JP2019123985A - Tool or tool component, device containing tool or tool component, manufacturing method of tool or tool component, and molding method of product from pulp slurry - Google Patents

Abstract

To provide a method for manufacturing a porous mold.SOLUTION: The porous mold contains a tool wall part having holes provided with a plurality of channels, the channel extends to contact with a product, from a product surface to a rear face of a wall on the opposite side toward the product surface through the tool wall part, and is straight or has a curvature at only one flexure point; the manufacturing method of a porous mold contains forming the channel by using an additive material production process.SELECTED DRAWING: None

Description

  The present disclosure relates to tools or tool parts used to shape products from slurry. The present disclosure also relates to methods of making such tools and various applications of such tools or tool parts.

  It is known to form products from pulp slurries by immersing the porous mold in the pulp slurry and subsequently drying and optionally pressing the thus shaped product. Examples of such products are egg cartons, shock absorbing packaging inserts and paper trays, paper cups, beverage output trays, mushroom boxes and strawberry boxes and other forms of industrial, agricultural and consumer packaging.

  Porous pulp molds are made of wire cloth material that is stretched and woven to conform to the mold surface. Such molds have several drawbacks in terms of the amount of strain or elongation that allows the wire cloth to conform to the mold surface. Also, as a further disadvantage, there is a tendency that the wire cloth is easily broken. The use of wire cloth is also associated with some limitations on the complexity of the product that can be molded. In particular, when forming the wire cloth in the mold, the mesh (pore) of the wire cloth is deformed and the distribution of the openings can not be controlled.

  Yet another drawback is the cost of making such molds. Since wire cloths are usually not self-supporting, it is necessary to provide a backing material (metal backing) specific to the product to be formed. Such tools are even more prone to clogging and are difficult to repair.

  For example, according to U.S. Pat. No. 3,067,470 it is known to provide a porous pulping mold from small spheres which are sintered together to provide a porous body. Such porous bodies can be made from polymeric materials as disclosed in US Pat. No. 3,067,470. However, this type of mold not only has disadvantages in terms of strength, but also limits the usable temperature range. Also, these molds suffer from the trade-off between surface quality and pressure drop (pressure drop). That is, the smaller the particles used on the surface, the smaller the flow path and the higher the pressure loss accordingly.

  WO2011059391A1 discloses a method for manufacturing a pulp-forming mold by sintering particles of a metal material such as bronze. Such molds can withstand higher temperatures compared to polymer-based molds, but their production requires higher temperatures, leading to a more difficult sintering process. Furthermore, the finished mold has the same advantages as those made of polymeric material.

  As such, there are several challenges associated with forming products from pulp. That is, providing a smoother surface structure, reducing energy consumption, providing a cheaper process for manufacturing the mold, and providing a mold that is durable and can be exposed to high temperatures It is desired. There is also a need to improve the quality control of the forming process.

  An object of the present disclosure is to provide an improved mold for forming a product from pulp slurry.

  The invention is defined by the attached independent claims, the embodiments of which are set forth in the appended dependent claims, the following description and the drawings.

  According to a first aspect, a tool or tool component is provided for use in a process of forming a product from pulp slurry. The tool or tool part comprises a self-supporting tool wall having a product surface for contacting a product and a back opposite to the wall with respect to said product surface. The tool wall exhibits holes provided by a plurality of channels extending from the product surface to the back through the tool wall. The channels are straight or curved, and those that are curved have only one inflection point.

  For the purposes of the present disclosure, the term "pulp" should be construed to include materials comprising fibers such as cellulose, minerals and starch and combinations of these materials. The pulp preferably has a liquid carrier, which can include water.

  The term "self-supporting" means that the tool wall is sufficiently rigid and the tool wall has a sufficiently high melting point so that it does not require a support structure to maintain its shape during operation means.

  The product surface may be either the molding surface of a slurry pick-up tool, the contact surface of a transfer tool, or the molding surface of a male or female pressing tool.

  The curved flow path may be curved in one or more planes.

  A tool or tool part according to the inventive concept provides for efficient removal, transfer or evaporation of the used pulp or molding while using less energy for vacuum generation as compared to the prior art Can.

  The tool or tool part can have a product surface presenting flat and convex surface portions.

