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 cellulose products (1) into a three-dimensional shape (S3D) from an air-formed cellulose blank structure (2). Cutting devices (6) are in a cutting operation (Oc) during a product forming operation (Op) configured for cutting out a plurality of pre-determined sections (2s) of the cellulose blank structure (2) having a two-dimensional flat pattern (P2D). When the pre-determined sections (2s) are arranged in a forming mould (M) between corresponding first forming elements (3a) and second forming elements (4a) during the product forming operation (Op), the pre-determined sections (2s) are configured for being folded into a configuration corresponding to the three-dimensional shape (S3D) of the cellulose products (1). The first forming elements (3a) and the corresponding second forming elements (4a) are configured to apply a forming pressure (PF) during the product forming operation (Op) onto the folded 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).

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 cellulose products into a three-dimensional shape from an airformed 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 into the forming mould 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 blank support structure comprises a plurality of sectioned openings, and 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. The forming mould comprises a plurality of cutting devices arranged in connection to the plurality of first forming elements and / or corresponding second forming elements. The cutting devices are in a cutting operation during the product forming operation configured for cutting out a plurality of pre-determined sections of the cellulose blank structure having a two- dimensional flat pattern. When the pre-determined sections are arranged in the forming mould between corresponding first forming elements and second forming elements during the product forming operation, the pre-determined sections are configured for being folded into a configuration corresponding to the three- dimensional shape of the cellulose products. The first forming elements and the corresponding second forming elements are configured to apply a forming pressure during the product forming operation onto the folded pre-determined 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.

[0013] Advantages with these features are that the cutting operation with the cutting devices, and the supporting of the cellulose blank structure by the blank support structure together with the folding of the cut out predetermined sections 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. By folding the pre-determined sections with the two-dimensional flat pattern into the configuration corresponding to the three-dimensional shape of the cellulose products, the pre-determined sections of the cellulose blank structure is preformed with a shape suitable for fitting between the forming elements. With the expression two-dimensional flat pattern is meant that the pre-determined sections have a flat configuration with main extensions in two dimensions that are considerably greater than the thickness of the pre-determined sections in a third dimension. Thus, the pre-determined sections with the two-dimensional flat pattern may have a certain thickness, but with a flat two-dimensional main configuration. With the expression configuration corresponding to the three-dimensional shape of the cellulose products is meant that the pre-determined sections are shaped into a three-dimensional structure resembling the shape of the cellulose products. It should be understood that the final shape of the cellulose products is established during the final part of the product forming operation when the forming pressure is applied onto the predetermined sections. The configuration corresponding to the three-dimensional shape of the cellulose products is suitably a three-dimensional body of cellulose fibres with a three-dimensional shape similar to the three-dimensional shape of the cellulose products, but with a thicker non-compressed configuration. The cutting operation and the blank support structure are together with the folding of the pre-determined sections used for proper forming of the cellulose products in the forming mould. This is especially of advantage for deep-drawn products, and the operational steps are supporting the forming of cellulose products with high quality by avoiding cracks, fibre separations, material fractures, or other unwanted structural weakenings.

[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. 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] In one embodiment, the multi-cavity forming mould system is configured for initiating the cutting operation when the forming mould moves from an open position to a closed position. The cutting operation is in this way taking place during the product forming operation for efficient forming of the cellulose products.

[0019] 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.

[0020] In one embodiment, the two-dimensional flat pattern of the pre-determined sections is arranged as a two-dimensional structure comprising two or more extending tabs with side edges. When upon folding of the pre-determined sections, the side edges of adjacent tabs are configured for being arranged in connection to each other. The two or more extending tabs are used for an efficient reshaping of the pre-determined sections arranged as two-dimensional structures to the configuration corresponding to the three-dimensional shape of the cellulose products. The arrangement with the pre-determined sections having extending tabs is preventing large overlapping sections when the pre-determined sections are folded from the two-dimensional to the three-dimensional configuration. The extending tabs are further enabling the arrangement of side edges of adjacent tabs in connection to each other for an efficient forming of the cellulose products in the forming mould, with an optimized amount of cellulose fibres.

