontal direction and have a press direction of the press member, specifically within 20 degrees from the horizontal direction, more specifically having a press direction parallel to the horizontal direction.

[0012] According to a second aspect of the present disclosure, a method for forming a non-flat cellulose product from an air-formed cellulose blank structure is provided. The method includes providing a cellulose product toggle press module having a toggle press and a mold. The toggle press has a press member movably disposed 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, and the mold has a movable first mold part attached to the press member and a second mold part. The method further includes installing the toggle press such that the press direction of the press member is mainly horizontally disposed, specifically such that the press direction of the press member is disposed within 20 degrees from the horizontal direction, more specifically such that the press direction of the press member is parallel to the horizontal direction. The method further includes supplying an air-formed cellulose blank structure into a press area defined by the spaced-apart first and second mold parts, and controlling the 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 press the first mold part against the second mold part to form a non-flat cellulose product from the air-formed cellulose blank structure.

[0013] Toggle mechanism clamps are well known in the field of injection molding, where, for example, a liquid-phase plastic material is injected at high pressure into a cavity formed by a closed mold. In the technical field of injection molding, the purpose of a toggle mechanism clamp is to simply close the injection mold parts and apply sufficient clamping force so that the mold parts do not separate due to the internal injection pressure within the mold.

[0014] However, toggle mechanisms are not very commonly used in compression molding applications where the pressure level is an important parameter that must be controlled with a certain accuracy. This is because, for one thing, the control of the press force is more complex due to the exponential amplification characteristics of the toggle mechanism, and for another, the resulting press force cannot be easily measured with good accuracy. For example, to determine the amplification level, the calculation of the press force requires information not only about the input press force generated by the press actuator assembly, but also about the angular position of the toggle mechanism.

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

[0016] Furthermore, toggle presses also have a particularly advantageous speed-force characteristic that can significantly shorten the cycle time of the cellulose product forming cycle compared to conventional high-capacity hydraulic or servo presses. In particular, the inherent force amplification characteristic of the toggle mechanism results in a relatively fast speed of the press member during the initial cycle time starting from the standby position, while on the other hand, this speed gradually decreases as it approaches the maximum stroke state of the toggle mechanism, resulting in the advantage of an amplified maximum press force. As a result, the initial movement of the press member is performed at a high speed and with a low maximum press force, and the movement of the press member during the actual pressing operation is performed at a low speed and with a high maximum press force.

[0017] Furthermore, the compact size and lightweight of the toggle press make it easier to install and orient the toggle press in a non-vertical position.

[0018] In fact, assembling and configuring a toggle press such that the pressing direction of the press member is mainly arranged in the horizontal direction enables the development of a very compact cellulose product forming unit with an integrated press module, which is particularly advantageous for compression molding non-flat cellulose products from an air-formed cellulose blank structure.

[0019] In particular, due to the compact size and light weight of the toggle press, it is possible to develop a very compact, fully integrated and standardized cellulose product forming unit that can be easily transported, installed and operated. The low cost of the toggle press helps to maintain the total cost of the cellulose product forming unit at a low level.

[0020] Furthermore, since the orientation of the toggle press is mainly horizontal, the overall height of the cellulose product forming unit can be reduced, enabling a non-linear material flow of continuously air-formed cellulose blank structures from the blank dry forming module to the press module. A non-linear material flow, for example, feeding an air-formed cellulose blank structure in a first direction, such as upward, and then in a second direction, such as downward, generally enables the development and manufacture of a more compact cellulose product forming unit. Since the web of cellulose fiber material is usually supplied to the press module at approximately right angles to the pressing direction of the press module, the mainly horizontal orientation of the toggle press is typically associated with a mainly vertically arranged supply flow of the cellulose blank structure. Therefore, it is clear that a press module arranged mainly in the horizontal direction is extremely beneficial when developing a compact cellulose product forming unit having a non-linear material flow of air-formed cellulose blank structures from the blank dry forming module to the press module.

[0021] Further advantages are achieved by implementing one or more of the features of the dependent claims. For example, in some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further comprises a press force display assembly, in which case the electronic control system is operably connected to the press force display assembly and is configured to control the operation of the press actuator assembly based on feedback information indicating the press force received from the press force display assembly. Thereby, better control of the pressing operation can be achieved.

[0022] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further has a front structure and a rear structure, in which case the toggle mechanism is also connected to the rear structure and the second die part is attached to the front structure. Thereby, a compact and cost-effective press module becomes possible.

[0023] In some exemplary embodiments, the second die part is stationary, i.e., a stationary second die part attached to the front structure. Thereby, generally, a design of the toggle press that is not complex and is most cost-effective becomes possible.

[0024] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press has a rigid frame structure defined by a front structure, a rear structure, and an intermediate linear guide assembly connecting the front structure to the rear structure, in which case the press member is movably attached to the linear guide assembly and is movable in the pressing direction. Thereby, a compact and cost-effective press module becomes possible.

[0025] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further includes a feeding device for feeding an air-formed cellulose blank structure into a press area located between a first mold part and a second mold part, and the feeding device is specifically arranged to feed the air-formed cellulose blank structure mainly vertically downward into the press area, more specifically, to feed the air-formed cellulose blank structure into the press area at an angle of less than 20 degrees from the vertical downward direction, and even more specifically, to feed the air-formed cellulose blank structure vertically downward into the press area. The feeding device mainly directed in the vertical direction enables easy feeding into the press area of the mold.

[0026] According to some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the feeding device for feeding an air-formed cellulose blank structure into the press area includes an elongated vacuum belt feeder. In this case, the elongated vacuum belt feeder is mainly arranged in the vertical direction, specifically arranged in an extending direction within 20 degrees from the vertical direction, and more specifically arranged parallel to the vertical direction. This enables a compact and cost-effective press module.

[0027] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the electronic control system is configured to obtain feedback information indicating the pressing force from the pressing force display assembly; and to stop the ongoing pressing movement of the pressing member when a value of a parameter derived from or related to the feedback information indicating the pressing force is at a predetermined threshold or within a predetermined range; or to control the operation of the pressing actuator assembly by using a feedback control device having a parameter related to the feedback information indicating the pressing force as a feedback process variable. Thereby, the resulting pressure applied to the cellulose blank structure to form the cellulose product can be relatively well controlled so as to avoid too low or too high pressure.

[0028] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the pressing force display assembly is a pressing member position detection assembly. In this case, the feedback information indicating the pressing force obtained from the pressing member position detection assembly represents the position of the pressing member or the die gap between the first die part and the second die part. The electronic control system is configured to stop the ongoing pressing movement of the pressing member when the detected position of the pressing member or the die gap between the first die part and the second die part is at a predetermined threshold or within a predetermined range; or to control the operation of the pressing actuator assembly by using a feedback control device having a parameter related to the feedback information indicating the pressing force as a feedback process variable. The information on the position of the pressing member can be utilized to reasonably and accurately estimate the pressing force based on the information on the pressing force of the pressing actuator assembly. The information on the position of the pressing member can also be utilized to determine the die gap, and this die gap can also be utilized to reasonably and accurately determine the pressing force.

[0029] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press force detection assembly. In this case, the feedback information indicating the press force obtained from the press force detection assembly represents the press force of the press member, and the electronic control system is configured to: stop the ongoing pressing movement of the press member when the detected press force of the press member is equal to or exceeds a predetermined threshold value; or control the operation of the press actuator assembly to use a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable. With the press force information, this system can stop the pressing movement at an appropriate position corresponding to the target press force.

[0030] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press has a front structure and a rear structure. In this case, the toggle mechanism is connected to the rear structure, and the second mold part is attached to the front structure. In this case, the toggle press further includes a mechanical adjustment mechanism capable of adjusting the distance between the front structure and the rear structure in the pressing direction, and an adjustment actuator assembly configured to drive the mechanical adjustment mechanism. Thereby, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0031] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further has a press force display assembly, and the electronic control system is operably connected to the press force display assembly. This control system is configured to control the operation of the adjustment actuator assembly based on feedback information indicating the press force received from the press force display assembly to adjust the distance between the front structure and the rear structure in the press direction during a period of continuous pressing operation. Thereby, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0032] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the electronic control system is configured to control the operation of the adjustment actuator assembly based on feedback information indicating the press force received from the press force display assembly to adjust the distance between the front structure and the rear structure in the press direction during a period of continuous pressing operation, with the goal that during the next press cycle, the press member stops at a position having a maximum press force in the range of exceeding 0 to 100%, particularly 5 to 50% of the press force generated when the pressing motion stops. Thereby, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0033] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the electronic control system: moves the pressing member forward while monitoring feedback information indicating the pressing force from the pressing force display assembly, and when a parameter value derived from or related to the feedback information indicating the pressing force is at a predetermined threshold or within a predetermined range, stops the ongoing pressing movement of the pressing member and starts the return movement of the pressing member, or controls the operation of the press actuator assembly to use a feedback control device having a parameter related to the feedback information indicating the pressing force as a feedback process variable; and during the period between successive pressing operations, to adjust the distance between the front structure and the rear structure in the pressing direction so that during the next pressing cycle, the pressing member stops at a position having a maximum pressing force in the range exceeding 0 to 100%, particularly 5 to 50%, of the pressing force generated when the pressing movement stops. It is configured to control the operation of the adjustment actuator assembly based on the feedback information indicating the pressing force received from the pressing force display assembly. Thereby, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0034] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the electronic control system: controls the operation of the press actuator assembly to provide a force of substantially fixed output to the toggle mechanism upon each press activation during normal operation of the cellulose product toggle press module; obtains information indicating the press force from the press force display assembly during press activation; and during the period between successive press activations, adjusts the distance between the front and rear structures and controls the adjustment actuator assembly to maintain a value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, at or within a predetermined threshold. Thereby, without relying on the press force detected during each press activation, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0035] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press member position detection assembly. In this case, the feedback information indicating the press force obtained from the press member position detection assembly represents the position of the press member or the die gap between the first die part and the second die part. In this case, the electronic control system: controls the operation of the press actuator assembly to move the press member forward and to provide a force of substantially fixed output to the toggle mechanism during each press operation, and then controls the operation of the press actuator assembly to move the press member backward; and obtains information indicating the press force from the press member position detection assembly during each press operation or every Nth press operation, and subsequently, during the period between successive press operations, adjusts the distance between the front structure and the rear structure and controls the adjustment actuator assembly to maintain a parameter value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, at a predetermined threshold or within a predetermined range. Thereby, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the forming die without relying on the press force detected during each press operation. The term "Nth" in this case means a number greater than 1, for example, every second, every third, every tenth, etc.

[0036] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press force detection assembly. In this case, the feedback information indicating the press force obtained from the press force detection assembly represents the press force of the press member. In this case, the electronic control system: during normal operation of the cellulose product toggle press module, controls the operation of the press actuator assembly to move the press member forward and to provide a force of substantially fixed output to the toggle mechanism during each press operation, and then controls the operation of the press actuator assembly to move the press member backward; and obtains information indicating the press force from the press force detection assembly during each press operation or every Nth press operation, and subsequently, during the period between consecutive press operations, adjusts the distance between the front structure and the rear structure, and controls the adjustment actuator assembly to maintain a parameter value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, within a predetermined threshold or within a predetermined range. Thereby, without relying on the press force detected during each press operation, the operating position of the toggle press can be adjusted to conform to the specific characteristics of the cellulose blank structure and the shape of the mold.

[0037] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, each of the first and second mold parts has a rigid plate-shaped main body having a surface configured to face the other mold part, and at least one press surface defining one or more molding cavities for molding the cellulose product, and may or may not be provided with additional accessories such as a spring-loaded cutting device and / or a mold alignment device, etc. In this case, the aforementioned surfaces of the rigid plate-shaped main bodies of the first and second mold forming parts do not come into direct contact with each other during the press cycle. Thereby, the mold can be used for press molding of a non-flat cellulose product at a predetermined molding pressure without unwanted interference between the aforementioned surfaces.

[0038] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle mechanism has a first link member and a second link member, and the press actuator assembly is directly or indirectly drivingly connected to the first or second link member such that the press member moves as a result of the operation of the press actuator assembly. Such a form of toggle mechanism provides a compact, cost-effective, and reliable toggle mechanism.

[0039] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle mechanism has a first link member and a second link member, each of these link members having first and second pivot connections, the first pivot connection of the first link member being pivotally connected to the rear structure, the first pivot connection of the second link member being pivotally connected to the press member, the second pivot connection of the first link member being pivotally connected to the second pivot connection of the second link member, and the press actuator assembly being directly or indirectly drivingly connected to the first or second link member so as to adjust the alignment level between the first and second link members such that the press member is moved as a result of the operation of the press actuator assembly. Such a form of toggle mechanism provides a compact, cost-effective, and reliable toggle mechanism.

[0040] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press module further has an operating motion limiting assembly configured to mechanically limit the forward operating motion of the press member and / or to mechanically prevent the toggle mechanism from reaching its maximum stroke state. This reduces the risk of unintentional overpressure during forming.

[0041] The present disclosure further relates to a product forming unit for manufacturing a non-flat cellulose product from an air-formed cellulose blank structure. The product forming unit has a buffer module and a toggle press module. The product forming unit is adapted to supply a cellulose blank structure to the buffer module, buffer the cellulose blank structure within the buffer module, and supply the cellulose blank structure from the buffer module to the toggle press module. The buffer module has a blank supply system configured to continuously supply the cellulose blank structure to the buffer module in a first supply direction and intermittently supply the cellulose blank structure from the buffer module in a second supply direction, where the second supply direction is different from the first supply direction.

[0042] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the product forming unit further has a blank dry forming module configured to provide a cellulose blank structure.

[0043] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the blank dry forming module has a mill, a forming chamber, and a forming wire disposed connected to the forming chamber. The mill is configured to separate fibers from a cellulose raw material, and the forming chamber is configured to distribute the separated fibers onto a forming section of the forming wire for forming a cellulose blank structure.

[0044] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the forming section extends in an upward blank forming direction.

[0045] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further comprises a press force display assembly, in which case the electronic control system is operably connected to the press force display assembly, and the step of controlling the operation of the press actuator assembly by the electronic control system is based on feedback information indicating the press force received from the press force display assembly.

[0046] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the method includes providing a toggle press having a supply device for supplying an air-formed cellulose blank structure into a press area located between a first type of part and a second type of part, and supplying, by the supply device, the air-formed cellulose blank structure mainly vertically downward into the press area, specifically, supplying the air-formed cellulose blank structure into the press area at an angle of less than 20 degrees from the vertical downward direction, and more specifically, further including the step of supplying the air-formed cellulose blank structure vertically downward into the press area.

