Method for forming a cellulose product in a mold system from a cellulose blank structure, mold system, and cellulose blank structure

Abstract

A method for forming a cellulosic product from an air-formed cellulosic blank structure (2) in a mould system, where the mould system comprises one or more moulds (3), each mould having a first mould part (3a) and a second mould part (3b) adapted to cooperate with each other during forming of the cellulosic product. The method comprises the steps of: providing a cellulose blank structure and defining in the cellulose blank structure one or more product segments (2a) and a residual segment (2b) surrounding or connected to the one or more product segments; compressing at least a portion of the residual segment to a first degree of compression higher than the degree of compression of the one or more product segments; feeding the cellulose blank structure in a feed direction to a molding position in a mold system, where each product segment is disposed between corresponding first and second mold parts; molding a cellulose product from the cellulose blank structure between the first and second mold parts by heating the cellulose blank structure to a molding temperature in the range of 100-300°C and pressing the cellulose blank structure at a molding pressure in the range of 1-100 MPa, preferably 4-20 MPa.

Description

[Technical Field]

[0001] The present disclosure relates to a method for forming a cellulosic product in a mold system from an air-formed cellulosic blank structure, the mold system having one or more molds, each mold having a first mold portion and a second mold portion configured to cooperate with each other during the forming of the cellulosic product. The disclosure further relates to the mold system and the cellulosic blank structure.

[0002] Background technology Cellulose fibers are often used as raw materials for manufacturing or creating products. Products made 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 made from cellulose fibers, and some examples are disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.

[0003] Molds are commonly used in fabricating cellulosic products from raw materials containing cellulose fibers, and traditionally, cellulosic products have been manufactured by wet-forming techniques. A commonly used material for wet-forming cellulosic fiber products is wet-formed pulp. Because wet-formed pulp is made from biomaterials and is recyclable after use, it has the advantage of being considered a sustainable packaging material. As a result, wet-formed pulp is rapidly gaining popularity for a variety of applications. Wet-formed pulp articles are generally formed by immersing a suction mold into a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers. When suction is applied, the pulp mass is formed into the desired product shape by fiber deposition onto the mold. All wet-forming techniques require drying of the wet-formed product, which is a time- and energy-consuming part of production. Demands on the aesthetic, chemical, and mechanical properties of cellulosic products are increasing, and the properties of wet-formed cellulosic products impose limitations on mechanical strength, flexibility, material thickness flexibility, and chemical properties. Additionally, it is difficult to precisely control the mechanical properties of the product in the wet molding process.

[0004] One development in the field of cellulose product manufacturing is the molding of cellulose fibers without using wet molding techniques. Instead of molding cellulose products from liquid or semi-liquid pulp suspensions or slurries, air-formed cellulose blank structures are used. The air-formed cellulose blank structures are inserted into a mold, and the cellulose blanks are subjected to high molding pressures and temperatures during molding. When inserting the cellulose blank structure into the mold, there is a risk that the cellulose blank structure will break in an undesirable manner, resulting in improper molding of the cellulose product. This is a common problem with conventional cellulose high-pressure molding methods, especially for deep-drawn products, and results in low-quality products. Another problem with conventional molding methods using standard cellulose blank structures, especially when molding deep-drawn products, is that cracks, fiber separation, material breakage, or other undesirable structural weakening of the cellulose blank structure can occur during insertion of the cellulose blank structure into the mold and during the molding process in the mold.

[0005] Therefore, there is a need for improved methods, mold systems, and cellulosic blank structures for forming cellulosic products from air-formed cellulosic blank structures.

[0006] overview The object of the present disclosure is to provide a method for forming a cellulose product in a mould system from a cellulose blank structure, a mould system and a cellulose blank structure which avoid the above-mentioned problems. This object is at least partly achieved by the features of the independent claims. The dependent claims contain further improvements of the method for forming a cellulose product in a mould system from a cellulose blank structure.

[0007] The present disclosure relates to a method for forming a cellulosic product from an air-formed cellulosic blank structure in a mold system, the mold system having one or more molds, each mold having a first mold portion and a second mold portion configured to cooperate with each other during the formation of the cellulosic product. The method includes the following steps: providing a cellulose blank structure and defining in the cellulose blank structure one or more product segments and a residual segment surrounding or connected to the one or more product segments; compressing at least a portion of the residual segment to a first compression degree higher than the compression degree of the one or more product segments; feeding the cellulose blank structure in a feed direction to a molding position in a molding system, where each product segment is disposed between a corresponding first mold section and a second mold section; and molding a cellulose product from the cellulose blank structure between the first mold section and the second mold section by heating the cellulose blank structure to a molding temperature in the range of 100 to 300°C and pressing the cellulose blank structure at a molding pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa.

[0008] The advantage of these features is that the risk of the cellulose blank structure being broken in an undesirable manner during transport and insertion into the mold is prevented. This solution results in successful molding of cellulose products with improved product quality, particularly for deep-drawn products. Cracking, fiber separation, material breakage, or other undesirable structural weakening of the cellulose blank structure during insertion into the mold and during the molding process in the mold is minimized by the present method by molding the product section and the remainder section. The remainder section, compressed to a first compression degree higher than the compression degree of one or more product sections, facilitates transport of the cellulose blank structure, and the relatively high compression degree of the remainder section allows for transport of the cellulose blank structure at a relatively high feed rate without structural breakdown. The relatively low compression of the product section allows for flexible fiber transport into the mold. The relatively high feed rate reduces the product molding cycle time.

[0009] According to one embodiment of the present disclosure, the cellulose blank structure further includes one or more transition sections disposed between the one or more product sections and the remainder section. In the one or more transition sections, the degree of compression changes between the first compression degree and the compression degree of the one or more product sections. The transition sections form a structure that supports the transport of fibers into the mold. The transition sections further prevent breakage of the fibers in the cellulose blank structure between the product section and the remainder section.

[0010] According to another aspect of the present disclosure, the method further includes compressing at least a portion of one or more product sections to a second degree of compression, where the first degree of compression is greater than the second degree of compression, prior to delivering the cellulosic blank structure to the forming location. The second degree of compression may vary for different types of products to be formed, with a lower degree of compression often being required for more deeply drawn products.

[0011] According to one aspect of the present disclosure, the method further comprises at least partially displacing the remainder section and one or more product sections relative to one another in a press direction of the mold system at the molding location prior to forming the cellulosic product, which displaces the remainder section and one or more product sections relative to one another in a press direction of the mold system to facilitate forming of the cellulosic product, particularly for deep-drawn products, by allowing fibers within the cellulosic blank structure to move relative to one another.

[0012] According to another aspect of the present disclosure, the method further includes disposing a cutting pattern at least partially around each product segment in the remainder and / or transition section. Each cutting pattern forms at least one bridge structure in the remainder and / or transition section to maintain a partial connection of each product segment to the remainder and / or transition section. The cutting pattern supports the shaping of the cellulosic product, allowing the product segment to move relative to the remainder of the cellulosic blank structure. The bridge structure effectively maintains the position of the product segment relative to the mold during the product shaping operation.

[0013] According to a further aspect of the present disclosure, each cutting pattern has discontinuous first cut portions connected to and circumferentially disposed around a corresponding product section. The discontinuous first cut portions have one or more first cut lines, and the first cut lines have one or more first intermediate sections between the one or more first cut lines. The one or more first intermediate sections form at least one bridge structure. A cutting pattern having such a configuration is simple to design.

[0014] According to one aspect of the present disclosure, each cutting pattern includes a first cutting portion connected to and circumferentially disposed around a corresponding product section, the first cutting portion including a first cutting line with a first intermediate section forming at least one bridge structure.

[0015] According to another aspect of the present disclosure, each cut pattern includes a discontinuous first cut portion connected to and circumferentially disposed within a corresponding product segment, and a discontinuous second cut portion circumferentially disposed outside the discontinuous first cut portion relative to the product segment, the first cut portion and the second cut portion effectively cooperating to form at least one bridge structure.

[0016] According to a further aspect of the present disclosure, the discontinuous first cuts include one or more first cut lines, the first cut lines having one or more first intermediate sections between the one or more first cut lines. The discontinuous second cuts include one or more second cut lines, the second cut lines having one or more second intermediate sections between the one or more second cut lines. The one or more first intermediate sections and the one or more second intermediate sections form at least one bridge structure. This type of cut pattern effectively allows for displacement of product sections relative to the remainder of the cellulosic blank structure during the product forming operation and is suitable for deep-draw products.

