Multi-cavity forming mould system and method for dry-forming cellulose products in a multi-cavity forming mould system

Abstract

A multi-cavity forming mould system (S) for dry-forming a plurality of discrete three-dimensional cellulose products (1) from an air-formed cellulose blank structure (2). The forming mould system comprises a forming mould (M) having a first mould part (3) and a second mould part (4) arranged for cooperating with each other during a product forming operation (Op). The first mould part comprises a plurality of first forming elements (3a) and the second mould part comprises a plurality of corresponding second forming elements (4a). The forming mould system comprises a blank transporting unit (T) configured to feed the cellulose blank structure (2) onto a blank support structure (5) arranged between the first mould part (3) and the second mould part (4) before the product forming operation. The blank support structure (5) is configured for holding the cellulose blank structure (2) in position between the first mould part (3) and the second mould part (4). The first forming elements (3a) and the corresponding second forming elements (4a) are configured to apply a forming pressure during the product forming operation onto pre-determined sections (2s) of the cellulose blank structure (2) associated with the first forming elements (3a) and the second forming elements (4a), such that the pre-determined sections (2s) are formed into the cellulose products (1). The forming mould (M) comprises first cutting devices (6) configured to pre-cut one or more openings (O) in the cellulose blank structure (2) in a pre-cutting operation (Opc) during the product forming operation (Op). The forming mould (M) comprises second cutting devices (7) configured to cut out the cellulose products (1) from the cellulose blank structure (2) in a cutting operation (Oc) during the product forming operation (Op) or after the product forming operation (Op). The blank support structure (5) comprises a plurality of sectioned openings (5op). The sectioned openings (5op) are configured for allowing passage of the first forming elements (3a) and / or the corresponding second forming elements (4a) during the product forming operation (Op).

Description

[0001] MULTI-CAVITY FORMING MOULD SYSTEM AND METHOD FOR DRY-FORMING

[0002] CELLULOSE PRODUCTS IN A MULTI-CAVITY FORMING MOULD SYSTEM

[0003] TECHNICAL FIELD

[0004] The present disclosure relates to a multi-cavity forming mould system for dry-forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure. The forming mould system comprises a forming mould having a first mould part and a second mould part arranged for cooperating with each other during a product forming operation. The first mould part comprises a plurality of first forming elements and the second mould part comprises a plurality of corresponding second forming elements. The disclosure further relates to a method for dry-forming a plurality of discrete three-dimensional cellulose products from an airformed cellulose blank structure in a multi-cavity forming mould system.

[0005] BACKGROUND

[0006] Cellulose fibres are commonly used as raw material for producing or manufacturing cellulose products. Products formed of cellulose fibres can be used in many different situations where there is a need for sustainable products. A wide range of cellulose products can be produced from cellulose fibres, such as disposable plates and cups, cutlery, lids, bottle caps, coffee pods, packaging materials for holding or storing articles, coffee pods, or containers for holding or storing articles.

[0007] Forming mould systems are commonly used when manufacturing cellulose products from raw materials including cellulose fibres, and traditionally the cellulose products have been produced by wet-forming methods. With the wet-forming methods, there is a need for drying of the wet moulded product, where the drying process is a time and energy consuming part of the production. One development in the field of producing cellulose products is dry-forming of cellulose products without using wetforming methods. Instead of forming the cellulose products from a liquid or semi liquid pulp suspension or slurry, an air-formed cellulose blank structure is used. The airformed cellulose blank structure is inserted into a forming mould, and during the dry- forming of the cellulose products the cellulose blank is subjected to a high forming pressure and a high forming temperature.

[0008] Traditional forming systems used for forming cellulose products from air-formed cellulose blank structures are often limited in production capacity, since the forming of the cellulose products take place in forming systems with relatively long cycle times. It is therefore desirable to use multi-cavity forming mould systems, where a plurality of cellulose products are formed simultaneously during a product forming operation.

[0009] When inserting the cellulose blank structure into multi-cavity forming moulds, there is a risk that the cellulose blank structure breaks apart in an undesired manner, which leads to an improper forming of the cellulose products. This is a common issue with traditional cellulose high pressure forming methods, especially for deep-drawn products, leading to products with low quality. Other problems with traditional forming methods using standard cellulose blank structures, especially when forming deepdrawn products, are that that cracks, fibre separations, material fractures, or other unwanted structural weakenings of the cellulose blank structure are occurring during the insertion of the cellulose blank structure into the forming mould and during the forming process in the forming mould.

[0010] There is thus a need for an improved multi-cavity forming mould system for dryforming cellulose products from an air-formed cellulose blank structure, and method for dry-forming cellulose products from an air-formed cellulose blank structure.

[0011] SUMMARY

[0012] An object of the present disclosure is to provide a multi-cavity forming mould system and a method for dry-forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure in a multi-cavity forming mould system, where the previously mentioned problems are avoided. This object is at least partly achieved by the features of the independent claims. The dependent claims contain further developments of the multi-cavity forming mould system and the method for dry-forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure in a multi-cavity forming mould system. The disclosure concerns a multi-cavity forming mould system for dry-forming a plurality of discrete three-dimensional cellulose products from an air-formed cellulose blank structure. The forming mould system comprises a forming mould having a first mould part and a second mould part arranged for cooperating with each other during a product forming operation. The first mould part comprises a plurality of first forming elements and the second mould part comprises a plurality of corresponding second forming elements. The forming mould system comprises a blank transporting unit configured to feed the cellulose blank structure onto a blank support structure arranged between the first mould part and the second mould part before the product forming operation. The blank support structure is configured for holding the cellulose blank structure in position between the first mould part and the second mould part. The first forming elements and the corresponding second forming elements are configured to apply a forming pressure during the product forming operation onto predetermined sections of the cellulose blank structure associated with the first forming elements and the second forming elements, such that the pre-determined sections are formed into the cellulose products. The forming mould comprises first cutting devices configured to pre-cut one or more openings in the cellulose blank structure in a pre-cutting operation during the product forming operation. The forming mould comprises second cutting devices configured to cut out the cellulose products from the cellulose blank structure in a cutting operation during the product forming operation or after the product forming operation. The blank support structure comprises a plurality of sectioned openings. The sectioned openings are configured for allowing passage of the first forming elements and / or the corresponding second forming elements during the product forming operation.

[0013] Advantages with these features are that the pre-cutting operation with the first cutting devices together with the supporting of the cellulose blank structure by the blank support structure are enabling forming of cellulose products with high quality and finish by limiting the risk for the cellulose blank structure to break apart in an undesired manner during the forming operation in the forming mould. The pre-cutting operation and the blank support structure are supporting proper forming of the cellulose products in the forming mould. This is especially of advantage for deep-drawn products, and the pre-cutting operation is supporting the forming of cellulose products with high quality by avoiding cracks, fibre separations, material fractures, or other unwanted structural weakenings. The pre-cutting operation avoids competition of the cellulose blank structure between the different forming elements of the forming mould within the multi-cavity forming mould configuration. In other words, the pre-cutting operation is allowing the cellulose blank structure to be separated into portions suitable for supplying enough fibre material to each individual forming element being part of the forming mould. The pre-cutting operation further allows for cutting of the mainly two-dimensional cellulose blank structure into designed portions in connection to the pre-determined sections that transition or fold into desired three-dimensional shaped structures between the forming elements. The designed portions can be formed such that elements in each of the designed portions overlap, or at least touches each other, when transitioned or folded into the three-dimensional form in order to get a coherent product after the product forming operation.

