Method for edge molding of cellulose products in a mold system and mold system for edge molding of cellulose products

Abstract

A method and mold system (S) for edge-forming a cellulose product in a mold system, the mold system adapted to form a cellulose product from an air-formed cellulose blank structure (2). The mold system includes a first mold part (3) and a second mold part (4) arranged to cooperate with each other. The first mold part includes an edge-forming device (5) with protruding elements (5a) configured to compress and separate fibers of the cellulose blank structure. The edge-forming device is movably arranged relative to a base structure (3a) of the first mold part, and the edge-forming device is adapted to interact with a pressure member (6) arranged within the base structure. The method includes the steps of providing an air-formed cellulose blank structure, placing the cellulose blank structure between the first mold part and the second mold part, and forming a compressed edge structure of the cellulose product by separating the fibers of the cellulose blank structure with the protruding elements, applying an edge-forming temperature to the cellulose blank structure, and compressing the cellulose blank structure by applying an edge-forming pressure to the cellulose blank structure between the protruding elements and the second mold part using the pressure member.

Description

[Technical Field]

[0001] This disclosure relates to a method for edge-molding a cellulose product in a mold system, the mold system being adapted to mold a cellulose product from an air-molded cellulose blank structure. The mold system comprises a first mold portion and a second mold portion arranged to cooperate with each other. This disclosure further relates to a mold system for molding the edges of a cellulose product.

[0002] background Cellulose fibers are often used as a raw material for producing or manufacturing products. Products molded from cellulose fibers can be used in many different situations where sustainable products are needed. The range of products that can be manufactured from cellulose fibers is wide, and some examples include disposable plates and cups, tableware, lids, bottle caps, coffee pods, and packaging materials.

[0003] When manufacturing cellulose products from raw materials containing cellulose fibers, molds are commonly used, and traditionally, cellulose products have been manufactured using wet molding techniques. The material commonly used for wet molding of cellulose fiber products is wet-molded pulp. Wet-molded pulp has the advantage of being made from biological materials and recyclable after use, thus being considered a sustainable packaging material. For this reason, wet-molded pulp is rapidly gaining popularity in various applications. Wet-molded pulp articles are generally formed by immersing a suction mold in a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers. When suction is applied, the fibers accumulate in the mold, forming a mass of pulp with the desired product shape. In all wet molding techniques, drying of the wet-molded product is necessary, and drying is a very time- and energy-intensive part of the manufacturing process. There are increasing demands for aesthetic, chemical, and mechanical properties of cellulose products, and the properties of wet-molded cellulose products limit mechanical strength, flexibility, freedom of material thickness, and chemical properties. Furthermore, in wet molding processes, it is difficult to control the mechanical properties of the product with high precision.

[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 structure is inserted into a mold, and during the molding of the cellulose product, the cellulose blank structure is subjected to high molding pressure and high molding temperature, for example, by using a standard press. When using this molding method, the edge structure of the molded cellulose product tends to absorb moisture to a greater degree than other parts of the product, which can weaken the product's structure. Furthermore, if the cellulose product is composed of different material layers, the materials can easily delaminate at the edge structure, especially when exposed to moisture. Another problem is that the tolerances allowed when shaping edges with conventional cutting tools in the mold are very small, which is particularly problematic in multi-cavity molds that mold multiple products in a single molding step where the cutting blades of the mold parts overlap each other. Such cutting processes can also lead to loosening of cellulose fibers at the edges of the product.

[0005] Therefore, improved methods and systems are needed for forming cellulose products from air-molded cellulose blank structures.

[0006] overview The object of this disclosure is to provide a method for edge-forming a cellulose product in a mold system and a mold system for edge-forming a cellulose product, which avoids the problems described above. This object is achieved at least in part by the features of the independent claim. The dependent claims include further developments of the method for edge-forming a cellulose product in a mold system and the mold system for edge-forming a cellulose product.

[0007] This disclosure relates to a method for edge-forming a cellulose product in a mold system, the mold system being adapted to form a cellulose product from an air-formed cellulose blank structure. The mold system comprises a first mold section and a second mold section arranged to cooperate with each other. The first mold section comprises an edge-forming device having protruding elements configured to compress and separate the fibers of a cellulose blank structure. The edge-forming device is movably positioned relative to the base structure of the first mold section, and the edge-forming device is adapted to interact with a pressurizing member located within the base structure. The method includes the steps of providing an air-formed cellulose blank structure and positioning the cellulose blank structure between the first mold section and the second mold section, and forming a compressed edge structure of a cellulose product by separating the fibers of the cellulose blank structure with the protruding elements, applying an edge-forming temperature to the cellulose blank structure, and compressing the cellulose blank structure by applying an edge-forming pressure using a pressurizing member to the cellulose blank structure between the protruding elements and the second mold section.

[0008] The advantages of these features are that the highly compressed edge section is molded into the cellulose product, preventing delamination and loosening of fibers in the edge section. Furthermore, the molded edge section with a highly compressed cellulose blank structure tends to absorb less moisture. The interaction between the edge forming device and the second mold section allows for a simpler mold system with better tolerances. The interaction between the pressurizing member and the second mold section allows for variations in the alignment between the mold sections during the edge forming operation. This also results in a less expensive and easier-to-maintain structure.

[0009] According to aspects of the present disclosure, the molding system comprises a heating unit. The method further includes the steps of applying an edge molding temperature level in the range of 50 to 300°C, preferably in the range of 100 to 300°C, to the cellulose blank structure by the heating unit, and applying an edge molding pressure level in the range of at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa, to the cellulose blank structure by a pressurizing member. The heating unit heats the cellulose blank structure to the desired edge molding temperature, and the heating unit may be placed, for example, within the mold portion to heat the cellulose blank structure during the molding process.

[0010] According to another aspect of the present disclosure, the method further includes the step of applying an edge molding temperature to the cellulose blank structure by a protruding element and / or a second mold portion. By applying heat to the cellulose blank structure from the protruding element and / or the second mold portion, efficient heat transfer to the cellulose blank structure is achieved.

[0011] According to aspects of the present disclosure, the mold system comprises stop members positioned in a first mold portion and / or a second mold portion. The method further includes the step of preventing contact between a protruding element and a second mold portion by means of the stop members during the molding of a compressed edge structure. The stop members prevent contact between the protruding element and the second mold portion for an efficient edge molding process. In the operating state of the mold system, a gap is formed between the protruding element and the second mold portion, and the stop members prevent the protruding element and the second mold portion from moving further toward each other.

[0012] According to another aspect of the present disclosure, the method further includes the step of establishing an edge forming pressure in a cellulose blank structure as the edge forming apparatus moves relative to the base structure due to interaction from a pressurizing member. The movement of the edge forming apparatus allows for efficient control of the edge pressure exerted on the cellulose blank structure for an edge forming process that forms high-quality edges.

[0013] According to a further aspect of this disclosure, the pressurizing member comprises one or more springs positioned between the base structure and the edge forming device. The one or more springs establish the edge forming pressure in the cellulose blank structure between the protruding element and the second mold portion. The one or more springs efficiently control the edge forming pressure and are suitable for use as a pressurizing member in interaction with a movable edge forming device. As the first and second mold portions cooperate with each other during the molding of the cellulose product, the one or more springs establish a specified edge forming pressure applied to the cellulose blank structure. The molding pressure is controlled in conjunction with the one or more springs by the movable configuration of the edge forming device relative to the base structure.

[0014] According to aspects of this disclosure, the pressurizing member comprises a hydraulic unit. The hydraulic unit comprises a pressure chamber positioned between the base structure and the edge forming device. The hydraulic unit establishes the edge forming pressure in the cellulose blank structure between the protruding element and the second mold portion. The hydraulic unit is suitable for use as an alternative pressurizing member through interaction with a movable edge forming device. The hydraulic unit establishes the edge forming pressure exerted on the cellulose blank structure as the first and second mold portions cooperate with each other during the molding of the cellulose product. The hydraulic unit is used to exert hydraulic pressure on the edge forming device to establish a specified edge forming pressure. The edge forming pressure is established accurately and efficiently when the edge forming device is moved by hydraulic pressure toward the second mold portion.