[0021] In one embodiment, upon folding of the pre-determined sections, the side edges of adjacent tabs are configured for being arranged in connection to each other in an overlapping relationship. The overlapping side edges are preventing the risk with weak sections in the formed cellulose products. The disclosure further concerns a method for dry-forming a plurality of discrete cellulose products into a three-dimensional shape from an air-formed cellulose blank structure in a multi-cavity 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. 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 a plurality of cutting devices arranged in connection to the plurality of first forming elements and / or corresponding second forming elements. The forming mould system comprises a blank transporting unit configured to feed the cellulose blank structure into the forming mould, and a blank support structure arranged between the first mould part and the second mould part. The blank support structure comprises a plurality of sectioned openings, where the sectioned openings are configured for allowing passage of the first forming elements and / or the corresponding second forming elements. The method comprises the steps: feeding the cellulose blank structure by the blank transporting unit onto the blank support structure for holding the cellulose blank structure in position between the first mould part and the second mould part; cutting out a plurality of pre-determined sections of the cellulose blank structure by the cutting devices, wherein the pre-determined sections are having a two-dimensional flat pattern, wherein the pre-determined sections are arranged in the forming mould between corresponding first forming elements and second forming elements; folding the pre-determined sections into a configuration corresponding to the three- dimensional shape of the cellulose products; applying a forming pressure by the first forming elements and corresponding second forming elements onto the folded predetermined sections of the cellulose blank structure, for forming the folded predetermined sections into the cellulose products.

[0022] Advantages with the method are that the cutting operation with the cutting devices, and the supporting of the cellulose blank structure by the blank support structure together with the folding of the cut out predetermined sections 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. By folding the pre-determined sections with the two-dimensional flat pattern into the configuration corresponding to the three-dimensional shape of the cellulose products, the pre-determined sections of the cellulose blank structure is pre- formed with a shape suitable for fitting between the forming elements. With the expression two-dimensional flat pattern is meant that the pre-determined sections have a flat configuration with main extensions in two dimensions that are considerably greater than the thickness of the pre-determined sections in a third dimension. Thus, the pre-determined sections with the two-dimensional flat pattern may have a certain thickness, but with a flat two-dimensional main configuration. With the expression configuration corresponding to the three-dimensional shape of the cellulose products is meant that the pre-determined sections are shaped into a three-dimensional structure resembling the shape of the cellulose products. It should be understood that the final shape of the cellulose products is established during the final part of the product forming operation when the forming pressure is applied onto the predetermined sections. The configuration corresponding to the three-dimensional shape of the cellulose products is suitably a three-dimensional body of cellulose fibres with a three-dimensional shape similar to the three-dimensional shape of the cellulose products, but with a thicker non-compressed configuration. The cutting operation and the blank support structure are together with the folding of the pre-determined sections used for proper forming of the cellulose products in the forming mould. This is especially of advantage for deep-drawn products, and the operational steps are supporting the forming of cellulose products with high quality by avoiding cracks, fibre separations, material fractures, or other unwanted structural weakenings.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] In one embodiment, the method comprises the steps: initiating the cutting operation when the forming mould moves from an open position to a closed position. The cutting operation is in this way taking place during the product forming operation for efficient forming of the cellulose products.

[0027] 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.

[0028] In one embodiment, the two-dimensional flat pattern of the pre-determined sections is arranged as a two-dimensional structure comprising two or more extending tabs with side edges. The method further comprises the step: folding the pre-determined sections into a configuration where the side edges of adjacent tabs are arranged in connection to each other. The two or more extending tabs are used for an efficient reshaping of the pre-determined sections arranged as two-dimensional structures to the configuration corresponding to the three-dimensional shape of the cellulose products. The arrangement with the pre-determined sections having extending tabs is preventing large overlapping sections when the pre-determined sections are folded from the two-dimensional to the three-dimensional configuration. The extending tabs are further enabling the arrangement of side edges of adjacent tabs in connection to each other for an efficient forming of the cellulose products in the forming mould, with an optimized amount of cellulose fibres.