[0017] According to one aspect of the present disclosure, the discontinuous first cuts and the discontinuous second cuts are disposed in an overlapping relationship relative to one another, with one or more first cut lines overlapping one or more second intermediate sections and one or more second cut lines overlapping one or more first intermediate sections.

[0018] According to another aspect of the present disclosure, each cutting pattern further includes at least one additional discontinuous cut portion disposed outside and around the second discontinuous cut portion relative to the product segment. Each of the at least one additional discontinuous cut portion includes one or more additional cut lines, and the additional cut lines include one or more additional intermediate sections between the one or more additional cut lines. This type of cutting pattern effectively allows for displacement of the product segment relative to the remainder of the cellulosic blank structure during the product forming operation and is suitable for deep-draw products.

[0019] According to a further aspect of the present disclosure, each cut extends entirely through the cellulosic blank structure, thus forming an opening in the cellulosic blank structure for effective displacement of the product segments.

[0020] According to one aspect of the present disclosure, at least one of the intermediate sections has a cutout extending partially through the cellulosic blank structure, which can support positioning of the product section relative to the mold during transport of the cellulosic blank structure.

[0021] According to another aspect of the present disclosure, the method further comprises placing one or more cut patterns in the remainder and / or transition sections around each product section by a cutting unit, which may have different configurations such as a rotary die cutter or a press cutting device, used to form the cut patterns.

[0022] According to a further aspect of the present disclosure, the cutting unit is configured as a rotary die cutter, and the method further comprises forming one or more cut patterns and compressing at least a portion of the remainder section in a single operating step with the rotary die cutter; or forming one or more cut patterns, compressing at least a portion of the remainder section, and compressing at least a portion of the one or more product sections in a single operating step with the rotary die cutter.

[0023] According to an aspect of the present disclosure, the method further comprises cutting the cellulose product from the cellulose blank structure in the mold system during molding of the cellulose product, whereby the cellulose product can be cut from the cellulose blank structure that is directly connected to the mold when the cellulose blank structure is positioned in the molding position.

[0024] According to another aspect of the present disclosure, the product segments are arranged on the cellulosic blank structure in a pattern that corresponds to the arrangement of one or more molds in a mold system.

[0025] The cellulosic blank structure may be conveyed in a feed direction by one or more feed belts, which provide an efficient and simple means of conveying the cellulosic blank structure.

[0026] The present disclosure also relates to a mold system for forming a cellulose product from an air-formed cellulose blank structure. The cellulose blank structure has one or more defined product segments and a defined remainder segment surrounding or connected to the one or more product segments. The mold system includes one or more molds, each having a first mold section and a second mold section configured to cooperate with each other during forming of the cellulose product. The mold system further includes a compaction unit configured to compress at least a portion of the remainder segment to a first degree of compression that is higher than the degree of compression of the one or more product segments; and a feed unit configured to feed the cellulose blank structure in a feed direction to a forming position within the mold system. At the forming position, each product segment is positioned between a corresponding first mold section and a corresponding second mold section. The one or more molds are configured to form a cellulose product from the cellulose blank structure between the first mold part and the second mold part by 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. An advantage of including these system features is that the risk of undesired fracture of the cellulose blank structure when inserting it into the mold is prevented. This solution results in good forming of the cellulose product, particularly for deep-drawn products.

[0027] The present disclosure further relates to a cellulose blank structure for forming a cellulose product in a mold system. The cellulose blank structure is air-formed and has one or more defined product segments and a defined remainder segment surrounding or connected to the one or more product segments. At least a portion of the remainder segment has a first degree of compression higher than the degree of compression of the one or more product segments. The cellulose blank structure further has one or more transition segments disposed between the one or more product segments and the remainder segment. In the transition segments, the degree of compression changes between the first degree of compression and the degree of compression of the one or more product segments. The cellulose blank structure further has cut patterns at least partially around each product segment in the remainder segment and / or transition segment. Each cut pattern forms at least one bridge structure in the remainder segment and / or transition segment. The system minimizes cracking, fiber separation, material breakage, or other undesirable structural weakening of the cellulose blank structure during insertion into the mold and during the forming process in the mold by forming the product segments and remainder segment. With the remainder section compressed to a first degree of compression that is higher than the degree of compression of one or more product sections, transport of the cellulosic blank structure is simplified.

[0028] The present disclosure will now be described in detail with reference to the accompanying drawings. [Brief explanation of the drawings]

[0029] [Figure 1a] FIG. 1 is a schematic perspective view of a cellulose blank structure according to the present disclosure. [Figure 1b] 1 is a perspective view of a mold system with a compact unit according to the present disclosure; FIG. [Figure 2a] FIG. 1 is a perspective view schematically illustrating a cellulose blank structure with a cutting pattern according to the present disclosure. [Figure 2b] 1 is a perspective view schematically illustrating a mold system with a cutting unit according to the present disclosure; FIG. [Figure 2c] 1 is a perspective view schematically illustrating a mold system with a cutting unit according to the present disclosure; FIG. [Figure 3a] 1 is a schematic plan view of a cellulose blank structure with a cutting pattern in a multi-cavity configuration according to the present disclosure. FIG. [Figure 3b] FIG. 1 is a schematic front view of a cellulose blank structure with a cutting pattern in a multi-cavity configuration according to the present disclosure. [Figure 4a] 1 is a plan view that schematically illustrates a cellulose blank structure with a cutting pattern in a single cavity structure or in a section of a multi-cavity structure according to the present disclosure. FIG. [Figure 4b] 1 is a front view of a schematic illustration of a cellulosic blank structure with a cutting pattern in a single cavity structure or in a section of a multi-cavity structure according to the present disclosure. FIG. [Figure 5a] FIG. 1 is a front view schematic of a mold system according to the present disclosure. [Figure 5b] FIG. 1 is a front view schematic of a mold system according to the present disclosure. [Figure 5c] FIG. 1 is a front view schematic of a mold system according to the present disclosure. [Figure 5d] FIG. 1 is a front view schematic of a mold system according to the present disclosure. [Figure 5e] FIG. 1 is a front view schematic of a mold system according to the present disclosure. [Figure 6a] 1 is a schematic perspective view of a mold system shown without a first mold part and a feed unit with a feed belt according to the present disclosure; FIG. [Figure 6b] 1 is a schematic perspective view of a mold system shown without a first mold part and a feed unit with a feed belt according to the present disclosure; FIG. [Figure 6c] 1 is a schematic perspective view of a mold system shown without a first mold part and a feed unit with a feed belt according to the present disclosure; FIG. [Figure 7a]FIG. 1 is a schematic plan view of a cellulose blank structure with a cutting pattern according to the present disclosure. [Figure 7b] 1A-1C are schematic plan views of cellulosic blank structures with different cutting patterns according to the present disclosure. [Figure 7c] 1A-1C are schematic plan views of cellulosic blank structures with different cutting patterns according to the present disclosure. [Figure 7d] 1A-1C are schematic plan views of cellulosic blank structures with different cutting patterns according to the present disclosure. [Figure 7e] 1A-1C are schematic plan views of cellulosic blank structures with different cutting patterns according to the present disclosure. [Figure 8a] FIG. 1 is a perspective view that schematically illustrates a cellulose blank structure according to an alternative embodiment of the present disclosure. [Figure 8b] FIG. 1 is a perspective view that schematically illustrates a mold system according to an alternative embodiment of the present disclosure. [Figure 8c] FIG. 10 is a front view that schematically illustrates a mold system according to an alternative embodiment of the present disclosure. [Figure 9a] FIG. 10 is a front view that schematically illustrates a mold system with a cutting unit according to an alternative embodiment of the present disclosure. [Figure 9b] FIG. 10 is a front view that schematically illustrates a mold system with a cutting unit according to an alternative embodiment of the present disclosure.

[0030] Description of exemplary embodiments Various aspects of the present disclosure are described below with reference to the accompanying drawings, which are intended to illustrate, not limit, the disclosure, where like designations refer to like elements, and variations of the described aspects are not limited to the specifically illustrated embodiments but may be applicable to other variations of the disclosure.