[0014] In one embodiment, the blank support structure is configured as a grid-like structure comprising a plurality of first grid elements and a plurality of second grid elements. The first grid elements are extending in a first direction and arranged at a distance from each other. The second grid elements are extending in a second direction and arranged at a distance from each other. The first direction and the second direction are different from each other. The grid-like structure is used for a simple and reliable construction of the blank support structure, and may be formed from cutting our openings from a sheet metal structure or by forming the blank support structure from a plurality of joined grid elements made from a suitable material.

[0015] In one embodiment, the plurality of sectioned openings of the blank support structure are formed by the plurality of first grid elements and the plurality of second grid elements. The grid-like structure is enabling a simple and efficient construction of the blank support structure, allowing passage of the first forming elements and / or the corresponding second forming elements through the sectioned openings during the product forming operation.

[0016] In one embodiment, the forming mould system comprises a blank holding member arranged between the first mould part and the second mould part. The blank holding member comprises a plurality of sectioned openings configured for allowing passage of the first forming elements and / or the corresponding second forming elements during forming of the cellulose products. The blank transporting unit is configured to feed the cellulose blank structure between the blank support structure and the blank holding member. The blank holding member is configured for pushing the cellulose blank structure towards the blank support structure for holding the cellulose blank structure in position between the first mould part and the second mould part. The interaction between the blank holding member and the blank support structure is efficiently holding parts of the cellulose blank structure in place during the forming operation in the forming mould. The blank holding member is together with the blank support structure securing efficient positioning of the cellulose blank structure for forming cellulose products with high quality and finish by limiting the risk for the cellulose blank structure to break apart in an undesired manner during the forming operation in the forming mould.

[0017] In one embodiment, the blank holding member is configured as a grid-like structure comprising a plurality of first grid elements and a plurality of second grid elements. The first grid elements are extending in a first direction and arranged at a distance from each other. The second grid elements are extending in a second direction and arranged at a distance from each other. The first direction and the second direction are different from each other. The grid-like structure is used for a simple and reliable construction of the blank holding member, and may be formed from cutting our openings from a sheet metal structure or by forming the blank holding member from a plurality of joined grid elements made from a suitable material.

[0018] In one embodiment, the plurality of sectioned openings of the blank holding member are formed by the plurality of first grid elements and the plurality of second grid elements. The grid-like structure is enabling a simple and efficient construction of the blank holding member, allowing passage of the first forming elements and / or the corresponding second forming elements through the sectioned openings during the product forming operation.

[0019] In one embodiment, the cellulose blank structure comprises a residual section surrounding or arranged in connection to the pre-determined sections. The first cutting devices are configured for arranging a cutting pattern formed by the one or more openings in the residual section at least partly around each pre-determined section. The residual section is remaining after the product forming operation and may be recycled for forming cellulose products. In the recycling process, the entire residual section, such as the parts of the cellulose blank structure remaining after the precutting and cutting operations, can be fed to a mill for defibration into cellulose fibres and / or bundles of cellulose fibres. The entire residual section can further be compressed, before feeding it to the mill, into a density similar to a pulp structure initially used for forming the cellulose blank structure.

[0020] In one embodiment, the first cutting devices are configured for forming at least one connecting structure by the cutting pattern between each pre-determined section and the residual section for connecting each pre-determined section to the residual section. The connecting structures are used for connecting each pre-determined section to the residual section, and is holding the pre-determined sections in position relative to the mould parts during the product forming operation. The connecting structures are suitably constituted by non-cut areas or sections of the cellulose blank structure.

[0021] In one embodiment, the first cutting devices are configured for arranging the cutting pattern to extend through the cellulose blank structure. The extension of the cutting pattern through the cellulose blank structure is enabling efficient positioning of the pre-determined sections relative to the forming elements, by allowing the predetermined sections to move into the forming mould.

[0022] In one embodiment, the second cutting devices are arranged in connection to each of the first forming elements and / or the corresponding second forming elements. The first cutting devices are arranged in connection to the second cutting devices, at a distance and radially outwardly from the second cutting devices. This configuration of the respective cutting devices are enabling a simple and reliable construction of the forming mould.

[0023] In one embodiment, the multi-cavity forming mould system is configured for initiating the pre-cutting operation when the first mould part moves from an open position to a closed position. The first cutting devices are configured for pre-cutting the cellulose blank structure before the cutting operation is initiated. By completing the pre-cutting operation before the initiation of the cutting operation, the pre-determined sections are allowed to move into the forming elements during the forming of the cellulose products in the forming mould.

[0024] In one embodiment, the forming mould is configured for dry-forming the cellulose products by pressing and heating the pre-determined sections with a forming pressure in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and with a forming temperature in the range of 60-300 °C, preferably in the range of 100-200 °C, more preferably in the range of 120-170 °C. These parameters are used for an efficient forming of the cellulose products.

[0025] The disclosure further concerns a method for dry-forming a plurality of discrete three- dimensional cellulose products from an air-formed cellulose blank structure in a multicavity forming mould system. The forming mould system comprises a forming mould having a first mould part and a second mould part arranged for cooperating with each other during a product forming operation. The first mould part comprises a plurality of first forming elements and the second mould part comprises a plurality of corresponding second forming elements. The forming mould comprises first cutting devices and second cutting devices. The forming mould system comprises a blank transporting unit and a blank support structure arranged between the first mould part and the second mould part. The method comprises the steps: feeding the cellulose blank structure onto the blank support structure for holding the cellulose blank structure in position between the first mould part and the second mould part, and precutting one or more openings in the cellulose blank structure when arranged onto the blank support structure with the first cutting devices; applying a forming pressure onto pre-determined sections of the cellulose blank structure associated with the first forming elements and the second forming elements by means of the first forming elements and the corresponding second forming elements for forming the predetermined sections into cellulose products, wherein the blank support structure comprises a plurality of sectioned openings configured for allowing passage of the first forming elements and / or the corresponding second forming elements during forming of the cellulose products; cutting out the cellulose products from the cellulose blank structure with the second cutting devices during forming of the cellulose products or after forming of the cellulose products.

[0026] Advantages with the method are that the pre-cutting operation with the first cutting devices together with the supporting of the cellulose blank structure by the blank support structure are enabling forming of cellulose products with high quality and finish by limiting the risk for the cellulose blank structure to break apart in an undesired manner during the forming operation in the forming mould. The pre-cutting operation and the blank support structure are used for proper forming of the cellulose products in the forming mould. This is especially of advantage for deep-drawn products, and the pre-cutting operation is supporting the forming of cellulose products with high quality by avoiding cracks, fibre separations, material fractures, or other unwanted structural weakenings.

[0027] In one embodiment, the method further comprises the step: feeding the cellulose blank structure into a position between the first mould part and the second mould part where the pre-determined sections are aligned with the sectioned openings of the blank support structure. This is enabling an efficient positioning of the cellulose blank structure relative to the forming elements and the blank support structure.

[0028] In one embodiment, the forming mould system comprises a blank holding member arranged between the first mould part and the second mould part. The blank holding member comprises a plurality of sectioned openings configured for allowing passage of the first forming elements and / or the corresponding second forming elements during forming of the cellulose products. The method comprises the steps: feeding the cellulose blank structure between the blank support structure and the blank holding member; pushing the cellulose blank structure towards the blank support structure with the blank holding member for holding the cellulose blank structure in position between the first mould part and the second mould part. The blank holding member is together with the blank support structure securing efficient positioning of the cellulose blank structure during the forming of the cellulose products for forming cellulose products with high quality and finish by limiting the risk for the cellulose blank structure to break apart in an undesired manner during the forming operation in the forming mould.

[0029] In one embodiment, the method further comprises the step: feeding the cellulose blank structure into a position between the first mould part and the second mould part where the pre-determined sections are aligned with the sectioned openings of the blank holding member. This is enabling an efficient positioning of the cellulose blank structure relative to the forming elements and the blank holding member.