[0029] In one embodiment, the method further comprises the step: folding the predetermined sections into a configuration where the side edges of adjacent tabs are arranged in connection to each other in an overlapping relationship. The overlapping side edges are preventing the risk with weak sections in the formed cellulose products.

[0030] BRIEF DESCRIPTION OF DRAWINGS

[0031] The disclosure will be described in detail in the following, with reference to the attached drawings, in which

[0032] 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,

[0033] Fig. 2 shows schematically, in a perspective view, the cellulose blank structure with pre-determined sections having a two-dimensional flat pattern,

[0034] Fig. 3a-g show schematically, in side views, operational steps of the forming mould during forming of the cellulose products, and

[0035] Fig. 4a-c show schematically, in perspective views, folding of the pre-determined sections from a two-dimensional flat pattern into a configuration corresponding to the three-dimensional shape of the cellulose products.

[0036] DESCRIPTION OF EXAMPLE EMBODIMENTS

[0037] 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.

[0038] Figures 1a-b schematically shows a multi-cavity forming mould system S for dryforming a plurality of discrete cellulose products 1 into a three-dimensional shape SSD from an air-formed 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] In the exemplified embodiment shown in figure 2, the plurality of pre-determined sections 2s are arranged as shaped 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.

[0048] 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.

[0049] 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.

[0050] 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, for example in close connection to the second mould part 4. Alternatively, the blank support structure 5 is attached to any other suitable structure of the multi-cavity forming mould system S.

[0051] 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 la- fa. 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.

[0052] 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.

[0053] 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.

[0054] The forming mould M comprises cutting devices 6, as shown in figures 1a-b. In the shown embodiment, the forming mould M comprises a plurality of cutting devices 6 that are arranged in connection to corresponding first forming elements 3a. The cutting devices 6 are configured to cut out a plurality of pre-determined sections 2s of the cellulose blank structure 2 in a cutting operation Oc during the product forming operation OP. The pre-determined sections 2s cut out from the cellulose blank structure 2 are having a two-dimensional flat pattern P2D, as shown in for example figure 4a. The cutting operation Oc is enabling the forming of 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 cutting devices 6 may be made of steel or other suitable materials.

[0055] The cutting devices 6 can be configured with a plurality of cutting elements that together cuts the cellulose blank structure into the desired shape, or can be configured as one continuous cutting element.

[0056] With the expression two-dimensional flat pattern P2D of the pre-determined sections 2s is meant that the pre-determined sections 2s have a flat configuration with main extensions in two dimensions that are considerably greater than the thickness of the pre-determined sections in a third dimension, as understood from for example figure 4a. Thus, the pre-determined sections 2s with the two-dimensional flat pattern P2D may have a certain thickness, but with a flat two-dimensional main configuration.

[0057] The two-dimensional flat pattern P2D of the pre-determined sections 2s is suitably arranged as a two-dimensional structure comprising two or more extending tabs 20 with side edges 21.

[0058] In the embodiment shown in figure 4a, the two-dimensional flat pattern P2D of the predetermined sections 2s is arranged as a two-dimensional structure comprising four extending tabs 20 with side edges 21 . When the pre-determined sections 2s are being folded, the side edges 21 of adjacent tabs 20 are arranged in connection to each other, as illustrated in figures 4b-c for shaping the pre-determined sections 2s into configurations corresponding to the three-dimensional shape SSD of the cellulose products 1. Suitably, when the pre-determined sections 2s are being folded into a three-dimensional configuration corresponding to the three-dimensional shape SSD of the cellulose products 1 , the side edges 21 of adjacent tabs 20 are arranged in connection to each other in an overlapping relationship Ro, as shown in figure 4c. In this way, the risk for weak sections in the formed cellulose products 1 is eliminated through the overlapping side edges 21. The final shape of the formed cellulose product 1 is schematically shown in figure 3g, and as understood from figures 4b-c, the folded pre-determined sections 2s, as shown in figure 4c, have configurations corresponding to the three-dimensional shape SSD of the cellulose products 1.