[0015] According to another aspect of the present disclosure, the pressurizing member comprises one or more detent mechanisms located within the base structure. The one or more detent mechanisms are configured to interact with an edge forming device to establish an edge forming pressure in the cellulose blank structure between a protruding element and a second mold portion. The method further includes the steps of applying an applied force to the edge forming device by the second mold portion, and releasing one or more detent mechanisms when the applied force is equal to or greater than a predetermined release force that allows the edge forming device to move relative to the base structure. With this system configuration, the edge forming pressure is efficiently controlled by the pressurizing member, the release function of one or more detent mechanisms allows the edge forming operation to be performed before the product forming operation, and the release function releases the edge forming pressure when the edge structure of the cellulose product is formed, so that much of the total available pressure of the mold system can be used for the next product forming operation step.

[0016] This disclosure further relates to a mold system for forming edges of cellulose products, the mold system being adapted to form a cellulose product from an air-formed cellulose blank structure. The mold system comprises a first mold section and a second mold section arranged to cooperate with each other. The first mold section comprises an edge forming device with protruding elements configured to compress and separate the fibers of the cellulose blank structure, the edge forming device being movably positioned relative to the base structure of the first mold section. The edge forming device is adapted to interact with a pressurizing member located within the base structure. The mold system is configured to form a compressed edge structure of a cellulose product by separating the fibers of the cellulose blank structure with the protruding elements, applying an edge forming temperature to the cellulose blank structure, and compressing the cellulose blank structure by applying an edge forming pressure using the pressurizing member to the cellulose blank structure between the protruding elements and the second mold section. This configuration of the mold system forms a highly compressed edge section in the cellulose product, preventing delamination of the edge section and loosening of the fibers in the edge section. Furthermore, the formed edge section with a highly compressed cellulose blank structure tends to absorb less moisture. The interaction between the edge forming device and the second mold section allows for a simpler mold system with better tolerances. This also results in a less expensive and easier-to-maintain structure.

[0017] According to aspects of the present disclosure, the mold system further comprises a heating unit. The heating unit is configured to apply an edge molding temperature level in the range of 50 to 300°C, preferably in the range of 100 to 300°C, to the cellulose blank structure, and the pressurizing member is configured to apply an edge molding pressure level in the range of at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa, to the cellulose blank structure. The heating unit heats the cellulose blank structure to the desired edge molding temperature, and the heating unit may be placed in the mold portion, for example, to heat the cellulose blank structure during the molding process.

[0018] According to another aspect of the present disclosure, the heating unit is configured to apply edge molding temperature to the cellulose blank structure via protruding elements and / or a second mold portion. These configurations achieve efficient heat transfer to the cellulose blank structure.

[0019] According to a further aspect of the present disclosure, the mold system comprises a stopper member positioned in the first mold portion and / or the second mold portion. The stopper member is configured to prevent contact between the protruding element and the second mold portion during the molding of a compressed edge structure for an efficient edge molding process. In the operating state of the mold system, a gap is formed between the protruding element and the second mold portion, and the stopper member prevents the protruding element and the second mold portion from moving further toward each other.

[0020] According to aspects of the present disclosure, the protruding element comprises an edge section facing a second mold portion. The edge section, together with the second mold portion, is configured to form a high-pressure zone in the cellulose blank structure between the protruding element and the second mold portion during the molding of a compressed edge structure. The edge section is used to establish a high edge molding pressure in the cellulose blank structure in order to mold a highly compressed edge structure with high finishability.

[0021] According to another aspect of the present disclosure, the second mold portion comprises a high-pressure surface facing the edge section. The high-pressure surface, together with the protruding elements, is configured to form a high-pressure zone during the molding of the compressed edge structure. The high-pressure surface prevents damage to the mold portion for efficient molding of the cellulose product. The high-pressure surface is preferably flat and / or coplanar with the adjacent surrounding surface of the second mold portion.

[0022] According to aspects of this disclosure, the mold system is configured to establish an edge forming pressure when the edge forming device moves relative to the base structure due to interaction with a pressurizing member. The edge forming pressure applied by the movement of the edge forming device can be efficiently controlled.

[0023] According to another aspect of this disclosure, the pressurizing member comprises one or more springs positioned between the base structure and the edge forming device. The one or more springs efficiently control the edge forming pressure. The one or more springs are suitable for use as a pressurizing member through interaction with a movably positioned edge forming device. As the first mold portion and the second mold portion cooperate with each other during the molding of the cellulose product, the one or more springs establish a specified edge forming pressure applied to the cellulose blank structure. The molding pressure is controlled in conjunction with the one or more springs by the movable configuration of the edge forming device relative to the base structure.

[0024] According to a further aspect of the present disclosure, the pressurizing member comprises a hydraulic unit, the hydraulic unit comprising a pressure chamber positioned between the base structure and the edge forming device. The hydraulic unit is suitable for use as an alternative pressurizing member through interaction with a movable edge forming device. The hydraulic unit establishes the edge forming pressure applied to the cellulose blank structure as the first and second mold portions cooperate with each other during the molding of the cellulose product. The hydraulic unit is used to apply hydraulic pressure to the edge forming device in order to establish a specified edge forming pressure. The edge forming pressure is established accurately and efficiently as the edge forming device is moved by hydraulic pressure toward the second mold portion.

[0025] According to aspects of this disclosure, the pressurizing member comprises one or more detent mechanisms disposed within a base structure, the one or more detent mechanisms configured to interact with an edge forming apparatus. The one or more detent mechanisms are suitable as alternative pressurizing members for efficiently controlling the edge forming pressure.

[0026] According to another aspect of this disclosure, the base structure comprises an inner mold section, and the edge molding apparatus extends to surround the inner mold section. This configuration allows the edge molding apparatus to easily and efficiently mold the edge structure of a cellulose product. [Brief explanation of the drawing]

[0027] This disclosure is described in detail below with reference to the attached drawings. [Figure 1] This is a schematic perspective cross-sectional view showing a first mold portion equipped with an edge molding apparatus for a mold system according to the present disclosure. [Figure 2a] This is a schematic side cross-sectional view illustrating a mold system equipped with an edge molding device according to the present disclosure. [Figure 2b] This is a schematic side cross-sectional view illustrating a mold system equipped with an edge molding device according to the present disclosure. [Figure 2c] This is a schematic side cross-sectional view illustrating a mold system equipped with an edge molding device according to the present disclosure. [Figure 2d] This is a schematic side cross-sectional view illustrating a mold system equipped with an edge molding device according to the present disclosure. [Figure 3a] This is a schematic side cross-sectional view showing the protruding elements of an edge forming apparatus at different edge forming positions according to embodiments of the present disclosure. [Figure 3b] This is a schematic side cross-sectional view showing the protruding elements of an edge forming apparatus at different edge forming positions according to embodiments of the present disclosure. [Figure 3c] This is a schematic side cross-sectional view showing the protruding elements of an edge forming apparatus at different edge forming positions according to embodiments of the present disclosure. [Figure 3d] This is a schematic side cross-sectional view showing the protruding elements of an edge forming apparatus at different edge forming positions according to embodiments of the present disclosure. [Figure 3e] This is a schematic side cross-sectional view showing the protruding elements of an edge forming apparatus at different edge forming positions according to embodiments of the present disclosure. [Figure 4] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure. [Figure 5] This is a schematic perspective view showing an edge molding apparatus in a first mold portion of a mold system having a multi-cavity configuration, according to another embodiment of the present disclosure. [Figure 6]This is a schematic side cross-sectional view showing a protruding element of an edge forming apparatus with an edge section according to another embodiment of the present disclosure. [Figure 7a] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure. [Figure 7b] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure. [Figure 7c] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure. [Figure 8a] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure. [Figure 8b] This is a schematic side cross-sectional view showing a mold system with an edge forming apparatus according to another embodiment of the present disclosure.

[0028] Description of Exemplary Embodiments Hereinafter, various aspects of the disclosure will be described, in conjunction with the accompanying illustrative drawings, without limiting the disclosure, where similar symbols mean similar elements, and variations of the described aspects are not limited to the embodiments specifically shown but are applicable to other variations of the disclosure.

[0029] Those skilled in the art will understand that the steps, services, and functions described herein may be implemented at least in part using individual hardware circuits, using software that works 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). Where the disclosure is described in terms of methods, it will also be understood that it may be embodied in one or more processors and one or more memories coupled to one or more processors, the one or more memories storing one or more programs that, when executed by one or more processors, perform the steps, services, and functions disclosed herein.

