Method and device for producing molded bodies

Abstract

The invention relates to a method for producing molded bodies made of a fiber-based material, in particular paper, wherein a starting material is fed to a processing station (5) and the starting material is shaped and / or pressed into molded bodies (2) in the processing station (5). Material blanks (3) are fed to the processing station as starting material, wherein each molded body (2) is formed from one material blank (3). The invention further relates to a device for producing molded bodies made of a fiber-based material, in particular paper.

Description

[0001] Method and apparatus for the production of shaped bodies

[0002] SCOPE OF APPLICATION AND STATE OF THE ART

[0003] The invention relates to a method and a device for producing shaped bodies from a fiber-based material, in particular paper.

[0004] In the context of this application, a shaped body is defined as a three-dimensional hollow body. A shaped body is, for example, a container or vessel for the packaging industry, which has an opening through which a product can be poured. The opening can be closed after filling, in particular by attaching a lid and / or a sealing film.

[0005] Due to their suitability for recycling, fiber-based materials are increasingly being used for packaging in the packaging industry, some of which are also made from already recycled materials.

[0006] A fiber-based material is defined as a material comprising at least one layer of a fibrous material, for example pulp, wood pulp and / or recycled paper pulp, in particular paper and / or cardboard.

[0007] In one embodiment, the molded body serves as a capsule shell for a coffee capsule for use in single-serve coffee machines. However, numerous other applications for molded bodies made from a fiber-based material are known and / or conceivable.

[0008] Devices for manufacturing shaped bodies from fiber-based materials are known, comprising a first tool element with a tool surface and a second tool element with a counter surface complementary to the tool surface, wherein the tool surface and the counter surface are designed as a negative forming surface, also referred to as a die, and as a positive forming surface, also referred to as a punch or male die. The first tool element and the second tool element are adjusted relative to each other in a pressing direction to form a blank arranged between the tool elements into the shaped body or a semi-finished product. The forming of the blank is also referred to as pressing. Such a method of manufacturing a shaped body from a multilayer fiber-based material is known, for example, from WO 2019 / 209160 A1. The layers of the fiber-based material are each provided as a continuous material web. TASK AND SOLUTION

[0009] The object of the invention is to provide a method and a device which allow the automated production of shaped bodies, in particular shaped bodies made of a single- or multi-layer fiber-based material, at high process speeds.

[0010] According to a first aspect, a process for manufacturing shaped bodies, in particular shaped bodies made of a single- or multi-layer fiber-based material, is created, wherein a starting material is fed to a processing station and the starting material is formed and / or pressed into shaped bodies in the processing station. The process provides that material blanks are fed to the processing station as starting material and that one shaped body is formed from each material blank.

[0011] Material blanks are flat or pre-shaped objects whose form and / or dimensions are adapted to the molded body to be produced. In certain configurations, rotationally symmetrical molded bodies are formed from these material blanks. Material blanks for rotationally symmetrical and / or other molded bodies are circular in certain configurations. The adaptation of the material blanks to the molded body is achieved, in particular, in such a way that, during demolding and any subsequent trimming or punching of the molded body to its final shape, no or only a minimal amount of waste remains.

[0012] The use of individual material blanks, as opposed to a larger format material blank or a material web, makes it possible to avoid influences and / or interactions between molded bodies formed from different material blanks due to material distortion during forming and / or pressing in the processing station.

[0013] Unless otherwise indicated by the context, the terms "a," "an," "one," etc., are used in the description and claims solely as indefinite articles and not as modifiers. In particular, the second tool element in certain embodiments has more than one mating surface. The terms "first," "second," etc., serve only to distinguish individual components and / or elements and do not indicate any sequence. Furthermore, the mention of the term "first," "first," "first," etc., does not require the presence of a second component or element. According to the invention, exactly one molded body is formed from exactly one single- or multi-layered material blank.

[0014] The fiber-based material and / or at least one layer of a multilayer fiber-based material is, in various embodiments, a fiber-based tissue material. In the context of this application, a fiber-based tissue material is defined as a creped material, supplied as sheets or in web form, made from a fibrous material, such as pulp, wood pulp, and / or recycled paper pulp. The fiber-based tissue material is, in particular, tissue paper. Due to the creping, the tissue material exhibits improved extensibility compared to other fiber-based materials. In one embodiment, the fiber-based tissue material is single-layer. In other embodiments, a multilayer fiber-based tissue material is provided, wherein at least one layer of the multilayer tissue material is creped for improved extensibility.

[0015] Alternatively or additionally, the fiber-based material and / or at least one layer of a multi-layered fiber-based material in certain configurations is a so-called air-iaid paper. The air-iaid process, also known as the airlaid process, refers here to a method for producing a fiber-based material from cellulose, in which cellulose fibers are formed using compressed air rather than water. A material produced in this way is called air-iaid paper, or airlaid paper. Depending on the configuration, air-iaid paper can be provided as a single- or multi-layered continuous web from which blanks are die-cut, or as a sheet or pre-formed blank, and processed in the processing station.

[0016] Depending on the application, the processing station can be designed to apply the necessary pressure for forming.