[0059] With the expression configuration corresponding to the three-dimensional shape SSD of the cellulose products 1 is meant that the pre-determined sections 2s are shaped into a three-dimensional structure resembling the shape of the cellulose products 1. It should be understood that the final shape of the cellulose products 1 is established during the final part of the product forming operation OP when the forming pressure is applied onto the pre-determined sections 2s. The configuration corresponding to the three-dimensional shape SSD of the cellulose products 1 is suitably a three- dimensional body of cellulose fibres with a three-dimensional shape similar to the three-dimensional shape of the cellulose products 1 , but with a thicker noncompressed configuration. It should be understood that specific designed or shaped sections of the final cellulose products 1 , such as for example rim sections or other structural sections of the cellulose products 1 , may be formed in the final pressing step.

[0060] The cutting devices 6 are used for cutting out the shaped pre-determined sections 2s of the cellulose blank structure 2 in the cutting operation Oc, and the pre-determined sections 2s cut out from the cellulose blank structure 2 are having a two-dimensional flat pattern P2D. The cutting patterns forming the pre-determined sections 2s in the cutting operation Oc 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.

[0061] In the shown embodiment in figures 1a-b and 3a-g, the cutting devices 6 are arranged in connection to each of the first forming elements 3a. In other non-illustrated embodiments, the cutting devices 6 may instead be arranged in connection to each of the second forming elements 4a, or the cutting devices 6 may alternatively be arranged as cooperating cutting edges in connection to both first forming elements 3a and second forming elements 4b.

[0062] The multi-cavity forming mould system S is in the shown embodiment configured for initiating the cutting operation Oc when the first mould part 3 moves from an open position Po to a closed position Pc.

[0063] 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 connection to 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.

[0064] 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.

[0065] 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.

[0066] In other non-illustrated embodiments, the first mould part 3 may instead be stationary and the second mould part 4 is movably arranged in relation to the first mould part 3 in the pressing direction DP, or both the first mould part 3 and the second mould part 4 are movably arranged relative to each other in the pressing direction Dp.

[0067] 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.

[0068] The forming mould M is applying the forming pressure Pp by pressing the cut out predetermined sections 2s of 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 predetermined sections 2s 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 pre-determined sections 2s in the product forming operation OP. The cellulose products 1 are dry-formed in the forming mould M by pressing the predetermined 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 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.

[0069] 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 Dp, 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 pre-determined sections 2s of 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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 arranged for being 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. 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.

[0074] During movement of the first mould part 3 towards the second mould part 4, the cutting devices 6 are cutting out the pre-determined sections 2s from the cellulose blank structure 2, as shown in figures 3b-c. In this way, the cutting operation Oc is initiated when the first mould part 3 moves from an open position Po shown in figure 3a towards the closed position Pc shown in figure 3d. During the cutting operation Oc, the cutting devices 6 are cutting out the pre-determined sections 2s with the two- dimensional flat pattern P2D, as understood from figure 3b, and in this way the predetermined sections 2s are separated from the cellulose blank structure 2. The residual section 2R of the cellulose blank structure 2 is surrounding or arranged in connection to the pre-determined sections 2s, as shown in figure 3b, and when the pre-determined sections 2s are cut out from the cellulose blank structure 2 the remaining residual section 2R surrounding the pre-determined sections 2s are formed.

[0075] 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 cut out predetermined 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 two-dimensional flat pattern P2D, allowing the predetermined sections 2s to easily be drawn into corresponding second forming elements 4a through the pushing action from the first forming elements 3a. When the pre-determined sections 2s are drawn into the corresponding second forming elements 4a, the pre-determined sections 2s are folded into a configuration corresponding to the three-dimensional shape SSD of the cellulose products 1 , as indicated in figure 3c and shown in figures 4a-c. Thus, the pre-determined sections 2s are reshaped from the two-dimensional flat pattern P2D to the folded configuration corresponding to the three-dimensional shape SSD of the cellulose products 1 upon movement of the first forming elements 3a towards the second forming elements 4a, where the movement of the first forming elements 3a towards the second forming elements 4a are causing the folding of the pre-determined sections 2s.