[0031] Those skilled in the art will understand that the steps and functions described herein may be performed using discrete hardware circuits, using software working in conjunction with a programmed microprocessor or general-purpose computer, using one or more application-specific integrated circuits (ASICs), and / or using one or more digital signal processors (DSPs). Also, where the present disclosure is described in terms of a method, it will be understood that the present disclosure may be embodied in one or more processors and one or more memories coupled to the one or more processors, where the one or more memories store one or more programs that, when executed by the one or more processors, perform the steps, services, and functions disclosed herein.

[0032] Figures 1b, 2b, 5a-5e and 9a-9b show schematically a mould system S for forming a cellulose product 1 from a single air-formed cellulose blank structure 2. The mould system S has one or more moulds 3, each having a first mould part 3a and a second mould part 3b configured to cooperate with each other during the forming of the cellulose product 1. A control unit connected to the mould system S is suitably used to control the various forming steps.

[0033] FIGS. 1a, 2a, 3a-3b, and 4a-4b schematically illustrate an air-formed cellulose blank structure 2. The air-formed cellulose blank structure 2 according to the present disclosure refers to a substantially air-formed fibrous web structure made from cellulose fibers. Air-forming the cellulose blank structure 2 refers to forming the cellulose blank structure in a dry-forming process, in which cellulose fibers are air-formed to produce the cellulose blank structure 2. When forming the cellulose blank structure 2 in the air-forming process, air is used as a carrier medium to transport the cellulose fibers and form them into the fibrous blank structure 2. This differs from typical papermaking processes or conventional wet-forming processes, in which water is used as a carrier medium for the cellulose fibers when forming paper or fibrous structures. In the air-forming process, small amounts of water or other substances may be added to the cellulose fibers as needed to change the properties of the cellulose product, but air is still used as a carrier medium in the forming process. The cellulose blank structure 2 may have a dryness that primarily corresponds to the ambient humidity of the atmosphere surrounding the air-formed cellulose blank structure 2, if appropriate. Alternatively, the dryness of the cellulosic blank structure 2 can be controlled to have an appropriate dryness level when forming the cellulosic product 1 .

[0034] The air-formed cellulose blank structure 2 may be formed from cellulose fibers in a conventional air-forming process and may be constructed in a variety of ways. For example, the cellulose blank structure 2 may have a composition including fibers of the same origin or alternatively a mixture of two or more types of cellulose fibers, depending on the desired properties of the cellulose product 1. The cellulose fibers used in the cellulose blank structure 2 are strongly bonded to each other by hydrogen bonds during the forming process of the cellulose product 1. As described further below, the cellulose fibers may be mixed with other substances or compounds to a certain extent. Cellulose fibers refer to any type of cellulose fiber, such as natural or manufactured cellulose fibers. The cellulose blank structure 2 may specifically comprise at least 95% cellulose fibers, or more specifically, at least 99% cellulose fibers.

[0035] The air-formed cellulose blank structure 2 may have a single layer or a multi-layer structure. A cellulose blank structure 2 having a single layer structure refers to a structure formed from one layer containing cellulose fibers. A cellulose blank structure 2 having a multi-layer structure refers to a structure formed from two or more layers containing cellulose fibers, where the layers may have the same or different compositions or structures.

[0036] The cellulose blank structure 2 may have a reinforcing layer containing cellulose fibers, which may be arranged as a support layer for the other layers of the cellulose blank structure 2. The reinforcing layer may have a higher tensile strength than the other layers of the cellulose blank structure 2. This is effective to prevent the cellulose blank structure 2 from being destroyed during the formation of the cellulose product 1 if one or more air-formed layers of the cellulose blank structure 2 have a low tensile strength composition. The reinforcing layer having a higher tensile strength thus serves as a support structure for the other layers of the cellulose blank structure 2. The reinforcing layer may have a different composition from the other layers of the cellulose blank structure, such as a tissue layer containing cellulose fibers, an air-laid structure with cellulose fibers, or any other suitable layer structure. Therefore, the reinforcing layer does not have to be an air-formed layer. The cellulose blank structure 2 may have two or more reinforcing layers, if appropriate.

[0037] The one or more air-formed layers of the cellulose blank structure 2 are a fluffy, airy structure in which the cellulose fibers forming the structure are relatively loosely arranged relative to one another. The fluffy cellulose blank structure 2 is used for efficient shaping of the cellulose product 1, allowing the cellulose fibers to efficiently shape the cellulose product 1 during the shaping process.

[0038] As shown in Figures 1a, 2a, 3a-3b, 4a-4b, 7a-7e, 8a, and 9a-9b, for example, the cellulose blank structure 2 has one or more defined product sections 2a and a defined residual section 2b. The one or more product sections 2a are defined as areas or portions of the cellulose blank structure 2 that correspond to the positions of one or more molds 3 when forming the cellulose product 1. The residual section 2b surrounds or is connected to one or more product sections 2a. Prior to the forming operation in the mold system, at least a portion of the residual section 2b is compressed to a degree D of compression of one or more product sections 2a, as can be seen from the figures.C The first compression degree D is higher than C1 One or more product sections 2a may be uncompressed, or alternatively, at least a portion of one or more product sections 2a may be compressed to a second degree of compression D C2 is compressed to

[0039] In certain embodiments, the cellulose blank structure 2 may have one or more defined residual sections 2b, where each residual section 2b is arranged surrounding or connected to one or more product sections 2a. Prior to the molding operation in the mold system, at least a portion of the residual sections 2b may be compressed to a degree D of compression of one or more product sections 2a. C The first compression degree D is higher than C1 is compressed to

[0040] As shown in the illustrated embodiment, the remaining section 2b is compressed to a first degree D C1 The remaining section 2b is compressed appropriately to 40-1300 kg / m 3 a first compression degree D having a density in the range of C1 The density of the remaining section 2b may be measured by cutting a sample piece of material immediately after the cellulose blank structure 2 has been compressed, for example between compaction rollers. The thickness of the sample piece of the remaining section 2b is measured with a caliper within one minute of compression, after which the sample piece is weighed. The sample piece is suitably between 400 and 2000 mm 2 The specimen has a square or circular shape with an area in the range of . When measuring the thickness of a specimen with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the specimen. The weight [m] of the specimen, together with the thickness [t] and area [A], is calculated using the formula ρ=m / At is used to calculate the density [ρ] according to

[0041] In Figure 1a, the first sample piece P1 of the remaining section 2b is shown by a dotted line for illustrative purposes, and in the illustrated embodiment, the first sample piece P1 has a rectangular shape. Figure 1a also shows a first area A1 and a first thickness direction T1 of the first sample piece P1.

[0042] The remaining section 2b may have an embossed pattern, for example a waffle surface-like structure, on one or both sides to increase the stiffness and strength of the cellulosic blank structure 2.

[0043] The cellulose blank structure 2 further comprises one or more transition sections 2c disposed between the one or more product sections 2a and the remainder section 2b. In the transition sections 2c, the degree of compression is greater than the first compression degree D C1 and one or more product categories 2a compression degree D C The transition section 2c may have other compression degrees if appropriate.

[0044] In certain embodiments, one or more product sections 2a may be formed by forming the cellulose blank structure 2 at a forming position F POS before feeding to the second compression degree D C2 The first compression degree D C1 is the second compression degree D C2 One or more product categories 2a, as appropriate, are between 15 and 400 kg / m 3 a second compression degree D having a density in the range C2 The density of the one or more product sections 2a may be measured by cutting a sample piece of material immediately after the cellulosic blank structure 2 has been compressed, for example between compaction rollers. The thickness of the sample piece of the one or more product sections 2a is measured with a caliper within one minute of compression, after which the sample piece is weighed. The sample piece is suitably between 400 and 2000 mm 2 The specimen has a square or circular shape with an area in the range of . When measuring the thickness of a specimen with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the specimen. The weight [m] of the specimen, together with the thickness [t] and area [A], is calculated using the formula ρ=m / At is used to calculate the density [ρ] according to

[0045] In Figure 1a, a second sample piece P2 of one or more product sections 2a is shown by a dotted line for illustrative purposes and, in the illustrated embodiment, has a rectangular shape. Figure 1a also shows a second area A2 and a second thickness direction T2 of the second sample piece P2.