[0030] In one embodiment, the cellulose blank structure comprises a residual section surrounding or arranged in connection to the pre-determined sections. The method comprises the step: arranging the one or more openings as a cutting pattern in the residual section at least partly around each pre-determined section. The residual section is remaining after the product forming operation and may be recycled for forming cellulose products.

[0031] In one embodiment, the method comprises the step: forming at least one connecting structure by the cutting pattern between each pre-determined section and the residual section for connecting each pre-determined section to the residual section. The connecting structures are used for connecting each pre-determined section to the residual section, and is holding the pre-determined sections in position relative to the mould parts during the product forming operation. The connecting structures are suitably constituted by non-cut areas or sections of the cellulose blank structure.

[0032] In one embodiment, the method comprises the step: arranging the cutting pattern to extend through the cellulose blank structure. This is enabling efficient positioning of the pre-determined sections relative to the forming elements.

[0033] In one embodiment, the method comprises the steps: initiating the pre-cutting operation when the first mould part moves from an open position to a closed position, and pre-cutting the cellulose blank structure before the cutting operation is initiated. By completing the pre-cutting operation before the initiation of the cutting operation, the pre-determined sections are allowed to move into the forming elements during the forming of the cellulose products in the forming mould.

[0034] In one embodiment, the method further comprises the steps: dry-forming the cellulose products by pressing and heating the pre-determined sections with a forming pressure in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and with a forming temperature in the range of 60-300 °C, preferably in the range of 100-200 °C, more preferably in the range of 120-170 °C. These parameters are used for an efficient forming of the cellulose products.

[0035] BRIEF DESCRIPTION OF DRAWINGS

[0036] The disclosure will be described in detail in the following, with reference to the attached drawings, in which Fig. 1a-b show schematically, in a side view and in a perspective view, a multicavity forming mould system for dry-forming a plurality of discrete three- dimensional cellulose products from an air-formed cellulose blank structure, where the forming mould system comprises a forming mould with a first mould part and a second mould part,

[0037] Fig. 2 shows schematically, in a perspective view, the cellulose blank structure with pre-determined sections,

[0038] Fig. 3a-g show schematically, in side views, operational steps of the forming mould during forming of the cellulose products, and

[0039] Fig. 4 shows schematically, in a perspective view, the cellulose blank structure with pre-determined sections and cutting pattern,

[0040] Fig. 5a-b show schematically, in side views, alternative pre-cutting operational steps of the forming mould during forming of the cellulose products, and

[0041] Fig. 6a-b show schematically, in side views, further alternative pre-cutting operational steps of the forming mould during forming of the cellulose products.

[0042] DESCRIPTION OF EXAMPLE EMBODIMENTS

[0043] Various aspects of the disclosure will hereinafter be described in conjunction with the appended drawings to illustrate and not to limit the disclosure, wherein like designations denote like elements, and variations of the described aspects are not restricted to the specifically shown embodiments, but are applicable on other variations of the disclosure.

[0044] Figures 1a-b schematically shows a multi-cavity forming mould system S for dryforming a plurality of discrete three-dimensional cellulose products 1 from an airformed cellulose blank structure 2. The forming mould system S comprises a forming mould M having a first mould part 3 and a second mould part 4. The first mould part 3 and the second mould part 4 are arranged for cooperating with each other during a product forming operation OP, as will be further described below. The first mould part 3 comprises a plurality of first forming elements 3a and the second mould part 4 comprises a plurality of corresponding second forming elements 4a. The plurality of first forming elements 3a and the plurality of corresponding second forming elements 4a are forming a plurality of forming cavities C when arranged in connection to each other during the product forming operation OP.

[0045] The cellulose blank structure 2 is air-formed from cellulose fibres. With an air-formed cellulose blank structure 2 is meant an essentially air-formed fibrous web structure produced from cellulose fibres, where the cellulose fibres are carried and formed to the cellulose blank structure 2 by air as carrying medium. The cellulose blank structure 2 comprises loose and separated cellulose fibres that are compressed upon forming of the cellulose products 1 in the forming mould M.

[0046] With loose and separated cellulose fibres is meant cellulose fibres that are separated from each other, and where the cellulose fibres are loosely arranged relative to each other within the cellulose blank structure 2. The loose and separated cellulose fibres may include cellulose fibres or cellulose fibre bundles that are separated from each other and loosely arranged relative to each other within the cellulose blank structure 2.

[0047] The cellulose fibres may originate from a suitable cellulose raw material, such as a pulp material. Suitable pulp materials are for example fluff pulp, paper structures, or other cellulose fibre containing structures. The cellulose fibres may also be extracted from agricultural waste materials, for example wheat straws, fruit and vegetable peels, bagasse, or from other suitable sources. When for example using pulp as raw material for the cellulose blank structure 2, the pulp structure commonly needs to be separated in a separating unit, such as a suitable mill unit, before the air-forming of the cellulose blank structure 2. In the separating unit, the pulp structure is separated into individual cellulose fibres, or into individual cellulose fibres and cellulose fibre bundles, and the better milling process the more individual cellulose fibres are produced. In other embodiments, only individual cellulose fibres may be used as raw material for the cellulose blank structure 2. With air-forming of the cellulose blank structure 2 is meant the formation of the cellulose blank structure in a dry and controlled fibre forming process in which the cellulose fibres are air-formed to produce the cellulose blank structure 2. When forming the cellulose blank structure 2 in the air-forming process, the cellulose fibres are carried and formed to the cellulose blank structure 2 by air as carrying medium. It should be understood that even if the cellulose blank structure 2 is slightly compacted before the forming of the cellulose products 1 in the forming mould M, such as compacting the cellulose blank structure 2 for feeding or transportation purposes, the cellulose blank structure 2 still comprises loose and separated cellulose fibres.

[0048] The air-forming process for forming the cellulose blank structure 2 is different from a normal papermaking process or a traditional wet-forming process, where water is used as carrying medium for the cellulose fibres when forming the paper or fibre structure. In the air-forming process, small amounts of water or other substances may if desired be added to the cellulose fibres in order to change the properties of the cellulose products, but air is still used as carrying medium in the air-forming process. The cellulose blank structure 2 may, if suitable have a dryness that is mainly corresponding to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2. As an alternative, the dryness of the cellulose blank structure 2 can be controlled in order to have a suitable dryness level when forming the cellulose products 1 in the forming mould M.

[0049] The air-formed cellulose blank structure 2 may be formed of cellulose fibres in a conventional air-forming process or in a cellulose blank air-forming module. The cellulose blank structure 2 may have a composition where the cellulose fibres are of the same origin or alternatively contain a mix of two or more types of cellulose fibres. Suitably, the cellulose fibres in the cellulose blank structure 2 are during the forming process of the cellulose products 1 in the forming mould M bonded or interconnected to each other with hydrogen bonds into a three-dimensional compressed fibre structure, due to applied forming pressure and forming temperature together with adequate moist content in the cellulose blank structure 2. The cellulose fibres may be mixed with other substances to a certain amount. With cellulose fibres is meant any type of cellulose fibres, such as natural cellulose fibres or manufactured cellulose fibres. The cellulose blank structure 2 may specifically comprise at least 95% dry weight cellulose fibres, or more specifically at least 99% dry weight cellulose fibres.

[0050] The air-formed cellulose blank structure 2 may have a single-layer or a multi-layer configuration. A cellulose blank structure 2 having a single-layer configuration is referring to a structure that is formed of one layer containing cellulose fibres. A cellulose blank structure 2 having a multi-layer configuration is referring to a structure that is formed of two or more layers comprising cellulose fibres, where the layers may have the same or different compositions or configurations.