[0076] As described above, the two-dimensional flat pattern P2D of the pre-determined sections 2s is arranged as a two-dimensional structure comprising two or more extending tabs 20 with side edges 21. When the pre-determined sections 2s are being folded, the side edges 21 of adjacent tabs 20 are configured for being arranged in connection to each other. Suitably, when the pre-determined sections 2s are being folded, the side edges 21 of adjacent tabs 20 are configured for being arranged in connection to each other in an overlapping relationship Ro, as shown in figure 4c. In this way, the risk for weak sections in the formed cellulose products 1 is eliminated.

[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 PF and the forming temperature TF are applied onto the pre-determined sections 2s of the cellulose blank structure 2.

[0078] When the forming pressure PF and forming temperature TF are applied onto the cellulose fibres, the cellulose product 1 is formed in the forming cavities C of the forming mould M from the pre-determined sections 2s of the cellulose blank structure 2. Suitably, through the specific shaping of the pre-determined sections 2s with the two-dimensional flat pattern P2D, there is no need for further finishing of the formed cellulose products 1. The pre-determined sections 2s are thus suitably designed with an amount of cellulose fibers enough for forming the cellulose products 1 without any residual fibre amount. The cellulose product 1 may be formed into any suitable three- dimensional shape in the forming mould M, depending on the design and construction of the cellulose products 1 .

[0079] 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 predetermined sections 2s of the cellulose blank structure 2 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 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. In this way, the cellulose fibres are integrated into the compressed fibre structures.

[0080] 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 PF, 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.

[0081] 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.

[0082] It should further be noted that each of the first and second forming elements 3a, 4a can have different shape depending on desired cellulose product. In figures 1 -3g, the cellulose product 1 is formed with an upper flange extending in a radial direction from an upper portion of the cellulose product 1 , and the first forming element 3a is shaped correspondingly. In figures 4a-4c, the cellulose product 1 is formed as a cup with a rim in the upper portion and no flange. Here, not show, the first forming element 3a is shaped correspondingly, i.e. with a flange extending in a radial direction that presses the upper portion of the cellulose product 1 , i.e. an upper portion of the folded cellulose blank structure 2 in the second forming element 4a, into the rim during the pressing operation. One advantage here is that any irregularities in shape of the upper portion of the cellulose product will be smoothed out in the pressing operation to give an even rim, as depicted in figure 4c.

[0083] 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.

[0084] 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.