[0047] According to some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the supply device for supplying the air-formed cellulose blank structure into the press area includes an elongated vacuum belt feeder or an elongated tractor belt feeder, and the method includes arranging the elongated vacuum belt feeder mainly in the vertical direction, specifically, in an extending direction within 20 degrees from the vertical direction, and more specifically, parallel to the vertical direction.

[0048] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of controlling the operation of the press actuator assembly by the electronic control system includes obtaining feedback information indicating the press force from the press force display assembly, and when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold value or within a predetermined range, stopping the ongoing press movement of the press member; or using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable to control the operation of the press actuator assembly.

[0049] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press member position detection assembly, in which case the feedback information indicating the press force obtained from the press member position detection assembly represents the position of the press member or the die gap between the first die part and the second die part. In this case, the step of controlling the operation of the press actuator assembly by the electronic control system includes: stopping the ongoing press movement of the press member when the detected position of the press member or the die gap between the first die part and the second die part is at a predetermined threshold value or within a predetermined range; or using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable.

[0050] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press force detection assembly, and the feedback information indicating the press force obtained from the press force detection assembly represents the press force of the press member. In this case, the step of controlling the operation of the press actuator assembly by the electronic control system includes stopping the ongoing pressing movement of the press member when the detected press force of the press member is equal to or exceeds a predetermined threshold value; or using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable.

[0051] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further includes a front structure, a rear structure, a mechanical adjustment mechanism, and an adjustment actuator assembly configured to drive the mechanical adjustment mechanism. The toggle mechanism is connected to the rear structure, and the second type part is attached to the front structure. In this case, the mechanical adjustment mechanism can adjust the distance between the front structure and the rear structure in the pressing direction, and the method further includes the step of controlling the operation of the adjustment actuator assembly to adjust the distance between the front structure and the rear structure in the pressing direction.

[0052] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of controlling the operation of the adjustment actuator assembly is to adjust the distance between the front structure and the rear structure in the pressing direction based on the feedback information indicating the press force received from the press force display assembly so that during the period between continuous pressing operations, in the next pressing cycle, the press member stops at a position having a maximum press force in the range exceeding 0 to 100%, particularly 5 to 50%, of the press force generated when the pressing movement stops. The step includes controlling the operation of the adjustment actuator assembly.

[0053] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of controlling the press actuator assembly includes: while monitoring feedback information indicating the press force from the press force display assembly, moving the press member forward, and when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold value or within a predetermined range, stopping the ongoing press movement of the press member and starting the return movement of the press member, or by using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable, including the step of controlling the operation of the press actuator assembly; the step of controlling the operation of the adjustment actuator assembly is to target that during the period between consecutive press operations, during the next press cycle, the press member stops at a position having a maximum press force exceeding 0 to 100%, particularly 5 to 50% of the press force generated when the press movement stops, so as to adjust the distance between the front structure and the rear structure in the press direction, including the step of controlling the operation of the adjustment actuator assembly based on the feedback information indicating the press force received from the press force display assembly.

[0054] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the toggle press further includes a press force display assembly, the electronic control system is operably connected to the press force display assembly, and the step of controlling the operation of the adjustment actuator assembly to adjust the distance between the front structure and the rear structure in the press direction is performed during the period between consecutive press operations and is based on the feedback information indicating the press force received from the press force display assembly.

[0055] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of controlling the operation of the press actuator assembly to form a non-flat cellulose product from an air-formed cellulose blank structure includes, during normal operation of the cellulose product toggle press module, controlling the operation of the press actuator assembly to provide a substantially fixed output force to the toggle mechanism at each press actuation; obtaining information indicating the press force from the press force display assembly during the press actuation; and adjusting the distance between the front structure and the rear structure during the period between successive press actuations and controlling an adjustment actuator assembly to maintain a parameter value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, at or within a predetermined threshold value.

[0056] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press member position detection assembly, in which case the feedback information indicating the press force obtained from the press member position detection assembly represents the position of the press member or the die gap between the first die portion and the second die portion. In this case, the steps of controlling the operation of the press actuator assembly to form a non-flat cellulose product from the air-formed cellulose blank structure are: during normal operation of the cellulose product toggle press module, controlling the operation of the press actuator assembly to move the press member forward and to provide a force of substantially fixed output to the toggle mechanism at each press operation, then controlling the operation of the press actuator assembly to move the press member backward; and obtaining information indicating the press force from the press member position detection assembly at each press operation or every Nth press operation, and subsequently, during the period between successive press operations, adjusting the distance between the front structure and the rear structure and controlling the adjustment actuator assembly to maintain a parameter value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, at or within a predetermined threshold value or a predetermined range.

[0057] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the press force display assembly is a press force detection assembly. In this case, the feedback information indicating the press force obtained from the press force detection assembly represents the press force of the press member. In this case, the steps of controlling the operation of the press actuator assembly to form a non-flat cellulose product from the air-formed cellulose blank structure are: during the normal operation of the cellulose product toggle press module, controlling the operation of the press actuator assembly to move the press member forward and to provide a force of substantially fixed output to the toggle mechanism at each press operation, then controlling the operation of the press actuator assembly to move the press member backward; and obtaining information indicating the press force from the press force detection assembly at each press operation or every Nth press operation, and subsequently, during the period between successive press operations, adjusting the distance between the front structure and the rear structure and controlling the adjustment actuator assembly to maintain a parameter value derived from or related to the information indicating the press force, which represents the resulting maximum press force, within a predetermined threshold or within a predetermined range.

[0058] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of forming a cellulose product from a cellulose blank structure in a mold includes heating the cellulose blank structure to a forming temperature in the range of 100 to 300 °C and pressing the cellulose blank structure at a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa.

[0059] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the method includes providing a cellulose blank structure, supplying the cellulose blank structure to a buffer module, buffering the cellulose blank structure in the buffer module, and supplying the cellulose blank structure from the buffer module to a press module, where the cellulose blank structure is continuously supplied to the buffer module in a first supply direction and intermittently supplied from the buffer module in a second supply direction, the second supply direction being different from the first supply direction.

[0060] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of providing a cellulose blank structure includes providing a cellulose raw material, supplying the cellulose raw material to a blank dry forming module, and dry forming a cellulose blank structure from the cellulose raw material in the blank dry forming module.

[0061] In some exemplary embodiments that can be combined with any one or more of the above-described embodiments, the step of dry forming a cellulose blank structure from a cellulose raw material in a blank dry forming module includes separating fibers from the cellulose raw material in a mill, distributing the separated fibers onto a forming wire of the blank dry forming module to form the cellulose blank structure, and transporting the formed cellulose blank structure in an upward blank forming direction toward the buffer module.

[0062] In some embodiments of the cellulose product toggle press module, aspects related to performing a forming process based on feedback information indicating the pressing force received from the pressing force display assembly are focused on. For this purpose, the present disclosure further provides a cellulose product toggle press module for forming a non-flat cellulose product from an air-formed cellulose blank structure, the toggle press module comprising: a press member movably disposed in a pressing direction, a toggle mechanism drivingly connected to the press member, a press actuator assembly drivingly connected to the toggle mechanism, a pressing force display assembly, and an electronic control system operably connected to the press actuator assembly and the pressing force display assembly. A toggle press having a mold including a movable first mold part attached to the press member and a second forming mold; wherein the electronic control system is configured to use the toggle mechanism to drive the press member in the pressing direction and to press the first mold part against the second mold part based on feedback indicating the pressing force received from the pressing force display assembly, thereby forming a non-flat cellulose product from the air-formed cellulose blank structure. To control the operation of the press actuator assembly. This can achieve better control of the pressing operation.

[0063] Further features and advantages of the present invention will become apparent upon consideration of the appended claims and the following description. Those skilled in the art will recognize that, without departing from the scope of the present disclosure, different features of the present disclosure may be combined to form embodiments other than those explicitly described above and below.

[0064] The cellulose product toggle press module according to the present disclosure and related methods for forming non-flat cellulose will be described in detail below with reference to the accompanying drawings.

Brief Description of the Drawings

[0065]

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[0066] Description of Exemplary Embodiments Various aspects of the present disclosure will be described below with reference to the accompanying drawings. This aspect is for illustrative purposes only and does not limit the present disclosure. In this case, like reference numerals refer to like elements, and variations of the described aspects are not limited to the specifically shown embodiments but are applicable to other variations of the present disclosure.

[0067] The cellulose product toggle press module according to the present disclosure will first be described in relation to a product forming unit U for manufacturing a non-flat cellulose product 1 from an air-formed cellulose blank structure 2.

[0068] Figures 1a - 1b schematically show a product forming unit U for manufacturing a non-flat cellulose product 1 from an air-formed cellulose blank structure 2. The product forming unit U has a buffer module 5 and a press module 6, as will be described in more detail later. The cellulose product 1 is manufactured from the cellulose blank structure 2 in the product forming unit U. The cellulose blank structure 2 is provided from a suitable source and supplied to the buffer module 5 and the press module 6. The forming of the cellulose product 1 is performed in the press module 6. A non-flat product means a product having a three-dimensional spread, different from a flat product such as a blank or a sheet.

[0069] The air-formed cellulose blank structure 2 according to the present disclosure means a substantially air-formed fiber web structure made of 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 forming of the cellulose blank structure 2 means the forming 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 an air forming process, the cellulose fibers are transported by air as a transport medium and formed into the fiber blank structure 2. This is different from the normal papermaking process or the conventional wet forming process in which water is used as the transport medium for cellulose fibers when forming paper or fiber structures. In the air forming process, a small amount of water or other substances may be added to the cellulose fibers as necessary to change the properties of the cellulose product, but air is still used as the transport medium in the forming process. The cellulose blank structure 2 may, if appropriate, have a dryness corresponding mainly to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2. Alternatively, the dryness of the cellulose blank structure 2 can be controlled to have an appropriate dryness level when forming the cellulose product 1.

[0070] Incorporated in the product forming unit U shown in FIGS. 1a to 1b and shown in more detail in FIG. 1c, the blank dry forming module 4 has a horizontal spraying direction of cellulose fibers directed from the mill 4a towards the forming wire 4c. Since the length of the fiber transport distance by air inside the forming chamber 4b must be long enough to minimize turbulence and / or produce a uniform flow of cellulose fibers, this embodiment with a horizontal spraying direction reduces the height of the product forming unit and enables access to the mill for maintenance from the factory floor without adding a floor structure or platform that raises the height.

[0071] In particular, the cellulose raw material R is provided from a suitable source and is supplied to the blank dry forming module 4. The cellulose blank structure 2 is dry formed from the cellulose raw material R within the blank dry forming module 4, and then this cellulose blank structure 2 is supplied from the blank dry forming module 4 to the buffer module 5. The blank dry forming module 4 has a mill 4a, a forming chamber 4b, and a forming wire 4c arranged connected to the forming chamber 4b. The fibers F of the cellulose raw material R are separated from the cellulose raw material R by the mill 4a, and the separated fibers F are distributed within the forming chamber 4b and reach onto the forming wire 4c to form the cellulose blank structure 2. The mill 4a is configured to separate the cellulose fibers F from the cellulose raw material R, and the forming chamber 4b is configured to distribute the separated fibers F onto the forming section 4d of the forming wire 4c for forming the cellulose blank structure 2. The forming section 4d is arranged connected to the forming chamber opening 4e of the forming chamber 4b. In the illustrated embodiment, the forming section 4d extends in the upward blank forming direction D U . The cellulose blank structure 2 is formed on the forming section 4d and is conveyed from the forming section 4d in the upward blank forming direction D U towards the buffer module 5. The upward blank forming direction D U is useful for the compact structure and layout of the product forming unit U and enables efficient positioning of the various modules of the product forming unit U relative to each other. After the cellulose blank structure 2 is formed on the forming section 4d, the formed cellulose blank structure 2 is conveyed from the forming section 4d in the upward blank forming direction D U towards the buffer module 5.

[0072] Mill 4a separates 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 veil, sheet or roll of fluff pulp, paper structure, or other suitable cellulose fiber-containing structure, which are supplied to the mill 4a. The mill 4a may be of any conventional type, such as a hammer mill, a sawtooth mill, or other types of pulp defibering machines. The pulp structure 20 is supplied into the mill 4a through the inlet opening, and the separated fibers F are distributed to the forming chamber 4b through the outlet opening of the mill 4a, which is arranged connected to the forming chamber 4b.

[0073] The forming chamber 4b is arranged to distribute the separated fibers onto the forming wire 4c in order to form 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 surrounds the volume in which the separated fibers F are distributed from the mill 4a to the forming wire 4c.

[0074] The forming wire 4c may be of any suitable conventional type and may be formed as an endless belt structure as shown in FIGS. 1a - 1b. A vacuum box 4f may be arranged connected to the forming wire 4c and the forming chamber 4b to control the air flow in the forming chamber 4b and distribute the separated fibers F onto the forming wire 4c.

[0075] 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-1b and may be configured in various ways. For example, the cellulose blank structure 2 may have a composition that includes fibers of the same origin or alternatively a mixture of two or more 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 described further below, the cellulose fibers may be mixed with other substances or compounds to a certain extent. The cellulose fibers mean any type of cellulose fibers, such as natural cellulose fibers or manufactured cellulose fibers. The cellulose blank structure 2 may specifically include at least 95% cellulose fibers, or more specifically at least 99% cellulose fibers.

[0076] The air-formed cellulose blank structure 2 may have a single-layer structure or a multi-layer structure. The cellulose blank structure 2 having a single-layer structure means a structure formed from one layer containing cellulose fibers. The cellulose blank structure 2 having a multi-layer structure means a structure formed from two or more layers containing cellulose fibers, and in this case, these layers may have the same or different compositions or structures.

[0077] The cellulose blank structure 2 may have a reinforcing layer containing cellulose fibers, and this reinforcing layer 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 in avoiding the cellulose blank structure 2 being broken during the shaping of the cellulose product 1 when one or more air-formed layers of the cellulose blank structure 2 have a composition with low tensile strength. The reinforcing layer having a higher tensile strength thus functions as a support structure for the other layers of the cellulose blank structure 2. The reinforcing layer may be a composition different from the other layers of the cellulose blank structure, for example, a tissue layer containing cellulose fibers, an air-laid structure having cellulose fibers, or other suitable layer structures. Therefore, the reinforcing layer does not necessarily have to be an air-formed layer. The cellulose blank structure 2 may have two or more reinforcing layers if appropriate.