[0030] This disclosure relates to a method for edge-molding a cellulose product 1 in a mold system S, and to a mold system S for molding the edges of a cellulose product 1. The mold system S is adapted to mold a cellulose product 1 from an air-molded cellulose blank structure 2. Figures 1 and 2a-2d schematically illustrate a first exemplary embodiment of the mold system S. Alternative exemplary embodiments of the mold system S are schematically shown in Figures 4, 5, 7a-7c, and 8a-8b. Figures 3a-3e and 6 schematically illustrate details of different embodiments of the system.

[0031] The air-formed cellulose blank structure 2 in this disclosure means a fiber web structure manufactured from cellulose fibers. Air forming of the cellulose blank structure 2 means forming the cellulose blank structure in a dry forming process that produces the cellulose blank structure 2 by air forming the cellulose fibers. 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 differs from the usual papermaking process or conventional wet forming process that uses water as a transport medium for cellulose fibers when forming paper or fiber structures. In the air forming process, small amounts of water or other substances may be added to the cellulose fibers as desired to change the properties of the cellulose product, but the forming process still uses air as a transport medium. The cellulose blank structure 2 may, if preferred, have a degree of dryness that mainly corresponds to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2. Alternatively, the degree of dryness of the cellulose blank structure 2 can be controlled to have a dryness level suitable when forming the cellulose product 1.

[0032] The air-formed cellulose blank structure 2 is formed from cellulose fibers in a conventional air-forming process and may be composed in different ways. For example, depending on the desired properties of the cellulose product 1, the cellulose blank structure 2 may have a certain composition if the fibers originate from the same source, or it may contain a mixture of two or more types of cellulose fibers. The cellulose fibers used in the cellulose blank structure 2 are strongly bonded to each other by hydrogen bonds during the molding process of the cellulose product 1. The cellulose fibers may be mixed with certain amounts of other substances or compounds, as will be further described below. Cellulose fibers refer to any type of cellulose fiber, such as natural cellulose fibers or manufactured cellulose fibers. Specifically, the cellulose blank structure 2 may contain at least 95% cellulose fibers, and more specifically, at least 99% cellulose fibers.

[0033] The air-molded cellulose blank structure 2 may have a single-layer configuration or a multi-layer configuration. A single-layer cellulose blank structure 2 refers to a cellulose blank structure molded with one layer containing cellulose fibers. A multi-layer cellulose blank structure 2 refers to a cellulose blank structure molded with two or more layers containing cellulose fibers, where the layers may have the same or different compositions or configurations. The cellulose blank structure 2 may include a reinforcing layer containing cellulose fibers, which serves 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 useful to avoid the cellulose blank structure 2 breaking during the molding of the cellulose product 1 when one or more layers of the cellulose blank structure 2 have compositions with low tensile strength. The reinforcing layer with higher tensile strength thus functions as a support structure for the other layers of the cellulose blank structure 2. The reinforcing layer may be, for example, a tissue layer containing cellulose fibers, an air-laid structure containing cellulose fibers, or other suitable layer structures.

[0034] The air-molded cellulose blank structure 2 has a fluffy, airy structure, and the cellulose fibers that form the structure are arranged relatively loosely from one another. The fluffy cellulose blank structure 2 is used to efficiently mold the cellulose product 1, allowing the cellulose fibers to efficiently mold the cellulose product 1 during the molding process.

[0035] As shown in Figures 1 and 2a to 2d, the multi-cavity mold system S comprises a first mold portion 3 and a second mold portion 4 arranged to cooperate with each other during the molding of the cellulose product 1 and during the edge molding of the cellulose product 1.

[0036] The first mold portion 3 and the second mold portion 4 are movably positioned relative to each other, and the first mold portion 3 and the second mold portion 4 are pressed relative to each other in the direction D P It is configured to move in the direction D. In the embodiments shown in Figures 1 and 2a to 2d, the first mold portion 3 is stationary, and the second mold portion 4 is pressed in the direction D relative to the first mold portion 3. P It is movably positioned. As shown by the double arrow in Figure 2a, the second mold portion 4 is pressed in the direction D P The second mold portion 4 is configured to move in a linear motion along an axis extending to the first mold portion 3, and to move away from the first mold portion 3. In an alternative embodiment, the second mold portion 4 may be stationary and the first mold portion 3 may be movably positioned relative to the second mold portion 4, or both mold portions may be movably positioned relative to each other.

[0037] For all embodiments of this disclosure, pressing direction D P The expression "to move" refers to the pressing direction D. P It should be understood that this includes movement along an axis extending to the form, and the movement may be carried out in opposite directions along the axis. The expression further includes, for all embodiments, both linear and nonlinear movement of the mold portion, and the movement during molding is in the pressing direction D P This results in the rearrangement of the type portion.

[0038] The first mold section 3 comprises an edge molding device 5, as schematically shown in Figures 1, 2a-2d, 3a-3e, and 6. The edge molding device 5 comprises a protruding element 5a configured to compress and separate the fibers 2a of the cellulose blank structure 2. The protruding element 5a is configured to have an edge section 5b facing the second mold section 4. Preferably, the protruding element 5a is configured as a continuous element extending to surround the edge molding device 5, as shown in Figure 1, and the protruding element 5a has a circular extension corresponding to the edge shape or outer contour of the cellulose product 1 manufactured in the molding system S. However, it should be understood that the protruding element 5a may have any suitable extension, such as a discontinuous one, depending on the shape of the cellulose product 1 to be molded. The protruding element 5a further comprises an edge section 5b as shown in Figures 2a-2d and 3a-3e, or a pointed cross-sectional configuration comprising an edge section 5b with a flat top surface 5e as shown in Figure 6. The protruding element 5a with the edge section 5b may have other suitable cross-sectional configurations, such as a rounded edge section 5b, in other embodiments not shown. The edge forming device 5 is movably positioned relative to the base structure 3a of the first mold section 3, as shown by the double arrow in Figure 2a, and the edge forming device 5 is adapted to interact with a pressurizing member 6 located within the base structure 3a. The base structure 3a comprises an inner mold section 3b, and the edge forming device 5 extends to surround the inner mold section 3b. The inner mold section 3b is configured to form the cellulose product 1 through interaction with the cooperating mold section of the second mold section 4. During the molding of the cellulose product 1, the cellulose blank structure 2 is preferably subjected to a product molding pressure P in the range of at least 1 MPa, preferably in the range of 4 to 20 MPa. PF , and product molding temperature T in the range of 100℃ to 300℃ PFis exerted. When forming the cellulose product 1, strong hydrogen bonds are formed between the cellulose fibers of the cellulose blank structure 2 disposed between the inner forming die section 3b and the second die part 4. The temperature and pressure levels are measured in the cellulose blank structure 2 during the forming process, for example, by suitable sensors disposed within or associated with the cellulose fibers of the cellulose blank structure 2.

[0039] As shown in FIG. 1, the movably arranged edge forming device 5 has an annular configuration in the illustrated embodiment. However, it should be understood that the edge forming device 5 may have any suitable shape and configuration depending on the shape and configuration of the cellulose product 1. The edge forming device 5 is, for example, slidably configured in the pressing direction D with respect to the base structure 3a. P The base structure 3a includes a recess 3c for accommodating the edge forming device 5. The recess 3c preferably has a shape corresponding to the shape of the edge forming device 5. The edge forming device 5 and the base structure 3a may be made of any suitable material, such as steel, aluminum, other metals or metal materials, or from composite materials or combinations of different materials.

[0040] The pressing member 6 may include one or more springs 6a disposed between the base structure 3a and the edge forming device 5. In the embodiments shown in FIGS. 1 and 2a - 2d, the pressing member 6 includes a plurality of springs 6a disposed between the base structure 3a and the edge forming device 5 and spaced apart. The plurality of springs 6a spaced apart are disposed within the recess 3c as shown. Each spring 6a may be configured as a single spring or as two or more cooperating springs forming a spring unit. The one or more springs are preferably compression springs. In the embodiments shown in FIGS. 1 and 2a - 2d, each spring 6a is configured as a stack of cooperating disc springs, and the plurality of springs 6a exert an edge forming pressure P on the cellulose blank structure 2 during the forming of the cellulose product 1. EFIt is configured to establish [something]. Other springs that may be used instead of disc springs are, for example, coil springs or other types of washer springs.