[0085] REFERENCE SIGNS

[0086] 1 : Cellulose product

[0087] 2: Cellulose blank structure

[0088] 2c: Connecting structure

[0089] 2R: Residual section

[0090] 2s: Pre-determined section

[0091] 3: First mould part

[0092] 3a: First forming elements

[0093] 4: Second mould part

[0094] 4a: Second forming elements

[0095] 5: Blank support structure

[0096] 5a: First grid elements

[0097] 5b: Second grid elements

[0098] 5OP: Sectioned opening

[0099] 6: Cutting devices

[0100] 8: Blank holding member

[0101] 8a: First grid elements

[0102] 8b: Second grid elements

[0103] 8OP: Sectioned opening

[0104] 20: Tab

[0105] 21 : Side edge

[0106] C: Forming cavities

[0107] D1 : First direction

[0108] D2: Second direction

[0109] Dp: Feeding direction

[0110] Dp: Pressing direction

[0111] M: Forming mould

[0112] OP: Product forming operation

[0113] Oc: Cutting operation

[0114] ?2D: Two-dimensional flat pattern

[0115] Po: Open position

[0116] Pc: Closed position

[0117] Ro: Overlapping relationship S: Forming mould system

[0118] SSD: Three-dimensional shape

[0119] T: Blank transporting unit

Claims

CLAIMS1 . A multi-cavity forming mould system (S) for dry-forming a plurality of discrete cellulose products (1) into a three-dimensional shape (SSD) 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) into the forming mould (M) 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 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), wherein the forming mould (M) comprises a plurality of cutting devices (6) arranged in connection to the plurality of first forming elements (3a) and / or corresponding second forming elements (4a), wherein the cutting devices (6) in a cutting operation (Oc) during the product forming operation (OP) are configured for cutting out a plurality of pre-determined sections (2s) of the cellulose blank structure (2) having a two-dimensional flat pattern (PZD), wherein when the pre-determined sections (2s) are arranged in the forming mould (M) between corresponding first forming elements (3a) and second forming elements (4a) during the product forming operation (OP), the predetermined sections (2s) are configured for being folded into a configuration corresponding to the three-dimensional shape (SSD) of the cellulose products (1), 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 the folded pre-determined sections (2s) ofthe 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).

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 secondgrid 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 preceding claim, wherein the multi-cavity forming mould system (S) is configured for initiating the cutting operation (Oc) when the forming mould (M) moves from an open position (Po) to a closed position (Pc).

8. 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.

9. The multi-cavity forming mould system (S) according to any preceding claim, wherein the two-dimensional flat pattern (P2D) of the pre-determined sections (2s) is arranged as a two-dimensional structure comprising two or more extending tabs (20) with side edges (21), wherein upon folding of the predetermined sections (2s), the side edges (21) of adjacent tabs (20) are configured for being arranged in connection to each other.

10. The multi-cavity forming mould system (S) according to claim 9,wherein upon folding of the pre-determined sections (2s), the side edges (21) of adjacent tabs (20) are configured for being arranged in connection to each other in an overlapping relationship (Ro).11 . A method for dry-forming a plurality of discrete cellulose products (1) into a three- dimensional shape (SSD) 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, 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 a plurality of cutting devices (6) arranged in connection to the plurality of first forming elements (3a) and / or 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) into the forming mould (M), and a blank support structure (5) arranged between the first mould part (3) and the second mould part (4), 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), wherein the method comprises the steps: feeding the cellulose blank structure (2) by the blank transporting unit (T) 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); cutting out a plurality of pre-determined sections (2s) of the cellulose blank structure (2) by the cutting devices (6), wherein the pre-determined sections (2s) are having a two-dimensional flat pattern (PZD), wherein the pre-determined sections (2s) are arranged in the forming mould (M) between corresponding first forming elements (3a) and second forming elements (4a); folding the pre-determined sections (2s) into a configuration corresponding to the three-dimensional shape (SSD) of the cellulose products (1); applying a forming pressure (Pp) by the first forming elements (3a) and corresponding second forming elements (4a) onto the folded pre-determinedsections (2s) of the cellulose blank structure (2), for forming the folded predetermined sections (2s) into the cellulose products (1).

12. The method according to claim 11 , 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).

13. The method according to claim 11 or 12, 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).

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 (8OP) of the blank holding member (8).

15. The method according to any of claims 11 to 14, wherein the method comprises the steps: initiating the cutting operation (Oc) when the forming mould (M) moves from an open position (Po) to a closed position (Pc).

16. The method according to any of claims 11 to 15,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 (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.

17. The method according to any of claims 11 to 16, wherein the two-dimensional flat pattern (P2D) of the pre-determined sections (2s) is arranged as a two-dimensional structure comprising two or more extending tabs (20) with side edges (21), wherein the method further comprises the step: folding the pre-determined sections (2s) into a configuration where the side edges (21) of adjacent tabs (20) are arranged in connection to each other.

18. The method according to claim 17, wherein the method further comprises the step: folding the predetermined sections (2s) into a configuration where the side edges (21) of adjacent tabs (20) are arranged in connection to each other in an overlapping relationship (Ro).

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