[0051] The one or more air-formed layers of the cellulose blank structure 2 are fluffy and airy structures, where the cellulose fibres forming the structures are arranged relatively loosely in relation to each other. The fluffy cellulose blank structure 2 are used for an efficient dry-forming of the cellulose products 1 , allowing the cellulose fibres to form the cellulose products 1 in an efficient way during the dry-forming process in the forming mould M.

[0052] The cellulose blank structure 2 comprises a plurality of pre-determined sections 2s. The pre-determined sections 2s are arranged as specific sections or areas of the cellulose blank structure 2 used for forming the cellulose products 1. The cellulose blank structure 2 further comprises a residual section 2R surrounding or arranged in connection to the pre-determined sections 2s.

[0053] In the exemplified embodiment shown in figure 2, the plurality of pre-determined sections 2s are arranged as circular sections of the cellulose blank structure 2, and as understood from the figure, the residual section 2R is surrounding the predetermined sections 2s. The cellulose products 1 formed by the pre-determined sections 2s will during the product forming operation OP, or in connection to the product forming operation OP, be cut out from the cellulose blank structure 2, as will be further described below. The residual section 2R is remaining after the product forming operation OP, and the residual section 2R is suitably recycled. It should be understood that the pre-determined sections 2s may have any suitable shape and configuration depending on the shape of the cellulose products 1 formed from the cellulose blank structure 2.

[0054] As shown in figure 1a, the forming mould system S comprises a blank transporting unit T. The blank transporting unit T may have any suitable configuration and is feeding the cellulose blank structure 2 to the forming mould M. In the shown embodiment, the blank transporting unit T is arranged as a belt conveyor.

[0055] The forming mould system S comprises a blank support structure 5 arranged between the first mould part 3 and the second mould part 4, as shown in figures 1a-b. The blank support structure 5 is arranged for holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during the forming of the cellulose products 1 in the forming mould M. The blank support structure 5 comprises a plurality of sectioned openings 5OP. The sectioned openings 5OP are allowing passage of the first forming elements 3a and / or the corresponding second forming elements 4a during the product forming operation OP, depending on the construction of the forming mould M. In this way, the first forming elements 3a and / or the corresponding second forming elements 4a can pass through the sectioned openings 5OP when forming the cellulose products in the forming mould M.

[0056] In the embodiment shown in figures 1a-b, the blank support structure 5 is configured as a grid-like structure comprising a plurality of first grid elements 5a and a plurality of second grid elements 5b. The first grid elements 5a are extending in a first direction D1 and arranged at a distance from each other. The second grid elements 5b are extending in a second direction D2 and arranged at a distance from each other. The first direction D1 and the second direction D2 are different from each other. The plurality of sectioned openings 5OP of the blank support structure 5 are formed by the plurality of first grid elements 5a and the plurality of second grid elements 5b. The blank support structure 5 may be attached to the first mould part 3 or to the second mould part 4. If attached to the first mould part 3, as illustrated in figures 1a-b, the blank support structure 5 may be arranged to move with the first mould part 3 during the product forming operation OP, and suitably the blank support structure 5 is movably arranged relative to the first mould part 3. If attached to the second mould part 4, the blank support structure 5 may be arranged as a stationary unit. Alternatively, the blank support structure 5 is attached to any other suitable structure of the multi-cavity forming mould system S.

[0057] The forming mould system S further comprises a blank holding member 8 arranged between the first mould part 3 and the second mould part 4, as shown in figures 1a- b. The blank holding member 8 is arranged for holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during the forming of the cellulose products 1 in the forming mould M, by pressing the cellulose blank structure 2 towards the blank support structure 5. The blank holding member 8 comprises a plurality of sectioned openings 8OP configured for allowing passage of the first forming elements 3a and / or the corresponding second forming elements 4a during forming of the cellulose products 1 , depending on the construction of the forming mould M. In this way, the first forming elements 3a and / or the corresponding second forming elements 4a can pass through the sectioned openings 8OP when forming the cellulose products in the forming mould M.

[0058] In the embodiment shown in figures 1a-b, the blank holding member 8 is configured as a grid-like structure comprising a plurality of first grid elements 8a and a plurality of second grid elements 8b. The first grid elements 8a are extending in a first direction D1 and arranged at a distance from each other, and the second grid elements 8b are extending in a second direction D2 and arranged at a distance from each other. The first direction D1 and the second direction D2 are different from each other. The plurality of sectioned openings 8OP of the blank holding member 8 are formed by the plurality of first grid elements 8a and the plurality of second grid elements 8b. The blank holding member 8 may be attached to the first mould part 3 or to the second mould part 4. If attached to the first mould part 3, as illustrated in figures 1a-b, the blank holding member 8 may be arranged to move with the first mould part 3 during the product forming operation OP, and suitably the blank holding member 8 is movably arranged relative to the first mould part 3. Alternatively, the blank holding member 8 is attached to any other suitable structure of the multi-cavity forming mould system S.

[0059] The blank support structure 5 and the blank holding member 8 are movably arranged relative to each other, and the blank holding member 8 is configured for pushing the cellulose blank structure 2 towards the blank support structure 5 for holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part. The blank transporting unit T is configured to feed the cellulose blank structure 2 into the forming mould M between the blank support structure 5 and the blank holding member 8, and thereafter the blank holding member 8 is suitably moved towards the blank support structure 5. In this way, the blank holding member 8 is pushing the cellulose blank structure 2 towards the blank support structure 5 for holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4.

[0060] The forming mould M comprises first cutting devices 6, as shown in figures 1a-b. In the shown embodiment, the forming mould M comprises a plurality of first cutting devices 6 that are arranged in connection to corresponding first forming elements 3a. The first cutting devices 6 are configured to pre-cut one or more openings O in the cellulose blank structure 2 in a pre-cutting operation OPC during the product forming operation OP, as schematically illustrated in figure 4. The pre-cutting operation OPC is enabling deep drawn cellulose products 1 , where the pre-determined sections 2s of the cellulose blank structure 2 need to be transported deeply into the forming mould M during the product forming operation OP. The first cutting devices 6 may be made of steel or other suitable materials.

[0061] The first cutting devices 6 are as shown in figure 4 used for forming a cutting pattern X formed by the one or more openings O in the residual section 2R at least partly around each pre-determined section 2s. The first cutting devices 6 are in the shown embodiment forming connecting structures 2c by the cutting pattern X between each pre-determined section 2s and the residual section 2R. The connecting structures 2c are suitably constituted by non-cut areas or sections of the cellulose blank structure 2. The connecting structures 2c are connecting each pre-determined section 2s to the residual section 2R, and is holding the pre-determined sections 2s in position relative to the mould parts during the product forming operation OP. Suitably, the first cutting devices 6 are configured for arranging the cutting pattern X between each predetermined section 2s and the residual section 2R to extend all the way through the cellulose blank structure 2 for an efficient separation between the pre-determined sections 2s and the residual section 2R. The cutting patterns X formed in the precutting operation OPC may have any suitable shape or configuration enabling efficient transportation of the pre-determined sections 2s into the first forming elements 3a and / or the corresponding second forming elements 4a during the product forming operation OP.

[0062] The forming mould M further comprises second cutting devices 7, as shown in figures 1a-b. In the shown embodiment, the forming mould M comprises a plurality of second cutting devices 7 that are arranged in connection to corresponding first forming elements 3a. The first cutting devices 7 are configured to cut out the cellulose products 1 from the cellulose blank structure 2 in a cutting operation Oc during the product forming operation OP or after the product forming operation OP. Suitably, the first cutting devices 6 are arranged in connection to the second cutting devices 7, at a distance and radially outwardly from the second cutting devices 7. The second cutting devices 7 may be made of steel or other suitable materials.