[0041] In order to form a cellulose product 1 from an air-formed cellulose blank structure 2 in a mold system S, according to the embodiments shown in Figures 1 and 2a to 2d, the air-formed cellulose blank structure 2 is first supplied from a suitable source. The cellulose blank structure 2 may be air-formed from cellulose fibers and placed in a roll or stack. The roll or stack may then be positioned in association with the mold system S. Alternatively, the cellulose blank structure may be air-formed from cellulose fibers in association with the mold system S and supplied directly to the mold portion. The cellulose blank structure 2 is positioned between a first mold portion 3 and a second mold portion 4, as shown in Figure 2a. Then, as shown in Figure 2c, the second mold portion 4 is pressed in the pressing direction D P In this process, the first mold portion 3 is moved towards the product molding position. With the cellulose blank structure 2 positioned between the mold portions, during the molding of the cellulose product 1, when the second mold portion 4 is pressed toward the first mold portion 3, a molding cavity 9 for molding the cellulose product 1 is formed between the first mold portion 3 and the second mold portion 4. Product molding pressure P PF and product molding temperature T PF This is added to the cellulose blank structure 2 within the molding cavity 9.

[0042] A deformation element 10 for establishing the product molding pressure may be positioned in association with the first mold portion 3 and / or the second mold portion 4. In the embodiments shown in Figures 1 and 2a to 2d, the deformation element 10 is attached to the first mold portion 3. By using the deformation element 10, the product molding pressure P PF This allows for isotropic molding pressure.

[0043] In all embodiments, the first mold portion 3 and / or the second mold portion 4 may include a deformation element 10, which applies product molding pressure P to the cellulose blank structure 2 in the molding cavity 9 during the molding of the cellulose product 1. PF It is configured to exert the deformation pressure P. The deformation element 10 may be attached to the first mold portion 3 and / or the second mold portion 4 by suitable mounting means such as adhesive or mechanical fasteners. During the molding of the cellulose product 1, the deformation element 10 exerts the product molding pressure P on the cellulose blank structure 2 in the molding cavity 9. PF The deformation element 10 is deformed in such a way that a uniform pressure distribution is achieved even if the cellulose product 1 has a complex three-dimensional shape or the cellulose blank structure 2 has thickness variations. Required product molding pressure P PF To exert force on the cellulose blank structure 2, the deformation element 10 is made of a material that can deform when force or pressure is applied, and preferably the deformation element 10 is made of an elastic material that can recover its size and shape after deformation. The deformation element 10 is further made of a high level of product molding pressure P used when molding the cellulose product 1. PF and product molding temperature T PF It may be made of a material having suitable properties to withstand. Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the deformation element 10 is made of such a material, a uniform pressure distribution can be achieved in the molding process, where the pressure exerted from the deformation element 10 on the cellulose blank structure 2 is equal or essentially equal in all directions between the mold parts. When the deformation element 10 becomes fluid-like during pressurization, a uniform fluid-like pressure distribution is achieved. Therefore, if such a material is used, the product molding pressure P PFThe deformation element 10 is applied to the cellulose blank structure 2 from all directions, thereby applying isotropic molding pressure to the cellulose blank structure 2 during the molding of the cellulose product 1. The deformation element 10 may be made of a suitable structure of one or more elastomer materials, for example, the deformation element 10 may be made of a lump structure or essentially lump 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 element 10 may be, for example, suitable gel materials, liquid crystal elastomers, and MR fluids.

[0044] As shown in Figure 2b, when the first mold portion 3 and the second mold portion 4 are positioned relative to each other, the cellulose blank structure 2 is compressed between the first mold portion 3 and the second mold portion 4. Simultaneously, the molding of the compressed edge structure 1a of the cellulose product 1 is established by the edge molding device 5. As the second mold portion 4 moves toward the first mold portion 3, the protruding element 5a of the edge molding device 5 separates some of the fibers 2a of the cellulose blank structure 2 by the force applied to the cellulose blank structure 2 by the protruding element 5a, and this fiber separation is shown in detail in Figures 3a to 3b. As shown in Figure 2b, when the second mold portion 4 reaches the first mold portion 3, a stop member 7 positioned in the first mold portion 3 prevents direct contact between the protruding element 5a and the second mold portion 4 during the molding of the compressed edge structure 1a as shown in Figures 3c to 3d. In the embodiments shown in Figures 1 and 2a to 2d, the stop member 7 is in the pressing direction D P The extension of the second mold portion 4 is greater than the extension of the protruding element 5a, and is positioned as a protruding part of the edge forming apparatus 5. When the second mold portion 4 reaches the first mold portion 3, as shown in Figure 2b, the stopping member 7 comes into contact with the second mold portion 4 and is pressed in the pressing direction D PThe greater extension in prevents direct contact between the protruding element 5a and the second mold portion 4. The stop member 7 may be arranged as a continuous element extending to surround the edge forming apparatus 5, as shown in Figure 1, or as one or more protrusions extending from the edge forming apparatus 5. Alternatively, the stop member 7 may be located on the second mold portion 4, or on both the first mold portion 3 and the second mold portion 4.

[0045] Therefore, the stopping member 7 prevents contact between the protruding element 5a and the second mold portion 4 during the molding of the compressed edge structure 1a, and this arrangement ensures that the protruding element 5a is positioned at a small distance from the second mold portion 4, as shown in Figures 3c and 3d. As shown in Figures 3d and 6, a small gap G is formed between the protruding element 5a and the second mold portion 4. Therefore, the gap G is formed between the protruding element 5a and the second mold portion 4 during the operation of the molding die system S, and the stopping member 7 prevents the protruding element 5a and the second mold portion 4 from moving further toward each other. While the second mold portion 4 is moving further toward the first mold portion 3, the edge molding apparatus 5 applies a product molding pressure P PF The cellulose blank structure 2 is established in the molding cavity 9 and is pushed into the recess 3c to the product molding position shown in Figure 2c. When the edge molding device 5 is pushed into the recess 3c, the edge structure 1a of the cellulose product 1 is formed. Once the edge structure 1a is formed, the fibers 2a of the cellulose blank structure 2 are gathered in the region between the protruding element 5a and the second mold portion 4, as shown in Figures 3d to 3e and Figure 6. At the same time, the cellulose blank structure 2 is subjected to the edge molding temperature T EF In addition, as shown in Figures 3d to 3e and Figure 6, an edge molding pressure P is applied to the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4 using the pressurizing member 6. EF The following is added. Edge molding temperature T EF and edge forming pressure P EF When added to the cellulose blank structure 2, a highly compressed edge structure 1a is formed.

[0046] The pressurizing member 6 applies edge molding pressure P during the molding of the edge structure 1a. EF It is configured to establish the following. As shown in Figure 2b, when the second mold portion 4 is in contact with the stop member 7, the edge forming device 5 is pressed in the pressing direction into the recess 3c of the base structure 3a of the first mold portion 3 as the second mold portion 4 moves further toward the first mold portion 3. When the edge forming device 5 is pressed into the base structure 3b, the spring 6a is compressed, and the compression causes the edge forming pressure P EF However, this is applied to the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4. Therefore, the molding system S, when the edge molding device 5 moves relative to the base structure 3a due to interaction from the pressurizing member 6, applies edge molding pressure P EF It is configured to establish the product molding pressure P. PF A suitable control unit may be used to determine the movement of the first mold portion 3 relative to the second mold portion 4 for controlling the edge molding pressure P EF To decide.

[0047] Edge forming pressure P EF As described above, the suitable edge molding pressure level P is established by the pressurizing member 6 and applied to the cellulose blank structure 2. EFL The edge forming pressure level P of the pressurizing member 6 is at least 10 MPa, preferably in the range of 10 to 4000 MPa, and more preferably in the range of 100 to 4000 MPa. EFL It is designed and configured to be added to the cellulose blank structure 2. Edge molding tests reveal that, within the temperature range described later, the edge molding pressure level P is suitable for adding to the cellulose blank structure 2. EFL It was shown that the edge molding pressure level P exceeds 10 MPa to obtain the desired results. Tests showed that an edge molding pressure level P exceeding 100 MPa is required. EFL This further demonstrated that high-quality and faster edge forming operation can be obtained for the edge structure 1a of cellulose product 1. Edge forming pressure level P up to 4000 MPa EFLTests were conducted, and high-quality edge forming operation was obtained for edge structure 1a. However, it should be understood that even higher pressure levels may be used.