  The convex portions may be convex in one or two mutually orthogonal planes.

  The tool wall can have a thickness that is smaller, preferably 30 to 70% smaller, or 40 to 60% smaller on the convex portion than on the flat surface portion.

  The convex portion can have a higher porosity than the flat surface portion.

  Thus, a vacuum is provided as needed.

  The product surface can present flat and concave portions.

  Flat surface portions can have greater porosity as compared to concave portions.

  The concave portions may be recessed in one or two mutually orthogonal planes.

  The product surface may be a substantially flat surface and may have a pair of surface portions that are at an angle of 45 ° to 135 ° to one another, and exhibit a maximum angle to a horizontal plane during main operation of the tool or tool part The surface portion exhibits greater porosity than the other surface portions.

  The "tool main operation" is understood as part of the tool operation and performs its main function on the product to be formed during its operation. Thus, in the case of a pick-up tool, the main function is performed at the location where the pulp is being removed by the applied vacuum. Also, in the case of a transfer tool, the main operation is performed as the pulp is transferred from the pick-up tool to the transfer tool. Also, in the case of a press tool, the main operation is the pressing operation.

  At least some of the flow channels can exhibit a flow channel open area of the product surface that is smaller than the corresponding flow channel open area of the back surface.

  This reduces the risk of clogging.

  At least some of the flow channels can exhibit a cross section that tapers towards the product surface.

  At least some of the flow channels can exhibit a central axis extending at an angle of 40 to 90 degrees with respect to the product surface.

  At least some of the flow channels can exhibit a curved central axis.

  The product surface may have first and second juxtaposed surface portions, wherein the central axis of the flow path opening at the first surface portion is the second surface relative to the product surface of the surface portion It may extend at an angle different from the central axis of the flow passage which opens at a portion.

  The void volume inside the tool or tool part may be at least 20%, preferably at least 40%, at least 60%, or at least 80% of the total volume spanning the tool or tool part.

  The void volume is not a cavity, that is, a volume created by a void (air gap), not a heater, a support or the like.

  Thus, an enhanced distribution of vacuum over the product surface is achieved, reducing the need for vacuum forces.

  At least some of the channels can exhibit a length that exceeds the thickness of the wall near the channels.

  The product face openings of at least some of the flow channels can have a cross section with a maximum width of 0.1 to 2 mm.

  At least some of the flow paths can have at least one branch located between the product surface and the back surface.

  The tool wall has a thickness of 0.2 to 20 mm, preferably 0.3 to 15 mm or 0.5 to 10 mm.

  The tool wall may be formed as a homogeneous piece of material having less than 95%, preferably less than 99% or less than 99.9%, of voids between the flow paths.

  The tool or tool part can be formed with sufficient material and thickness to allow the tool or tool part to be self-supporting during operation.

  The back of the tool may be such that at least 50%, preferably at least 70% or at least 90%, is exposed to a chamber adapted to be applied with an air pressure other than atmospheric pressure.

The tool or tool part may form part of a tool selected from the following group:
A pick-up tool for removing pulp from the pulp slurry,
A transfer tool to receive an amount of pulp from another tool,
A press tool that press-presses a certain amount of pulp to form a molded product.

  The tool or tool part can comprise at least two tool walls that are interconnectable, preferably movably interconnectable.

  According to a second aspect, an apparatus for shaping a product from a pulp slurry, comprising at least one tool or tool component as described above, means for applying pulp to the product surface, vacuum drawing, and And / or means for applying a pressure greater than the back atmospheric pressure.

  The apparatus of the present invention may further comprise a heating element disposed on the back side of the tool wall and configured to supply heat to the tool wall.

  The heating element may be located in a heater section spaced from the tool wall.

  The heater portion may be integrally formed with the tool wall.

  The heater part can be formed by a separate part (separate part) which contacts the tool wall via at least one spacer element.

  This separate part may be made of a different material than the tool wall. The spacer element may be integrally formed with the tool wall or the heater part. The spacer elements are preferably arranged in such a way that they do not block any flow channels. This is facilitated by forming a spacer element on the back of the tool wall.

  Alternatively, the heating element may be integrated with the tool wall.

  For example, the heating element may be recessed at the back of the tool wall.