[0017] In some configurations, the material blanks are moistened and / or sprayed with process chemicals and / or barriers upstream of and / or at the processing station. These barriers serve in particular as oxygen, grease, oil, water, and / or steam barriers. In other configurations, the molded parts are dried by air supply in and / or downstream of the processing station. Alternatively or additionally, in other configurations, the material blanks are heated upstream of, in, and / or downstream of the processing station. In other configurations, a plurality of material blanks are held by a carrier element, and carrier elements, each holding several material blanks, are fed to the processing station, in particular in a timed manner.Depending on the application, the support elements are designed to accommodate multiple material blanks. In some configurations, the support elements feature recesses for these blanks. These recesses are arranged in one or more rows and columns, allowing the blanks to be held in the support elements in a matrix-like configuration. In some configurations, the support elements have a plate-shaped or board-like base. Support elements with recesses for material blanks are therefore also referred to here as cell boards. The arrangement of the recesses on the base is adapted to the processing station in some configurations. For this purpose, the material blanks can be positioned relative to each other at a defined distance according to a specific pattern, which may be determined by the arrangement of tools in the processing station.The receivers are arranged in configurations, particularly in a row or in a matrix comprising at least two rows. In a single-row configuration, several receivers are arranged side by side. In a multi-row configuration, several receivers are arranged side by side in each row, which is why this can be described as a matrix-like arrangement in multiple rows and multiple columns. The rows are arranged sequentially in the direction of transport, and the columns are arranged side by side perpendicular to the direction of transport.

[0018] In some embodiments, after demolding, the molded parts are transferred from the processing station to transport elements, and transport elements, each carrying at least one molded part, are removed from the processing station, particularly in a timed manner. Depending on the application, the transport elements are designed to accommodate multiple molded parts. In some embodiments, the transport elements have receptacles for the molded parts. In some embodiments, the transport elements have a plate-shaped or board-like base. The number of receptacles in a transport element is equal to the number of receptacles in a support element. In some embodiments, the receptacles for transport elements and / or support elements are designed as hole-like recesses in a flat, board-shaped element.

[0019] In certain embodiments, the transport elements and the support elements are transported in a common transport plane of a transport system, particularly in an alternating manner. The transport system serves to supply the material blanks to the processing station and to remove the formed parts from the processing station. In these embodiments, the transport elements and the support elements are distributed along the transport plane such that, in a clocked operation, the number of material blanks supplied in one cycle equals the number of receivers in the transport elements for formed parts.

[0020] In some embodiments, a transport element and a support element are designed as a single component, whereby when the components are transported to the processing station, a plurality of material blanks are fed to the processing station, and when the components are transported away from the processing station, a plurality of shaped bodies are removed from the processing station.

[0021] Depending on the design, the material blanks are produced inline, i.e., in a single process combined with the forming of the shaped parts, or entirely or partially offline, i.e., entirely or partially in a separate process. In certain designs, the material blanks are preferably produced in such a way that any resulting waste is minimized and / or can be directly recycled.

[0022] In various configurations, the material blanks are punched out upstream of the processing station from a continuous, single- or multi-layer material web, formed from a raw material, in particular formed in an air-assisted process, and / or taken from a stock.

[0023] In embodiments, it is provided that the machining station has at least one press tool comprising a first tool element with several tool surfaces comprising at least one first tool surface and a second tool surface and a second tool element with a counter surface complementary to the tool surfaces, wherein the first tool element is pivotably mounted about an axis of rotation between a first tool position and a second tool position.and wherein, in the first tool position, the first tool surface is arranged in a working position and is opposite the second tool element in a pressing direction, and in the second tool position, the second tool surface is arranged in the working position and is opposite the second tool element in the pressing direction. The method for producing shaped bodies in the machining station with at least one such pressing tool comprises the steps: a) arranging the first tool element in the first tool position such that the first tool surface is arranged in the working position; b) adjusting the first tool surface arranged in the working position and / or the opposing surface in the pressing direction to form and / or press a plurality of material blanks arranged between the first and the second tool element into one shaped body each; c) before,following or simultaneously with step b) equipping a second tool surface not in the working position with material blanks, d) pivoting the first tool element about the axis of rotation to position the first tool element in the second tool position, so that the second tool surface is in the working position; and e) adjusting the second tool surface in the working position and / or the counter surface in the pressing direction to form and / or press the material blanks arranged between the first and the second tool element.

[0024] A back-and-forth movement of the counter surface and / or the tool surface of the tool element arranged in the working position in the pressing direction for forming and / or pressing the at least one material blank arranged between the tool elements is also referred to as a stroke movement. The method particularly allows for pulsed operation, with a stroke movement occurring in each pulse.

[0025] Between two stroke movements, the tool position changes. Before, after, or especially at least partially during the stroke movement, it is possible to set up one of the tool surfaces not in the working position, or, in the case of more than two tool surfaces, one of the tool surfaces not in the working position.

[0026] In one embodiment, the formed parts remain attached to the tool surface and are pivoted away from the working position along with it. For this purpose, the tool surfaces can have suction openings that can be pressurized with a vacuum. Before the tool surface is fitted with further material blanks, the formed parts are removed from the tool surface.

[0027] In embodiments, it is provided that the second tool element has at least a first counter surface and a second counter surface, wherein the second tool element is adjusted between a first operating position in which the first counter surface is opposite the first tool element in the pressing direction and a second operating position in which the second counter surface is opposite the first tool element in the pressing direction, in particular being adjusted at least partially simultaneously with step d), wherein in particular the second tool element is pivoted about an axis of rotation between the first operating position and the second operating position, in particular about an axis of rotation perpendicular to the pressing direction.