[0048] The molding system S further applies an edge molding temperature T to the cellulose blank structure 2. EF The system includes a heating unit 8 that adds a heating element. The heating unit 8 sets an edge molding temperature level T in the range of 50 to 300°C, preferably in the range of 100 to 300°C, when forming the edge structure 1a. EFL The configuration is such that it is added to the cellulose blank structure 2. Edge molding tests show that within the pressure range described above, the edge molding temperature level T is suitable for adding to the cellulose blank structure 2. EFL It was shown that the temperature exceeds 50°C. Tests showed that the edge molding temperature level T exceeds 100°C. EFL This further demonstrated that high-quality and faster edge forming operation can be obtained for the edge structure 1a of cellulose product 1. Edge forming temperature level T up to 300°C EFL Tests were conducted, and high-quality edge molding operation was obtained for the edge structure 1a. The heating unit 8 preferably applies edge molding temperature T to the cellulose blank structure 2 via the protruding element 5a and / or the second mold portion 4. EF The heating unit 8 is configured to add [something]. The heating unit 8 may have any preferred configuration. Edge forming temperature T EF To establish this, a suitable heating unit may be used, such as one or more heated mold sections. The heating unit 8 may be incorporated into or cast into the first mold section 3 and / or the second mold section 4. Suitable heating devices include, for example, electric heaters such as resistive elements or fluid heaters. Other suitable heat sources may also be used.

[0049] The edge molding temperature and pressure level are measured in the cellulose blank structure 2 during the molding process by suitable sensors, for example, placed within or associated with the cellulose fibers of the cellulose blank structure 2.

[0050] The heating unit 8 also sets the product molding temperature T within the molding cavity 9. PF It may be used to establish [something]. In the embodiments shown in Figures 1 and 2a to 2d, the heating device 8 is preferably incorporated into the edge forming device 5.

[0051] As shown in detail in Figures 3a to 3e and Figure 6, the protruding element 5a includes an edge section 5b facing the second mold portion 4, as described above. Together with the second mold portion 4, the edge section 5b creates a high-pressure zone Z in the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4 during the molding of the compressed edge structure 1a. HP It is configured to form a high-pressure zone Z. HP Therefore, as described above, the edge forming pressure level P is at least 10 MPa, preferably in the range of 10 to 4000 MPa, and more preferably in the range of 100 to 4000 MPa. EFL This is added to the cellulose blank structure 2. This edge molding pressure level P EFL The edge forming temperature level T is in the range of 50 to 300°C, preferably in the range of 100 to 300°C. EFL At the same time, a strong impact is applied to the cellulose fibers 2a of the cellulose blank structure 2. The cellulose fibers are strongly bonded to each other by hydrogen bonds in order to form a highly compressed edge structure 1a of the cellulose product 1. The edge structure 1a is suitably formed as a thin edge section extending around the outer circumference of the cellulose product 1, and the highly compressed edge structure 1a efficiently prevents delamination and moisture absorption of the cellulose product 1. Along with the small distance between the edge section 5b and the second mold portion 4, a high edge molding pressure P is applied to the cellulose blank structure 2. EF Therefore, high-pressure zone Z HP The internal cellulose fibers 2a form a very thin, compressed cellulose structure that can be used to easily separate the molded cellulose product 1 from the remaining fibers 2b on the outside of the molded portion. High-pressure zone Z HP The highly compressed thin cellulose structure is subjected to high compressive stress, and during the edge forming process, the edge forming pressure P EF When a high pressure level is applied to the cellulose fiber 2a, a high-pressure zone Z is formed.HP The cellulose fibers 2a are broken by the stored energy, high tension, and / or tensile stress within the cellulose structure. The remaining fibers 2b that remain after molding the cellulose product 1 may be reused.

[0052] In all embodiments, the second mold portion 4 may be configured to include a high-pressure surface 4a facing the edge section 5b, as schematically shown in Figure 6. The high-pressure surface 4a is preferably incorporated into the second mold portion 4 and is made of a material capable of withstanding high pressure levels, such as copper, brass, or a lead alloy. The high-pressure surface 4a, together with the protruding element 5a, creates a high-pressure zone Z during the molding of the compressed edge structure 1a. HP The high-pressure surface 4a is configured to form a shape corresponding to the shape of the edge section 5b. The high-pressure surface 4a is preferably flat and / or coplanar with the adjacent surrounding surface of the second mold portion 4.

[0053] As described above, the preferred edge forming pressure level P EFL The edge forming pressure P is at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa. EF This is established by interaction from the pressurizing member 6. One or more springs 6a provide edge molding pressure P in the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4. EF Establish the edge forming pressure P. EF This is established by the movement of the edge molding device 5 relative to the base structure 3a due to interaction with the pressurizing member 6. When the cellulose product is molded in the multi-cavity mold system S, the second mold portion 4 is moved away from the second mold portion 4, as shown in Figure 2d, and the cellulose product 1 can be removed from the mold system S using, for example, an ejector rod or a similar device.

[0054] In the alternative embodiment shown in Figure 4, the pressurizing member 6 instead comprises a hydraulic unit 6b. The hydraulic unit 6b comprises a pressure chamber 6c defined by a recess 3c in the base structure 3a and the edge forming device 5. The edge forming device 5 comprises a protruding element 5a having an edge section 5b, and preferably has the function and design described in the above embodiment with reference to Figures 2a to 2d. In the embodiment shown in Figure 4, the pressure chamber 6c has a ring-shaped configuration corresponding to the shape of the edge forming device 5. Thus, the edge forming device 5 is configured as a hydraulic piston in the pressure chamber 6c, i.e., a double-acting hydraulic piston. By filling the pressure chamber 6c with a suitable pressure medium, such as hydraulic oil, edge forming pressure P is applied to the cellulose blank structure 2 via the edge forming device 5. EF It can exert an effect. Please understand that the pressure chamber 6c and the edge forming apparatus 5 may have any suitable corresponding shape depending on the edge shape of the cellulose product 1.

[0055] The pressure chamber 6c is connected to a hydraulic pump system, hydraulic cylinder, spring-loaded hydraulic cylinder, or other similar system or device, which generates pressure exerted on the edge forming apparatus 5 by a pressure medium via a passage located within the base structure 3a. In the embodiment shown in Figure 4, a hydraulic pump 11a may be connected to the pressure chamber 6c to establish hydraulic pressure in the system. The pressure medium exerts pressure on the lower surface 5c of the edge forming apparatus 5, which is positioned in relation to the pressure chamber 6c. The edge forming apparatus 5 may include a sealing element 5d that forms a tight seal between the pressure chamber 6c and the edge forming apparatus 5. The hydraulic pump 11a is driven, for example, by an electric motor and connected to the pressure chamber 6c via a pressure valve 11c for turning the hydraulic pressure on and off. A pressure control valve 11d may be used to adjust the pressure level. The pressure medium may be stored in a tank 11e and expanded in an accumulator tank 11b. The pressure medium flowing out of the pressure chamber 6c and out of the pressure control valve 11d may be returned to the tank 11e, as can be seen from Figure 4. The components of the hydraulic pump system are connected by suitable conduits.

[0056] Furthermore, in a further embodiment of the pressurizing member 6, a pneumatic cylinder or gas spring may be provided instead of a hydraulic unit.

[0057] In order to mold a cellulose product 1 from an air-formed cellulose blank structure 2 in a mold system S according to the embodiment shown in Figure 4, the air-formed cellulose blank structure 2 is first supplied from a suitable source. The cellulose blank structure 2 may be air-formed from cellulose fibers and placed in a roll or stack. The roll or stack may then be placed in association with the multi-cavity mold system S. Alternatively, the cellulose blank structure may be air-formed from cellulose fibers in association with the multi-cavity mold system S and supplied directly to the mold portion. The cellulose blank structure 2 is placed between the first mold portion 3 and the second mold portion 4, as shown in Figure 4.