[0046] As shown in FIG. 1b, the mold system S may further include a compression degree D of one or more product segments 2a. C The first compression degree D is higher than C1 The compacting unit 11 may include a compacting unit configured to densify or compress the remaining section 2b to a second compacting roller 11b. The compacting unit 11 includes a first compacting roller 11a that cooperates with a second compacting roller 11b. The first compacting roller 11a is positioned on opposite sides of the cellulose blank structure 2, and the cellulose blank structure 2 is compressed when the cellulose blank structure 2 is fed between the first compacting roller 11a and the second compacting roller 11b. As shown in FIG. 1b, the first compacting roller 11a has a plurality of recesses 12 that form the product sections 2a, and the areas of the first compacting roller 11a between the recesses 12 form the remaining section 2b of the cellulose blank structure 2 with a relatively high degree of compression. Each recess 12 has a shape and structure corresponding to the product section 2a. The recesses 12 compress the product section 2a to a second degree of compression D. C2 In this case, the second compression degree D can be used to compress the C2 is the first compression degree D C1 In an alternative embodiment not shown, the second compact roller 11b may be provided with recesses corresponding to the recesses 12 of the first compact roller 11a for forming the product sections 2a.

[0047] The mold system S may further include a cutting unit 9 configured to form one or more cutting patterns 4 in the cellulose blank structure 2. The cellulose blank structure 2 may have the cutting patterns 4 disposed at least partially around each product section 2a in the remainder section 2b and / or transition section 2c, as shown in Figures 2a-2b, 3a-3b, 4a-4b, 5a-5e, 6a-6c, and 7a-7e. Each cutting pattern 4, in the illustrated embodiment, partially separates the portion of the cellulose blank structure 2 connected to the product section 2a from the remainder of the cellulose blank structure 2. Each cutting pattern 4 forms at least one bridge structure 4a in the remainder section 2b and / or transition section 2c. The bridge structure 4a connects the portion of the cellulose blank structure 2 connected to the product section 2a with the remainder of the cellulose blank structure 2 and allows for displacement of the portion of the cellulose blank structure 2 connected to the product section 2a, as shown, for example, in Figures 5b-5c and 6b. The displacement facilitates shaping of the cellulose product 1 in one or more molds 3, especially if the cellulose product 1 has a deep-draw structure. The cutting pattern 4 may have any suitable structure for forming bridge structures 4a.

[0048] The cutting unit 9 may be arranged as a separate unit upstream of one or more molds 3, as shown in Figure 2b, or as one or more assemblies connected to one or more molds 3, as shown in Figures 9a-9b. The cutting units described below may be used with other embodiments of the mold system S.

[0049] In the embodiment shown in FIGS. 2b-2c, the cutting unit 9 is configured as a rotary die cutter 10. The illustrated rotary die cutter 10 includes a die cutter 10a and an anvil roll 10b. The die cutter 10a includes a plurality of cutting elements 10c that form a cut pattern 4 in the cellulose blank structure 2 when the cellulose blank structure 2 is fed between the die cutter 10a and the anvil roll 10b. The cutting elements 10c therefore have a structure corresponding to the shape of the cut pattern 4. The rotary die cutter 10 may also function as a compaction roller in a manner similar to that described above in connection with FIG. 1b. As shown in FIG. 2b, the die cutter 10a includes a plurality of recesses 12 that form the product sections 2a, and the areas of the die cutter 10a between the recesses 12 form the remaining sections 2b of the cellulose blank structure 2, which have a relatively high degree of compaction. Each recess 12 has a shape and structure corresponding to the product sections 2a. The recess 12 compresses the product section 2a to a second compression degree D C2 In this case, the second compression degree D can be used to compress the C2 is the first compression degree D C1 In an alternative embodiment not shown, the anvil roll 10b may be provided with recesses corresponding to the recesses 12 of the die cutter 10a for forming the product sections 2a. With such a configuration, the formation of one or more cutting patterns 4 and the compression of the cellulosic blank structure 2 are performed in a single operating step by the rotary die cutter 10.

[0050] The cutting unit 9 may have another suitable structure. In the embodiment shown in Figures 9a-9b, the cutting unit 9 is configured as a press-cutting device 20 connected to and arranged in the mold 3 of the mold system S. The press-cutting device 20 has a movably arranged common plate structure 20a having a plurality of cutting elements 20b with cutting edges that form a cutting pattern 4 in the cellulose blank structure 2 when the cellulose blank structure 2 is placed between the first mold part 3a and the second mold part 3b. As described above, the cutting pattern 4 is formed at least partially in the remainder section 2b and / or the transition section 2c around each product section 2a, and therefore the cutting elements 20b have a structure corresponding to the shape of the cutting pattern 4. In the non-cutting position shown in Figure 9a, the plate structure 20a with the cutting elements 20b is connected to and arranged in the second mold part 3b. In Figure 9a, a preformed cellulose blank structure 2 having a product section 2a and a remainder section 2b is connected to and arranged in the first mold part 3a. The press-cutting device 20 further includes a pressure cylinder 20c arranged to displace the plate structure 20a with the cutting elements 20b from a non-cutting position to a cutting position shown in Fig. 9b. In Fig. 9b, the cutting elements 20b abut against an anvil structure 20d arranged to be connected to the first mold part 3a to form a cut pattern 4 in the cellulose structure. The anvil structure 20d may be formed from a flexible plate structure made of a suitable material, for example, polyurethane. Once the cut pattern 4 has been formed in the cellulose blank structure 2, the plate structure 20a with the cutting elements 20b returns to the position shown in Fig. 9a, allowing the product-forming operation to be performed.

[0051] In a particular embodiment, each cutting pattern 4 has a first cutting portion 5 connected to and arranged around the corresponding product section 2a, in which case the first cutting portion 5 has a first cutting line 5a with a first intermediate section 5b forming at least one bridge structure 4a.

[0052] 7a, an exemplary spiral-shaped cutting pattern 4 is shown schematically, in which a first cutting portion 5 is connected to and disposed around the product section 2a. The first cutting portion 5 has a first cutting line 5a, which has a first intermediate section 5b between overlapping sections of the first cutting line 5a, as shown. The intermediate section 5b forms at least one bridge structure 4a.

[0053] In an alternative embodiment, each cut pattern 4 includes a discontinuous first cut portion 5 connected to and circumferentially disposed within a corresponding product section 2a, and a discontinuous second cut portion 6 disposed circumferentially outside the discontinuous first cut portion 5 relative to the product section 2a. The discontinuous first cut portion 5 includes one or more first cut lines 5a, each having one or more first intermediate sections 5b between the one or more first cut lines 5a. The discontinuous second cut portion 6 includes one or more second cut lines 6a, each having one or more second intermediate sections 6b between the one or more second cut lines 6a. The one or more first intermediate sections 5b and the one or more second intermediate sections 6b form at least one bridge structure 4a.

[0054] 2c, 3a-3b, 4a-4b, 6b, and 7b illustrate an exemplary cut pattern 4 having discontinuous first cut portions 5 connected to and circumferentially disposed corresponding product sections 2a and discontinuous second cut portions 6 disposed outside and circumferentially disposed relative to the product sections 2a. The discontinuous first cut portions 5 have a plurality of first cut lines 5a, each having a first intermediate section 5b between the first cut lines 5a. The discontinuous second cut portions 6 have a plurality of second cut lines 6a, each having a second intermediate section 6b between the second cut lines 6a. The first intermediate section 5b and the second intermediate section 6b form a bridge structure 4a. The discontinuous first cut portions 5 and the discontinuous second cut portions 6 may be arranged in an overlapping relationship relative to one another, as shown, where one or more first cut lines 5 a overlap one or more second intermediate sections 6 b, and one or more second cut lines 6 a overlap one or more first intermediate sections 5 b.

[0055] In an alternative embodiment, each cut pattern 4 may further include at least one additional discontinuous cut portion 7 located outside and around the second discontinuous cut portion 6 relative to the product section 2a, wherein each of the at least one additional discontinuous cut portion 7 includes one or more additional cut lines 7a, and the additional cut lines include one or more additional intermediate sections 7b between the one or more additional cut lines 7a.