  According to a third aspect, a method of manufacturing a tool or tool part for forming a product from a pulp slurry, which comprises preparing particles of material from which the tool or tool part is formed, a plurality of layers of said particles Are distributed continuously on the target surface, and in the position of each distribution layer of particles on the target surface corresponding to the cross section of the tool or tool part produced therein, such that the powder particles are fused and the particles come together A method is provided that includes directing an energy source.

  The method of the present invention further includes forming a tool wall having holes provided by a plurality of channels extending back from the product surface through the tool wall, the channels being straight or less than one Is a curved shape with a bending point of

  According to a fourth aspect, there is provided a method of forming a product from a pulp slurry. The method comprises preparing a mold as described above, applying a vacuum to the back of the mold and supplying a pulp slurry to the product side of the mold.

  The method of the present invention further comprises using a mold to remove the pulp slurry from the slurry container.

  The method of the present invention further comprises using a mold that pressure presses the pulp slurry to form a product, whereby at least some solvent is removed from the pulp slurry.

FIG. 1a is a schematic diagram showing an overview of a method of forming a product from pulp slurry. FIG. 1 b is a schematic diagram showing an overview of a method of forming a product from pulp slurry. FIG. 1 c is a schematic diagram showing an outline of a method of forming a product from pulp slurry. FIG. 1 d is a schematic diagram showing an overview of a method of forming a product from pulp slurry. FIG. 2a is a schematic view showing mold wall portions having different flow channel designs. FIG. 2b is a schematic showing mold wall portions having different flow channel designs. FIG. 2c is a schematic showing mold wall portions having different flow channel designs. FIG. 2 d is a schematic showing mold wall portions having different flow channel designs. FIG. 2e is a schematic diagram showing mold wall portions having different flow channel designs. FIG. 3 is a schematic view showing a portion of a mold wall. FIG. 4 is a schematic view showing a part of the press mold of the first embodiment. FIG. 5 is a schematic view showing a part of the press mold of the second embodiment. FIG. 6 is a schematic view showing a part of the press mold of the third embodiment.

  FIG. 1 a schematically shows a pick-up tool 10 partially immersed in a vessel 1 holding a pulp slurry 2. The pick-up tool is attached to the tool holder 11 and defines a vacuum chamber 12 connected to the pressure regulator P1 together with the pick-up tool. The pressure regulator may have the ability to selectively generate at least a partial vacuum (ie, an air pressure less than atmospheric pressure) and / or an air pressure greater than atmospheric pressure.

  While the pickup tool is immersed in the pulp slurry 2, the pressure regulator P 1 generates a vacuum to stick the pulp fibers 3 to the product surface of the pickup tool 10.

  FIG. 1 b schematically shows a pick-up tool 10 for transferring pulp fibers 3 to a transfer tool 20. The transfer tool may be connected to a second pressure regulator P2 capable of producing vacuum or air pressure. The transfer tool may be attached to the transfer tool holder 21 to define a vacuum chamber 22 connected to a second pressure regulator.

  During the transfer of the pulp fibers 3 from the pick-up tool to the transfer tool, an air pressure higher than atmospheric pressure is generated by the first pressure regulator P1 so that the pulp fibers 3 can be removed from the pick-up tool.

  Instead, or as a supplement, a vacuum is generated by the second pressure regulator P 2 and pulp fibers are received by the transfer tool 20.

  FIG. 1 c schematically shows a drying device having a heating device 5 and an energy source E. With this drying device it is possible to remove a sufficient amount of water from the pulp 3, adjust it for further processing and / or complete the formation of the product 3 '.

  FIG. 1 d schematically shows a pressing device comprising a male press tool 30 and a female press tool 40. One or both of the pressing tools are attached to the respective tool holders 31 and 41 respectively and connected to the respective vacuum chambers 32 and 34 respectively. The vacuum chamber can be connected to each pressure regulator P3, P4 respectively.

  One or both of the pressing tools can be provided with heating elements 33, 43 which are energized by the energy sources E1, E2 and possibly controlled by the control device C. Heating can be accomplished by electrical heating elements, hot air or liquid or induction.

  The pressing tools and their associated tool holders are relatively movable between an open position and a pressing position, into which the partially shaped pulp product can be inserted, the pressing tools being pressed together, the product 3 "Formed on the product surface of each tool 30, 40".