[0058] Subsequently, the first mold portion 3 and the second mold portion 4 are moved toward each other, and in the embodiment shown in Figure 4, the second mold portion 4 is moved toward the first mold portion 3, as described in relation to Figures 2a to 2d. While the second mold portion 4 is moving toward the first mold portion 3, the protruding element 5a of the edge forming apparatus 5 separates a portion of the fibers 2a of the cellulose blank structure 2 by the force applied by the protruding element 5a, as shown in Figures 3a to 3b. When the second mold portion 4 reaches the first mold portion 3, a stop member 7 positioned in the first mold portion 3 prevents direct contact between the protruding element 5a and the second mold portion 4 during the molding of the compressed edge structure 1a. Preferably, the stop member 7 is positioned in a pressing direction D greater than the extension of the protruding element 5a, as described in the embodiments described above in relation to Figures 2a to 2d. P It is positioned as a protrusion on the edge forming apparatus 5 having an extension. When the second mold portion 4 reaches the first mold portion 3, the stopping member 7 contacts the second mold portion 4 and presses in the direction D PThe greater extension in this area prevents contact between the protruding element 5a and the second mold portion 4. The stopping member 7 may be positioned as a continuous element extending around the edge forming apparatus 5, or as one or more protrusions extending from the edge forming apparatus 5. Alternatively, the stopping member 7 may be positioned on the second mold portion 4, or on both the first mold portion 3 and the second mold portion 4.

[0059] As shown in Figure 4, when the edge molding device 5 and the second mold portion 4 are arranged in relation to each other, the edge molding device 5 applies edge molding pressure P to the cellulose blank structure 2. EF To exert this effect, a hydraulic pressure is established within the pressure chamber 6c by a pressure medium. Using the established hydraulic pressure, the edge molding apparatus 5 is moved toward the second mold portion 4 by the established hydraulic pressure. As described above, a preferred edge molding pressure level P is applied to the cellulose blank structure 2. EFL The pressure is at least 10 MPa, preferably in the range of 10 to 4000 MPa, and more preferably in the range of 100 to 4000 MPa. When the pressure medium flows into the pressure chamber 6c, the edge forming apparatus 5 applies edge forming pressure P to the cellulose blank structure 2 positioned between the protruding element 5a and the second mold portion 4. EF To exert this effect, it is pushed in the direction toward the second mold portion 4. Therefore, edge forming pressure P EF This is established by the movement of the edge forming device 5 relative to the base structure 3a due to interaction with the pressurizing member 6. A suitable control unit may be used to control the hydraulic pressure exerted on the edge forming device 5 by the pressure medium. During the forming of the edge structure 1a of the cellulose product 1, the cellulose blank structure 2 is subjected to an edge forming temperature level T in the range of 50 to 300°C, preferably in the range of 100 to 300°C. EFL It is heated. The edge forming operation may be performed simultaneously with the product forming operation, or before or after the product forming operation.

[0060] When the edge structure 1a and the cellulose product 1 are molded in the mold system S, the second mold portion 4 is moved away from the first mold portion 3. To return the edge molding device 5 to its initial position after the hydraulic pressure is released, a spring, a cylinder such as a double-acting cylinder, or a similar device may be used in association with the edge molding device 5.

[0061] The molding system S of the embodiment shown in Figure 4 may further include a heating unit 8, and the edge molding temperature level T is in the range of 50 to 300°C, preferably in the range of 100 to 300°C, as described in the above embodiments in relation to Figures 2a to 2d. EFL However, this is added to the cellulose blank structure 2 by the heating unit 8. Edge molding temperature T EF Preferably, this is applied to the cellulose blank structure 2 by the protruding element 5a and / or the second mold portion 4. Edge molding pressure P EF As described above, this pressure is applied to the cellulose blank structure 2 when the edge molding device 5 moves relative to the base structure 3a due to interaction from the pressurizing member 6. The pressurizing member 6 comprises a hydraulic unit 6b, which applies edge molding pressure P to the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4. EF To establish.

[0062] In alternative embodiments not shown, the mold system S may be configured without the stop member 7. The protruding element 5a may be configured to have the same function as described in the different embodiments above. The compressed edge structure 1a is formed by separating the fibers 2a of the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4, and by applying edge molding pressure P to the cellulose blank structure 2 between the protruding element 5a and the second mold portion 4 using the pressurizing member 6. EF The cellulose blank structure 2 is compressed by the addition of [the specified substance] and molded in the same manner as described above. Edge molding temperature T EF This is added to the cellulose blank structure 2 during the edge molding process.

[0063] The edge molding apparatus 5 is further suitable for use in a multi-cavity mold system S in which two or more molds are incorporated into a single mold unit. Figure 5 schematically shows the first mold section 3 of a multi-cavity mold system S having four molds. As shown in Figure 5, the first mold section comprises four edge molding apparatuses 5 with protruding elements 5a, arranged within a common base structure 3a of the first mold section 3, and the edge molding apparatuses 5 can have the same configuration and function as described in the embodiments above. In the multi-cavity mold system S shown in Figure 5, four cellulose products can be molded in a single pressing step for efficient production of cellulose products.

[0064] In further alternative embodiments shown in Figures 7a to 7c, the pressurizing member 6 instead comprises one or more detent mechanisms 12 located within a recess 3c of the base structure 3a. The one or more detent mechanisms 12 are arranged to cooperate with the edge forming apparatus 5. The edge forming apparatus 5 comprises a protruding element 5a with an edge section 5b, and preferably has the function and design described in the embodiments above in relation to Figures 2a to 2d.

[0065] In the embodiments shown in Figures 7a to 7c, the pressurizing member 6 comprises one or more spring-ball type detent mechanisms 12, each comprising a spring 12a and a detent ball 12b arranged in a passage 12c or similar structure associated with the outer side wall 3d of the recess 3c. The detent ball 12b is configured to interact with the outer side edge 5f of the edge forming apparatus 5. The outer side edge 5f has an inclined configuration in the illustrated embodiments, but may have any preferred shape. Preferably, the pressurizing member 6 comprises a plurality of detent mechanisms 12 arranged to surround the recess 3c, as shown in Figures 7a to 7c.

[0066] In this arrangement of the pressurizing members shown in Figures 7a to 7c, the edge forming device 5 is subjected to the applied force F A The predetermined release force F REA predetermined release force F of the edge forming apparatus 5 is smaller than that, as shown in Figures 7a and 7b, by the second mold portion 4. RE Pressing in the direction D by the pressurizing member 6 until the pressure is applied P It is held in a predetermined position. The spring-loaded detent ball 12b is held in place by the applied force F. A The predetermined release force F RE When the value is smaller than the predetermined release force F, the edge forming device 5 is prevented from moving into the recess 3c. RE This is determined by the configuration of the spring 12a and the configuration of the outer side edge 5f. The spring 12a and the outer side edge 5f may be modified for different molding applications, and a specific desired edge molding pressure level P EFL Determined to match. Spring 12a may be any suitable type, such as a compression spring. As described above, a suitable edge forming pressure level P EFL The edge forming pressure P is at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa. EF This is established by interaction with the pressurizing member 6.

[0067] The molding system S of the embodiment shown in Figures 7a to 7c may further include a heating unit, as described in the above embodiment in relation to Figures 2a to 2d, and an edge molding temperature level T in the range of 50 to 300°C, preferably in the range of 100 to 300°C. EFL However, it is added to the cellulose blank structure 2 by the heating unit.