[0078] One or more air-formed layers of the cellulose blank structure 2 are structures like fluffy air, and the cellulose fibers forming this structure are arranged relatively loosely with respect to each other. The fluffy cellulose blank structure 2 is used for the efficient shaping of the cellulose product 1, and during the shaping process, it enables the cellulose fibers to efficiently shape the cellulose product 1.

[0079] The product shaping unit U may further have a barrier coating module 8 arranged upstream of the buffer module 5, as shown in FIGS. 1a to 1b. The barrier coating module 8 is configured to apply a barrier composition to the cellulose blank structure 2 before shaping the cellulose product 1 with one or more shaping dies 3.

[0080] One preferred property of cellulose product 1 is, for example, the ability to hold or withstand liquids, such as when the cellulose product is used in contact with beverages, foods, and other aqueous substances. The barrier composition may be one or more additives used in manufacturing the cellulose product, such as AKD or latex, or other suitable barrier compositions. Other suitable barrier compositions are combinations of AKD and latex, in which case tests have shown that when forming cellulose product 1, a combination of AKD and latex added to the air-formed cellulose blank structure 2 can achieve unique product properties. When using a combination of AKD and latex, a high level of hydrophobicity can be achieved, resulting in a cellulose product 1 that has a high ability to withstand liquids such as water without adversely affecting the mechanical properties of cellulose product 1.

[0081] The barrier coating module 8 may be arranged connected to the cellulose blank structure 2 as a hood structure, and this hood structure has spray nozzles 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 coating module 8. The barrier composition may be applied to only 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 part or some sections of the surface of the cellulose blank structure 2. The hood structure of the barrier coating module prevents the barrier composition from splashing into the surrounding environment. Other coating techniques for applying the barrier structure may include, for example, slot coating and / or screen printing.

[0082] The product forming unit U shown in FIGS. 1a to 1b has 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 is further adapted to form the non-flat cellulose product 1 from the cellulose blank structure 2 in one or more forming dies 3 by heating the cellulose blank structure 2 to a forming temperature T F and by pressing the cellulose blank structure 2 with a forming pressure. One or more forming dies 3 are adapted to form the non-flat cellulose product 1 from the cellulose blank structure 2 by heating the cellulose blank structure 2 to a forming temperature T F in the range of 100 to 300 °C and by pressing the cellulose blank structure 2 with a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa.

[0083] The buffer module 5 is arranged upstream of the press module 6, as shown for example in FIGS. 1a to 1b, and this buffer module 5 has the purpose of converting the supply mode of the cellulose blank structure 2 from continuous supply to intermittent supply. Due to the relatively brittle structural properties of the cellulose blank structure 2, continuous supply from the cellulose blank structure source is suitable. However, due to the intermittent operation of the press module 6, the continuous supply has to be converted to an intermittent supply without destroying the cellulose blank structure 2. To achieve this, the buffer module 5 has a blank supply system 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.

[0084] The blank supply system further supplies the cellulose blank structure 2 in a first supply direction D F1and continuously supply it to the buffer module 5, and the cellulose blank structure 2 is in the second supply direction D F2 configured to be intermittently supplied from the buffer module 5, in which case the second supply direction D F2 is different from the first supply direction D F1 is different from the first supply direction D F1 and the second supply direction D F2 is different, which enables a compact structure and layout of the product forming unit U, and enables an effective and compact positioning of various modules of the product forming unit U relative to each other. During the operation of the product forming unit U, the cellulose blank structure 2 is buffered in the buffer module 5 and supplied from the buffer module 5 to the press module 6. The cellulose blank structure 2 is continuously supplied to the buffer module 5 in the first supply direction D F1 and intermittently supplied from the buffer module 5 in the second supply direction D F2

[0085] In the illustrated embodiment, the first supply direction D F1 is the upward direction, and the second supply direction D F2 is the downward direction, which enables a compact and effective structure of the product forming unit U

[0086] For clarity, the supply path and supply direction of the cellulose blank structure 2 in the exemplary embodiments of FIGS. 1a-1b are schematically shown in FIG. 1d, and when compared with the conventional linear horizontal path of the cellulose product compression molding process, a compact configuration and layout of the product forming unit U made possible by sending the cellulose blank structure 2 first mainly upward, then mainly horizontally, and then mainly downward can be clearly understood

[0087] ​Alternatively, as schematically shown in FIG. 1e, the blank dry forming module 4 may be arranged such that it feeds the cellulose blank structure 2 upward, then mainly horizontally, and subsequently mainly downward into the press module 6, i.e., it has a mainly horizontally directed feed path and feed direction for the cellulose blank structure 2, i.e., it has a forming wire 4c that is mainly horizontally directed in the region of the forming chamber opening 4e. Such an arrangement of the product forming unit U may also be utilized to provide a compact product forming unit U.

[0088] Referring to FIGS. 1d - 1e, when not considering the blank recycling module 7, the blank dry forming module 4 typically forms the start of the feed path, and the press module 6 typically forms the end of the feed path. Other modules such as the buffer module 5 and the barrier coating module 8 are arranged at any suitable position between the dry forming module 4 and the press module 6, i.e., downstream of the dry forming module 4 and upstream of the press module 6, and are not necessarily arranged at the exemplary positions of the embodiments of FIGS. 1a - 1b.

[0089] Feeding the cellulose blank structure mainly downward while passing through the press module 6 is beneficial in terms of the easy feeding of the cellulose blank structure 2 and the easy removal of the cellulose product 1 after completion of the forming process, i.e., when leaving the press module 6.

[0090] In particular, the 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 due to damage to the cellulose blank structure 2 or changes in the properties of the cellulose blank structure 2, such as changes in the thickness of the cellulose blank structure 2. However, the toggle press is mainly in the horizontal direction D HIt is arranged at [specific location] and supplies the cellulose blank structure mainly downward to the pressing module 6, so that this supply process is assisted by gravity. As a result, the necessary force to be applied by the supply device to supply the air-formed cellulose blank structure 2 to the pressing area 15 of the pressing module 6 is less, thereby reducing the risk of damage and / or change in characteristics of the cellulose blank structure 2.

[0091] Furthermore, the removal of the completed and discharged cellulose product 1 after the completion of the forming process can also be facilitated mainly by the vertical feeding of the cellulose blank structure 2 through the mold 3. Because, also in this case, gravity can assist and simplify the removal of the completed and discharged cellulose product 1 from the mold 3 and its subsequent conveyance to a storage chamber or a conveyor belt, etc.

[0092] The pressing module 6 has one or more molds 3 as shown in FIGS. 1a - 1b and 2a. Each mold 3 has a first mold part 3a and a second mold part 3b. The corresponding first and second mold parts cooperate with each other during the forming of the non-flat cellulose product 1 in the pressing module 6. Each first mold part 3a and the corresponding second mold part 3b are movably arranged relative to each other, and the first mold part 3a and the second mold part 3b are configured to move relative to each other in the pressing direction D P in such a way.

[0093] In the embodiments shown in FIGS. 1a - 1b and 2a - 2e, the second mold part 3b is stationary, and the first mold part 3a is movably arranged relative to the second mold part 3b in the pressing direction D P As shown by the double-headed arrow in FIG. 2b, the first mold part 3a is configured to move in both directions towards and away from the second mold part 3b in a linear motion along an axis extending in the pressing direction D P in such a way.

[0094] In an alternative embodiment, the first type portion 3a may be stationary and the second type portion 3b may be movably arranged relative to the first type portion 3a, or both the first type portion 3a and the second type portion 3b may be movably arranged relative to each other.

[0095] The press module 6 may be of a single cavity structure or alternatively a multi-cavity structure. A single cavity press module has only one molding die 3 with first and second type portions. A multi-cavity press module has two or more molding dies 3 each with cooperating first and second type portions. In the embodiments shown in FIGS. 1a - 1b and 2a, the press module 6 is arranged as a multi-cavity press module having a plurality of molding dies 3 with first and second type portions, and the movement of the type portions is appropriately synchronized for simultaneous molding operations. The portion of the press module 6 shown in FIGS. 2b - 2e shows a section with one molding die 3 of a single cavity structure or alternatively a multi-cavity structure. In the following, the press module 6 will be described with respect to a multi-cavity press module, but the present disclosure is equally applicable to a single cavity press module.

[0096] For all embodiments according to the present disclosure, the expression of movement in the press direction D P is to be understood to include movement in the press direction D P which movement may be in the reverse direction. This expression may further include both linear and non-linear movement of the type portions, in which case, as a result of the movement during molding, the type portions are repositioned in the press direction D P .

[0097] 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 fibers and arranged in a roll shape or laminated. The roll or laminate can then be connected and arranged to the mold system S. Alternatively, the cellulose blank structure 2 may be air-formed from cellulose fibers in the blank dry forming module 4 of the product forming unit U and directly supplied to the press module 6 via the buffer module 5.

[0098] The cellulose product 1 is formed from the cellulose blank structure 2 in one or more molds 3 by heating the cellulose blank structure 2 to a forming temperature T in the range of 100 to 300 °C F and pressing the cellulose blank structure 2 at a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa. As explained in FIGS. 2b to 2e, the first mold part 3a is arranged to form the non-flat cellulose product 1 by interaction with the corresponding second mold part 3b. During the forming of the cellulose product 1, the cellulose blank structure 2 is subjected to a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa, and a forming temperature T in the range of 100 to 300 °C within each mold 3. F is exposed. Thus, the cellulose blank structure 2 is at a forming temperature T in the range of 100 to 300 °C FBy heating and pressing the cellulose blank structure 2 at a molding pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa, a cellulose product 1 is formed from the cellulose blank structure 2 between each first mold part 3a and the corresponding second mold part 3b. When forming the cellulose product 1, strong hydrogen bonds are formed between the cellulose fibers in the cellulose blank structure 2 disposed between the first mold part 3a and the second mold part 3b. The temperature level and the pressure level are measured in the cellulose blank structure 2 during the molding process, for example, by appropriate sensors disposed within or connected to the cellulose fibers in the cellulose blank structure 2.

[0099] The press module 6 may further have a heating unit. The heating unit is configured to apply a molding temperature T to the cellulose blank structure 2 within each molding die 3. F The heating unit may have any suitable structure. The heating unit may be incorporated or cast into the first mold part 3a and / or the second mold part 3b, and suitable heating devices are, for example, electric heaters or fluid heaters such as resistor elements. Other suitable heat sources can also be used.

[0100] As shown in FIG. 2b, when the cellulose blank structure 2 is disposed at the molding position between the first mold part 3a and the second mold part 3b, the first mold part 3a is moved toward the second mold part 3b in the pressing direction D as indicated by the arrow in FIG. 2c. When the first mold part 3a is moved toward the second mold part 3b, the first mold part 3a is further moved toward the second mold part 3b, applying a molding pressure and a molding temperature T to the cellulose blank structure 2. P When the first mold part 3a is moved toward the second mold part 3b, the first mold part 3a is further moved toward the second mold part 3b, applying a molding pressure and a molding temperature T to the cellulose blank structure 2. FUntil it reaches the product forming position as shown in Figure 2d where pressure is applied, the cellulose blank structure 2 is increasingly compressed between the press surfaces 3c, 3d of the mold parts. During the forming of the cellulose product 1, with each first mold part 3a being pushed towards the corresponding second mold part 3b and the cellulose blank structure 2 being disposed between these mold parts, a forming cavity C for forming the cellulose product 1 is formed between each first mold part 3a and the second mold part 3b. The forming pressure and the forming temperature T F are applied to the cellulose blank structure 2 within 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 this case, the 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. For such operations, for example, an edge forming device and a cutting or separating device may be disposed on the mold parts, or alternatively, the edge may be formed by the cutting or separating operation of the product. When the cellulose product 1 is formed within the forming mold system S, the first mold part 3a is moved away from the second mold part 3b as shown in Figure 2e, and the cellulose product 1 can be taken out from the press module 6 using, for example, an ejector rod or a similar device.

[0101] Deformation elements E for establishing the forming pressure may be connected and disposed on each first mold part 3a and / or the second mold part 3b. In the embodiments shown in Figures 2b - 2e, the deformation element E is attached to the first mold part 3a. By using the deformation element E, the forming pressure can be generated as an isotropic forming pressure.

[0102] The first type of part 3a and / or the second type of part 3b may have a deformation element E, which is configured to apply a forming pressure to the cellulose blank structure 2 within the forming cavity C during the forming of the cellulose product 1. The deformation element E may be attached to the first type of part 3a and / or the second type of part 3b by suitable attachment means, such as adhesives or mechanical fixing means. During the forming of the cellulose product 1, the deformation element E is deformed to apply a forming pressure to the cellulose blank structure 2 within the forming cavity C, and due to the deformation of the deformation element E, an even pressure distribution is achieved even if the cellulose product 1 has a complex three-dimensional shape or the cellulose blank structure 2 has varying thicknesses. To apply the required forming pressure to the cellulose blank structure 2, the deformation element E is formed from a material that can deform when a force or pressure is applied, and the deformation element E is preferably formed from an elastic material that can recover its size and shape after deformation. The deformation element E further has suitable properties to withstand the high forming pressures and the forming temperature T F at which it is used during the forming of the cellulose product 1 and may be formed from a material having suitable properties.

[0103] Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the deformation element E is formed from such a material, an even pressure distribution can be achieved in the forming process, in which case the pressure applied from the deformation element E to the cellulose blank structure 2 within the forming cavity C is equal or substantially equal in all directions between the mold parts. Under pressure, when each deformation element E is in a fluid-like state, a uniform fluid-like pressure distribution is achieved. Thus, the forming pressure is applied to the cellulose blank structure 2 from all directions by such a material, and the deformation element E thus applies an isotropic forming pressure to the cellulose blank structure 2 during the forming of the cellulose product 1. Each deformation element E may be formed from a suitable structure of an elastic material. As an example, the deformation element E may be formed from a solid or substantially solid structure made of a gel material, silicone rubber, polyurethane, polychloroprene or rubber having a hardness in the range of 20 to 90 Shore A.