  When in the pressurized position, heat may be supplied by one or both of the heaters 33, 43.

  During the pressurization process, one or both pressure regulators P3, P4 can provide a vacuum which aids in the evacuation of the water vapor coming out of the product 3 '".

  Alternatively, one of the pressure regulators can provide a vacuum and the other can provide a pressure greater than atmospheric pressure.

  If desired, hot air or steam can be introduced through the mold during the pressurization process (FIG. 1d).

  It should be noted that two or more successive pressurization steps may be employed. Such a continuous pressing step can, for example, gradually form all or part of the product 3 '"and / or add additional features such as coatings and decorations to the product.

  In one embodiment, the process is carried out in accordance with what has been described with regard to FIGS. 1a, 1b and 1d.

  In one embodiment, the pick-up tool 10 can deliver pulp fibers directly to the drying apparatus. Such direct transfer may be assisted by the first pressure regulator P1 generating an air pressure greater than atmospheric pressure. Thus, in this embodiment, the steps are carried out according to what has been described only with regard to FIGS.

  In other embodiments, the pick-up tool 10 can also be used as a pressing tool. Thus, in this embodiment, the steps are performed according to the procedure described only with respect to FIGS. 1a and 1d.

  Figures 2a to 2e schematically show mold wall portions having different flow channel designs. The mold walls all have a product face Fp and a back face Fb. The product surface Fp is the face surface of the mold in contact with the product, and the back surface Fb is the opposite surface of the mold wall. The back side can typically define part of the vacuum chamber.

  The mold wall can have a thickness of 0.25 to 10 mm, preferably 0.5 to 5 mm. The wall thickness is different for different parts of the tool. Also, tools with different functions may have different thicknesses.

  The flow path connects the product surface Fp to the back surface Fb. The product surface opening area of the flow channel may be smaller than the back opening area of the flow channel, but it is not necessary to make it smaller. In this way, the flow path can have a cross-sectional area that decreases from the back towards the product surface.

  The flow path presents a central axis which can be defined as a straight line or curve passing through the center of gravity of each flow path section taken parallel to the product plane Fp.

  FIG. 2a schematically shows a pulp mold wall portion having a pair of channels of the same size and configuration. The flow path has a respective first flow path portion with a constant flow path cross section and a respective second flow path portion with a tapered cross section.

  FIG. 2 b schematically shows a pulp mold wall portion having a pair of flow paths that taper continuously from the back towards the product surface Fp.

  The flow paths of FIGS. 2a and 2b and their respective central axes extend perpendicularly to the product plane Fp.

  FIG. 2c schematically shows a pulp mold wall having channels whose central axis extends at an angle other than perpendicular to the product plane Fp. This angle may be in the interval 20 to 90 degrees, preferably 30 to 90 degrees or 60 to 90 degrees.

  The flow path of FIG. 2c can have a constant cross-sectional area or a decreasing cross-sectional area towards the product surface Fp.

  The mold wall may exhibit flow channels extending at different angles within said spacing.

  FIG. 2 d schematically shows a pulp mold wall with curved channels. In particular, such a curved channel may be curved in one plane or in two orthogonal planes as shown.

  The flow path of FIG. 2 d can have a constant cross-sectional area or a decreasing cross-sectional area towards the product surface Fp.

  FIG. 2e schematically shows a pulp mold wall portion having a curved flow path with one inflection point. Such curved channels may be curved in one plane or in two orthogonal planes as shown.

  The flow path of FIG. 2e can have a constant cross-sectional area, or a decreasing cross-sectional area towards the product surface Fp.

  It should be noted that one mold can exhibit a flow path formed according to one or more of FIGS. 2a-2e. In particular, the mold comprises at least one wall portion comprising channels formed according to any one of Figures 2a to 2e, and another channel comprising channels formed according to the other of Figures 2a to 2e. And can include a wall portion.

  Referring to FIGS. 2d and 2e, the bend radius of the flow channel is greater than half of the wall thickness of the flow channel, preferably greater than 3/4 of the thickness of the flow channel, or It can be larger than 1/1.