[0028] In some embodiments, the formed parts remain attached to the counter surface after demolding, while the second tool element, with the formed parts still attached, is pivoted from its operating position. For this purpose, the counter surfaces can be equipped with suction openings that can be pressurized with a vacuum. Before pivoting back into the operating position, the formed parts are removed from the counter surface. Removing the formed parts from the second tool element can be carried out, at least partially, simultaneously with setting up the first tool element.

[0029] According to a second aspect, a device for the production of shaped bodies, in particular shaped bodies made of a single- or multi-layer fiber-based material, is created comprising a processing station and a transport system, wherein the transport system is set up to supply an input material to the processing station, and the processing station is set up to transform and / or press a supplied input material into shaped bodies in a clocked operation.

[0030] The transport system is set up to supply material blanks to the processing station as input material, and the processing station is set up to form one shaped body from each material blank.

[0031] The use of individual material blanks for each molded body instead of a continuous material web or larger material blanks for forming multiple molded bodies allows for the avoidance of influences and / or interactions between molded bodies formed from different material blanks due to material distortion during forming and / or pressing in the processing station.

[0032] In certain embodiments, the transport system comprises support elements, each configured to hold multiple material blanks. The transport system is configured to feed support elements, each with at least one material blank, to the processing station, particularly in a timed manner. In some embodiments, the support elements have receptacles, each configured to hold a single material blank. The shape and / or size of the receptacle is adapted to a specific material blank to securely hold it without unwanted deformation. The number and / or arrangement of the receptacles is adapted to a specific processing station.In certain embodiments, the support elements are fed to and removed from the processing station in a transport direction. In these embodiments, the support elements comprise at least one series of receptacles, the receptacles being arranged transversely, and in particular perpendicularly, to the transport direction.

[0033] In some embodiments, the transport system includes transport elements, each of which is designed to take over the molded parts from the processing station after demolding, and the transport system is set up to remove transport elements with the molded parts they hold from the processing station, in particular to remove them in a timed manner.

[0034] The transport elements feature receptacles, each designed to hold a shaped part. The shape and / or size of the receptacle is adapted to the shaped part to securely hold it without unwanted deformation. The number and / or arrangement of the receptacles is adapted to a processing station.

[0035] In certain configurations, the transport system is designed to transport the transport elements and the support elements on a common transport plane. In these configurations, the transport elements and the support elements have identical or similar coupling elements for connection to a common drive system for transport on this transport plane. The transport elements and the support elements differ only in the shape of their receptacles and / or their dimensions in the transport direction.

[0036] In certain embodiments, a transport element and a support element are designed as a single component, with each component having first receptacles for a material blank and second receptacles for a shaped part, and / or the component having at least two receptacles into which either a material blank or a shaped part can be inserted. This design allows the combined transport and support element to have more compact dimensions overall, thus enabling a higher output of shaped parts. The arrangement of the receptacles on the component can be selected appropriately depending on the application. In particular, the first and second receptacles and / or the combined receptacles are arranged in a row, especially in a row perpendicular to the transport direction.

[0037] In some configurations, upstream of the processing station, a punching station is provided to punch out the material blanks from a continuous material web, a forming station is provided to shape the material blanks from a raw material, in particular in an air-assisted forming process, and / or a stock is provided to supply pre-made material blanks.

[0038] In embodiments, it is provided that the machining station has at least one pressing tool comprising a first tool element with several tool surfaces comprising at least a first tool surface and a second tool surface, and a second tool element with a counter surface complementary to the tool surfaces, wherein the first tool element is pivotably mounted about an axis of rotation between a first tool position and a second tool position, and wherein in the first tool position the first tool surface is arranged in a working position and is opposite the second tool element in a pressing direction, and in the second tool position the second tool surface is arranged in the working position and is opposite the second tool element in the pressing direction, wherein the machining station is configuredto adjust the tool surface and the counter surface in the working position relative to each other in the pressing direction for forming and / or pressing material blanks arranged between the first and second tool elements.

[0039] In some embodiments, the first tool element comprises exactly two tool surfaces arranged 180° apart around the axis of rotation, which are alternately brought into the working position. In other embodiments, the first tool element comprises more than two tool surfaces, distributed around the axis of rotation, particularly uniformly distributed, which are successively brought into the working position by rotating the first tool element.

[0040] In some embodiments, the second tool surface and / or another tool surface of the first tool element is arranged in a setup, removal, and / or cleaning position in the first tool position. In some embodiments, the device includes a setup unit configured to load material blanks onto the second tool surface and / or another tool surface arranged in the setup, removal, and / or cleaning position in the first tool position, particularly in a semi- or fully automated manner. Alternatively or additionally, some embodiments include a removal unit configured to remove molded parts from the second tool surface and / or another tool surface arranged in the setup, removal, and / or cleaning position in the first tool position, either semi- or fully automatically.

[0041] In embodiments, the second tool element has a first counter surface and at least one second counter surface, wherein the second tool element is adjustably mounted between a first operating position in which the first counter surface is opposite the first tool element in the pressing direction, and a second operating position in which the second counter surface is opposite the first tool element in the pressing direction.

[0042] In some embodiments, the second tool element is pivotably mounted about an axis of rotation between the first and second operating positions, in particular about an axis of rotation perpendicular to the pressing direction. In other embodiments, the second tool element comprises exactly two mating surfaces arranged offset by 180° about the axis of rotation, which are alternately brought into the operating position. In other embodiments, the second tool element comprises more than two mating surfaces, in particular uniformly distributed around the axis of rotation, which are successively brought into the operating position by rotating the second tool element.