[0104] Furthermore, in the embodiments shown in FIGS. 1a to 1b, the product forming unit U has a blank recycling module 7 for recycling cellulose fibers. The blank recycling module 7 is configured to return and supply the remaining portion 2a of the cellulose blank structure 2 from the press module 6 to the blank dry forming module 4 after the cellulose product 1 is formed. The blank recycling module 7 is arranged to convey the remaining cellulose blank fiber material from the press module 6 to the mill 4a. After the cellulose product 1 is formed in the mold 3, a remaining portion 2a of the cellulose blank structure containing the cellulose blank fiber material may occur. The blank recycling module 7 can recycle the remaining cellulose fibers or the remaining cellulose fibers and reuse them to form a new cellulose blank structure 2 together with the fibers from the cellulose raw material. FIGS. 1a to 1b schematically show an exemplary embodiment of the blank recycling module 7. The blank recycling module 7 includes a supply structure 7a such as a supply belt, a conveyor structure, or other suitable means for conveying the remaining portion 2a from the mold 3 to the mill 4a. The mill 4a may be arranged with a separate inlet opening for the remaining material, and from this inlet opening, the remaining portion 2a of the cellulose blank structure 2 is supplied into the mill 4a.

[0105] Some exemplary embodiments of the press module 6 will be described in more detail below with reference to the schematic diagrams in FIGS. 2a and 3a to 3b. In this case, FIG. 3a shows a toggle press 6a in an open state having a die gap 29 of approximately 20 to 100 mm, possibly depending on the type of material and the product, and FIG. 3b shows the same toggle press 6a having a die gap 29 of approximately 0.5 to 3 mm, i.e., during the press operation, depending on the type of material and the product.

[0106] The press module 6 is a cellulose product toggle press module 6 for forming the non-flat cellulose product 1 from the air-formed cellulose blank structure 2. The toggle press module 6 is in the press direction D PA toggle press 6a includes a press member 6d movably arranged therein, a toggle mechanism 6e drivingly connected to the press member 6d, a press actuator assembly 6f drivingly connected to the toggle mechanism 6e, and an electronic control system 6h operably connected to the press actuator assembly 6f. The toggle press module 6 further has a molding die 3 including a movable first die part 3a attached to the press member 6d and a stationary second die part 3b. The electronic control system 6h is configured to control the operation of the press actuator assembly 6f so as to drive the press member 6d in the press direction D P using the toggle mechanism 6e and to form a non-flat cellulose product 1 from the air-formed cellulose blank structure 2 by pressing the first die part 3a against the stationary second die part 3b. The toggle press 6a is mainly arranged in the horizontal direction D H and has a press direction D P of the press member 6d, specifically arranged within 20 degrees from the horizontal direction D H and having a press direction D P of the press member 6d, more specifically arranged to have a press direction D H parallel to the horizontal direction D P and is installed or arranged to be installed.

[0107] The cellulose product toggle press module 6 is particularly suitable for forming a non-flat cellulose product 1 from the air-formed cellulose blank structure 2. This is because the continuous cellulose blank structure 2 enables easy handling and supply of the blank structure 2 to the toggle press 6a, as well as easy supply of the remaining part 2a of the cellulose blank structure 2 to the blank recycling module 7. However, the cellulose product toggle press module 6 is also suitable for forming a non-flat cellulose product 1 from a discontinuous air-formed cellulose blank structure 2, such as individual sheet pieces of the air-formed cellulose blank structure 2.

[0108] The press actuator assembly 6f may include one or more hydraulic or pneumatic linear actuators, such as, for example, a cylinder-piston actuator. Alternatively, a motor having a rotating output shaft, such as, for example, an electric motor, a hydraulic motor, or a pneumatic motor, may be used to drive a mechanical actuator, particularly a linear mechanical actuator such as a ball screw, a threaded rod actuator, a rack and pinion actuator, etc. Further alternatively, the press actuator assembly 6f may include a high torque electric motor drivingly connected to the toggle mechanism 6e via a rotary-linear transmission device, such as an eccentric mechanism or a crankshaft assembly. Still further alternatively, the press actuator assembly 6f may include one or more high torque electric motors integrally attached to the toggle mechanism 6e and drivingly connected directly to a rotating member or a pivoting link of the toggle mechanism 6e.

[0109] The movable first mold part 3a may be attached directly or indirectly to the press member 6d. This means that, for example, there may be an intermediate member disposed between the movable first mold part 3a and the press member 6d, such as a load cell for detecting the pressing force, etc.

[0110] The stationary second mold part 3b is generally stationary during the press operation, but nevertheless, as will be described in more detail later, it may be adjustable in the press direction D P during the period between successive press operations.

[0111] In some exemplary embodiments, the toggle press 6a has a front structure 6b and a rear structure 6c, the toggle mechanism 6e is also connected to the rear structure 6c, and the stationary second mold part 3b is attached to the front structure 6b.

[0112] The second type of stationary part 3b may be attached directly or indirectly to the front structure 6b. This means that, for example, there may be an intermediate member disposed between the second type of stationary part 3b and the front structure 6b, such as a load cell for detecting the pressing force, etc.

[0113] The front structure 6b and the rear structure 6c of the toggle press 6a represent two rigid structurally related parts that must be interconnected by some structurally rigid structure to ensure that the front structure 6a and the rear structure 6c do not separate from each other during the pressing operation. The front structure 6b and the rear structure 6c may have many different shapes depending on the specific situation. For example, the front structure 6b and the rear structure 6c may have a shape like a plate, particularly a rectangular plate, which enables cost-effective manufacturing and allows the corner regions of the plate-shaped front structure 6b and rear structure 6c to be used for attachment to a common rigid frame structure.

[0114] In fact, the toggle press 6a typically has a 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.

[0115] 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 14 connecting the front structure 6b to the rear structure 6c. In this case, the press member 6d is movably attached to the linear guide assembly 14 and is movable in the pressing direction D P therein. The rigid frame structure may be disposed on the underlying support frame 38 to provide the desired height and angular inclination of the toggle press module 6.

[0116] In other words, the intermediate frame structure may be provided by an intermediate linear guide assembly 14 having a dual function in that it provides structural strength and rigidity to the toggle press 6a and provides a rigid connection between the front structure 6b and the rear structure 6c, and in addition provides an intermediate linear guide assembly 14 for guiding the press member 6d.

[0117] To enable a cost-effective and robust frame structure for the toggle press 6a, the intermediate linear guide assembly 14 may have four tie bars 37, one of these tie bars being arranged in each corner region of the plate-shaped front structure 6b and rear structure 6c. The tie bars may be, for example, cylindrical, and corresponding cylindrical holes may be provided in the corner regions of the plate-shaped front structure 6b and rear structure 6c to accommodate the aforementioned tie bars.

[0118] The press member 6d may have any structural shape. However, in some exemplary embodiments, the press member may also have at least partially a plate-like shape, in particular a rectangular plate-like shape, which enables cost-effective manufacturing and allows the corner regions of the plate-shaped press member 6d to be used for attachment to the intermediate linear guide assembly 14. Thus, in some exemplary embodiments, the toggle press 6a may be referred to as a three-platen press.

[0119] The toggle press 6a is installed, for example, as shown in FIGS. 1a - 1b, FIGS. 2a and FIGS. 3a - 3b, in a horizontal orientation having the pressing direction D of the press member 6d P However, referring to FIGS. 5a - 5b, depending on the situation, even when the toggle press 6a is mounted in a slightly inclined state, a beneficial aspect is obtained that enables an overall compact design of the cellulose product forming unit U having a low profile height. Thus, a beneficial aspect of the cellulose product toggle press module 6 is mainly in the horizontal direction D HThe pressing direction D of the pressing member 6d disposed therein P By the toggle press 6a arranged to have, that is, the vertical direction D V Rather than, a more horizontal direction D H The pressing direction D of the pressing member 6d disposed therein P It is considered that it can be obtained by the toggle press 6a arranged to have. In other words, the toggle press 6a may be arranged to have an installation angle 13 in the range of 0 to 44 degrees, particularly in the range of 0 to 20 degrees, and have the pressing direction DP of the pressing member 6d. In this case, the aforementioned installation angle is defined by the pressing direction D P And the horizontal direction D H And is defined by.

[0120] Furthermore, as shown in FIGS. 5a to 5b, a beneficial aspect that enables an overall compact design and a low overall height of the cellulose product forming unit U can be obtained both when the rear structure 6c of the toggle press 6a is arranged higher than the front structure 6b of the toggle press as shown in FIG. 5a, and when the front structure 6b of the toggle press 6a is arranged higher than the rear structure 6c of the toggle press as shown in FIG. 5b. As a mere example, in FIG. 5a, the power supply 39 for the press actuator assembly 6f is shown mounted below the support frame 38, and in FIG. 5b, for example, the product removal assembly 48 is shown mounted below the support frame 38.

[0121] In some exemplary embodiments, the toggle press 6a further includes a supply device 16 for continuously or intermittently supplying the air-formed cellulose blank structure 2 into the press area 15 located between the first mold part 3a and the second mold part 3b. In this case, the supply device 16 is specifically arranged to supply the air-formed cellulose blank structure 2 mainly vertically downward into the press area 15, more specifically, to supply the air-formed cellulose blank structure 2 into the press area 15 at a supply angle 49 of less than 20 degrees from the vertical direction downward, and even more specifically, to supply the air-formed cellulose blank structure vertically downward into the press area 15.

[0122] As described above, the expression "mainly vertical direction" in this case means supplying the blank structure in a direction that is more vertically arranged than the horizontal direction. In other words, the linear part of the supply device 16 is oriented to define an angle 49 in the range of 0 to 44 degrees, especially 0 to 20 degrees, with the vertical direction. Therefore, the supply device 16 may be considered to be mainly arranged above the mold 3.

[0123] Furthermore, the press direction D P is mainly in the horizontal direction D H As a result of the horizontal arrangement of the press module 6 such that the plane defined by the inside of the first mold part 3a and the second mold part 3b, typically by a substantially flat side surface, is mainly in the vertical direction D V is arranged, that is, it defines an angle in the range of 0 to 44 degrees, especially 0 to 20 degrees, with respect to the vertical direction D V The flat side surfaces inside the first mold part 3a and the second mold part 3b mean the surfaces of the first mold part 3a and the second mold part 3b that face each other and surround the press surface of the press cavity. [[ID=I7]]

[0124] According to some exemplary embodiments, the supply device 16 for supplying the air-formed cellulose blank structure 2 into the pressing area 15 may include an elongated vacuum belt feeder or an elongated tractor belt feeder, etc., which are mainly arranged in the vertical direction D V and specifically arranged in the vertical direction D V and arranged in an extending direction 17 within 20 degrees from the vertical direction D, and more specifically arranged parallel to the vertical direction D V and has an extending direction 17 of the belt portion of the supply device 16.

[0125] The toggle mechanism 6e of the toggle press 6a may have a wide variety of designs and implementation forms. The basic requirement of the toggle mechanism 6e is to generate an amplification of the pressing force, which enables the use of a relatively low-cost and low-capacity press actuator assembly 6f in terms of the pressing force. The amplification of the pressing force is achieved by correspondingly reducing the pressing speed of the press module. Therefore, the toggle mechanism 6e amplifies the pressing force / decelerates the pressing speed compared to the force / speed of the press actuator assembly 6f.

[0126] Generally, referring to the exemplary embodiments of FIGS. 1a - 1b, FIGS. 2a and FIGS. 3a - 3b, the toggle mechanism 6e has a first link member 18 and a second link member 19, and the press actuator assembly 6f is directly or indirectly drivingly connected to the first or second link member 18, 19 such that the press member 6d moves as a result of the operation of the press actuator assembly 6f.

[0127] More specifically, in some exemplary embodiments, the toggle mechanism 6e may have a first link member 18 and a second link member 19, each of these link members having first and second pivot connections 18a, 18b, 19a, 19b, respectively. The first pivot connection 18a of the first link member 18 is pivotally connected to the rear structure 6c, the first pivot connection 19a of the second link member 19 is pivotally connected to the press member 6d, the second pivot connection 18b of the first link member 18 is pivotally connected to the second pivot connection 19b of the second link member 19, and the press actuator assembly 6f is directly or indirectly drivingly connected to the first or second link members 18, 19 so as to adjust the alignment level between the first link member 18 and the second link member 19 such that, as a result of the operation of the press actuator assembly 5f, the press member 6d is moved.

[0128] The fact that the second pivot connection 18b of the first link member 18 is pivotally connected to the second pivot connection 19b of the second link member 19 means that the second pivot connection 18b of the first link member 18 is the same as the second pivot connection 19b of the second link member 19.

[0129] The effect of adjusting the alignment level between the first link member 18 and the second link member 19 is shown in FIGS. 3a to 3b. The alignment between the first link member 18 and the second link member 19 is determined by an alignment angle 22 defined by the longitudinal directions of the first and second link members 18, 19, as can be seen from the side views according to FIGS. 3a and 3b. In this case, the longitudinal direction 18d of the first link member 18 is defined by a straight line passing through the first and second pivot connection portions 18a, 18b of the first link member, and the longitudinal direction 19d of the second link member 19 is defined by a straight line passing through the first and second pivot connection portions 19a, 19b of the second link member 19. It is clear that the alignment angle 22 in FIG. 3b is smaller than the alignment angle 22 in FIG. 3a, and as a result of the operation of the press actuator assembly 5f, it is confirmed that the forward movement of the press member 6d, that is, the movement of the press member 6d toward the front structure 6b, occurs.

[0130] The toggle mechanism 6e shown in the exemplary embodiments of FIGS. 3a to 3b can also be referred to as a five-point double toggle mechanism, which is provided with two individual toggle mechanisms arranged side by side to provide a better press force distribution for the press member 6d, meaning that each of the two aforementioned individual toggle mechanisms has five pivot points.

[0131] In particular, in the exemplary embodiments of FIGS. 3a to 3b, the press actuator assembly 6f is drivingly connected to a single crosshead 20, and the crosshead link member 21 has a first connection portion 21a pivotally connected to the crosshead link member 21 and a second connection portion 21b pivotally connected to the third pivot connection portion 18c of the first link member 18.

[0132] In other words, the toggle mechanism 6e of the exemplary embodiments of FIGS. 3a-3b has a single crosshead that drives first and second individual toggle mechanisms arranged side by side with respect to each other, and the first and second toggle mechanisms each include a first link member 18, a second link member 19, and a crosshead link member 21. In this case, the first link member 18 is pivotally connected to the second link member 19 and the rear structure 6c, the second link member 19 is pivotally connected to the press member 6d, and the crosshead link member 21 is pivotally connected to the first link member 18 and the crosshead 20.

[0133] Within the scope of the present disclosure, a plurality of alternative designs of the toggle mechanism 6e are possible. For example, the crosshead link member 21 may be pivotally connected to the second link member 19 and the crosshead 20. Further, the second and third pivot connections 18b, 18c of the first link member 18 may alternatively be a common pivot connection.