  It should be noted that the flow path can present a cross section that varies over the flow path length. The channels may be square, triangular, pentagonal, hexagonal, heptagonal, octagonal, octagonal, decagonal, dodecagonal, dodecagonal, or other polyhedral shapes with internal angles from 60 ° to 180 °, etc. At least a portion having a circular, elliptical or polygonal cross section can be presented.

  FIG. 3 schematically shows a portion of the mold wall with the product side facing up / right and the back side facing down / left.

  The mold wall of FIG. 3 is a horizontal mold wall portion Ph, ie +/- 45 °, preferably +/- 30 ° or +/- 15 °, with respect to the horizontal, during the main operation phase of the mold It may have a mold wall portion. Such horizontal mold wall portions Ph may be flat or substantially flat. For example, such a substantially flat mold wall portion Ph may be curved out of the plane by less than 10%, preferably by less than 5%, along any direction in the plane.

  The mold wall portion may exhibit a convex mold wall portion Pcx, that is, a mold wall portion having a convex product surface Fp.

  It should be noted that the convex mold wall portions may be convex in one or two mutually orthogonal directions.

  Also, the mold wall portion is a vertical mold wall portion Pv, that is, a mold wall of +/− 45 °, preferably +/− 30 ° or +/− 15 ° to the vertical during the main operation phase of the mold It may have a part. Such vertical mold wall portions may be flat or substantially flat. For example, the substantially flat mold wall portion may be curved to deviate from the plane by less than 10%, preferably by less than 5%, along any direction in the plane.

  Also, the mold wall portion may exhibit a concave mold wall portion Pcv, that is, a mold wall portion having a concave product surface Fp.

  For the purpose of the present disclosure, the term "porosity" is defined as the ratio of the channel open area to the total wall area of a given wall portion (including channel openings).

  The pore openings in the product plane can have an outer diameter of 0.25 mm to 2 mm. The pore openings in the back can have an outer diameter of 0.3 to 4 mm.

Therefore, the pore openings on the product surface Fp can have an open area of 0.045 to 3.2 mm ² , preferably 0.045 to ² mm ² or 0.050 to ¹ mm ² on the product surface.

In addition, the pore opening in the back surface Fb can have an opening area of 0.45 to 13 mm ² , preferably 0.1 to ⁵ mm ² or 0.3 to ² mm ² .

  Thus, the ratio of the back opening area to the product surface opening area can be of the order of 1.1 to 6, preferably of the order of 1.2 to 5 or 1.4 to 4.

  The convex mold wall portion Pcx can show the maximum porosity of all the mold wall portions. Preferably, the convex mold wall portion has a porosity of 10 to 90%, preferably 20 to 60%.

  The vertical mold wall portion Pv can have a lower porosity than the convex mold wall portion Pcx. Preferably, the vertical mold wall portion Pv can have a porosity of 15% to 80%, preferably 25% to 60%.

  The horizontal mold wall portion Ph may have a lower porosity than the vertical mold wall portion Pv. Preferably, the horizontal mold wall part Ph can have a porosity of 20% to 75%, preferably 30% to 55%.

  The concave mold wall portion Pcv can exhibit lower porosity than the horizontal mold wall portion Ph, and preferably has a porosity of 1 to 70%, preferably 35 to 50%.

  The molds described above can be manufactured by an additive manufacturing process such as 3D printing. Such additive manufacturing processes may involve the selective sintering of powdered materials having an average particle size of 1 to 50 microns, preferably 5 to 30 microns. During the sintering process, the powder material is completely melted by the addition of energy by means of a laser beam or an electron beam.

  The material for making the mold may be either metal or alloy. Examples of such materials include, but are not limited to, titanium and titanium alloys, aluminum and aluminum alloys, copper and copper alloys, bronze, brass, cobalt and chromium alloys and stainless steel.

  Alternatively, the material may be a polymeric material such as a plastic material.

  Through such a forming process, a well-defined flow path connecting the product face Fp to the back face Fb is presented, the material between these flow paths being homogeneous, at least 95%, preferably 99% or 99.9 It becomes possible to achieve a porous mold without a percentage of voids.

  With reference to FIGS. 1a-1d above, it should be noted that one or more of the tools 10, 20, 30, 40 may be formed in accordance with the disclosure herein.