[0043] In some configurations, the second counter surface and / or another counter surface is arranged in a setup, removal and / or cleaning position in the first operating position.

[0044] In some embodiments, a setup device is provided that is configured to load at least one material blank onto the second counter surface and / or another counter surface arranged in the setup, removal, and / or cleaning position in the first operating position, particularly in a semi- or fully automated manner. Alternatively or additionally, some embodiments provide a removal device that is configured to remove molded parts from the second counter surface and / or another counter surface arranged in the setup, removal, and / or cleaning position in the first operating position, particularly in a semi- or fully automated manner. In some embodiments, the tool surfaces and / or the counter surface(s) have a stamping contour. The at least one molded part can be trimmed to its final shape during demolding.The material blank is selected in such a way that any residual material remaining after cutting with the punching contour is as small as possible. In configurations where the tool surfaces and / or the mating surface do not have a punching contour, the device may have a separate, downstream punching station.

[0045] BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Further advantages and aspects of the invention will become apparent from the claims and from the description of exemplary embodiments of the invention, which are explained below with reference to the figures. These figures show:

[0047] Fig. 1 shows a first embodiment of a device for producing

[0048] Molded bodies;

[0049] Fig. 2 shows a sectional view of the device according to Fig. 1;

[0050] Fig. 3 shows a detail of a support element for the device according to Fig. 1;

[0051] Fig. 4 shows a detail of a support element and a transport element for a

[0052] Device similar to Fig. 1;

[0053] Fig. 5 shows a second embodiment of a device for producing

[0054] Molded bodies;

[0055] Fig. 6 shows a perspective view of a support element for the device according to Fig. 5;

[0056] Fig. 7 shows a third embodiment of a device for producing

[0057] Molded bodies; and

[0058] Fig. 8 shows a cutaway view of a detail of a support element for the

[0059] Device according to Fig. 7. DETAILED DESCRIPTION OF THE EXAMPLES OF EXECUTION

[0060] Figures 1 and 2 schematically show a device 1 for producing shaped bodies 2, in particular for producing shaped bodies 2 from a single- or multi-layer fiber-based material. The device 1 shown comprises a transport system 4 and a processing station 5.

[0061] Processing station 5 is set up to reshape and / or press a supplied single- or multi-layer fiber-based material.

[0062] The illustrated processing station 5 comprises two press tools 50 arranged one behind the other in a transport direction 40 of the transport system 4, as indicated by an arrow in Fig. 1. Each press tool 50 comprises a first tool element 51 and a second tool element 52. In other embodiments, the processing station 5 comprises only one press tool 50 or more than two press tools 50 arranged one behind the other in the transport direction 40.

[0063] As schematically represented by a double arrow, the tool elements 51, 52 are adjustable relative to each other in a pressing direction 53 in order to form and / or press a starting material arranged between the tool elements 51, 52. In the illustrated embodiment, the pressing tools 50 each have a vertical pressing direction 53.

[0064] In the illustrated embodiment, the first tool elements 51 are designed as lower tools and the second tool elements 52 as upper tools. In this embodiment, the second tool elements 52, designed as upper tools, are adjustable, at least partially, in the direction of the first tool element 51 for forming and / or pressing in the pressing direction 53. A reciprocating movement of the second tool elements 52, or parts thereof, for forming and / or pressing a starting material arranged between the first tool element 51 and the second tool element 52 in the pressing direction 53 is also referred to as a stroke movement.

[0065] In the illustrated embodiment, the first tool elements 51 each have two tool surfaces 511, 512. The two tool surfaces 511, 512 are, in particular, identical in design. The second tool element 52 has a counter surface 521 that is complementary to the tool surfaces 511, 512. In the illustrated embodiment, the tool surfaces 511, 512 are designed as negative forming surfaces. The counter surface 521 is designed as a positive forming surface that is complementary to the negative forming surfaces.

[0066] The first tool element 51 is pivotable about a rotary axis 510 between a first tool position shown in Figure 1 and a second tool position rotated 180° relative to the first, in order to alternately arrange the first tool surface 511 or the second tool surface 512 in a working position opposite the second tool element 52. In other embodiments, more than two tool surfaces 511, 512 are provided, which are arranged distributed around the rotary axis 510, in particular uniformly distributed, and can be arranged successively in the working position by rotating the first tool element 51 about the rotary axis 510.

[0067] Depending on the configuration, the tool element 51 can be pivoted 180° in each direction between the first tool position and the second tool position. Alternatively or additionally, the tool element 51 can be pivoted 180° in each direction between the first tool position and the second tool position with a fixed direction of rotation. A movement with a fixed direction of rotation is particularly advantageous in configurations with more than two tool surfaces 511, 512.

[0068] The starting material is fed to the processing station 5 as material blank 3, wherein the material blanks 3 are dimensioned so that exactly one shaped body is formed from exactly one material blank 3.

[0069] In the illustrated embodiment, the press tools 50 are designed such that six molded bodies 2 are formed with a single stroke, see Fig. 2. However, this design is merely exemplary. In other embodiments, fewer than six molded bodies 2 or more than six molded bodies are formed with a single stroke. The tool surfaces 511, 512, designed as negative mold surfaces, have six recesses for forming the six molded bodies 2. The counter surface 521, designed as a positive mold surface, has six corresponding punch-like projections which interact with the six recesses to form one molded body between each recess and projection.