[0068] During the edge forming operation, the first mold part 3 and the second mold part 4 are moved in directions towards each other. In the embodiments shown in FIGS. 7a to 7c, the second mold part 4 is moved towards the first mold part 3 in the same manner as described in relation to FIGS. 2a to 2d. During the movement of the second mold part 4 towards the first mold part 3, the protruding element 5a of the edge forming device 5 separates a part of the fibers 2a of the cellulose blank structure 2 by the force applied to the cellulose blank structure 2 by the protruding element 5a, as shown in FIGS. 3a to 3b. The second mold part 4 is moved from the starting position shown in FIG. 7a towards the first mold part 3. As shown in FIG. 7b, when the second mold part 4 reaches the first mold part 3, the stop member 7 arranged on the first mold part 3 prevents direct contact between the protruding element 5a and the second mold part 4 during the forming of the compressed edge structure 1a. The stop member 7 is preferably arranged as a protruding part of the edge forming device 5 having an extension in the pressing direction D greater than the extension of the protruding element 5a, in the same manner as described in the above embodiments in relation to FIGS. 2a to 2d. When the second mold part 4 reaches the first mold part 3, the stop member 7 interacts with the second mold part 4 and prevents contact between the protruding element 5a and the second mold part 4 by virtue of the greater extension in the pressing direction D. The stop member 7 may be arranged as a continuous element extending so as to surround the edge forming device 5, or as one or more protruding parts extending from the edge forming device 5. Instead, the stop member 7 may be arranged on the second mold part 4, or on both the first mold part 3 and the second mold part 4. In this arrangement, the edge forming operation is carried out with the edge forming device 5 held in a predetermined position by a detent mechanism, as shown in FIG. 7b. P is arranged as a protruding part of the edge forming device 5 having an extension in the pressing direction D P wherein. When the second mold part 4 reaches the first mold part 3, the stop member 7 interacts with the second mold part 4 and prevents contact between the protruding element 5a and the second mold part 4 by virtue of the greater extension in the pressing direction D

[0069] During further movement of the second mold part 4 towards the first mold part 3, the force F A applied to the edge forming device 5 A increases to a level where the applied force F RE is equal to or exceeds a predetermined release force F A When the applied force F REWhen equal to or greater than, the edge forming device 5 is released by one or more detent mechanisms 12 and pressed in the pressing direction D by the second mold part 4 into the recess 3c as shown in FIG. 7c. P Upon release, the detent balls 12a are pushed into their respective passages 12c when their respective springs 12b are compressed, enabling the edge forming device 5 to be pushed into the recess 3c. The release of the edge forming device 5 allows the available system force to be used for the product forming operation. The molding system S may further include, in this embodiment, one or more return springs 13 for pushing the edge forming device 5 back to the position shown in FIG. 7a after the product forming operation shown in FIG. 7c.

[0070] In an alternative embodiment not shown, the one or more detent mechanisms 12 may instead be arranged in association with the inner side walls of the recess 3c and configured to interact with the inner side edges of the edge forming device 5. In a further alternative embodiment not shown, the one or more detent mechanisms may instead be arranged in association with both the inner and outer side walls of the recess 3c, which are configured to interact with the inner and outer side edges of the edge forming device 5.

[0071] Thus, in this system configuration shown in FIGS. 7a - 7c, the pressure member 6 with the detent mechanism 12 has the function of a release system when a predetermined release force F RE is reached or exceeded. The release function enables an edge forming operation to be performed prior to the product forming operation, and by releasing the edge forming pressure P EF when the edge structure 1a is formed, much of the total pressure of the available molding system can be used in the next product forming operation step.

[0072] The detent mechanism 12 may instead be of the plunger detent type. Instead of the detent mechanism, a predetermined release force F REA hydraulic, pneumatic, or magnetic mechanism may be used to hold the edge forming device in place until it reaches or exceeds a certain point. Alternatively, as shown in Figures 8a and 8b, the pressurizing member 6 presses between the edge forming device 5 and the recess 3c in the direction D P The configuration may include a leaf spring 6a extending in that direction. As shown in Figure 8a, the leaf spring 6a has a predetermined critical release force F RE For loads smaller than this, it maintains a straight position. In this configuration, a predetermined release force F RE The minimum applied force F that causes lateral deflection or buckling of the leaf spring 6a. A This is the critical load corresponding to [the specified value]. Therefore, the predetermined release force F RE When the load is equal to or greater than F, the leaf spring 6a deflects laterally, reducing the overall system force. Therefore, the leaf spring 6a releases a predetermined release force F. RE When it reaches or exceeds this point, it becomes possible to bend from the initial position shown in Figure 8a to the released position shown in Figure 8b. The applied force F A In Figure 8a, the predetermined release force F RE It is smaller than the release position shown in Figure 8b. By releasing the edge forming device 5, the available system force can be used in the product forming operation.

[0073] In this context and throughout this disclosure, "top" and "bottom" refer to the orientations shown in the figures. It should be understood that components, parts, or details may be oriented in other ways as desired.

[0074] The molding system S may further include a suitable control unit for controlling the molding of the cellulose product 1, as shown above. The control unit may include suitable software and hardware for controlling the multi-cavity molding system S, as well as different process and method steps carried out by the multi-cavity molding system S. The control unit may control, for example, temperature, pressure, molding time, and other process parameters. The control unit may further be connected to related process equipment such as, for example, a pressing unit, a heating unit, a cellulose blank structure transport unit, and a cellulose product transport unit.

[0075] This disclosure has been presented above with reference to specific embodiments. However, embodiments other than those described above are also possible and within the scope of this disclosure. Different method steps, which carry out the method by hardware or software, may be provided within the scope of this disclosure. Thus, according to an exemplary embodiment, a non-transient computer-readable storage medium is provided that stores one or more programs configured to be executed by one or more processors of a mold system, the one or more programs comprising instructions for carrying out the method according to any one of the embodiments described above. Alternatively, according to another exemplary embodiment, a cloud computing system may be configured to carry out any of the method embodiments presented herein. The cloud computing system may comprise distributed cloud computing resources that jointly carry out the method embodiments presented herein under the control of one or more computer program products. Furthermore, the processors may be connected to one or more communication interfaces and / or sensor interfaces for receiving and / or transmitting data with external entities such as sensors, off-site servers, or cloud-based servers.

[0076] One or more processors associated with a molding system may be, or include, any number of hardware components for performing data or signal processing or for executing computer code stored in memory. The system may have associated memory, which may be one or more devices for storing data and / or computer code for completing or facilitating the various methods described herein. Memory may include volatile memory or non-volatile memory. Memory may include database components, object code components, script components, or any other type of information structure for supporting the various activities described herein. According to exemplary embodiments, any distributed or local memory device may be used with the systems and methods described herein. According to exemplary embodiments, memory is communicably connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and contains computer code for performing one or more processes described herein.

[0077] It will be understood that the above description is essentially illustrative and not intended to limit the Disclosure, its application, or use. While specific examples have been described in the specification and shown in the drawings, it will be understood by those skilled in the art that various modifications may be made and elements may be substituted with equivalents without departing from the scope of the Disclosure as defined in the claims. Furthermore, modifications may be made to adapt the teachings of the Disclosure to specific circumstances or materials without departing from its essential scope. Thus, the Disclosure is intended to include any embodiments that fall within the foregoing description and the accompanying claims, not limited to the specific examples illustrated in the drawings and described in the specification, as the best possible mode for carrying out the teachings of the Disclosure. The reference numerals in the claims should not be considered to limit the scope of the subject matter protected by the claims, and their sole function is to make the claims easier to understand. [Explanation of symbols]

[0078] 1 Cellulose products 1a Edge structure 2. Cellulose blank structure 2a Fiber 2b Residual fibers 3. First type part 3a Base structure 3b Inner mold section 3c recess 3d side wall 4. Second type section 4a High-pressure surface 5. Edge forming machine 5a Protruding element 5b Edge section 5c Bottom side 5d sealing element 5e Top 5f Side Edge 6 Pressurizing member 6a spring 6b Hydraulic Unit 6c pressure chamber 7 Stopping member 8 Heating Unit 9. Molding cavity 10 deformation elements 11a Hydraulic pump 11b Accumulator Tank 11c Forming pressure valve 11d Pressure control valve 11e Tank 12 Detent Mechanism 12a spring 12b Detent Ball 12c aisle 13. Return spring D P Direction of pressure F A The force applied F RE predetermined release force G gap P EF Edge forming pressure P EFL Edge forming pressure level P PF Product molding pressure S molding system T EF Edge forming temperature T EFL Edge molding temperature level T PF Product molding temperature Z HP High-pressure zone

Claims

1. A method for edge-molding a cellulose product (1) in a mold system (S), wherein the mold system (S) is adapted to mold the cellulose product (1) from an air-molded cellulose blank structure (2), the mold system (S) comprises a first mold portion (3) and a second mold portion (4) arranged to cooperate with each other, the first mold portion (3) comprises an edge-molding device (5) having a protruding element (5a) configured to compress and separate the fibers (2a) of the cellulose blank structure (2), the edge-molding device (5) is movably positioned relative to a base structure (3a) of the first mold portion (3), the edge-molding device (5) is adapted to interact with a pressurizing member (6) located within the base structure (3a), and the method is The steps include providing the air-molded cellulose blank structure (2), supplying the air-molded cellulose blank structure (2) to the first and second mold portions (3, 4), and positioning the cellulose blank structure (2) between the first mold portion (3) and the second mold portion (4), The fibers (2a) of the cellulose blank structure (2) are separated by the protruding element (5a), and the cellulose blank structure (2) is subjected to an edge molding temperature (T ＥＦ ) is applied, and the cellulose blank structure (2) between the protruding element (5a) and the second mold portion (4) is subjected to edge molding pressure (P) using the pressurizing member (6). ＥＦ The steps include: compressing the cellulose blank structure (2) by adding ( ) to form the compressed edge structure (1a) of the cellulose product (1); A method for edge shaping, including the following.