[0063] In the shown embodiment, the first cutting devices 6 and the second cutting devices

[0064] 7 are arranged in connection to each of the first forming elements 3a. In other non- illustrated embodiments, the first cutting devices 6 may instead be arranged in connection to each of the second forming elements 4a, or alternatively in connection to both first forming elements 3a and second forming elements 4b. The second cutting devices 7 may instead be arranged in connection to each of the second forming elements 4a, or alternatively in connection to both first forming elements 3a and second forming elements 4b.

[0065] The multi-cavity forming mould system S is in the shown embodiment configured for initiating the pre-cutting operation OPC when the first mould part 3 moves from an open position Po to a closed position Pc, and the first cutting devices 6 are configured for pre-cutting the cellulose blank structure 2 before the cutting operation Oc is initiated.

[0066] To dry-form the cellulose products 1 from the air-formed cellulose blank structure 2 in the forming mould M, the cellulose blank structure 2 is first provided from a suitable source and thereafter arranged in the forming mould M. The cellulose blank structure 2 may be air-formed from cellulose fibres and arranged on rolls or in stacks. The rolls or stacks may thereafter be arranged in connection to the forming mould M, and transported to the forming mould M by the transporting unit T. As an alternative, the cellulose blank structure 2 may be air-formed from cellulose fibres in a non-illustrated cellulose blank air-forming module arranged in connection to the forming mould M, and transported to the forming mould M by the transporting unit T. The transporting unit T may be arranged as a feeding belt or any other suitable feeding, transporting or conveying arrangement. Suitably, the forming mould M is operated intermittently for dry-forming the cellulose products 1 from the cellulose blank structure 2.

[0067] In the embodiment illustrated in figures 1a-b, the forming mould M comprises the first mould part 3 and the second mould part 4 that are cooperating for forming the cellulose products 1 from the pre-determined sections 2s of the cellulose blank structure 2. The first mould part 3 with the first forming elements 3a and the second mould part 4 with the corresponding second forming elements 4a are movably arranged relative to each other, and the first mould part 3 and the second mould part 4 are configured for moving relative to each other in a pressing direction Dp. The product forming operation OP will be described in connection to figures 3a-g, which only show one of the of first forming elements 3a and one corresponding second forming element 4a of the forming mould M in figures 1a-b for illustrative purposes. In the embodiment shown in figures 1a-b and 3a-g, the second mould part 4 is stationary and the first mould part 3 is movably arranged in relation to the second mould part 4 in the pressing direction DP, during the product forming operation OP. The first mould part 3 is configured to move both towards the second mould part 4 and away from the second mould part 4 in linear movements along an axis extending in the pressing direction Dp.

[0068] It should be understood that for all embodiments, the expression moving in the pressing direction DP includes a movement in the pressing direction DP, and the movement may take place in opposite directions. The expression may further include both linear and non-linear movements of a mould part, where the result of the movement during forming is a repositioning of the mould part in the pressing direction DP.

[0069] The forming mould M is applying the forming pressure Pp by pressing the cellulose blank structure 2 in the forming cavities C formed between the plurality of first forming elements 3a and the plurality of corresponding second forming elements 4a when arranged in connection to each other during the product forming operation OP, as shown in figure 3d. Thus, the first forming elements 3a and the corresponding second forming elements 4a are applying the forming pressure Pp during the product forming operation OP onto the pre-determined sections 2s of the cellulose blank structure 2 associated with the first forming elements 3a and the second forming elements 4a. In this way, the pre-determined sections 2s are formed into the cellulose products 1 . The forming mould M is further applying the forming temperature Tp onto the cellulose blank structure 2 in the product forming operation OP. The cellulose products 1 are dry-formed in the forming mould M by pressing the pre-determined sections 2s with a forming pressure Pp in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and by heating the pre-determined sections 2s with a forming temperature Tp in the range of 60-300 °C, preferably in the range of 100-200 °C, more preferably in the range of 120-170 °C.

[0070] With the expression product forming operation OP is meant the operation of the mould parts for forming cellulose products 1 from the cellulose fibres in the cellulose blank structure 2. In the embodiment shown in figures 3a-g, the product forming operation OP starts when the first mould part 3 is moved from a stationary position. In this stationary position, as illustrated in figure 3a, the first mould part 3 and the second mould part 4 are arranged at a distance from each other in an open position Po, and a part of the cellulose blank structure 2 is fed into the forming mould M by the transporting unit T in a feeding direction DF, as illustrated with the arrow in figure 3a. The cellulose blank structure 2 is in this way fed by the transporting unit T between the first mould part 3 with the plurality of first forming elements 3a and the second mould part 4 with the plurality of corresponding second forming elements 4a, onto the blank support structure 5, and between the blank support structure 5 and the blank holding member 8, into a position where the cellulose products 1 can be formed from the cellulose fibres in the cellulose blank structure 2. The transporting unit T is feeding the cellulose blank structure 2 between the blank support structure 5 and the blank holding member 8 before the product forming operation OP in the forming mould M starts.

[0071] In the embodiment shown in figures 1a-b and 3a-g, the blank support structure 5 comprises a number of sectioned openings 5OP that are corresponding to the number of pre-determined sections 2s of the cellulose blank structure 2 fed into the forming mould M between the first mould part 3 and the second mould part 4. The blank holding member 8 comprises a number of sectioned openings 8OP that are corresponding to the number of pre-determined sections 2s of the cellulose blank structure 2 fed into the forming mould M between the first mould part 3 and the second mould part 4.

[0072] The cellulose blank structure 2 is fed by the transporting unit T between the blank support structure 5 and blank holding member 8, into a position between the first mould part 3 and the second mould part 4 where the pre-determined sections 2s of the cellulose blank structure 2 are aligned with the plurality of first forming elements 3a and corresponding second forming elements 4a, as well as aligned with the sectioned openings 5OP of the blank support structure 5 and the sectioned openings 8OP of the blank holding member 8. In this way, each pre-determined section 2s of the cellulose blank structure 2 is aligned with corresponding first forming element 3a, second forming element 4a, sectioned opening 5OP of the blank support structure 5, and sectioned opening 8OP of the blank holding member 8, when the cellulose blank structure 2 has been fed into the forming mould M and stopped between the first mould part 3 and the second mould part 4, as understood from figure 3. It should however be understood that the blank support structure 5 in other non-illustrated embodiments may be arranged with other suitable numbers of sectioned openings 5OP, and the blank holding member 8 with corresponding other suitable numbers of sectioned openings 8OP.

[0073] Depending on the design of the forming mould M, the plurality of sectioned openings 5OP of the blank support structure 5 are allowing passage of the first forming elements 3a and / or corresponding second forming elements 4a during forming of the cellulose products 1 , and the plurality of sectioned openings 8OP of the blank holding member 8 are allowing passage of the first forming elements 3a and / or corresponding second forming elements 4a during forming of the cellulose products 1.

[0074] When the feeding of the cellulose blank structure 2 has been stopped in the position shown in figure 3a, where the cellulose blank structure 2 is arranged between the blank support structure 5 and the blank holding member 8, the first mould part 3 is moved towards the second mould part 4, as shown in figures 3b-d. The blank holding member 8 is moved towards the blank support structure 5 for pushing the cellulose blank structure 2 towards the blank support structure 5, as shown in figure 3b. The blank support structure 5 together with the blank holding member 8 is holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during movement of the first mould part 3 towards the second mould part 4. In the shown embodiment, the first forming elements 3a of the first mould part 3 are passing through the sectioned openings 8OP of the blank holding member 8 and the sectioned openings 5OP of the of the blank support structure 5 during movement towards the second forming elements 4a. The sectioned openings 8OP of the blank holding member 8 and the sectioned openings 5OP of the of the blank support structure 5 are in this way allowing passage of the first forming elements 3a when moved towards the corresponding second forming elements 4a.