[0070] The illustrated transport system 4 comprises carrier elements 6, the carrier elements 6 being configured to feed a number of material blanks 3, adapted to the design of the press tools 50, to the press tools 50. In the embodiment according to Figures 1 to 3, the carrier elements 6 also serve as transport elements for formed parts 2, in order to remove formed parts 2 from the processing station 5. The illustrated carrier elements 6 have a base body 60 designed as a rectangular plate. A number of first receptacles 61 and a number of second receptacles 62 are provided in the base body 60, the number of first receptacles 61 preferably corresponding to the number of second receptacles 62. In the illustrated embodiment, six first receptacles 61 and six second receptacles 62 are provided.The first receptacles 61 and the second receptacles 62 are each arranged in a row transverse to the transport direction 40, in particular perpendicular to the transport direction 40. For a dense packing, the first receptacles 61 and the second receptacles 62 are arranged with a gap between them as shown in Fig. 3.

[0071] As shown in Fig. 3, the first recesses 61 are designed to each hold exactly one material blank 3. The second recesses 62 are designed to each hold exactly one shaped body 2.

[0072] As can be seen in Fig. 2, the distance between the first recordings 61 is chosen in the illustrated embodiment such that it corresponds to the distance between the six recesses on the tool surfaces 511 , 512.

[0073] In the illustrated embodiment, openings 64 are provided in the area of ​​the receptacles 61. The receptacles 61 are provided on a first side of the base body 60, and the material blanks 3 are inserted into the receptacles 61. As shown in Fig. 1, a setup device 81 comprising lifting cylinders 810 is provided at the machining station 5. The lifting cylinders 810 can be accessed from a side opposite the first side of the base body 60 via the openings 64 to the material blanks 3. The material blanks 3 can thus be accessed from the support elements 6 of the tool surface 511, 512, which is not in the working position, for setting up this tool surface with the material blanks 3. In the embodiment shown in Figs. 1 and 2, the first tool element 51 is in a first tool position, with the first tool surface 511 arranged in the working position and opposite the second tool element 52.The second tool surface 512 is in a setup and removal position and is accessible to the setup device 81 as shown in Fig. 1.

[0074] In the illustrated embodiment, the press tools 50 are designed to produce rotationally symmetrical molded bodies 2. The illustrated material blanks 2 are circular. As shown in Fig. 3, the first receptacles 61, in certain configurations, have an annular shoulder 611 surrounding the opening 64. The material blanks, not shown in Fig. 3, rest on the shoulder 611. To support the material blanks 3 when lifted by the lifting ram 810 up to an edge region, radially extending slots 612 are provided in the shoulder 611. The slots 612 are evenly distributed around the circumference of the receptacle 61. The lifting rams 810 are, in certain configurations, designed to be complementary and can be guided through the slots 612 to lift the material blanks 3.This ensures that the load on the material blanks 3 is evenly distributed during lifting and prevents them from tilting or warping. This allows the material blanks 3 to be transferred to the tool surfaces with high precision during setup.

[0075] In certain configurations, no forces are applied to the support element 6 when the material blanks 3 are lifted from the support element 6. After the material blanks 3 have been transferred to the first tool element 51, the lifting rams 810 can be disengaged from the support element 6 and the support element 6 can be transported away in the transport direction 40.

[0076] In the embodiment shown in Fig. 1, the press tools 50 are arranged such that the molded parts 2 remain on the tool surfaces 511, 512 after demolding and are pivoted into the setup and removal position with the tool surfaces 511, 512. For this purpose, the tool surfaces 511, 512 have suction openings in certain configurations which can be pressurized with negative pressure or vacuum.

[0077] After the device 1 has been started up, pre-formed molded parts 2 are to be removed from the tool surfaces 511, 512 before setup. In the embodiment shown in Fig. 1, a schematically depicted removal device 82 is provided, with which the molded parts 2 can be removed from the tool surfaces and transferred into the carrier elements 6. For at least semi-automated transfer, the removal device 82 comprises at least one manipulator. Here, a manipulator is defined as a single-axis or multi-axis system, in particular a two- to six-axis system, and especially a six-axis system. Depending on the specific configuration, a multi-axis system is designed as a serial mechanism, as parallel kinematics, or as a hybrid mechanism.

[0078] The processing station 5 with the two press tools 50 can be operated in a clocked mode, whereby with each cycle a lifting movement takes place, two carrier elements 6 with molded bodies 2 inserted therein are removed from the processing station, two carrier elements 6 with material blanks inserted therein are fed to the processing station, formed molded bodies 2 are transferred into the provided carrier elements 6 and the first tool elements 51 are set up with the supplied material blanks.

[0079] In the illustrated embodiment, the material blanks 3 are inserted into the support elements 6 by means of a transfer device 7. The transfer device 7 is configured to insert the material blanks 3 into the support elements 6 semi- or fully automatically. For at least semi-automated insertion, the transfer device 7 comprises at least one manipulator.

[0080] The material blanks 3, or one or more layers of a multi-layer material blank, are die-cut upstream of the transfer device 7 from a single- or multi-layer flat material, in particular paper, cardboard, carton, or a material containing cellulose or natural fibers. Alternatively or additionally, in other embodiments, the material blanks 3 and / or one or more layers of a multi-layer material blank are formed upstream of the transfer device 7 from a raw material, in particular in an airlaid process. In still other embodiments, material blanks are taken from a stock upstream of or by the transfer device 7.