2. The molding system (S) includes a heating unit (8), and the method is Edge forming temperature level (T) in the range of 50 to 300°C, preferably in the range of 100 to 300°C. ＥＦＬ The steps include adding the cellulose blank structure (2) to the heating unit (8), Edge forming pressure level (P) of at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa ＥＦＬ The steps include adding the cellulose blank structure (2) to the pressurizing member (6) and The edge forming method according to claim 1, further comprising:

3. The method involves the protruding element (5a) and / or the second mold portion (4) forming the cellulose blank structure (2) at the edge molding temperature (T ＥＦ The edge forming method according to claim 1 or 2, further comprising the step of adding ).

4. The edge molding method according to any one of claims 1 to 3, wherein the molding system (S) comprises a stopper member (7) positioned in the first mold portion (3) and / or the second mold portion (4), and the method further includes the step of preventing contact between the protruding element (5a) and the second mold portion (4) by the stopper member (7) during the molding of the compressed edge structure (1a).

5. The above method, when the edge forming device (5) moves relative to the base structure (3a) due to interaction from the pressurizing member (6), the edge forming pressure (P ＥＦ The edge forming method according to any one of claims 1 to 4, further comprising the step of establishing ).

6. The pressurizing member (6) comprises one or more springs (6a) positioned between the base structure (3a) and the edge forming device (5), and the one or more springs (6a) apply the edge forming pressure (P) in the cellulose blank structure (2) between the protruding element (5a) and the second mold portion (4). ＥＦ The edge forming method according to any one of claims 1 to 5, which establishes the following:

7. The pressurizing member (6) comprises a hydraulic unit (6b), the hydraulic unit (6b) comprises a pressure chamber (6c) positioned between the base structure (3a) and the edge molding device (5), and the hydraulic unit (6b) applies the edge molding pressure (P) in the cellulose blank structure (2) between the protruding element (5a) and the second mold portion (4). ＥＦ The edge forming method according to any one of claims 1 to 5, which establishes the following:

8. The pressing member (6) comprises one or more detent mechanisms (12) arranged within the base structure (3a), and the one or more detent mechanisms (12) are configured to interact with the edge forming device (5) in the cellulose blank structure (2) between the protruding element (5a) and the second mold part (4) to establish the edge forming pressure (P ＥＦ ). The method further comprises applying a force (F Ａ ) to the edge forming device (5) by the second mold part (4), and releasing the one or more detent mechanisms (12) when the applied force (F Ａ ) is equal to or greater than a predetermined release force (F ＲＥ ) that enables movement of the edge forming device (5) relative to the base structure (3a). The edge forming method according to any one of claims 1 to 4 further includes this step.

9. The edge molding method according to any one of claims 1 to 4, wherein the air-molded cellulose blank structure (2) has a multilayer structure.

10. The edge molding method according to any one of claims 1 to 4, wherein the first mold portion (3) and / or the second mold portion (4) comprises a deformation element (10) that applies product molding pressure to the cellulose blank structure (2).

11. A mold system (S) for forming the edges of a cellulose product (1), wherein the mold system (S) is adapted to form the cellulose product (1) from an air-formed cellulose blank structure (2), and the mold system (S) comprises a first mold portion (3) and a second mold portion (4) arranged to cooperate with each other, the mold system (S) provides the air-formed cellulose blank structure (2), supplies the air-formed cellulose blank structure (2) to the first and second mold portions (3, 4), and is adapted to position the cellulose blank structure (2) between the first mold portion (3) and the second mold portion (4), The first mold portion (3) comprises an edge forming device (5) having protruding elements (5a) configured to compress and separate the fibers (2a) of the cellulose blank structure (2), the edge forming device (5) being movably positioned relative to the base structure (3a) of the first mold portion (3), and the edge forming device (5) being adapted to interact with a pressurizing member (6) located within the base structure (3a), The molding system (S) separates the fibers (2a) of the cellulose blank structure (2) with the protruding element (5a), and applies an edge molding temperature (T) to the cellulose blank structure (2). ＥＦ ) is applied, and the cellulose blank structure (2) between the protruding element (5a) and the second mold portion (4) is subjected to edge molding pressure (P) using the pressurizing member (6). ＥＦ The system is configured to compress the cellulose blank structure (2) by adding ( ) to form a compressed edge structure (1a) of the cellulose product (1). A molding system (S) characterized by the following.

12. The molding system (S) further comprises a heating unit (8), wherein the heating unit (8) controls an edge molding temperature level (T) in the range of 50 to 300°C, preferably in the range of 100 to 300°C. ＥＦＬ The pressurizing member (6) is configured to apply the cellulose blank structure (2) to the cellulose blank structure (2), and the pressurizing member (6) is configured to apply an edge molding pressure level (P) of at least 10 MPa, preferably in the range of 10 to 4000 MPa, more preferably in the range of 100 to 4000 MPa. ＥＦＬ The molding system (S) according to claim 11, characterized in that it is configured to add ) to the cellulose blank structure (2).

13. The heating unit (8) heats the edge molding temperature (T) via the protruding element (5a) and / or the second mold portion (4). ＥＦ The molding system (S) according to claim 12, characterized in that it is configured to add ) to the cellulose blank structure (2).

14. The molding system (S) according to any one of claims 11 to 13, wherein the molding system (S) comprises a stopper member (7) positioned in the first mold portion (3) and / or the second mold portion (4), and the stopper member (7) is configured to prevent contact between the protruding element (5a) and the second mold portion (4) during the molding of the compressed edge structure (1a).

15. The protruding element (5a) has an edge section (5b) facing the second mold portion (4), and the edge section (5b), together with the second mold portion (4), creates a high-pressure zone (Z) in the cellulose blank structure (2) between the protruding element (5a) and the second mold portion (4) during the molding of the compressed edge structure (1a). ＨＰ A mold system (S) according to any one of claims 11 to 14, characterized in that it is configured to form a )

16. The second mold portion (4) comprises a high-pressure surface (4a) facing the edge section (5b), and the high-pressure surface (4a), together with the protruding element (5a), compresses the high-pressure zone (Z) during the molding of the compressed edge structure (1a). ＨＰ The molding system (S) according to claim 15, characterized in that it is configured to form ).

17. The molding system (S) generates an edge molding pressure (P) when the edge molding device (5) moves relative to the base structure (3a) due to interaction with the pressurizing member (6). ＥＦ A mold system (S) according to any one of claims 11 to 16, characterized in that it is configured to establish a )

18. The molding die system (S) according to any one of claims 11 to 17, characterized in that the pressurizing member (6) comprises one or more springs (6a) disposed between the base structure (3a) and the edge molding device (5).

19. The molding die system (S) according to any one of claims 11 to 17, characterized in that the pressurizing member (6) comprises a hydraulic unit (6b), and the hydraulic unit (6b) comprises a pressure chamber (6c) disposed between the base structure (3a) and the edge molding device (5).

20. The molding system (S) according to any one of claims 11 to 16, characterized in that the pressurizing member (6) comprises one or more detent mechanisms (12) disposed within the base structure (3a), and the one or more detent mechanisms (12) are configured to interact with the edge molding apparatus (5).

21. The mold system (S) according to any one of claims 11 to 20, characterized in that the base structure (3a) comprises an inner mold section (3b), and the edge molding device (5) extends to surround the inner mold section (3b).

22. The mold system (S) according to any one of claims 11 to 21, wherein the air-molded cellulose blank structure (2) has a multilayer structure.

23. The molding system (S) according to any one of claims 11 to 22, wherein the first mold portion (3) and / or the second mold portion (4) comprises a deformation element (10) that applies product molding pressure to the cellulose blank structure (2).

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