[0075] As shown in figure 3b, the blank holding member 8 is pushed towards the blank support structure 5 for holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during the product forming operation OP, and by pushing the cellulose blank structure 2 towards the blank support structure 5 with the blank holding member 8 an efficient positioning of the cellulose blank structure 2 is enabled. During movement of the first mould part 3 towards the second mould part 4, the first cutting devices 6 are pre-cutting one or more openings O in the cellulose blank structure 2, as shown in figures 3b-c. In this way, the pre-cutting operation OPC is initiated when the first mould part 3 moves from an open position Po shown in figure 3a towards the a closed position Pc shown in figure 3d. During the pre-cutting operation OPC, the first cutting devices 6 are forming the cutting pattern X in the cellulose blank structure through the established openings O. The residual section 2R of the cellulose blank structure 2 is surrounding or arranged in connection to the predetermined sections 2s, as shown in figure 4, and suitably the one or more openings O are arranged as the cutting pattern X in the residual section 2R at least partly around each pre-determined section 2s. The connecting structures 2c are formed by the cutting pattern X between each pre-determined section 2s and the residual section 2R for connecting each pre-determined section 2s to the residual section 2R. Suitably, the cutting pattern X is extending through the cellulose blank structure 2. The cutting pattern can be in the form of straight and / or curved slits in the cellulose blank structure strategically positioned between the multitude of first and second forming elements 3, 4 to remove the problem of material competition when the cellulose blank structure is pressed into the multitude of first and second forming elements 3. The cutting devices are positioned correspondingly.

[0076] As shown in figure 3c, the first forming elements 3a are upon movement of the first mould part 3 towards the second mould part 4 pushing corresponding pre-determined sections 2s of the cellulose blank structure 2 into the second forming elements 4a. This pushing of the pre-determined sections 2s of the cellulose blank structure 2 is simplified through the one or more openings O formed in the cellulose blank structure 2 during the pre-cutting operation OPC, and the one or more openings O are allowing the pre-determined sections 2s to easily be drawn into corresponding second forming elements 4a through the pushing action from the first forming elements 3a.

[0077] When the first forming elements 3a are arranged in connection to the second forming elements 4a with the pre-determined sections 2s of the cellulose blank structure 2 arranged in the forming cavities C formed between the first forming elements 3a and the corresponding second forming elements 4a, as shown in figure 3d, the forming pressure Pp and the forming temperature Tp are applied onto the pre-determined sections 2s of the cellulose blank structure 2. In the shown embodiment, the cellulose products 1 are cut out from the cellulose blank structure 2 with the second cutting devices 7 during forming of the cellulose products 1. In other non-illustrated embodiments, the cellulose products 1 may instead be cut out from the cellulose blank structure 2 with the second cutting devices 7 after forming of the cellulose products 1 . Suitably, the pre-cutting operation OPC of the cellulose blank structure 2 with the first cutting devices 6 is completed before the cutting operation Oc with the second cutting devices 7 is initiated.

[0078] When the forming pressure Pp and forming temperature Tp are applied onto the cellulose fibres, the cellulose product 1 is formed in the forming cavities C of the forming mould M. The cellulose product 1 may be formed into any suitable shape in the forming mould M, such as three-dimensional shapes. The forming mould M is in the product forming operation OP dry-forming the cellulose product 1 into compressed fibre structures by pressing and heating the pre-determined sections 2s of the cellulose blank structure 2 with a forming pressure Pp in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and a forming temperature Tp in the range of 60-300 °C, preferably in the range of 100- 200 °C, more preferably in the range of 120-170 °C. In this way, the cellulose fibres are integrated into the compressed fibre structures.

[0079] When the cellulose products 1 have been formed in the forming mould M, the first mould part 3 is moved away from the second mould part 4 back to the stationary position, as shown in figures 3e-g. When the first mould part 3 has reached the stationary position again, as shown in figure 3g, the product forming operation OP is completed. The product forming operation OP is thus defined as a pressing cycle during which the cellulose fibres in the pre-determined sections 2s are exerted to the forming pressure Pp, and the duration of the product forming operation OP is suitably calculated from the start of the movement of the first mould part 3 from the stationary position until the first mould part 3 has reached the stationary position again. In figure 3e, the first mould part 3 is moved away from the second mould part 4, and in figure 4, the blank holding member 8 is moved away from the blank support structure 5.

[0080] After a completed product forming operation OP, the cellulose products 1 are removed from the forming mould M, as shown in figure 3g. Thereafter a new section of the cellulose blank structure 2 with pre-determined sections 2s is fed into the forming mould M between the first mould part 3 and the second mould part 4, and a new product forming operation OP is initiated for a repeated operation of the forming mould M. In this way, the forming mould M is intermittently operated in a sequence of product forming operations OP following each other and the cellulose blank structure 2 is intermittently fed to the forming mould M between the product forming operations OP by the transporting unit T.

[0081] An alternative embodiment of the first cutting devices comprising first cutting edges 6a and cooperating second cutting edges 6b are schematically illustrated in figures 5a-b. In this embodiment, the second mould part 4 is stationary and the first mould part 3 is movably arranged in relation to the second mould part 4 during the product forming operation OP. In the shown embodiment, the first cutting edges 6a are arranged in connection to the first forming elements 3a and the cooperating second cutting edges 6b are arranged in connection to the second forming elements 4a. Through interaction between the first cutting edges 6a and corresponding second cutting edges 6b, the pre-cutting operation OPC is performed as a shear cutting process, where the cutting edges efficiently are pre-cutting the one or more openings O in the cellulose blank structure 2 in the pre-cutting operation OPC. The first cutting edges 6a and the second cutting edges 6b may be made of steel or other suitable materials. In the same way as described above, the first cutting edges 6a and cooperating second cutting edges 6b are as shown in figure 4 used for forming the cutting pattern X with the one or more openings O in the residual section 2R at least partly around each pre-determined section 2s. Suitably, the first cutting edges 6a and cooperating second cutting edges 6b are configured for arranging the cutting pattern X between each pre-determined section 2s and the residual section 2R to extend all the way through the cellulose blank structure 2 for an efficient separation between the pre-determined sections 2s and the residual section 2R. The cutting patterns X formed in the pre-cutting operation OPC may have any suitable shape or configuration enabling efficient transportation of the pre-determined sections 2s into the first forming elements 3a and / or the corresponding second forming elements 4a during the product forming operation OP as described above.

[0082] In figure 5a, the first mould part 3 and the second mould part 4 are arranged at a distance from each other in an open position Po, and a part of the cellulose blank structure 2 is fed into the forming mould M by the transporting unit T in a feeding direction Dp, as illustrated with the arrow in figure 5a. The cellulose blank structure 2 is in this way fed by the transporting unit T between the first mould part 3 with the plurality of first forming elements 3a and the second mould part 4 with the plurality of corresponding second forming elements 4a, onto the blank support structure 5, and between the blank support structure 5 and the blank holding member 8, into a position where the cellulose products 1 can be formed from the cellulose fibres in the cellulose blank structure 2.

[0083] In figure 5b, the pre-cutting operation OPC is schematically shown. In the embodiment shown in figures 5a-b, the blank support structure 5 is arranged in close connection to the second forming elements 4a for an efficient pre-cutting operation OPC. Suitably, the blank support structure 5 is attached to the second mould part 4.