[0081] The material blanks 3 inserted into the carrier elements 6 are transported to the processing station 5 along with the carrier elements 6. In some configurations, the movement of the carrier elements 6 within the transport system 4 is passive, with carrier elements 6 being moved along the transport system 4 by subsequent carrier elements 6. In other configurations, the carrier elements 6 are coupled to a drive system and / or parts of a drive system are used to move the carrier elements 6 to, through, and / or away from the processing station 5.

[0082] In the illustrated embodiment, the formed parts 2 are removed from the carrier elements 6 by means of a part transfer device 9 and transferred to a subsequent unit for further processing with a different stitch. Alternatively, in embodiments with the part transfer device 9, the parts 2 are stacked.

[0083] The shaped body transfer device 9 is configured to remove shaped bodies 2 from the carrier elements 6 in a semi- or fully automated manner. For at least semi-automated insertion in various configurations, the shaped body transfer device 9 includes at least one manipulator.

[0084] In some configurations, a quality control check of the molded parts 2 is carried out before, after or during the removal of the molded parts from the carrier elements 6.

[0085] In the embodiment according to Figs. 1 to 3, the support elements 6 each have first receptacles 61 for receiving material blanks 3 and second receptacles 62 for the shaped bodies 2.

[0086] In other embodiments, first receptacles 61 are provided for receiving material cutouts 3 and second receptacles 62 for shaped bodies 2 on different components, which are referred to here as support element 6 and transport element 66 for differentiation purposes.

[0087] Fig. 4 schematically shows a detail of an assembly comprising a support element 6 and a transport element 66, which are designed as separate components. In the illustrated embodiment, the support element 6 has two rows of first receptacles 61 arranged with a gap in the transport direction 40. The transport element 66 has two rows of second receptacles 62 arranged with a gap in the transport direction 40. The support elements 6 and the transport elements 66 can be fed to, transported through, and removed from a processing station 5 in an alternating sequence. In certain embodiments, the processing station has at least two press tools 5, each press tool being assigned to a row of first or second receptacles 61, 62.In other words, in certain embodiments, a press tool 50 removes the material blanks 3 from the first row of first receptacles 61, and a second press tool 50 removes the material blanks 3 from the second row of first receptacles 61. Likewise, in certain embodiments, shaped bodies 2 are inserted into the first row of second receptacles 62 by a press tool 50, and shaped bodies 2 are inserted into the second row of second receptacles 62 by a second press tool 50.

[0088] Fig. 5 shows a second embodiment of a device 1 for producing shaped bodies 2. The device 1 according to Fig. 5 is similar to the device 1 according to Figs. 1 and 2. Identical reference numerals are used for identical or similar components. For a detailed description, please refer to the above. In contrast to the design according to Figs. 1 and 2, the support elements 6 shown separately in Fig. 6 serve only to transport the material blanks 3 to the processing station 5.

[0089] The support elements 6 comprise receptacles for the material blanks 3 arranged in two rows. The illustrated processing station 5 comprises two press tools 50. In the illustrated embodiment, material blanks 3 arranged in a first of the two rows are fed to a first of the two press tools 50, and material blanks 3 arranged in a second of the two rows are fed to a second of the two press tools 50. The press tools 50 are essentially identical in design. For a compact arrangement of the material blanks 3 on the support element 6 and the press tools on the processing station 5, the rows of receptacles for the material blanks on the support element 6 and the press tools 50 are arranged transversely, in particular perpendicularly, to the transport direction 40.

[0090] In the embodiment shown in Fig. 5, the formed bodies 2 are not pivoted from the working position with the first tool element 51. In other embodiments, the formed bodies 2 are removed from the tool surfaces arranged in the working position before the tool elements 51 are pivoted.

[0091] In the embodiment shown in Fig. 5, the second tool element 52 has a first counter surface 521 and a second counter surface 522, wherein the second tool element 52 can be pivoted about an axis of rotation 520 perpendicular to the pressing direction 53 between a first operating position shown in Fig. 4, in which the first counter surface 521 is opposite the first tool element 51 in the pressing direction 53, and a second operating position, in which the second counter surface 522 is opposite the first tool element 51 in the pressing direction 53.

[0092] In the first operating position shown in Fig. 5, the second counter surface 522 is arranged in a removal and / or cleaning position and is accessible for removal of the molded parts 2 by the molded part transfer device 9. In some embodiments, the molded part transfer device 9 is configured to remove the molded parts 2 from the counter surfaces arranged in the removal and / or cleaning position semi- or fully automatically. In some embodiments, the molded part transfer device 9 transfers the molded parts 2 into transport elements (not shown). In other embodiments, the molded part transfer device 9 transfers the molded parts 2 to a subsequent station. Alternatively, in some embodiments, the molded parts 2 are stacked using the molded part transfer device 9. In some embodiments, a quality control check of the molded parts 2 is performed before, after, or during removal from the processing station 5.

[0093] For increased process speed, in an alternative embodiment (not shown), the processing station 5 of the device 1 according to Fig. 5 comprises four press tools 50, wherein material blanks 3 are fed to two press tools 50 by means of a carrier element 6, and all material blanks 3 are removed from one carrier element 6 in a single cycle. The processing station 5 can be scaled to any desired size if required. In various embodiments, the number of press tools 50 is equal to the number of rows of holders 61 in the carrier elements 6, or, for simultaneous feeding of several carrier elements 6 to the processing station, an integer multiple of the number of rows.