[0056] 7c shows an exemplary cut pattern 4 having a discontinuous first cut portion 5 connected to and circumferentially disposed corresponding product section 2a, a discontinuous second cut portion 6 disposed outside and circumferentially disposed relative to product section 2a of the discontinuous first cut portion 5, and a discontinuous additional cut portion 7 disposed outside and circumferentially disposed relative to product section 2a of the discontinuous second cut portion 6. The discontinuous additional cut portion 7 has a plurality of additional cut lines 7a with additional intermediate sections 7b between the additional cut lines 7a. 7d shows an exemplary cut pattern 4 having a discontinuous first cut portion 5 connected to and circumferentially disposed within a corresponding product section 2a, a discontinuous second cut portion 6 disposed outside and circumferentially relative to the product section 2a, and two additional discontinuous cut portions 7 disposed outside and circumferentially relative to the product section 2a. The first additional cut portion 7:1 is disposed outside and circumferentially relative to the product section 2a, and the second additional cut portion 7:2 is disposed outside and circumferentially relative to the product section 2a. Each of the additional cut portions 7 has a plurality of additional cut lines 7a with additional intermediate sections 7b between the additional cut lines 7a.

[0057] In an alternative embodiment, each cutting pattern 4 may instead have only discontinuous first cut portions 5 connected to and arranged around the corresponding product section 2a. The discontinuous first cut portions 5 have one or more first cut lines 5a, which have one or more first intermediate sections 5b between them, and the one or more first intermediate sections 5b form at least one bridge structure 4a.

[0058] 7e shows an exemplary cutting pattern 4 having only discontinuous first cut portions 5 connected to and arranged around the corresponding product sections 2a. The discontinuous first cut portions 5 have a plurality of first cut lines 5a, with first intermediate sections 5b between the first cut lines 5a. The first intermediate sections 5b form bridge structures 4a.

[0059] Each cut 5, 6, 7 extends suitably through the cellulose blank structure 2. In an alternative, not shown, embodiment, at least one of the intermediate sections 5b, 6b, 7b has a cut that extends partially through the cellulose blank structure 2.

[0060] In an alternative, not shown, embodiment, some of the intermediate sections 5b, 6b, 7b may be narrow and configured to break during the forming of the cellulose product 1. The narrow structure of the intermediate sections 5b, 6b, 7b allows them to transport the cellulose blank structure 2 without breaking or separating for secure positioning of the cellulose blank structure 2 relative to one or more forming dies 3.

[0061] As mentioned above, the mould system S comprises one or more moulds 3, each of which comprises a first mould part 3a and a second mould part 3b which cooperate with each other during the moulding of the cellulose product 1. The first mould part 3a and the second mould part 3b are arranged to be movable relative to each other, and the first mould part 3a and the second mould part 3b are arranged to be movable relative to each other in the pressing direction D. P In the embodiment shown in Figures 5a to 5e, the second mould part 3b is stationary and the first mould part 3a is configured to move relative to each other in the pressing direction D P As shown by the double-headed arrow in FIG. 5a, the first mold part 3a is arranged to be movable relative to the second mold part 3b in a pressing direction D P The second mold part 3b is adapted to move in both directions towards and away from the second mold part 3b with linear movement along an axis extending at .

[0062] In alternative embodiments, the first mold part 3a may be stationary and the second mold part 3b may be movably arranged relative to the first mold part 3a, or both mold parts may be movably arranged relative to each other.

[0063] The mold system S may be a single-cavity structure or, alternatively, a multi-cavity structure. A single-cavity mold system has only one mold 3 with first and second mold portions. A multi-cavity mold system has two or more molds 3 with first and second mold portions, respectively. In FIGS. 1b and 2b, the mold system S is arranged as a multi-cavity mold system having multiple molds 3 with first and second mold portions, with the movement of the mold portions appropriately synchronized for simultaneous molding operations. The portions of the mold system S shown in FIGS. 5a-5e and 6a-6c may be referred to as a single-cavity structure or, alternatively, as a section of a multi-cavity structure. While the mold system S will be described below with reference to a multi-cavity mold system, the present disclosure is equally applicable to single-cavity mold systems.

[0064] For all embodiments according to the present disclosure, the pressing direction D P The expression "movement in" refers to the pressing direction D P It should be understood that this expression also includes, for all embodiments, both linear and non-linear movements of the mold sections, where the movements during molding result in a change in the press direction D. P The mold part is rearranged.

[0065] To form a cellulose product 1 from a single air-formed cellulose blank structure 2 in a mold system S, the air-formed cellulose blank structure 2 is first provided from a suitable source. The cellulose blank structure 2 may be air-formed from cellulose fibers and arranged in a roll or stack. The roll or stack can then be connected to and arranged in the mold system S. Alternatively, the cellulose blank structure 2 may be air-formed from cellulose fibers while connected to the mold system S and fed directly to the mold section.

[0066] The forming system S is configured to feed the cellulose blank structure 2 in a feeding direction D F at molding position F in mold system S POS For example, as shown in Figures 1b, 2b, 5a to 5e, and 6a to 6c, the supply unit 8 may supply the cellulose blank structure 2 in a supply direction D. F At the molding position F between the first mold part 3a and the second mold part 3b POS The feed belts 8a may have any suitable structure for conveying the cellulose blank structure 2. The feed belts 8a are further used to hold the cellulose blank structure 2 in place during the forming process. The feed belts 8a may have any suitable structure for conveying the cellulose blank structure 2. In Figures 6a-6b, the feed belts 8a are shown in schematic perspective views. The feed belts 8a may be vacuum-type with suction passages 8b for holding the cellulose blank structure 2 during conveyance, as shown in Figures 6a-6c.

[0067] In the embodiment shown in Figures 5a-5e and 6a-6c, supply belts 8a are arranged on each side of the first mould section 3a. These supply belts 8a feed the cellulosic blank structure 2 to the moulding position F shown in Figure 5a. POS They work together to transport the material to the forming position F. POSIn the figure, the cellulose blank structure 2 is placed between a first mould part 3a and a second mould part 3b. The feeding unit 8 may have another suitable structure, such as a feeding roller.

[0068] The feeding unit 8 feeds the cellulose blank structure 2 in a feeding direction D F at molding position F in mold system S POS Molding position F POS 1b and 2b, each product section 2a is disposed between a corresponding first mold section 3a and second mold section 3b. Thus, the product sections 2a are disposed in the cellulose blank structure 2 in a pattern that corresponds to the arrangement of one or more molds 3 in the mold system S, as shown in FIGS.

[0069] The first mould sections 3a are arranged to interact with the corresponding second mould sections 3b to form the cellulose product 1. During the formation of the cellulose product 1, the cellulose blank structure 2 is subjected in each mould 3 to a product forming pressure P of at least 1 MPa, preferably in the range of 4-20 MPa. F , and product forming temperature T in the range of 100°C to 300°C F Therefore, the cellulose blank structure 2 is exposed to a molding temperature T F and the cellulose blank structure 2 is molded under a molding pressure P in the range of 1 to 100 MPa, preferably 4 to 20 MPa. F The cellulose blank structure 2 is pressed with a pressure of 1000 W at 1000 W. A cellulose product 1 is formed from the cellulose blank structure 2 between each first mold part 3 a and the corresponding second mold part 3 b. When the cellulose product 1 is formed, strong hydrogen bonds are formed between the cellulose fibers in the cellulose blank structure 2 disposed between the first mold part 3 a and the second mold part 3 b. Temperature and pressure levels are measured in the cellulose blank structure 2, for example, by suitable sensors disposed in or connected to the cellulose fibers in the cellulose blank structure 2 during the forming process.