[0134] Furthermore, as shown in FIG. 5a, the toggle mechanism 6e may be a three-point single toggle mechanism, in which case the toggle mechanism 6e has a first link member 18 pivotally connected to the second link member 19, the first link member 18 also being pivotally connected to the rear structure 6c, the second link member 19 being pivotally connected to the front structure 6d, and the press actuator assembly 6f being directly or indirectly drivingly connected to the first or second link members 18, 19 such that the press member 6d is moved as a result of the operation of the press actuator assembly 6f.

[0135] Furthermore, a further exemplary design of the toggle mechanism 6e is schematically shown in FIG. 6a, which shows two three-point double toggle mechanisms, i.e., two three-point single toggle mechanisms as described with reference to FIG. 5a, and these toggle mechanisms are provided with a press or pull actuator assembly 6f that is directly or indirectly drivingly connected to the first and / or second link members 18, 19 of both of the aforementioned single toggle mechanisms. Further, in this exemplary embodiment, an electric servo motor is shown as the actuator assembly 6f.

[0136] According to yet another exemplary embodiment, the toggle mechanism 6e as schematically shown in FIG. 6b includes two three-point double toggle mechanisms, i.e., two three-point single toggle mechanisms as described with reference to FIG. 5a, but in this case, these two single toggle mechanisms operate in opposite directions, and are provided with an actuator assembly 6f that is disposed between these two toggle mechanisms and is directly or indirectly drivingly connected to the first and / or second link members 18, 19 of both of the aforementioned single toggle mechanisms.

[0137] Referring to FIGS. 3a - 3b, in some exemplary embodiments, the toggle press 6a further has a front structure 6b and a rear structure 6c. In this case, the toggle mechanism 6e is connected to the rear structure 6c, and the stationary second mold part 3b is attached to the front structure 6b. In this case, the toggle press 6a has a mechanical adjustment mechanism 23 that can adjust the distance 24 between the front structure 6b and the rear structure 6c in the press direction D P and a control actuator assembly 25 configured to drive the mechanical adjustment mechanism 23.

[0138] For example, the mechanical adjustment mechanism 23 may have four gears 26a - 26d, each gear having an internal thread for attachment by screwing to the corresponding threaded end of the tie bar of the linear guide assembly 14, and each of the gears 26a - 26d having a tooth row of an external gear so as to be driven by one or more motors of the control actuator assembly 25.

[0139] For example, as shown in FIGS. 2a and 3a - 3b, each of the aforementioned four gears 26a - 26d of the mechanical adjustment mechanism 23 may be connected to a single central gear 27 that is powered by a single motor of the adjustment actuator assembly 25 and may be driven by this central gear.

[0140] The operation of the adjustment actuator assembly 25 causes the mechanical adjustment mechanism 23 to change the distance 24 between the front structure 6b and the rear structure 6c, thereby affecting the amplification level and operating behavior of the toggle mechanism.

[0141] In the exemplary embodiment of FIGS. 3a - 3b, the operation of the mechanical adjustment mechanism 23 displaces the rear structure 6c relative to the linear guide assembly 14 to change the distance 24 between the front structure 6b and the rear structure 6c.

[0142] Alternatively, the operation of the mechanical adjustment mechanism 23 displaces the front structure 6b relative to the linear guide assembly 14 to change the distance 24 between the front structure 6b and the rear structure 6c.

[0143] Such adjustment in the distance between the front structure 6b and the rear structure 6c is typically carried out during the period between successive pressing operations of the toggle press 6a.

[0144] Figure 4 schematically shows the main process steps of the press module 6 during normal operation. The flowchart of the pressing operation usually starts from the state where the press member is stationary at the standby position S related to the retracted toggle mechanism and the opened mold 3, as schematically shown in Figure 3a. When receiving a command or instruction to start the press cycle, the second step F of the flowchart is performed. This second step includes actuating the press actuator assembly 6f to push the press member 6d forward F. This actuation is carried out until the mold 3 is closed and a forming pressure of about 1 to 100 MPa, particularly 4 to 20 MPa, is applied to the cellulose blank structure in the third step P of the main process. Then, the fourth step R of the flowchart is performed, which includes starting the return movement of the press member 6d to the start position, that is, the standby position S.

[0145] In the case of high-speed manufacturing, the process may skip step S, that is, it may skip completely returning to the standby position S before restarting the second step F of the flowchart.

[0146] Figure 7a schematically shows the typical highly exponential amplification characteristics of an exemplary embodiment of the toggle press 6a. In particular, Figure 7a shows a press force curve plotted in a coordinate system with the press force in units of newtons (N) on the Y-axis and the mold gap of the mold 3 in units of millimeters on the X-axis. This specific example is included only for the purpose of explaining an exemplary embodiment of the cellulose product toggle press module and the corresponding method and should in no way be construed as limiting, particularly with respect to the exemplary mold gap data. Furthermore, different types of toggle mechanisms provide different levels of exponential amplification characteristics, and an appropriate type of toggle mechanism may be selected for each specific cellulose product and / or cellulose blank structure 2.

[0147] The maximum press force curve 28 is shown in FIG. 7a. This curve represents that the maximum press force of a particular toggle press 6a can be provided as a function of the die gap at a particular setting of the distance 24 between the front structure 6b and the rear structure 6c, and in particular the setting at zero die gap is achieved when the first link member and the second link member are just aligned, and as a result, logically, as seen by the asymptotic characteristics of the maximum press force curve 28 in FIG. 7a, an infinite press force is generated.

[0148] When operating the toggle press in the asymptotic region of the press force curve 28, that is, when the first and second link members 18, 19 are substantially or completely aligned and the alignment angle 22 is substantially or exactly 180 degrees, due to the asymptotic amplification characteristics of this region, the toggle press is extremely sensitive with respect to the press force as a function of the force input from the press actuator assembly 6f to the toggle mechanism.

[0149] The term maximum stroke state used hereinafter means the maximum forward position obtained by the toggle mechanism when not obstructed by the mold, the cellulose blank structure or other parts, for example, the alignment state of the first and second link members 18, 19 in the exemplary embodiments of FIGS. 3a - 3b, the bottom dead center (BDC), or the operating state shown in FIG. 8c.

[0150] The operating window 30 of the toggle press 6a may correspond, for example, to the rectangular window shown by the dashed line in the graph of FIG. 7a, and an enlarged view of the aforementioned operating window 30 is shown in FIG. 7b including the aforementioned maximum press force curve 28.

[0151] The maximum press force curve 28 indicates that, for example, at point A corresponding to a die gap of 2.0 mm, the maximum press force that can be provided is N Newtons. The maximum press force curve 28 as a function of the die gap can be derived, for a predetermined distance 24 between the front structure 6b and the rear structure 6c, by inserting a plurality of non-compressible plates such as steel plates with a gradually changing thickness, for example, and detecting the maximum pressure applied by a toggle press to each plate by means of a suitable press force detection assembly such as a load cell or a strain gauge force sensor. In the figure of this example, the maximum press force curve 28 is determined such that the first and second link members 18, 19 reach an alignment angle 22 of 180 degrees, or such that the toggle mechanism 6e reaches a maximum stroke state when the die gap 29 reaches zero, i.e., for a toggle press adjusted accordingly.

[0152] In FIG. 7b, the central press force - die gap curve 31 may represent, for example, the pressing of the first type of cellulose blank structure 2. As a result of the low density and low elasticity of the first type of cellulose blank structure 2, first, the press force increases more rapidly at a die gap of approximately 1.5 mm (the thickness of the cellulose product), and the target press force PF T is reached at point B at a die gap of approximately 0.9 mm (the thickness of the cellulose product), at which point B the pressing movement of the press member 6d may be stopped. The target press force PF T may, in this case, approximately correspond to a target forming pressure of 4 to 20 Mpa.

[0153] The central press force - die gap curve 31 and all other press force - die gap curves shown in the present disclosure have relatively smooth and continuous characteristics, except for a relatively small stepped reduction 55 of the press force at the intermediate position. Since the die part may have an incorporated cutting device, this stepped reduction corresponds to the above-described cutting operation in the press module 6 where the cellulose product 1 is separated from the cellulose blank structure 2 during the forming of the cellulose product 1. However, if such cutting is performed in a separate product cutting operation, i.e., separately from the forming operation, the press force - die gap curve does not have such a stepped reduction 55 in the press force curve.

[0154] However, the specific exemplary toggle press 6a schematically described with reference to FIG. 7b has a relatively narrow operating range, whereby if the cellulose blank structure 2 supplied to the forming die consists of, for example, a thicker and / or more densely compressed fiber material, the forming process follows the press force - die gap curve 32 on the right side of FIG. 7b, which represents the pressing of the second type of cellulose blank structure 2. As a result of the relatively high density and thickness of the second type of cellulose blank structure 2, the press force already increases more steeply at a die gap of approximately 2.5 mm (thickness of the cellulose product), and at a die gap of approximately 1.1 mm (thickness of the cellulose product) at point C, the toggle press reaches the maximum press force that can be provided for this die gap, so that the press member 6d stops its forward movement. In other words, at point C, the target press force PF T has not been reached.

[0155] Therefore, in order to successfully form a cellulose product based on the second type of cellulose blank structure 2, the adjustment actuator device 25 is operated to adjust the distance 24 between the front structure 6b and the rear structure 6c, and in particular to increase the distance 24, thereby effectively moving the right press force - die gap curve 32 in FIG. 7b in the direction of the first arrow 34 to bring it to a new position approximating the position of the central press force - die gap curve 31. As a result, the second type of cellulose blank structure 2 can be appropriately compressed and formed, and although the second type of cellulose blank structure 2 has a relatively high density and thickness, the pressing operation of the press member 6d can be stopped at approximately point B where the target press force PF T can be reached.

[0156] Similarly, if the cellulose blank structure 2 supplied into the mold consists of, for example, a thinner and / or lower - density compressed fiber material, the forming process follows the press force - die gap curve 33 on the left side of FIG. 7b, and this curve 33 represents the pressing of the third type of cellulose blank structure 2. Due to the relatively low density and thin thickness of the third type of cellulose blank structure 2, first, the press force increases more rapidly at a die gap (thickness of the cellulose product) of approximately 1.0 mm, and at a die gap (thickness of the cellulose product) of approximately 0.5 mm, the target press force PF T is reached at point D. However, due to the aforementioned relatively narrow operating range of the specific exemplary toggle press 6a schematically described with reference to FIG. 7b, the operating point D is located relatively close to the asymptotic region 35 of the toggle press, whereby the desired target press force PF TIt may become more difficult to control and obtain. In other words, in order to reduce the risk of unintended excessive compression of the cellulose product, the distance 24 between the front structure 6b and the rear structure 6c is adjusted, particularly by reducing the distance 24, thereby effectively moving the left press force - die gap curve 33 in Fig. 7b in the direction of the second arrow 36 to bring it to a new position approximating the position of the central press force - die gap curve 31. As a result, the third - type cellulose blank structure 2 can also be appropriately compressed and shaped in a more easily controllable operating region, that is, in a force - amplification operating region that is not relatively sensitive. Even though the third - type cellulose blank structure 2 has a relatively low density and a thin thickness, the press operation of the press member 6d can be stopped at approximately point B where the target press force PF T can be reached.

[0157] In other words, the adjustment by the adjustment actuator assembly 25 between the front structure 6b and the rear structure 6c may be beneficial and desirable depending on the structure, thickness, and density of the cellulose blank structure 2 and the mold 3.

[0158] The asymptotic region 35 in Fig. 7b is illustrated as having a clearly defined boundary, but this is merely schematic and for illustrative purposes. In reality, the asymptotic region 35 does not have a clearly defined boundary and simply decreases gradually as the distance from the maximum - stroke state of the toggle mechanism 6e increases. The press operation and the shaping operation within the asymptotic region may, depending on the situation, not be desirable due to the sensitivity and difficulty of controlling the press force in this region, but in some situations, for example, when a relatively small - capacity toggle press is used and it can only provide the required press force within this asymptotic region, it may be essential and / or planned to operate in this region.

[0159] In some exemplary embodiments, each of the first and second type portions 3a, 3b has a rigid plate-shaped main body having a typically substantially flat surface configured to face the other type portion, and at least one press surface 3c, 3d defining one or more molding cavities C for molding the cellulose product 1, with or without additional accessories such as spring-loaded cutting devices and / or mold alignment devices, etc. In this case, the aforementioned substantially flat surfaces of the rigid plate-shaped main bodies of the first and second molding portions 3a, 3b do not come into direct contact with each other during the press cycle. Thus, the aforementioned surfaces of the rigid plate-shaped main bodies are not intended to contact each other and are not intended to prevent further pressing movement of the first and second molding portions 3a, 3b. However, other portions of the first and second type portions 3a, 3b, which are not the aforementioned surfaces of the first and second type portions 3a, 3b, such as spring-loaded cutting devices and / or mold alignment devices, etc., may still be in contact with each other during the press operation.

[0160] The pressing operation of the press module 6 may be performed in various ways. For example, the toggle press 6a may be operated in an open-loop manner, as schematically shown in FIG. 7c, for example, in which case no feedback of parameters such as the pressing force or the position of the pressing member is required. In particular, the combination of the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a and the fixed maximum pressing force of the press actuator assembly 6f causes the pressing member 6d to follow the pressing force - die gap curve 31 and reach approximately the operating position F corresponding to the target pressing force PF when pressing a predetermined cellulose blank structure 2. T It may be initially adjusted to an appropriate value, for example, manually or automatically by an electronic control system 6h, so as to automatically reach the appropriate operating position. In other words, the press actuator assembly 6f may simply be controlled to provide a predetermined fixed pressing force each time, and the return movement of the pressing member may be initiated after a predetermined time has elapsed since the start of the forward movement, etc.

[0161] Figures 8a to 8c schematically show how an exemplary toggle press 6a can be adjusted to obtain various levels of maximum press force as described above. In Figure 8a, the distance 24 between the front structure 6b and the rear structure 6c is adjusted to be relatively short, thereby providing a relatively low press force for a given predefined maximum press force of the press actuator assembly 6f. In Figure 8b, the distance 24 between the front structure 6b and the rear structure 6c is slightly widened, thereby providing an intermediate press force for a given predefined maximum press force of the press actuator assembly 6f. In Figure 8c, the distance 24 between the front structure 6b and the rear structure 6c is adjusted to be relatively long, thereby providing the maximum press force for a given predefined maximum press force of the press actuator assembly 6f. This position of the toggle mechanism in Figure 8a corresponds to the maximum stroke state of the toggle mechanism 6e.