[0094] Fig. 7 shows a third embodiment of a device 1 for producing shaped bodies 2. The device 1 according to Fig. 7 is similar to the device 1 according to Figs. 1 and 2. Identical reference numerals are used for identical or similar components. For a detailed description, see above.

[0095] Fig. 8 shows a cutaway view of a detail of a support element 6 of the device according to Fig. 7.

[0096] In contrast to the design according to Fig. 1, the support elements 6 according to Figs. 7 and 8 have receptacles 63 which are configured to receive either shaped bodies 2 or material blanks 3. In Fig. 8, a shaped body 2 and a material blank 3 are arranged in a common receptacle 63. However, this arrangement serves only for illustration. In practice, preferably either a material blank 3 or a shaped body 2 is arranged in the receptacle 63.

[0097] The processing station 5 shown in Fig. 7 comprises two press tools 50. The processing station can be operated in a clocked mode, with each press tool 50 performing a stroke movement with each cycle. With each cycle, a carrier element 6 with two rows of shaped parts 2 inserted therein is removed from the processing station 5, a carrier element 6 with material blanks 3 inserted therein is fed into the processing station 5, and a carrier element 6 is repositioned within the processing station 5. The carrier elements 6 are fed into and repositioned within the processing station 5 in such a way that the two press tools 50 remove the material blanks 3 from different rows and replace the shaped parts 2 in different rows. The illustrated embodiments are merely examples, and numerous variations are conceivable.In particular, components and / or features that are shown and / or described in connection with an exemplary embodiment can be combined with components and / or features of further exemplary embodiments in order to obtain further exemplary embodiments.

[0098] As shown in Fig. 6, the support elements 6 in various embodiments comprise guide elements 65 with which the support elements 6 are adjustable along guide rails of the transport system 4. For transport in a common transport plane, the transport elements 66 (see Fig. 4) in various embodiments comprise identical or similar guide elements 65 with which the transport elements are adjustable along the same guide rails of the transport system 4.

[0099] The illustration with the guide elements 65 is merely an example. In other embodiments, differently designed guide elements are provided, for example, guide grooves integrated into the base body 60, and / or guide elements are omitted altogether. Depending on the application, the support elements 6 are moved passively or by a drive. In some embodiments, the support elements 6 are driven by a chain drive. In other embodiments, the support elements 6 are designed as the rotor of a linear motor and / or coupled to a rotor of a linear motor.

Claims

Patent claims 1. Method for producing shaped bodies (2), in particular shaped bodies (2) from a single- or multi-layer fiber-based material, wherein a starting material is supplied to a processing station (5) and the starting material is formed and / or pressed into shaped bodies (2) in the processing station (5), characterized in that material blanks (3) are supplied to the processing station as starting material and each shaped body (2) is formed from each material blank (3).

2. Method according to claim 1, characterized in that a plurality of material blanks (3) are received by a carrier element (6) and carrier elements (6) with several material blanks (3) received thereon are fed to the processing station, in particular are fed in a timed manner.

3. Method according to claim 1 or 2, characterized in that after demolding the molded parts (2) are transferred from the processing station (5) to transport elements (66) and transport elements (66) with at least one molded part (2) each being taken up thereon are taken up from the processing station, in particular in a timed manner.

4. Method according to claim 3 insofar as it relates back to claim 2, characterized in that the transport elements (66) and the support elements (6) are transported in a common transport plane of a transport system, in particular are transported alternately, and / or each transport element (66) and support element are designed as a common component, wherein, when transporting the components to the processing station (5), a plurality of material blanks (3) received thereon are supplied to the processing station with the components, and when transporting the components away from the processing station (5), a plurality of shaped bodies (2) received thereon are removed from the processing station (5).

5. Method according to one of the preceding claims, characterized in that the material blanks (3) are punched out from a continuous material web upstream of the processing station, formed from a raw material, in particular formed in an air-assisted process, and / or taken from a stock.

6. Method according to one of the preceding claims, characterized in that the machining station (5) has at least one pressing tool (50) comprising a first tool element (51) with several tool surfaces comprising at least a first tool surface (511) and a second tool surface (512) and a second tool element (52) with a counter surface (521, 522) complementary to the tool surfaces (511, 512), wherein the first tool element (51) is pivotably mounted about a rotary axis (510) between a first tool position and a second tool position, and wherein in the first tool position the first tool surface (511) is arranged in a working position and is opposite the second tool element (52) in a pressing direction (53), and in the second tool position the second tool surface (512) is arranged in the working position and is opposite the second tool element (52) in the pressing direction (53).The method comprises the steps of: a) arranging the first tool element (51) in the first tool position such that the first tool surface (511) is in the working position; b) adjusting the first tool surface (511) and / or the counter surface (521, 522) arranged in the working position in the pressing direction to form and / or press a plurality of material blanks (3) arranged between the first and the second tool element into a molded body (2); c) before, after, or simultaneously with step b), equipping a second tool surface (512) not arranged in the working position with material blanks (3); d) pivoting the first tool element (51) about the axis of rotation (510) to arrange the first tool element (51) in the second tool position.so that the second tool surface (512) is arranged in the working position; and e) adjusting the second tool surface (512) arranged in the working position and / or the counter surface (521, 522) in the pressing direction (53) for forming and / or pressing the at least one material blank (3) arranged between the first and the second tool element.