[0070] The cellulose blank structure 2 is positioned at the forming position F between the first mold part 3a and the second mold part 3b. POS , the first mold part 3a is pressed in the pressing direction D as shown by the arrow in FIG. P 6b, the position of the cellulose blank structure 2 in FIG. 5b is shown diagrammatically in a perspective view, with the first mold section 3a omitted for illustrative purposes. POS Before forming the cellulose product 1, the residual section 2b and one or more product sections 2a are pressed in the pressing direction D of the mold system S, as shown schematically in FIG. 6b. P As the first mold part 3a is moved towards the second mold part 3b, the cellulose blank structure 2 is compressed between the mold parts. In the position shown in Figure 5d, the first mold part 3a is moved further towards the second mold part 3b to reach a product forming position, where the cellulose blank structure 2 is subjected to a forming pressure P F and molding temperature T F During the molding of the cellulose product 1, each first mold part 3a is pressed towards a corresponding second mold part 3b, with the cellulose blank structure 2 being placed between these mold parts, and a molding cavity C for molding the cellulose product 1 is formed between the first mold part 3a and the second mold part 3b. F and molding temperature T F is applied to the cellulose blank structure 2 in each mold cavity C. The molding of the cellulose product 1 may further include a cutting operation, in which case the cellulose product 1 is cut from the cellulose blank structure 2 in the mold system S during molding of the cellulose product 1. For example, a cutting device may be arranged in the mold parts for such an operation. Once the cellulose product 1 has been molded in the mold system S, the first mold part 3a is moved away from the second mold part 3b, as shown by the arrow in Figure 5e, and the cellulose product 1 can be removed from the mold system S, as shown in Figure 6c, for example, using an ejector rod or similar device.

[0071] 5c-5d show positions of an exemplary mold system S during an edge forming operation for forming an edge structure 1a of the cellulose product 1. The edge forming operation may be used instead of a cutting operation for separating the cellulose product 1 from the cellulose blank structure 2 and simultaneously forming the edge structure 1a. Each first mold section 3a includes an edge forming device 14 having protruding elements 14a configured to compress and separate the fibers of the cellulose blank structure 2. The protruding elements 14a have edge sections 14b arranged facing the second mold section 3b. The protruding elements 14a are suitably arranged as continuous elements extending around the periphery of the edge forming device 14, and the protruding elements 14a have an extension corresponding to the edge shape or outer contour of the cellulose product 1 produced in the mold system S. However, it should be understood that the protruding elements 14a may have any suitable extension, for example, a discontinuous extension, depending on the shape of the cellulose product 1 to be formed. The protruding elements 14a may further have a pointed cross-sectional configuration with edge sections 14b, as shown in Fig. 5d. The protruding elements 14a with edge sections 14b may have another suitable cross-sectional configuration, such as a rounded or flat edge section, in another embodiment not shown.

[0072] The edge forming device 14 may be arranged movably relative to the base structure of the first mould part 3a, as shown in Figures 5a to 5e, and the edge forming device 14 is adapted to interact with a pressure member arranged on the base structure. The edge forming device 14 may have any suitable shape and structure depending on the shape and structure of the cellulose product 1. The edge forming device 14 may be arranged, for example, in the pressing direction D PThe edge shaping device 14 may be arranged slidably relative to the base structure. The pressure member may have one or more springs 14c arranged between the base structure and the edge shaping device 14. The pressure member may alternatively be arranged as a hydraulic or pneumatic device. In an alternative, not shown, embodiment, the edge shaping device 14 may be configured as a stationary structure with protruding elements 14a arranged in the first mold part 3a. Alternatively, the edge shaping device may be arranged in the second mold part 3b or in both the first and second mold parts 3a, 3b.

[0073] While the first mold part 3a moves towards the second mold part 3b, the protruding elements 14a of each edge forming device 14 separate some of the fibers of the cellulose blank structure 2 by the force exerted by the protruding elements 14a on the cellulose blank structure 2. As shown in Figures 5c-5d, when the first mold part 3a reaches the second mold part 3b, the stop members 14d arranged on each edge forming device 14 prevent direct contact between the protruding elements 14a and the second mold part 3b during the forming of the compressed edge structure 1a, as shown in Figure 5d. In the embodiment shown in Figures 5a-5e, the stop members 14d are positioned in the pressing direction D, which is greater than the extension of the protruding elements 14a. P When the first mold part 3a reaches the second mold part 3b, each stopper member 14d abuts against the corresponding second mold part 3b, as shown in Figs. 5c-5d, and the stopper members 14d are arranged as protrusions on the edge forming device 14, each having an extension in the pressing direction D. P5d。 As can be seen in FIG. 5d, the stopper members 14d may be arranged as a continuous element extending around the periphery of each edge forming device 14, or alternatively as one or more protrusions extending from each edge forming device 14. Alternatively, the stopper members 14d may be arranged on the second mold part 3b or on both the first and second mold parts 3a, 3b.

[0074] Each stopper member 14d prevents contact between the protruding element 14a and the corresponding second mold section 3b during the shaping of the compressed edge structure 1a, and this arrangement positions the protruding element 14a at a small distance from the second mold section 3b. A small gap is formed between the protruding element 14a and the second mold section 3b. As the first mold section 3a moves further toward the second mold section 3b, the edge shaping device 14 is pushed into the first mold section 3a, reaching the edge shaping position shown in FIG. 5d. When the edge shaping device 14 is pushed into the first mold section 3a, the edge structure 1a of the cellulose product 1 is shaped. As the edge structure 1a is shaped, the fibers of the cellulose blank structure 2 gather in the area between each protruding element 14a and the corresponding second mold section 3b. At the same time, the edge shaping pressure P EF and edge forming temperature T EF and is applied to the cellulose blank structure 2. Edge forming pressure P EF and edge forming temperature T EF When the edge section 14b is applied to the cellulose blank structure 2, a highly compressed edge structure 1a is formed. The edge structure 1a is suitably formed as a thin edge extending around the periphery of the cellulose product 1, and the highly compressed formed edge structure 1a effectively prevents delamination of the cellulose product 1 and moisture absorption into the cellulose product 1. With a small distance between each edge section 14b and the corresponding second mold part 3b, a high edge forming pressure P EFThe application of pressure to the cellulose blank structure 2 results in a very thin, compressed cellulose structure that can be used to easily separate the cellulose product 1 and the cellulose blank structure 2 outside the mold section. The highly compressed, thin cellulose structure is subjected to high compressive stresses during the edge forming operation, and the energy, high tension, and / or tensile stress stored in the cellulose structure during the edge forming process can result in a high pressure level, referred to as the edge forming pressure P. EF When the adhesive is applied to the cellulose fibers, the cellulose fibers are broken down. Residual fibers in the cellulose blank structure 2 remaining after forming of the cellulose product 1 may be recycled. The edge forming operation is performed by the edge forming device 14 along with the product forming operation.

[0075] When forming the edge structure 1a, an appropriate edge forming pressure P is applied to the cellulose blank structure 2. EF is at least 10 MPa, preferably in the range of 10 to 4000 MPa, or more preferably in the range of 100 to 4000 MPa. EF The temperature is in the range of 50 to 300°C, preferably in the range of 100 to 300°C.

[0076] A deformation element E for establishing the product forming pressure may be arranged connected to each first mold part 3a and / or second mold part 3b. In the embodiment shown in Figures 5a to 5e, the deformation element E is attached to the first mold part 3a. By using the deformation element E, the forming pressure P F may be the isostatic molding pressure.

[0077] For all embodiments, the first mold part 3a and / or the second mold part 3b may have a deformation element E, which applies a molding pressure P to the cellulose blank structure 2 in the molding cavity C during the molding of the cellulose product 1. FThe deformation element E may be attached to the first mould part 3a and / or the second mould part 3b by suitable attachment means, for example by adhesive or mechanical fastening means. During the moulding of the cellulose product 1, the deformation element E applies a moulding pressure P to the cellulose blank structure 2 in the moulding cavity C. F The deformation of the deformation element E allows for uniform pressure distribution even if the cellulose product 1 has a complex three-dimensional shape or the cellulose blank structure 2 has a variable thickness. F In order to apply a force or pressure to the deformation element E, the deformation element E is made of a material that can be deformed when a force or pressure is applied, and the deformation element E is suitably made of an elastic material that can recover its size and shape after deformation. The deformation element E furthermore has a high molding pressure P used during the molding of the cellulose product 1. F and molding temperature T F It may be made of a material with suitable properties to withstand the level.