[0162] An exemplary embodiment of a control system 40 suitable for controlling the open-loop toggle press 6a is schematically shown in Figure 9a. In this exemplary embodiment, the press actuator assembly 6f is a hydraulic cylinder, and this hydraulic cylinder is fluid-controlled by a solenoid-operated direction control valve 41 fluid-connected to a variable displacement hydraulic pump 42 and a fluid tank 43. In this case, the operating state of the direction control valve 41 may be controlled by an electronic control system 6h. However, the systems and methods according to the present disclosure are not limited to the exemplary embodiments described with reference to Figures 9a to 9c.

[0163] An alternative method for operating the open-loop toggle press 6a is that the press force - die gap curve 31 * presses a predetermined cellulose blank structure 2, and when the maximum stroke state is reached, the approximate operating position F corresponding to the target press force PF T *It may include adjusting the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a so as to reach. In other words, the press actuator assembly 6f simply displaces the press member 6d to the maximum forward position, that is, to the 180-degree alignment angle or the maximum stroke state of the toggle mechanism 6e, and as a result, the resulting press force is the target press force PF T It may be controlled to have a distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a that is pre-adjusted to be equal to.

[0164] However, in order to ensure better control of the pressing operation, the electronic control system 6h may be configured to control the pressing operation based on feedback data from the press force detection or display assembly. Therefore, variations in process parameters can be more appropriately addressed to ensure an improvement in the quality of the cellulose product 1.

[0165] Therefore, in some exemplary embodiments, the toggle press 6a further has a press force display assembly 6g. In this case, the electronic control system 6h is operably connected to the press force display assembly 6g and is configured to control the operation of the press actuator assembly 6f based on the feedback information indicating the press force received from the press force display assembly 6g.

[0166] The press force display assembly 6g typically includes several measuring devices for measuring parameters such as the press force, the linear position of the press member, the angular position of the link member of the toggle mechanism, the supply of current to the electric motor, the level of hydraulic or pneumatic pressure, etc. Therefore, the feedback information indicating the press force usually includes or is derived from the measured process variables of the toggle press 6a.

[0167] For the operation control of the press actuator assembly 6f based on the feedback information indicating the press force received from the press force display assembly 6g, for example, press force feedback control, position feedback control, or open-loop control with automatic self-adjustment between consecutive press cycles may be included.

[0168] The press force display assembly may correspond to, for example, one or more press force sensors of some form located at one or more appropriate positions in the press module 6. For example, a load cell such as a strain gauge force sensor may be provided on or within the mold 3, or between the toggle mechanism 6e and the rear structure 6c, or between the toggle mechanism 6e and the mold 6.

[0169] Alternatively, or in combination with the above, the press force display assembly may correspond to a deformation sensor, for example, a strain gauge sensor configured to detect the deformation of one, two, or all of the tie bars of the intermediate linear guide assembly 14. Alternatively, a deformation sensor such as a strain gauge sensor may be provided to detect the deformation of the front structure 6b, or the rear structure 6c, or the press member 6d, or the toggle mechanism 6e.

[0170] Alternatively, or in combination with the above, since the detection position of the press member can be used for the calculation of the current press force amplification of the toggle mechanism, the press force display assembly may correspond to the detection of the press force of the press actuator assembly 6f combined with the detection position of the press member. The position detection of the press member may be performed, for example, using a linear position encoder. Alternatively, the position of the press member 6d may be derived from the operating position of the toggle mechanism 6e or the operating position of the press actuator assembly 6f. The detection of the press force of the press actuator assembly 6f may be achieved, for example, by detecting the hydraulic pressure or pneumatic pressure by a hydraulic or pneumatic cylinder actuator, or by detecting the current consumption or power output of the servo motor.

[0171] An exemplary embodiment of a control system 40 suitable for controlling the toggle press 6a based on feedback information indicating the press force received from the press force display assembly 6g is schematically shown in FIG. 9b, which corresponds to FIG. 9a but additionally includes a press member position detection device 44 and a press force detection device 45 of the press actuator assembly 6f.

[0172] Accordingly, in some exemplary embodiments, the electronic control system 6h obtains feedback information indicating the press force from the press force display assembly 6g and controls the operation of the press actuator assembly 6f to stop the ongoing press movement of the press member 6d when a value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range. According to an alternative exemplary embodiment, the electronic control system 6h obtains feedback information indicating the press force from the press force display assembly 6g and is configured to control the operation of the press actuator assembly 6f using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable. These two exemplary control scenarios correspond to, for example, the central press force - die gap curve 31 in FIG. 7b.

[0173] The parameter value derived from or related to the feedback information indicating the press force may correspond to, for example, the position of the press member, the die gap, the thickness of the cellulose product, or the press force.

[0174] After the press member 6d stops the ongoing press operation, the press member 6d is controlled to start a return movement of the press member towards the standby position.

[0175] In particular, when a value derived from or related to the feedback information indicating the pressing force corresponds to, for example, the position of the pressing member, the die gap, or the thickness of the cellulose product, the pressing force display assembly may be a pressing member position detection assembly. In this case, the feedback information indicating the pressing force obtained from the pressing member position detection assembly represents the position of the pressing member 6d or the die gap 29 between the first die part 3a and the second die part 3b. The electronic control system 6h is configured to control the operation of the press actuator assembly 6f to stop the ongoing pressing movement of the pressing member 6d when the detected position of the pressing member 6d or the die gap 29 is at a predetermined threshold value or within a predetermined range. According to an alternative exemplary embodiment, the electronic control system 6h is configured to use a feedback control device having a parameter related to the feedback information indicating the pressing force as a feedback process variable.

[0176] The pressing member position detection assembly may be, for example, a linear position encoder configured to detect the position of the pressing member 6d, or a position encoder for detecting the operating position of the toggle mechanism 6e, or a position encoder for detecting the operating position of the press actuator assembly 6f, etc.

[0177] In some exemplary embodiments, the pressing force display assembly 6g is a pressing force detection assembly. The feedback information indicating the pressing force obtained from the pressing force detection assembly represents the pressing force of the pressing member. The electronic control system is configured to control the operation of the press actuator assembly to stop the ongoing pressing movement of the pressing member when the detected pressing force of the pressing member is equal to or exceeds a predetermined threshold value. According to an alternative exemplary embodiment, the electronic control system 6h is configured to use a feedback control device having a parameter related to the feedback information indicating the pressing force as a feedback process variable.

[0178] Feedback information indicating the press force obtained from a press force detection assembly, which may be utilized to represent the press force of a press member, may correspond to one or more press force sensors of some form disposed at one or more suitable locations on a press module 6, such as a load cell, a strain gauge force sensor, and the like.

[0179] In some exemplary embodiments, the electronic control system may be configured to control an adjustment actuator assembly to set a toggle press to more appropriate, more robust, and more easily controllable operating conditions, as described above with reference to FIG. 7b, or alternatively, to adjust the maximum press force of the toggle press for a particular cellulose blank structure, as described above with reference to FIG. 7c.

[0180] Accordingly, the toggle press may have a press force display assembly 6g, and the electronic control system may be operably connected to the press force display assembly 6g. This control system may be configured to control the operation of the adjustment actuator assembly based on feedback information indicating the press force received from the press force display assembly 6g to adjust the distance between the front structure and the rear structure in the press direction during a period of continuous pressing operation. As a result, the electronic control system may be able to shift the operating position of the toggle press towards the asymptotic region 35, or away from the asymptotic region 35, or adjust the maximum press force by laterally moving the maximum press force curve 28 in FIG. 7b.

[0181] This is done, for example, by receiving feedback information indicating the pressing force from the pressing force display assembly 6g during the first pressing cycle, determining whether the adjustment of the current operating position of the toggle press, i.e., the distance 24 between the front structure 6b and the rear structure 6c, is appropriate, and if not, adjusting the distance 24 between the front structure 6b and the rear structure 6c by the appropriate operation of the adjustment actuator assembly 25 so that the operating position and / or the pressing force during the next pressing cycle more closely match the target operating position and / or the target pressing force. In other words, the electronic control system does not require active control and adjustment of the force input to the toggle mechanism 6e provided by the pressing actuator assembly 6f to adapt the pressing force of the pressing member 6d. Instead, it may rely only on the active control of the adjustment actuator assembly 25.

[0182] Such a control method will be described in more detail with reference to FIG. 7d. In this case, the electronic control system is configured to control the operation of the pressing actuator assembly so as to provide a force of maximum output substantially fixed to the toggle mechanism during each pressing operation during the normal operation of the cellulose product toggle press module. The first pressing force - die gap curve 46 in FIG. 7d represents such a pressing operation during the normal operation of the toggle press 6a. The electronic control system is further configured to obtain information indicating the pressing force from the pressing force display assembly 6g during the pressing operation of the above-described normal operation of the toggle press 6a, and the information indicating the pressing force indicates, for example, that the pressing force PF exceeds the target pressing force PF T [[ID=e6]]over a set of pressing cycles. Therefore, the electronic control system is configured to control the adjustment actuator assembly to adjust the distance between the front structure and the rear structure during the period between consecutive pressing operations, and to maintain the parameter value derived from or related to the information indicating the pressing force, which represents the resulting maximum pressing force PF, at a predetermined threshold or within a predetermined range.

[0183] The result of this adjustment is indicated by arrow 34 in Fig. 7d. In this case, the adjustment of the distance is set to shift the operation so as to follow the second press force - die gap curve 47, i.e., to slightly reduce the distance 24 to shift the operating position from G to H for the next press cycle. The term "resulting maximum press force" means, in this case, the maximum press force PF actually provided by the press member 6d during a specific press operation.

[0184] Alternatively, this control method may be implemented by adjusting the distance 24 between the front structure 6b and the rear structure 6c such that the toggle press module 6 reaches the maximum stroke state of the toggle mechanism 6e corresponding to the operating position H in Fig. 7d * at the same time as reaching the target press force PF. In other words, the electronic control system is configured to obtain information indicating the press force from the press force display assembly 6g during the press operation of the aforementioned normal operation of the toggle press 6a corresponding to the first press force - die gap curve 46 in Fig. 7d. For example, if the information indicating the press force shows that the press force PF continues to exceed the target press force PF T over a set of press cycles, i.e., when the cellulose product 1 is molded at the operating position G * the distance 24 between the front structure 6b and the rear structure 6c of the toggle press 6a is adjusted during the continuous press operation such that the resulting press force equals the target press force PF. T The result of this adjustment is indicated by arrow 34 in Fig. 7d. In this case, the increase in distance is set to shift the operation so as to follow the second press force - die gap curve 47 * to shift the operating position from G T to H * for the next press cycle. * * *

[0185] In the control scenario described with reference to FIG. 7d, the press operation is not restricted by the detected press force or the detected position of the press member, and the electronic control system may be configured to control the operation of the press actuator assembly to stop the ongoing press operation of the press member and initiate the return movement of the press member towards the start position when, for example, the press speed becomes zero, or after the press member has remained stationary for a predetermined period, or after a parameter value indicating the press force derived from or related to the information indicating the press force has been constant for a predetermined period, or when the alignment positions of the first and second link members 18, 19 are detected.

[0186] Furthermore, for the aforementioned control of the press actuator assembly 6f for providing the aforementioned maximum output force substantially fixed to the toggle mechanism during each press operation, for example, an open-loop control of the press actuator assembly 6f for increasing from approximately zero to a predetermined maximum output force that is predefined and fixed is included.

[0187] Furthermore, in some exemplary embodiments, the electronic control system 6h may be configured to control both the press actuator assembly 6f and the adjustment actuator assembly 25 based on feedback information indicating the press force, i.e., to perform closed-loop control of both the press actuator assembly 6f and the adjustment actuator assembly 25. This is to move the press member 6d forward while monitoring the feedback information indicating the press force from the press force display assembly 6g; to stop the ongoing press movement of the press member 6d and initiate the return movement of the press member 6d when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range, so as to control the operation of the press actuator assembly 6f; and additionally, during the period between successive press operations, to adjust the distance 24 between the front structure 3b and the rear structure 3c in the press direction so that the press member stops at a position having a maximum press force in the range of exceeding 0 to 100%, particularly 5 to 50%, of the press force generated when the press movement stops during the next press cycle, which may be achieved by having an electronic control system 6h configured to control the operation of the adjustment actuator assembly 25 based on the feedback information indicating the press force received from the press force display assembly 6g.

[0188] According to an alternative exemplary embodiment, instead, the electronic control system 6h may be configured to control the operation of the press actuator assembly 6f using a feedback controller having a parameter related to the feedback information indicating the press force as a feedback process variable.

[0189] Such a control method will be described in more detail with reference to FIG. 7e, where, in this case, the electronic control system 6h is configured to control the operation of the press actuator assembly 6f while monitoring the feedback information indicating the press force from the press force display assembly 6g so as to move the press member 6d forward.

[0190] The electronic control system 6h is further configured to stop the ongoing pressing movement of the pressing member 6d and initiate the return movement of the pressing member when a parameter value derived from or related to the feedback information indicating the pressing force is at a predetermined threshold value or within a predetermined range. This corresponds to the operating position G in FIG. 7e.

[0191] The electronic control system then evaluates the current operating position by comparing the maximum pressing force PF M2 at the current die gap position with the target pressing force PF T at the same die gap position. The target pressing force PF T is typically predetermined based on a specific mold and cellulose blank structure, and the maximum pressing force PF M2 may be estimated, for example, based on the current operating settings of the toggle press, i.e., the current distance 24 between the front structure 3a and the rear structure 3b, and the maximum pressing force that can be provided by the press actuator assembly 6f. In FIG. 7e, the maximum pressing force PF M2 is more than 100% greater than the target pressing force PF T at position G. Therefore, the electronic control system may be configured to shift the operating position, i.e., adjust the distance 24 between the front structure 6b and the rear structure 6c, to reach an operating position further away from the asymptotic region that is more robust and better controllable. Such an adjustment of the distance 24 is performed in the unloaded state, i.e., outside of the press operation.

[0192] In other words, the electronic control system further determines, during the period between consecutive pressing operations, that during the next pressing cycle, when the pressing force PF T generated when the pressing movement of the pressing member stops at point G exceeds the maximum pressing force PF M1The operation of the adjustment actuator assembly is configured to be controlled based on feedback information indicating the pressing force received from the pressing force display assembly 6g so as to adjust the distance 24 between the front structure and the rear structure in the pressing direction, aiming to stop at the position H having []. The result of this adjustment is indicated by the arrow 34 in FIG. 7e. In this case, the adjustment of the distance is set to shift the operation from the first pressing force - die gap curve 46 to the second pressing force - die gap curve 47, that is, to shift the operating position from G to H for the next pressing cycle.