7. A method according to one of the preceding claims, characterized in that the second tool element (52) has at least a first counter surface (521) and a second counter surface (522), wherein the second tool element (52) is adjusted between a first operating position in which the first counter surface (521) is opposite the first tool element (51) in the pressing direction (53), and a second operating position in which the second counter surface (522) is opposite the first tool element (51) in the pressing direction (53), in particular being adjusted at least partially simultaneously with step d), wherein in particular the second tool element (52) is pivoted about a rotational axis (520) between the first operating position and the second operating position, in particular about a rotational axis perpendicular to the pressing direction, wherein in particular the second tool element (52) is pivoted with the at least one mold body from the operating position,wherein, before pivoting back into the operating position, at least one molded part is removed from the first tool surface.

8. Device for producing shaped bodies (2), in particular shaped bodies (2) from a single- or multi-layer fiber-based material, comprising a processing station (5) and a transport system (4), wherein the transport system (4) is configured to supply a starting material to the processing station (5), and the processing station (5) is configured to transform and / or press a supplied starting material into shaped bodies (2) in a clocked operation, characterized in that the transport system (4) is configured to supply material blanks (3) to the processing station as starting material and the processing station is configured to form one shaped body (2) from each material blank (3).

9. Device according to claim 7, characterized in that the transport system (4) comprises carrier elements (6), wherein the carrier elements (6) are each configured to receive a plurality of material blanks (3), and wherein the transport system (4) is configured to supply carrier elements (6) with each a plurality of material blanks (3) received thereon to the processing station (5), in particular to supply them in a timed manner, wherein in particular the carrier elements (6) have receptacles, wherein the receptacles are each configured to receive a material blank (3).

10. Device according to claim 7 or 8, characterized in that the transport system (4) comprises transport elements (66), wherein the transport elements (66) are each configured to receive the molded parts (2) after demolding from the processing station (5), and the transport system is configured to remove transport elements (66) with molded parts (2) received thereon from the processing station, in particular to remove them in a timed manner.

11. Device according to claim 10 insofar as it relates back to claim 9, characterized in that the transport system is configured to transport the transport elements (66) and the support elements in a transport plane, in particular to transport them alternately, and / or each transport element (66) and each support element are designed as a common component, wherein the component has first receptacles (61) for material blanks (3) and second receptacles (62) for shaped bodies (2) and / or the component has at least two receptacles into which either a material blank (3) or a shaped body (2) can be inserted.

12. Device according to one of claims 8 to 11, characterized in that upstream of the processing station a punching station, configured to punch out the material blanks (3) from a continuous material web, a forming station, configured to form the material blanks from a raw material, in particular in an air-assisted forming process, and / or a stock, configured to provide pre-made material blanks, is provided.

13. Device according to one of claims 8 to 12, characterized in that the machining station (5) has at least one pressing tool (50) comprising a first tool element (51) with several tool surfaces comprising at least a first tool surface (511) and a second tool surface (512) and a second tool element (52) with a counter surface (521, 522) complementary to the tool surfaces (511, 512), wherein the first tool element (51) is pivotably mounted about a rotary axis (510) between a first tool position and a second tool position, and wherein in the first tool position the first tool surface (511) is arranged in a working position and is opposite the second tool element (52) in a pressing direction (53), and in the second tool position the second tool surface (512) is arranged in the working position and is opposite the second tool element (52) The tool element (52) is positioned opposite the pressing element (53), the machining station (5) being configured to adjust the tool surface (511, 512) arranged in the working position and the counter surface (521, 522) relative to each other in the pressing direction (53) for forming and / or pressing material blanks (3) arranged between the first and second tool elements (51, 52), wherein, in particular, in the first tool position, the second tool surface (512) and / or a further tool surface is arranged in a setup, removal, and / or cleaning position, wherein a setup device is provided, is configured to set up the second tool surface (512) and / or a further tool surface arranged in the setup, removal, and / or cleaning position for material blanks in the first tool position, and / or wherein a removal device is provided, is configuredto remove formed bodies from the second tool surface (512) and / or a further tool surface arranged in the setup, removal, and / or cleaning position in the first tool position.

4. Device according to one of claims 8 to 13, characterized in that the second tool element (52) has a first counter surface (521) and at least one second counter surface (522), wherein the second tool element (52) is adjustably mounted between a first operating position, in which the first counter surface (521) is opposite the first tool element (51) in the pressing direction (53), and a second operating position, in which the second counter surface (522) is opposite the first tool element (51) in the pressing direction (53), wherein, in particular, the second tool element (52) is pivotably mounted about a pivot axis (520) between the first operating position and the second operating position.in particular a rotation axis (520) perpendicular to the pressing direction, wherein in particular in the first operating position the second counter surface (522) and / or a further counter surface is arranged in a setup, removal and / or cleaning position, wherein a setup device is provided, is configured to equip the second counter surface (522) and / or a further counter surface arranged in the setup, removal and / or cleaning position with at least one material blank in the first operating position and / or wherein a removal device is provided, is configured to remove at least one molded part from the second counter surface (522) and / or a further counter surface arranged in the setup, removal and / or cleaning position in the first operating position.

15. Device according to claim 13 or 14, characterized in that the tool surfaces (511 , 512) and / or the counter surface(s) (521, 522) have / have a stamping contour.

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