[0084] When the feeding of the cellulose blank structure 2 has been stopped in the position shown in figure 5a, where the cellulose blank structure 2 is arranged between the blank support structure 5 and the blank holding member 8, the first mould part 3 is moved towards the second mould part 4, in the same way as described in the embodiment above. The blank holding member 8 is moved towards the blank support structure 5 for pushing the cellulose blank structure 2 towards the blank support structure 5, and the blank support structure 5 together with the blank holding member 8 is holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during movement of the first mould part 3 towards the second mould part 4. During movement of the first mould part 3 towards the second mould part 4, the first cutting edges 6a and cooperating second cutting edges 6b are pre-cutting one or more openings O in the cellulose blank structure 2, as shown in figure 5b.

[0085] A further alternative embodiment of the first cutting devices comprising first cutting edges 6a and cooperating second cutting edges 6b are schematically illustrated in figures 6a-b. In this embodiment, the second mould part 4 is stationary and the first mould part 3 is movably arranged in relation to the second mould part 4 during the product forming operation OP. In the shown embodiment, the first cutting edges 6a are arranged as inner edges of downwards extending parts of the first forming elements 3a, and the cooperating second cutting edges 6b are arranged as outer edges of the second forming elements 4a. Through interaction between the first cutting edges 6a and corresponding second cutting edges 6b, the pre-cutting operation OPC is performed as a shear cutting process, where the cutting edges efficiently are pre-cutting the one or more openings O in the cellulose blank structure 2 in the pre-cutting operation OPC. The first cutting edges 6a and the second cutting edges 6b may be made of steel or other suitable materials. In the same way as described above, the first cutting edges 6a and cooperating second cutting edges 6b are as shown in figure 4 used for forming the cutting pattern X with the one or more openings O in the residual section 2R at least partly around each pre-determined section 2s. Suitably, the first cutting edges 6a and cooperating second cutting edges 6b are configured for arranging the cutting pattern X between each pre-determined section 2s and the residual section 2R to extend all the way through the cellulose blank structure 2 for an efficient separation between the pre-determined sections 2s and the residual section 2R. The cutting patterns X formed in the pre-cutting operation OPC may have any suitable shape or configuration enabling efficient transportation of the pre-determined sections 2s into the first forming elements 3a and / or the corresponding second forming elements 4a during the product forming operation OP as described above.

[0086] In figure 6a, the first mould part 3 and the second mould part 4 are arranged at a distance from each other in an open position Po, and a part of the cellulose blank structure 2 is fed into the forming mould M by the transporting unit T. The cellulose blank structure 2 is in this way fed by the transporting unit T between the first mould part 3 with the plurality of first forming elements 3a and the second mould part 4 with the plurality of corresponding second forming elements 4a, onto the blank support structure 5, and between the blank support structure 5 and the blank holding member 8, into a position where the cellulose products 1 can be formed from the cellulose fibres in the cellulose blank structure 2.

[0087] In figure 6b, the pre-cutting operation OPC is schematically shown. In the embodiment shown in figures 6a-b, the blank support structure 5 is arranged in close connection to the second forming elements 4a for an efficient pre-cutting operation OPC. Suitably, the blank support structure 5 is attached to the second mould part 4.

[0088] When the feeding of the cellulose blank structure 2 has been stopped in the position shown in figure 6a, where the cellulose blank structure 2 is arranged between the blank support structure 5 and the blank holding member 8, the first mould part 3 is moved towards the second mould part 4, in the same way as described in the embodiments above. The blank holding member 8 is moved towards the blank support structure 5 for pushing the cellulose blank structure 2 towards the blank support structure 5, and the blank support structure 5 together with the blank holding member 8 is holding the cellulose blank structure 2 in position between the first mould part 3 and the second mould part 4 during movement of the first mould part 3 towards the second mould part 4. During movement of the first mould part 3 towards the second mould part 4, the first cutting edges 6a and cooperating second cutting edges 6b are pre-cutting one or more openings O in the cellulose blank structure 2, as shown in figure 6b.

[0089] It will be appreciated that the above description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art 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 the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within the foregoing description and the appended claims. Reference signs mentioned in the claims should not be seen as limiting the extent of the matter protected by the claims, and their sole function is to make claims easier to understand.

[0090] REFERENCE SIGNS

[0091] 1 : Cellulose product

[0092] 2: Cellulose blank structure

[0093] 2c: Connecting structure

[0094] 2R: Residual section

[0095] 2s: Pre-determined section

[0096] 3: First mould part

[0097] 3a: First forming elements

[0098] 4: Second mould part

[0099] 4a: Second forming elements

[0100] 5: Blank support structure

[0101] 5a: First grid elements

[0102] 5b: Second grid elements

[0103] 5OP: Sectioned opening

[0104] 6: First cutting devices

[0105] 6a: First cutting edge

[0106] 6b: Second cutting edge

[0107] 7: Second cutting devices

[0108] 8: Blank holding member

[0109] 8a: First grid elements

[0110] 8b: Second grid elements

[0111] 8OP: Sectioned opening

[0112] C: Forming cavities

[0113] D1 : First direction

[0114] D2: Second direction

[0115] DF: Feeding direction

[0116] Dp: Pressing direction

[0117] M: Forming mould

[0118] O: Opening

[0119] Oc: Cutting operation

[0120] OP: Product forming operation

[0121] OPC: Pre-cutting operation

[0122] Po: Open position Pc: Closed position

[0123] S: Forming mould system

[0124] T: Blank transporting unit

[0125] X: Cutting pattern

Claims

CLAIMS1 . A multi-cavity forming mould system (S) for dry-forming a plurality of discrete three-dimensional cellulose products (1) from an air-formed cellulose blank structure (2), wherein the forming mould system (S) comprises a forming mould (M) having a first mould part (3) and a second mould part (4) arranged for cooperating with each other during a product forming operation (OP), wherein the first mould part (3) comprises a plurality of first forming elements (3a) and the second mould part (4) comprises a plurality of corresponding second forming elements (4a), wherein the forming mould system (S) comprises a blank transporting unit (T) configured to feed the cellulose blank structure (2) onto a blank support structure (5) arranged between the first mould part (3) and the second mould part(4) before the product forming operation (OP), wherein the blank support structure(5) is configured for holding the cellulose blank structure (2) in position between the first mould part (3) and the second mould part (4), wherein the first forming elements (3a) and the corresponding second forming elements (4a) are configured to apply a forming pressure (Pp) during the product forming operation (OP) onto pre-determined sections (2s) of the cellulose blank structure (2) associated with the first forming elements (3a) and the second forming elements (4a), such that the pre-determined sections (2s) are formed into the cellulose products (1), wherein the forming mould (M) comprises first cutting devices (6) configured to pre-cut one or more openings (O) in the cellulose blank structure (2) in a pre-cutting operation (OPC) during the product forming operation (OP), wherein the forming mould (M) comprises second cutting devices (7) configured to cut out the cellulose products (1) from the cellulose blank structure (2) in a cutting operation (Oc) during the product forming operation (OP) or after the product forming operation (OP), wherein the blank support structure (5) comprises a plurality of sectioned openings (5OP), wherein the sectioned openings (5OP) are configured for allowing passage of the first forming elements (3a) and / or the corresponding second forming elements (4a) during the product forming operation (OP).

2. The multi-cavity forming mould system (S) according to claim 1 ,wherein the blank support structure (5) is configured as a grid-like structure comprising a plurality of first grid elements (5a) and a plurality of second grid elements (5b), wherein the first grid elements (5a) are extending in a first direction (D1) and arranged at a distance from each other, wherein the second grid elements (5b) are extending in a second direction (D2) and arranged at a distance from each other, wherein the first direction (D1) and the second direction (D2) are different from each other.