[0193] An exemplary embodiment of a control system 40 suitable for controlling the toggle press 6a based on feedback information indicating the pressing force received from the pressing force display assembly 6g, as described above with reference to FIGS. 7d and 7e, is schematically shown in FIG. 9c. FIG. 9c corresponds to FIG. 9b, and additionally includes an adjustment actuator assembly 25 such as a servo motor for controlling the operation of a mechanical adjustment mechanism used to adjust the distance 24 between the front structure 6b and the rear structure 6c.

[0194] The toggle press module 6 may further have an operating motion limiting assembly 50 configured to mechanically limit the forward operating motion of the pressing member 6d. In particular, in some exemplary embodiments, the operating motion limiting assembly 50 is configured to mechanically prevent the toggle mechanism 6e from reaching its maximum stroke state, that is, the maximum force amplification state of the toggle mechanism 6e. One reason for providing the operating motion limiting assembly 50 in the toggle press module 6 is to reduce the risk of such an unintended overpressure in the mold 3 because the overpressure may damage the cellulose product and / or the toggle press module 6.

[0195] The toggle mechanism 6e usually brings about extremely exponential force amplification characteristics that may make the force control process of the press member 6d difficult when low-cost and reliable motion control is desired, especially when combined with a high-speed press cycle. Therefore, it may be desirable to mechanically prevent the toggle mechanism 6e and / or the press member 6d from moving to a position that is too close to the maximum stroke state, thereby providing a limit to the press force.

[0196] Considering the extremely exponential force amplification characteristics of the toggle mechanism, the actuating motion limiting assembly 50 may be configured to mechanically limit the forward motion of the press member 6d when, for example, it is disposed in the range of 0.5 to 100 mm, specifically 0.5 to 25 mm, and more specifically 0.5 to 5 mm from the position associated with the maximum stroke state of the toggle mechanism 6e.

[0197] One exemplary embodiment of the toggle press module 6 having an actuating motion limiting assembly 50 configured to mechanically limit the forward actuating motion of the press member 6d is shown in FIGS. 15a - 15b. FIG. 15a shows the toggle press 6a in a standby operating state, and FIG. 15b shows the toggle press 6a in an operating state of the maximum press actuation where the actuating motion limiting assembly 50 mechanically limits and blocks further forward motion of the press member 6d.

[0198] The toggle press module 6 schematically shown in FIGS. 15a - 15b corresponds to the toggle press module 6 described above with reference to FIGS. 3a - 3b. For details of the toggle press module 6, in this case, the disclosure regarding FIGS. 3a - 3b is referred to, except for the adjustment actuator assembly 25 schematically shown as an electric ball screw linear actuator. The ball screw linear actuator may have, for example, a rod having a helical track for holding rolling balls that can circulate in a track in the crosshead 20, which is drivingly connected to an electric motor.

[0199] In the exemplary embodiments of FIGS. 15a-15b, the toggle press 6a includes a five-point double toggle mechanism 6e having first and second individual toggle mechanisms 54a, 54b arranged side by side. In this case, the actuating movement limiting assembly 50 has a first limiting link 51 pivotally connected to the second link member 19 of the first individual toggle mechanism 54a and a second limiting link 52 pivotally connected to the second link member 19 of the second individual toggle mechanism 54b. The first and second limiting links 51, 52 are pivotally connected to each other at a common pivot joint 53.

[0200] The lengths, sizes, and shapes of the first and second limiting links 51, 52, and the connection points of the first and second limiting links to the second link members 19 of the first and second individual toggle mechanisms 54a, 54b are selected to mechanically prevent the toggle mechanism 6e from reaching a fully maximum stroke state, i.e., a maximum extension state.

[0201] The length of at least one of the first and second limiting links 51, 52 and / or the position of at least one of the connection points between the first and second limiting links 51, 52 and the second link members 19 of the first and second individual toggle mechanisms 54a, 54b may be adjustable to enable adjustment of the actuating movement length, thereby providing a more flexible toggle press module 6e.

[0202] Many alternative designs of the actuating movement limiting assembly 50 are possible depending on, for example, the selected design of the toggle mechanism 6e and the selected design of the adjustment actuator assembly 25. For example, the actuating movement limiting assembly 50 may have a flexible wire or belt instead of two pivot links. Further, in some exemplary embodiments, the actuating movement limiting assembly 50 is implemented by mechanically limiting the angular movement range of one or more link members 18, 19, 21 of the toggle mechanism 6e or by mechanically limiting the actuating movement length of the adjustment actuator assembly 25.

[0203] The basic steps of a method for forming a non-flat cellulose product from an air-formed cellulose blank structure will be described below with reference to FIG. 10. This method includes a first step S1 of providing a cellulose product toggle press module 6 having a toggle press 6a and a mold 3, where the toggle press 6a has a press member 6d movably arranged in the press direction, a toggle mechanism 6e connected to the press member 6d, a press actuator assembly 6f connected to the toggle mechanism, and an electronic control system 6h operably connected to the press actuator assembly. In this case, the mold has a movable first mold part 3a attached to the press member and a stationary second mold part 3b.

[0204] This method further includes a second step S2 of installing the toggle press 6a so that it is arranged mainly in the horizontal direction and has the press direction of the press member, specifically within 20 degrees from the horizontal direction, and more specifically has a press direction parallel to the horizontal direction.

[0205] Furthermore, this method includes a third step S3 of supplying the air-formed cellulose blank structure 2 into the press area defined by the spaced-apart first and second mold parts.

[0206] Finally, this method includes a fourth step S4 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h so as to drive the press member in the press direction using the toggle mechanism and to press the first mold part against the stationary second mold part to form a non-flat cellulose product from the air-formed cellulose blank structure.

[0207] The aforementioned fourth step S4 of controlling the operation of the press actuator assembly 6f may be performed in a number of different ways while continuing to address the problem of forming a non-flat cellulose product from an air-formed cellulose blank structure using a low-cost, compact, and low-weight cellulose product pressing module.

[0208] For example, another detailed exemplary embodiment for performing the aforementioned fourth step S4 will be described below with reference to FIG. 11, where steps S1 - S3 are the same as those described with reference to FIG. 10. In particular, the fourth step S4 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h may include a first sub-step S41 of obtaining feedback information indicating the press force from the press force display assembly 6g, and a second sub-step S42 of controlling the operation of the press actuator assembly 6f to stop the ongoing pressing movement of the press member 6d when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range.

[0209] A further exemplary embodiment for performing the fourth step S4 described above will be described below with reference to FIG. 12, where steps S1 - S3 are the same as those described with reference to FIG. 10, and the fourth step S4 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h may include a first sub-step S41 of obtaining feedback information indicating the press force from the press force display assembly 6g, and a second sub-step S45 of controlling the operation of the press actuator assembly 6f using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable.

[0210] The feedback control device can be implemented in a variety of alternative ways known to those skilled in the art, such as, for example, a P control device, a PI control device, a PID control device, or an optimal control such as a linear quadratic (LQ) control device, etc.

[0211] For example, a PID (Proportional-Integral-Derivative) controller is a control loop mechanism that uses feedback to provide continuously modulated control of a process to be controlled. For example, a feedback controller such as a PID controller continuously calculates an error value as the difference between a target setpoint (SP) and a measured process variable (PV), and applies a correction based on the proportional, integral, and derivative terms of the aforementioned error value. The setpoint (SP) may be, for example, a specific predefined compression force-time curve, and the measured process variable (PV) may be, for example, a measured press force as detected by a strain gauge force sensor disposed on the tie bar 37 of the toggle press 6a.

[0212] The basic steps of an exemplary embodiment of a method for forming a non-flat cellulose product from an air-formed cellulose blank structure will be further described below with reference to FIG. 13, where steps S1 to S3 are the same as those described with reference to FIG. 10, and the fourth step S4 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h includes a first sub-step S42a of controlling the operation of the press actuator assembly 6f by moving the press member 6d forward while monitoring feedback information indicating the press force from the press force display assembly 6g; a second sub-step S42b of stopping the ongoing press movement of the press member 6d when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range; and a third sub-step S42c of starting the return movement of the press member 6d. Then, during the period between successive press operations, the method aims to adjust the distance 24 between the front structure 6b and the rear structure 6c in the press direction so that during the next press cycle, the press member 6d stops at a position having a maximum press force in the range exceeding 0 to 100%, particularly 5 to 50%, of the press force generated when the press movement stops. This may include a fifth step S5 of controlling the operation of the adjustment actuator assembly 25 based on the feedback information indicating the press force received from the press force display assembly 6g.

[0213] For example, the forward movement of the pressing member 6d in the exemplary embodiment described with reference to FIGS. 11 and 13 may be implemented in various ways. For example, to move the pressing member 6d forward, controlling the press actuator assembly 6f using an on / off regulator means that the press actuator assembly 6f is simply operated at a predetermined power level or speed until the aforementioned parameter values reach a predetermined threshold or fall within a predetermined range. Alternatively, to move the pressing member 6d forward, controlling the press actuator assembly 6f using an on / off regulator combined with variable power or speed means that the press actuator assembly 6f is operated at a speed that is gradually and / or stepwise reduced during the forward movement until the aforementioned parameter values reach a predetermined threshold or fall within a predetermined range. The gradually and / or stepwise reduced speed of the press actuator assembly 6f reduces the risk of excessive press force, enabling a more precise and reliable molding process. In both of the aforementioned alternative control methods, the press actuator assembly 6f may be controlled using an open-loop controller to move the pressing member 6d forward.

[0214] The basic steps of an exemplary embodiment of a method for forming a non-flat cellulose product from an air-formed cellulose blank structure are further described below with reference to FIG. 14, where steps S1 to S3 are the same as those described with reference to FIG. 10, and the fourth step S4 of controlling the operation of the press actuator assembly 6f by the electronic control system 6h may include a first sub-step S41 of obtaining feedback information indicating the press force from the press force display assembly 6g, and a second sub-step S45 of controlling the operation of the press actuator assembly 6f using a feedback controller having a parameter related to the feedback information indicating the press force as a feedback process variable. [[ID=*]] [[ID=*]]

[0215] [[ID=*]] Next, this method aims to cause the press member 6d to stop at a position having a maximum press force in the range exceeding 0 to 100%, particularly 5 to 50%, of the press force generated when the press movement stops during the period between consecutive press operations. To adjust the distance 24 between the front structure 6b and the rear structure 6c in the press direction, it may include a fifth step S5 of controlling the operation of the adjustment actuator assembly 25 based on the feedback information indicating the press force received from the press force display assembly 6g.

[0216] Referring to the toggle press module 6 and method described above in relation to FIGS. 1a to 15b, the present disclosure further relates to a cellulose product toggle press module for forming a non-flat cellulose product from an air-formed cellulose blank structure. This cellulose product toggle press module is not limited to a specific angular orientation of the toggle press module 6. Instead, it includes a press force display assembly 6g. In this case, the electronic control system is configured to control the operation of the press actuator assembly based on the feedback indicating the press force received from the press force display assembly 6g.

[0217] In other words, the present disclosure further relates to a toggle press module 6, which has a toggle press 6a including a press member 6d movably arranged in the press direction, a toggle mechanism 6e drivingly connected to the press member 6d, a press actuator assembly 6f drivingly connected to the toggle mechanism 6e, a press force display assembly 6g, and an electronic control system 6h operably connected to the press actuator assembly 6f and the press force display assembly 6g. The toggle press module 6 further has a molding die 3 including a movable first die part 3a attached to the press member 3d and a stationary second die part 3b. The electronic control system 6h is configured to control the operation of the press actuator assembly 6f to drive the press member in the press direction using the toggle mechanism 6e and to press the first die part against the stationary second die part so as to form a non-flat cellulose product from the air-formed cellulose blank structure based on feedback indicating the press force received from the press force display assembly 6g.

[0218] Similarly, the present disclosure further relates to a method for forming a non-flat cellulose product from an air-formed cellulose blank structure, the method comprising the step of providing a cellulose product toggle press module 6 having a toggle press 6a and a mold 3, wherein the toggle press 6a has a press member 6d movably arranged in the press direction, a toggle mechanism 6e drivingly connected to the press member 6d, a press actuator assembly 6f drivingly connected to the toggle mechanism 6e, a press force display assembly 6g, and an electronic control system 6h operably connected to the press actuator assembly 6f and the press force display assembly 6g, and wherein the mold 3 has a movable first mold part 3a attached to the press member 6d and a second mold part 3b. The method further comprises the steps of supplying an air-formed cellulose blank structure 2 into a press area defined by the spaced-apart first and second mold parts 3a, 3b, and using the toggle mechanism 6e to drive the press member 6d in the press direction to press the first mold part 3a against the second mold part 3b to form a non-flat cellulose product 1 from the air-formed cellulose blank structure 2, and controlling the operation of the press actuator assembly 6f by the electronic control system 6h based on feedback information indicating the press force received from the press force display assembly 6g.

[0219] The use of a toggle press module to form a non-flat cellulose product from an air-formed cellulose blank structure has many advantages over the use of a conventional large-capacity hydraulic press without toggles, such as low cost, low weight, high-speed cycle operation, and compactness. Thus, the toggle press module 6 can be beneficial as an alternative to a conventional hydraulic press in a given environment and has an electronic control system configured to control the operation of the press actuator assembly based on feedback information indicating the press force received from the press force display assembly 6g, whereby better force control of the forming operation can be achieved. An exemplary embodiment of a method for forming a non-flat cellulose product from an air-formed cellulose blank structure, described with reference to FIGS. 10-14, is still appropriate for such exemplary embodiments of the present disclosure even when omitting the second step S2 of installing a toggle press 6a having a press direction of a press member disposed mainly in the horizontal direction.

[0220] It will be understood that the foregoing description is essentially exemplary only and is not intended to limit the application or use of the present disclosure. Although specific examples are described in the specification and shown in the drawings, those skilled in the art will understand that various changes may be made without departing from the scope of the present disclosure as defined in the claims, and equivalents may be used in place of its elements. Further, the features of the exemplary embodiments described herein may be combined with those of other exemplary embodiments described herein. For example, the toggle press module of FIGS. 3a-3b may be provided with a toggle mechanism as described with reference to FIGS. 2a, 6a, 6b, 8a or 15a or an adjustment actuator assembly 25 as described with reference to FIGS. 6a, 6b or 15a. Further, modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its essential scope. Accordingly, 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, and the scope of the present disclosure will include any embodiment included in the foregoing description and the appended claims. The reference numerals recited in the claims should not be construed as limiting the scope of the matter protected by the claims, and the sole function of the reference numerals is to make the claims easier to understand.