[0078] Some elastic or deformable materials have fluid-like properties when subjected to high pressure levels. If the deformation elements E are made of such materials, an even pressure distribution can be achieved in the molding process, where the pressure exerted by the deformation elements E on the cellulose blank structure 2 in the molding cavity C is equal or substantially equal in all directions between the mold parts. If each deformation element E is in a fluid-like state under pressure, an even fluid-like pressure distribution is achieved. Therefore, the molding pressure P Fis applied to the cellulose blank structure 2 from all directions by such a material, and the deformation elements E thus apply an isotropic molding pressure to the cellulose blank structure 2 during the molding of the cellulose product 1. Each deformation element E may consist of a suitable structure of elastic material, and by way of example, the deformation elements E may be formed from a solid or substantially solid structure of silicone rubber, polyurethane, polychloroprene or rubber having a hardness in the range of 20 to 90 Shore A. Other materials for the deformation elements E may be, for example, suitable gel materials, liquid crystal elastomers and MR fluids.

[0079] The mold system S further comprises a heating unit, which heats the cellulose blank structure 2 in each mold cavity C to a molding temperature T F The heating unit is further suitably configured to apply an edge forming temperature T EF The heating unit may have any suitable configuration. A suitable heating unit, such as a heated mold section, may be configured to apply a molding temperature T F and edge forming temperature T EF The heating unit may be built into or cast into the first mold part 3a and / or the second mold part 3b, and suitable heating devices are, for example, electric heaters such as resistor elements or fluid heaters. Another suitable heat source may also be used.

[0080] In Fig. 8a an alternative embodiment of a cellulose blank structure 2 is shown in a schematic manner. The cellulose blank structure 2 has one or more defined product sections 2a and a residual section 2b, where the residual section 2b is arranged connected to one or more product sections 2a. Prior to the forming operation in the mould system S, the residual section 2b is arranged to have a degree of compression D of one or more product sections 2a, as can be seen from the figure. C The first compression degree D is higher than C1The cellulose blank structure 2 further comprises one or more transition sections 2c disposed between the one or more product sections 2a and the remainder section 2b. In the transition sections 2c, the degree of compression is equal to or less than the first compression degree D C1 and one or more product categories 2a compression degree D C In this embodiment, one or more product sections 2a have a second compression degree D C2 In this case, the first compression degree D C1 is the second compression degree D C2 Each section may have a density as described above.

[0081] The construction of the cellulose blank structure 2 in FIGS. 1a, 2a and 8a is carried out at the forming position F using the feeding unit 8 described above. POS In an alternative embodiment shown in Figures 8b-8c, instead of the configuration described above, the supply unit 8 may supply the cellulose blank structure 2 to a supply position F POSThe supply unit 8 has a tractor feed structure for conveying the cellulose blank structure 2 to the row R of the cellulose blank structure 2. The supply unit 8 has a first roller 15a and a cooperating second roller 15b, and the cellulose blank structure 2 is positioned between these rollers as shown in FIG. 8b. The first roller 15a and the second roller 15b compress the cellulose blank structure 2 to form a product section 2a and a remainder section 2b. The first roller 15a has a recessed portion 16a for forming the product section 2a in a manner similar to that described with reference to FIGS. 1b and 2b. The non-recessed portions 16b of the first roller 15a are positioned on either side of the recessed portion 16a for forming the remainder section 2b. The first roller 15a has a plurality of perforation cutters 17 in the non-recessed portions 16b adjacent to the recessed portions 16a for forming tractor feed holes 18 arranged in the row R of the cellulose blank structure 2. The tractor feed holes 18 are used to convey the cellulose blank structure 2. In the embodiment shown in Figure 8b, the first roller 15a is provided with five rows of perforation cutters 17, one on each side of each recessed portion 16a. In this way, the perforation cutters 17 form five rows R of tractor feed holes 18 in the cellulose blank structure 2. The feeding unit 8 feeds the cellulose blank structure 2 to the feeding position F. POS8c shows the first roller 15a and the second roller 15b in more detail, along with a plurality of perforation cutters 17. The perforation cutters 17 are arranged as sharp protrusions that cut the tractor feed holes 18 in the cellulose blank structure 2. The tractor feed holes 18 can be partially cut by the perforation cutters to prevent the remaining cut pieces 18a of material from being separated, as shown in the enlarged partial view of the cellulose blank structure 2 in FIG. 8b. The tractor feed holes 18 are engaged with the sprocket wheel 19 during the feeding operation. The partially cut tractor feed holes 18 may have a connecting portion 18b having a hinge-like structure to hold the cut pieces 18a of fibrous material connected to the cellulose blank structure 2, as shown in FIG. 8b. The rotational placement of the connecting portions 18b relative to the partially cut tractor feed holes 18 may alternate in the cutting pattern, as shown in the enlarged partial view of the cellulose blank structure 2 in Figure 8b, to improve alignment between the tractor feed holes 18 and the sprocket wheels 19. In Figure 8b, the connecting portions 18b of two adjacent tractor feed holes 18 are located on opposite sides of each tractor feed hole 18.

[0082] The present disclosure has been presented above with respect to specific embodiments. However, other embodiments than those described above are possible and within the scope of the present disclosure. Method steps other than those described above, implementing the method by hardware or software, may be provided within the scope of the present disclosure. Thus, according to an exemplary embodiment, a non-transitory computer-readable storage medium storing one or more programs configured to be executed by one or more processors of a control unit of a mold system S is provided, the one or more programs including instructions for performing a method according to any one of the above-described embodiments. Alternatively, according to another exemplary embodiment, a cloud computing system may be configured to perform any of the aspects of the methods presented herein. The cloud computing system may include distributed cloud computing resources that collectively perform aspects of the methods presented herein under the control of one or more computer program products. Additionally, the processor may be connected to one or more communication and / or sensor interfaces for receiving and / or transmitting data from external entities, such as sensors, off-site servers, or cloud-based servers.

[0083] The processor of the mold system S may be or include any number of hardware components for performing data or signal processing or for executing computer code stored in memory. The system may have associated memory, which may be one or more devices for storing data and / or computer code for completing or facilitating the various methods described herein. The memory may include volatile or non-volatile memory. The memory may include database components, object code components, script components, or any other type of information structure for supporting the various activities herein. According to exemplary embodiments, any distributed or local memory device may be utilized with the systems and methods herein. According to exemplary embodiments, the memory is communicatively connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and includes computer code for performing one or more processes described herein.

[0084] It will be understood that the above description is merely exemplary in nature and is not intended to limit the application or uses of the present disclosure. While specific examples have been described in the specification and shown in the drawings, those skilled in the art will recognize that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure, as defined in the claims. Furthermore, modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its essential scope. Therefore, the present disclosure is not limited to the particular examples illustrated in the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure; the scope of the present disclosure will include any embodiment encompassed by the foregoing description and the appended claims. Reference signs in the claims should not be construed as limiting the scope of the subject matter protected by the claims; their sole function is to facilitate understanding of the claims. [Explanation of symbols]

[0085] 1. Cellulose products 1a Edge structure 2. Cellulose blank structure 2a Product classification 2b Residual classification 2c Transition Category 3 Molding mold 3a First mold part 3b Second mold part 4 Cutting Pattern 4a Bridge structure 5 First cut 5a First cutting line 5b First intermediate division 6 Second cut 6a Second cutting line 6b Second intermediate division 7 Additional Cuts 7a Additional cutting lines 7b Additional intermediate divisions 8 Supply Unit 8a Supply belt 8b Suction passage 9 Cutting Unit 10 Rotary Die Cutter 10a die cutter 10b Anvil Roll 11 Compact Unit 11a First compact roller 11b Second compact roller 12 recess 14 Edge forming device 14a Protruding element 14b Edge division 14c spring 14d Stopper member 15a First Roller 15b Second Roller 16a Recessed part 16b Non-recessed portion 17 Drilling cutter 18 Tractor feed hole 18a Cut-out piece 18b Connection part 19 Sprocket Wheel 20 Press cutting device 20a Plate structure 20b Cutting element 20c Pressure Cylinder 20d anvil structure C Molding cavity D C1 First compression degree D C2 Second compression degree D F Supply direction D P Press Direction E Transformation Element F POS Molding position P EF Edge forming pressure P F Molding pressure R column T EF Edge forming temperature T F Molding temperature S Mold System

Claims

1. A method for forming a cellulose product (1) from a cellulose blank structure (2) in a mould system (S), said mould system (S) having one or more moulds (3), each mould (3) having a first mould part (3a) and a second mould part (3b) configured to cooperate with each other during the forming of said cellulose product (1), said method comprising the following steps, namely: providing the cellulose blank structure (2), defining in the cellulose blank structure (2) one or more product sections (2a) and a remainder section (2b) surrounding the one or more product sections (2a) or connected to the one or more product sections (2a); At least a portion of the remaining section (2b) is compressed to a degree of compression (D) of the one or more product sections (2a). Ｃ ) higher than the first compression degree (D Ｃ１ ) compressing the The cellulose blank structure (2) is fed in the feeding direction (D Ｆ ) at the molding position (F ＰＯＳ ) to the molding position (F ＰＯＳ ) each product section (2a) is placed between a corresponding first mold section (3a) and second mold section (3b); The cellulose blank structure (2) is molded at a molding temperature (T Ｆ ) and the cellulose blank structure (2) is molded at a molding pressure (P Ｆ forming the cellulose product (1) from the cellulose blank structure (2) between the first mold part (3a) and the second mold part (3b) by pressing with a press; A method having the following.