3. The multi-cavity forming mould system (S) according to claim 2, wherein the plurality of sectioned openings (5OP) of the blank support structure (5) are formed by the plurality of first grid elements (5a) and the plurality of second grid elements (5b).

4. The multi-cavity forming mould system (S) according to any preceding claim, wherein the forming mould system (S) comprises a blank holding member (8) arranged between the first mould part (3) and the second mould part(4), wherein the blank holding member (8) comprises a plurality of sectioned openings (8OP) configured for allowing passage of the first forming elements (3a) and / or the corresponding second forming elements (4a) during forming of the cellulose products (1), wherein the blank transporting unit (T) is configured to feed the cellulose blank structure (2) between the blank support structure (5) and the blank holding member (8), wherein the blank holding member (8) is configured for pushing the cellulose blank structure (2) towards the blank support structure(5) for holding the cellulose blank structure (2) in position between the first mould part (3) and the second mould part (4).

5. The multi-cavity forming mould system (S) according to claim 4, wherein the blank holding member (8) is configured as a grid-like structure comprising a plurality of first grid elements (8a) and a plurality of second grid elements (8b), wherein the first grid elements (8a) are extending in a first direction (D1) and arranged at a distance from each other, wherein the second grid elements (8b) are extending in a second direction (D2) and arranged at a distance from each other, wherein the first direction (D1) and the second direction (D2) are different from each other.

6. The multi-cavity forming mould system (S) according to claim 5, wherein the plurality of sectioned openings (8OP) of the blank holding member (8) are formed by the plurality of first grid elements (8a) and the plurality of second grid elements (8b).

7. The multi-cavity forming mould system (S) according to any of claims 1 to 3, wherein the cellulose blank structure (2) comprises a residual section (2R) surrounding or arranged in connection to the pre-determined sections (2s), wherein the first cutting devices (6) are configured for arranging a cutting pattern (X) formed by the one or more openings (O) in the residual section (2R) at least partly around each pre-determined section (2s).

8. The multi-cavity forming mould system (S) according to claim 7, wherein the first cutting devices (6) are configured for forming at least one connecting structure (2c) by the cutting pattern (X) between each predetermined section (2s) and the residual section (2R) for connecting each predetermined section (2s) to the residual section (2R).

9. The multi-cavity forming mould system (S) according to claim 7 or 8, wherein the first cutting devices (6) are configured for arranging the cutting pattern (X) to extend through the cellulose blank structure (2).

10. The multi-cavity forming mould system (S) according to any preceding claim, wherein the second cutting devices (7) are arranged in connection to each of the first forming elements (3a) and / or the corresponding second forming elements (4b), wherein the first cutting devices (6) are arranged in connection to the second cutting devices (7), at a distance and radially outwardly from the second cutting devices (7).11 . The multi-cavity forming mould system (S) according to any preceding claim, wherein the multi-cavity forming mould system (S) is configured for initiating the pre-cutting operation (OPC) when the first mould part (3) moves from an open position (Po) to a closed position (Pc), wherein the first cutting devices(6) are configured for pre-cutting the cellulose blank structure (2) before the cutting operation (Oc) is initiated.

12. The multi-cavity forming mould system (S) according to any preceding claim, wherein the forming mould M is configured for dry-forming the cellulose products (1) by pressing and heating the pre-determined sections (2s) with a forming pressure (PF) in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and with a forming temperature (TF) in the range of 60-300 °C, preferably in the range of 100-200 °C, more preferably in the range of 120-170 °C.

13. A method for dry-forming a plurality of discrete three-dimensional cellulose products (1) from an air-formed cellulose blank structure (2) in a multi-cavity forming mould system (S), wherein the forming mould system (S) comprises a forming mould (M) having a first mould part (3) and a second mould part (4) arranged for cooperating with each other during a product forming operation (OP), wherein the first mould part (3) comprises a plurality of first forming elements (3a) and the second mould part (4) comprises a plurality of corresponding second forming elements (4a), wherein the forming mould (M) comprises first cutting devices (6) and second cutting devices (7), wherein the forming mould system (S) comprises a blank transporting unit (T) and a blank support structure (5) arranged between the first mould part (3) and the second mould part (4), wherein the method comprises the steps: feeding the cellulose blank structure (2) onto the blank support structure (5) for holding the cellulose blank structure (2) in position between the first mould part (3) and the second mould part (4), and pre-cutting one or more openings (O) in the cellulose blank structure (2) when arranged onto the blank support structure (5) with the first cutting devices (6); applying a forming pressure (PF) onto pre-determined sections (2s) of the cellulose blank structure (2) associated with the first forming elements (3a) and the second forming elements (4a) by means of the first forming elements (3a) and the corresponding second forming elements (4a) for forming the predetermined sections (2s) into cellulose products (1), wherein the blank support structure (5) comprises a plurality of sectioned openings (5OP) configured forallowing passage of the first forming elements (3a) and / or the corresponding second forming elements (4a) during forming of the cellulose products (1); cutting out the cellulose products (1) from the cellulose blank structure (2) with the second cutting devices (7) during forming of the cellulose products (1) or after forming of the cellulose products (1).

14. The method according to claim 13, wherein the method further comprises the step: feeding the cellulose blank structure (2) into a position between the first mould part (3) and the second mould part (4) where the pre-determined sections (2s) are aligned with the sectioned openings (5OP) of the blank support structure (5).

15. The method according to claim 13 or 14, wherein the forming mould system (S) comprises a blank holding member (8) arranged between the first mould part (3) and the second mould part (4), wherein the blank holding member (8) comprises a plurality of sectioned openings (8OP) configured for allowing passage of the first forming elements (3a) and / or the corresponding second forming elements (4a) during forming of the cellulose products (1), wherein the method comprises the steps: feeding the cellulose blank structure (2) between the blank support structure (5) and the blank holding member (8); pushing the cellulose blank structure (2) towards the blank support structure (5) with the blank holding member (8) for holding the cellulose blank structure (2) in position between the first mould part (3) and the second mould part (4).

16. The method according to claim 15, wherein the method further comprises the step: feeding the cellulose blank structure (2) into a position between the first mould part (3) and the second mould part (4) where the pre-determined sections (2s) are aligned with the sectioned openings (8OP) of the blank holding member (8).

17. The method according to any of claims 13 to 16, wherein the cellulose blank structure (2) comprises a residual section (2R) surrounding or arranged in connection to the pre-determined sections (2s),wherein the method comprises the step: arranging the one or more openings (O) as a cutting pattern (X) in the residual section (2R) at least partly around each predetermined section (2s).

18. The method according to claim 17, wherein the method comprises the step: forming at least one connecting structure (2c) by the cutting pattern (X) between each pre-determined section (2s) and the residual section (2R) for connecting each pre-determined section (2s) to the residual section (2R).

19. The method according to claim 17 or 18, wherein the method comprises the step: arranging the cutting pattern (X) to extend through the cellulose blank structure (2).

20. The method according to any of claims 13 to 19, wherein the method comprises the steps: initiating the pre-cutting operation (OPC) when the first mould part (3) moves from an open position (Po) to a closed position (Pc); and pre-cutting the cellulose blank structure (2) before the cutting operation (Oc) is initiated.

21. The method according to any of claims 13 to 20, wherein the method further comprises the steps: dry-forming the cellulose products (1) by pressing and heating the pre-determined sections (2s) with a forming pressure (Pp) in the range of 1-600 MPa, preferably in the range of 1-100 MPa, more preferably in the range of 4-20 MPa, and with a forming temperature (Tp) in the range of 60-300 °C, preferably in the range of 100-200 °C, more preferably in the range of 120-170 °C.

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