Description of the Reference Numerals

[0221] 1 Cellulose product 2 Cellulose blank structure 2a Remaining part 3 Molding die 3a First die part 3b Second die part 4 Blank dry forming module 4a Mill 4b Forming chamber 4c Forming wire 4d Forming section 4e Forming chamber opening 5 Buffer module 6 Press module 6a Toggle Press 6b Front Structure 6c Rear Structure 6d Press Member 6e Toggle Mechanism 6f Press Actuator Assembly 6g Press Force Display Assembly 6h Electronic Control System 7 Blank Cycle Module 7a Supply Structure 8 Barrier Coating Module 9 Blank Supply Roller 10 Actuator 11 Intermediate Roller 12 Buffer Actuator 13 Installation Angle of Toggle Press 14 Linear Guide Assembly 15 Press Area 16 Feeding Device 17 Extension Direction of Feeding Device 18 First Link Member 19 Second Link Member 20 Crosshead 21 Crosshead Link Member 22 Alignment Angle 23 Mechanical Adjustment Mechanism 24 Distance between Front Structure and Rear Structure 25 Adjustment Actuator Assembly 26a~26d Gears 27 Single Central Gear 28 Maximum Press Force Curve 29 Die Clearance 30 Operating Window 31 Central Press Force - Die Clearance Curve 32 Right - hand Press Force - Die Clearance Curve 33 Left - hand Press Force - Die Clearance Curve 34 First Arrow 35 Asymptotic Region 36 Second Arrow 37 Tybar 38 Support Frame 39 Power Supply 40 Control System 41 Valve 42 Pump 43 Tank 44 Position Detection Device 45 Press Force Detection Device 46 First Press Force - Die Clearance Curve 47 Second Press Force - Die Clearance Curve 48 Extraction Assembly 49 Supply Angle 50 Actuating Motion Limiting Assembly 51 First Limiting Link 52 Second Limiting Link 53 Swivel Joint of the Limiting Link 54a First Individual Toggle Mechanism 54b Second Individual Toggle Mechanism 55 Step - shaped Reduction Portion C Molding Cavity D F1 First Supply Direction D F2 Second Supply Direction D P Press Direction D U Upward Blank Forming Direction D H Horizontal Direction D V Vertical Direction E Deformation Element E B Buffer Extension F Fiber M B Buffer Mode M CONT Continuous Flow Mode M F Supply Mode M INT Intermittent Flow Mode N Exemplary Maximum Press Force PF Press Force PF T Target Press Force R Cellulose Raw Material T F Molding Temperature U Product Molding Unit V IInput speed V O Output speed

Claims

1. A product forming unit (U) for manufacturing a non-flat cellulose product (1) from an air-formed cellulose blank structure (2), wherein the product forming unit (U) has a cellulose product toggle press module (6) for forming the non-flat cellulose product (1) from the air-formed cellulose blank structure (2), and the cellulose product toggle press module (6) comprises: A toggle press (6a) comprising a press member (6d) movably arranged in the press direction, a toggle mechanism (6e) drivingly connected to the press member (6d), a press actuator assembly (6f) drivingly connected to the toggle mechanism (6e), and an electronic control system (6h) operably connected to the press actuator assembly (6f), and A forming die (3) including a movable first die part (3a) attached to the press member (6d) and a second die part (3b) There is, The electronic control system (6h) is configured to control the operation of the press actuator assembly (6f) to drive the press member (6d) in the press direction using the toggle mechanism (6e) and to form the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first die part (3a) against the second die part (3b). The toggle press (6a) is arranged, or arranged to be arranged, such that the press direction of the press member (6d) is mainly in the horizontal direction, specifically within 20 degrees from the horizontal direction, more specifically having a press direction parallel to the horizontal direction. The product forming unit (U) further has a buffer module (5). 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 cellulose product toggle press module (6). The buffer module (5) continuously supplies the cellulose blank structure (2) to the buffer module (5) in a first supply direction (D Ｆ１ ) and has a blank supply system configured to intermittently supply the cellulose blank structure (2) from the buffer module (5) in a second supply direction (D Ｆ２ ), wherein the second supply direction (D Ｆ２ ) is different from the first supply direction (D Ｆ１ ). The product forming unit (U) further has a blank dry forming module (4) configured to provide the cellulose blank structure (2). The blank dry forming module (4) has a mill (4a), a forming chamber (4b), and a forming wire (4c) arranged connected to the forming chamber (4b). The mill (4a) is configured to separate fibers (F) from a cellulose raw material (R), and the forming chamber (4b) is configured to distribute the separated fibers (F) onto a forming section (4d) of the forming wire (4c) for forming the cellulose blank structure (2). The forming section (4d) extends in an upward blank forming direction (D Ｕ ). Product forming unit (U). **Claim 2** The toggle press (6a) further includes a supply device (16) for supplying the air-formed cellulose blank structure (2) into a press region located between the first mold part (3a) and the second mold part (3b). The supply device (16) is arranged to supply the air-formed cellulose blank structure (2) mainly vertically downward into the press region, specifically, to supply the air-formed cellulose blank structure (2) into the press region at an angle of less than 20 degrees from the vertical downward direction, and more specifically, to supply the air-formed cellulose blank structure (2) vertically downward into the press region. The product forming unit (U) according to claim 1. **Claim 3** The toggle press (6a) further includes a press force display assembly (6g), and the electronic control system (6h) is operably connected to the press force display assembly (6g) and is configured to control the operation of the press actuator assembly (6f) based on feedback information indicating the press force received from the press force display assembly (6g). The product forming unit (U) according to claim 1 or 2. **Claim 4** The electronic control system (6h) is configured to obtain feedback information indicating the press force from the press force display assembly (6g), and to stop the ongoing pressing movement of the press member (6d) when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range; or To use a feedback control device having a parameter related to feedback information indicating the press force as a feedback process variable, The product forming unit (U) according to claim 3, which is configured to control the operation of the press actuator assembly (6f).

5. The toggle press (6a) further includes a front structure (6b) and a rear structure (6c), the toggle mechanism (6e) is connected to the rear structure (6c), and the second mold part (3b) is attached to the front structure (6b). The toggle press (6a) includes a mechanical adjustment mechanism (23) capable of adjusting the distance between the front structure (6b) and the rear structure (6c) in the press direction, and an adjustment actuator assembly (25) configured to drive the mechanical adjustment mechanism (23). The product forming unit (U) according to any one of claims 1 to 4, further comprising:

6. The electronic control system (6h) is: - While monitoring the feedback information indicating the press force from the press force display assembly (6g), move the press member (6d) forward, and then, when the parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range, stop the ongoing press movement of the press member (6d), and then start the return movement of the press member (6d), or - To use a feedback control device having a parameter related to feedback information indicating the press force as a feedback process variable, To control the operation of the press actuator assembly (6f), and During the period between consecutive press operations, in order to adjust the distance between the front structure (6b) and the rear structure (6b) in the press direction so that the press member (6d) stops at a position having a maximum press force in a range exceeding 0 to 100% of the press force generated when the press movement stops during the next press cycle, based on the feedback information indicating the press force received from the press force display assembly (6g), control the operation of the adjustment actuator assembly (25). The product forming unit (U) according to claim 5, which is configured as such.

7. The toggle press (6a) further comprises a press force display assembly (6g), the electronic control system (6h) is operably connected to the press force display assembly (6g), and the electronic control system is configured to adjust the distance (24) between the front structure (6b) and the rear structure (6c) in the press direction during a period of continuous pressing operation, based on feedback information indicating the press force received from the press force display assembly (6g), to control the operation of the adjustment actuator assembly (25). The product forming unit (U) according to claim 5.

8. The electronic control system (6h) is: During normal operation of the cellulose product toggle press module (6), to control the operation of the press actuator assembly (6f) to provide a force of output substantially fixed to the toggle mechanism (6e) during each pressing operation. During the pressing operation, to obtain information indicating the press force from the press force display assembly (6g). During a period between successive pressing operations, to adjust the distance (24) between the front structure (6b) and the rear structure (6c), and to control the adjustment actuator assembly (25) to maintain a parameter value derived from or related to the information indicating the press force, which indicates the resulting maximum press force, at a predetermined threshold or within a predetermined range. The product forming unit (U) according to claim 7, which is configured as such.

9. Each of the first and second mold parts (3a, 3b) has a rigid plate-shaped main body having a surface configured to face the other mold part, and at least one press surface (3c, 3d) defining one or more forming cavities (C) for forming the cellulose product (1), with or without additional accessories. The surfaces of the rigid plate-shaped main bodies of the first and second mold parts (3a, 3b) do not come into direct contact with each other during the press cycle. The product forming unit (U) according to any one of claims 1 to 8.

10. The product forming unit (U) according to any one of claims 1 to 9, wherein the forming die (3) forms the cellulose product (1) from the cellulose blank structure (2) by heating the cellulose blank structure (2) to a forming temperature in the range of 100 to 300 °C and pressing the cellulose blank structure (2) at a forming pressure in the range of 1 to 100 MPa.

11. A method for forming a non-flat cellulose product from an air-formed cellulose blank structure, the method comprising: providing a cellulose product toggle press module (6) having a toggle press (6a) and a forming die, wherein the toggle press (6a) has a press member (6d) movably arranged in the press direction, a toggle mechanism (6e) connected to the press member (6d), a press actuator assembly (6f) connected to the toggle mechanism (6e), and an electronic control system (6h) operably connected to the press actuator assembly (6f), and the forming die has a movable first die part (3a) attached to the press member (6d) and a second die part (3b); installing the toggle press (6a) such that the press direction of the press member (6d) is mainly arranged in a horizontal direction, specifically arranged within 20 degrees from the horizontal direction, more specifically arranged such that the press direction of the press member (6d) is parallel to the horizontal direction; feeding the air-formed cellulose blank structure (2) into a press area defined by the spaced-apart first and second die parts (3a, 3b); controlling the operation of the press actuator assembly (6f) by the electronic control system (6h) so as to drive the press member (6d) in the press direction using the toggle mechanism (6e) and to press the first die part (3a) against the second die part (3b) to form the non-flat cellulose product from the air-formed cellulose blank structure; comprising The step of providing the cellulose blank structure (2) comprises: providing a cellulose raw material (R), supplying the cellulose raw material (R) to a blank dry forming module (4), and dry forming the cellulose blank structure (2) in the blank dry forming module (4) from the cellulose raw material (R). In the blank dry forming module (4), the step of dry forming the cellulose blank structure (2) from the cellulose raw material (R) includes separating fibers (F) from the cellulose raw material (R) in a mill (4a), distributing the separated fibers (F) onto a forming wire (4c) of the blank dry forming module (4) to form the cellulose blank structure (2), and conveying the formed cellulose blank structure (2) in an upward blank forming direction (D Ｕ ) toward a buffer module (5). Method. Claim 12 The toggle press (6a) further comprises a press force display assembly (6g), the electronic control system (6h) is operably connected to the press force display assembly (6g), and the step of controlling the operation of the press actuator assembly (6f) by the electronic control system (6h) is based on feedback information indicating the press force received from the press force display assembly (6g). The method according to claim 11 Claim 13 The step of controlling the operation of the press actuator assembly (6f) by the electronic control system (6h) comprises: obtaining feedback information indicating the press force from the press force display assembly (6g), and when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range, stopping the ongoing pressing movement of the pressing member (6d); or using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable, the step of controlling the operation of the press actuator assembly (6f), The method according to claim 12, comprising. Claim 14 The toggle press (6a) further includes a front structure (6b), a rear structure (6c), a mechanical adjustment mechanism (23), and an adjustment actuator assembly (25) configured to drive the mechanical adjustment mechanism (23). The toggle mechanism (6e) is connected to the rear structure (6c), the second type portion (3b) is attached to the front structure (6b), and the mechanical adjustment mechanism (23) can adjust the distance (24) between the front structure (6b) and the rear structure (6c) in the pressing direction. The method further includes controlling the operation of the adjustment actuator assembly (25) to adjust the distance (24) between the front structure (6b) and the rear structure (6c) in the pressing direction, according to any one of claims 11 to 13.

15. The step of controlling the press actuator assembly (6f) includes moving the press member (6d) forward while monitoring feedback information indicating the press force from the press force display assembly (6g); when a parameter value derived from or related to the feedback information indicating the press force is at a predetermined threshold or within a predetermined range, stopping the ongoing pressing movement of the press member (6d) and starting the return movement of the press member (6d); or using a feedback control device having a parameter related to the feedback information indicating the press force as a feedback process variable, including the step of controlling the operation of the press actuator assembly (6f), The step of controlling the operation of the adjustment actuator assembly (25) includes, during a period between successive pressing operations, aiming for the press member (6d) to stop at a position having a maximum press force in a range exceeding 0 to 100% of the press force generated when the pressing movement stops during the next press cycle. Based on the feedback information indicating the press force received from the press force display assembly (6g), the method includes controlling the operation of the adjustment actuator assembly (25) to adjust the distance (24) between the front structure (6b) and the rear structure (6b) in the pressing direction, according to the method of claim 14.

16. The toggle press (6a) further comprises a press force display assembly (6g), the electronic control system (6h) is operably connected to the press force display assembly (6g), and the step of controlling the operation of the adjustment actuator assembly to adjust the distance (24) between the front structure (6b) and the rear structure (6c) in the press direction is performed during a period between successive pressing operations and is based on feedback information indicating a press force received from the press force display assembly (6g). The method according to claim 14.

17. The step of forming the cellulose product (1) from the cellulose blank structure (2) in the mold (3) includes heating the cellulose blank structure (2) to a forming temperature in the range of 100 to 300 °C and pressing the cellulose blank structure (2) at a forming pressure in the range of 1 to 100 MPa. The method according to any one of claims 11 to 16.

18. The method comprises: providing the cellulose blank structure (2) and supplying the cellulose blank structure (2) to a buffer module (5); Buffering the cellulose blank structure (2) with the buffer module (5) and supplying the cellulose blank structure (2) from the buffer module (5) to the cellulose product toggle press module (6), the step of supplying the cellulose blank structure (2) continuously to the buffer module (5) in a first supply direction (D Ｆ１ ) and intermittently supplying from the buffer module (5) in a second supply direction (D Ｆ２ ), and the second supply direction (D Ｆ２ ) is different from the first supply direction (D Ｆ１ ). The method according to any one of claims 11 to 17, further comprising.

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