2. The cellulose blank structure (2) further comprises one or more transition sections (2c) disposed between the one or more product sections (2a) and the remainder section (2b), and in the one or more transition sections (2c), the degree of compression is greater than or equal to the first degree of compression (D Ｃ１ ) and the degree of compression (D Ｃ 2. The method of claim 1, wherein the temperature varies between 0.1 and 1.2°C.

3. The method comprises: placing the cellulose blank structure (2) in the forming position (F ＰＯＳ ), at least a portion of the one or more product segments (2a) is compressed to a second degree of compression (D Ｃ２ ) to the first degree of compression (D Ｃ１ ) is the second compression degree (D Ｃ２ 3. The method according to claim 1, further comprising the step of:

4. The method comprises the steps of: before forming the cellulose product (1), ＰＯＳ ) the remaining section (2b) and the one or more product sections (2a) are pressed in the pressing direction (D) of the mold system (S). Ｐ 4. The method according to claim 1, further comprising the step of at least partially displacing the two components relative to one another.

5. 3. The method according to claim 2, further comprising the step of arranging a cutting pattern (4) at least partially around each product section (2a) in the remainder section (2b) and / or the transition section (2c), each cutting pattern (4) forming at least one bridge structure (4a) in the remainder section (2b) and / or the transition section (2c) for partially connecting each product section (2a) to the remainder section (2b) and / or the transition section (2c).

6. 6. The method according to claim 5, wherein each cutting pattern (4) comprises discontinuous first cut portions (5) connected to a corresponding product section (2a) and arranged around said product section (2a), said discontinuous first cut portions (5) comprising one or more first cutting lines (5a), said first cutting lines comprising one or more first intermediate sections (5b) between said one or more first cutting lines (5a), said one or more first intermediate sections (5b) forming said at least one bridge structure (4a).

7. 6. The method according to claim 5, wherein each cutting pattern (4) has a first cutting portion (5) connected to a corresponding product section (2a) and arranged around said product section (2a), said first cutting portion (5) having a first cutting line (5a) with a first intermediate section (5b) forming said at least one bridge structure (4a).

8. 6. The method according to claim 5, wherein each cutting pattern (4) has a discontinuous first cut portion (5) connected to a corresponding product section (2a) and arranged around the periphery of said product section (2a), and a discontinuous second cut portion (6) arranged around the periphery of said product section (2a) outside said discontinuous first cut portion (5) relative to said product section (2a).

9. 9. The method according to claim 8, wherein the discontinuous first cut portion (5) comprises one or more first cut lines (5a), the first cut lines comprising one or more first intermediate sections (5b) between the one or more first cut lines (5a), the discontinuous second cut portion (6) comprises one or more second cut lines (6a), the second cut lines comprising one or more second intermediate sections (6b) between the one or more second cut lines (6a), and the one or more first intermediate sections (5b) and the one or more second intermediate sections (6b) form the at least one bridge structure (4a).

10. 10. The method of claim 9, wherein the discontinuous first cut portions (5) and the discontinuous second cut portions (6) are arranged in an overlapping relationship relative to each other, and the one or more first cut lines (5 a) overlap the one or more second intermediate sections (6 b), and the one or more second cut lines (6 a) overlap the one or more first intermediate sections (5 b).

11. 11. The method according to any one of claims 8 to 10, wherein each cutting pattern (4) further comprises at least one additional discontinuous cut portion (7) arranged around the product section (2a) outside the second discontinuous cut portion (6) relative to the product section (2a), each of the at least one additional discontinuous cut portion (7) comprising one or more additional cut lines (7a), the additional cut lines comprising one or more additional intermediate sections (7b) between the one or more additional cut lines (7a).

12. 12. A method according to any one of claims 6 to 11, wherein each cut (5, 6, 7) extends entirely through the cellulose blank structure (2).

13. 12. The method according to any one of claims 6, 7, 9 to 11, wherein at least one of the intermediate sections (5b, 6b, 7b) has a cut extending partially through the cellulose blank structure (2).

14. 14. The method according to any one of claims 5 to 13, further comprising the step of arranging the one or more cutting patterns (4) in the residual section (2b) and / or the transition section (2c) around each product section (2a) by means of a cutting unit (9).

15. The cutting unit (9) is arranged as a rotary die cutter (10), and the method comprises the steps of:

15. The method of claim 14, further comprising the steps of: forming the one or more cut patterns (4) and compressing at least a portion of the remaining section (2b) in a single operating step using the rotary die cutter (10); or forming the one or more cut patterns (4), compressing at least a portion of the remaining section (2b), and compressing at least a portion of the one or more product sections (2a) in a single operating step using the rotary die cutter (10).

16. 16. The method according to any one of claims 1 to 15, further comprising the step of cutting the cellulose product (1) from the cellulose blank structure (2) in the mould system (S) during the moulding of the cellulose product (1).

17. 17. The method according to any one of claims 1 to 16, wherein the one or more product sections (2a) are arranged on the cellulose blank structure (2) in a pattern corresponding to the arrangement of the one or more molds (3) in the mold system (S).

18. A mould system (S) for forming a cellulose product (1) from a cellulose blank structure (2), the cellulose blank structure having one or more defined product sections (2a) and defined residual sections (2b) surrounding the one or more product sections (2a) or arranged connected to the one or more product sections (2a), the mould system (S) having one or more moulds (3), each mould (3) having a first mould part (3a) and a second mould part (3b) configured to cooperate with each other during the forming of the cellulose product (1), The mold system (S) is configured to compress at least a portion of the remaining section (2b) to a degree of compression (D) of the one or more product sections (2a). Ｃ ) higher than the first compression degree (D Ｃ１ a compaction unit (11) configured to compress the cellulose blank structure (2) in a feeding direction (D Ｆ ) at the molding position (F ＰＯＳ a supply unit (8) configured to supply the molding position (F ＰＯＳ ) each product section (2a) further comprises a supply unit (8) arranged between the corresponding first mold part (3a) and second mold part (3b), The one or more molding dies (3) are configured to heat the cellulose blank structure (2) at a molding temperature (T Ｆ ) and the cellulose blank structure (2) is molded at a molding pressure (P Ｆ ) to form the cellulose product (1) from the cellulose blank structure (2) between the first mold part (3a) and the second mold part (3b). Mold system (S).

19. A cellulose blank structure (2) for forming a cellulose product (1) in a mold system (S), the cellulose blank structure (2) having one or more defined product sections (2a) and a defined residual section (2b) surrounding the one or more product sections (2a) or connected to the one or more product sections (2a), at least a portion of the residual section (2b) being in a position that is less than the compression degree (D) of the one or more product sections (2a). Ｃ ) higher than the first compression degree (D Ｃ１ ) and the cellulose blank structure (2) has one or more transition sections (2c) arranged between the one or more product sections (2a) and the remainder section (2b), in which the degree of compression is greater than or equal to the first degree of compression (D Ｃ１ ) and the degree of compression (D Ｃ one or more transition sections (2c) that change between a cutting pattern (4) in the remaining section (2b) and / or the transition section (2c) at least partially around each product section (2a), each cutting pattern (4) forming at least one bridge structure (4a) in the remaining section (2b) and / or the transition section (2c); The cellulose blank structure (2) further comprises:

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