  Furthermore, it should be noted that, for example, the pick-up tool 10 and / or the transfer tool 20 may be formed of a material having a thinner wall and / or a lower melting point than the pressing tools 30, 40.

  The tool can be manufactured as one complete tool or as at least two tool parts joined by soldering, welding, adhesive or fusion.

  Furthermore, the tool can be formed as a pair of tool parts provided with a hinge mechanism connecting the tool parts. Tools formed in this way can enable the production of more complex products.

  FIG. 4 is a view schematically showing a part of a pressure mold wall according to the first embodiment. Although FIG. 4 is directed to the male form, it is understood that the same design may be employed for the female form.

  The pressure mold provides a mold wall 101 having a recess 1015 in which the heating element 33 is disposed. Mold wall 101 provides a flow path 102 that may be formed in accordance with the disclosure of any of FIGS. 2a-3.

  The recess and the heating element can be formed by an elongated lead for resistive heating or a channel for guiding a heated liquid or gas. Alternatively, the recess can receive a magnetic material that can be inductively heated. Such magnetics can be formed as discrete islands or as one or more elongated rods.

  The recess and the heating element can span all or part of the back surface. The recesses and the sections of the heating element can be regarded as necessary and spaced apart from one another.

  The recess 1015 can extend into the mold wall from its back surface. Non-limiting examples of distances that can extend into the mold wall can be about 3⁄4 or about 1⁄2 or about 1⁄4 of the mold wall thickness at the relevant wall portion.

  If the recess is open towards the back, the heating element 33 may be inserted after the mold wall portion has been manufactured. It is also possible to replace the heating element 33 as required.

  In the present embodiment, the back surface Fb is opened toward the vacuum chamber 32, and can be evacuated as indicated by the arrow in FIG.

  FIG. 5 schematically shows part of a pressure mold according to a second embodiment. Although FIG. 5 is directed to a male mold, it is understood that the same design may be employed for a female mold.

  The pressure mold includes an outer portion 1011 and a heater portion 1013 with a gap 1021 therebetween. A spacer 1012 extends between the heater portion 1013 and the outer portion 1011 and spans the gap 1021.

  The flow path 102 of the outer portion 1011 connects the product surface Fp to the back surface Fb. These flow paths can be formed in accordance with the disclosure of any of Figures 2a-3.

  A recess 1015 may be present on the back surface Fb2 of the heater unit 1013, and the heating element 33 may be disposed in the recess 1015 according to any of the options described in connection with FIG.

  The back surface of the heater unit 1013 may be open toward the vacuum chamber 32.

  The manifold channel 1022 also connects the gap 1021 to the back surface Fb2 of the heater unit 1013. These manifold channels have a larger cross-section than the channels 102, and the number is smaller than the number of channels 102. For example, the main width of the manifold channel 1022 may be on the order of 10 to 1000 times the width of the channel 102.

  Furthermore, the number of manifold channels 1022 may be approximately 1/10 to 1/10000 of the number of channels 102. The total flow cross section of the manifold channel 1022 can be equal to or greater than the total flow cross section of the channel 102. For example, the total flow cross section of the manifold channel 1022 can be about 100 to 300% of the total flow cross section of the channel 102.

  The outer portion 1011, the heater portion 1013 and the spacer 1012 may be integrally formed.

  FIG. 6 is a view schematically showing a part of a pressure mold according to a third embodiment. This embodiment is similar to that of FIG. 5 in that the mold provides an outer portion 1011 integrally formed with the spacer 1012. The flow path 102 can be formed as described with respect to FIGS. 2 a-3 and 5.

  In the embodiment of FIG. 6, the heater portion 1013 ′ and optionally the spacer 1012 are formed of a different material than the separate piece of material and the outer portion 1011. The heating element may be disposed in the heater portion as in the heater portion 1013 of FIG.

  Instead of this, the heating element 33 may be enclosed in the heater 1013. In any case, the manifold channel 1022 may penetrate the heater portion 1013 'in the manner described with reference to FIG.

  The heater unit 1013 ′ may include a main body formed of a metal material.

  An insulator 1014 may be provided on the rear side of the heater unit 1013 ′. Insulator 1014 may abut heater portion 1013 'to allow distribution of vacuum from inlet channel 1024 extending through insulator 1014 to manifold channel 1022, or heater portion 1013'. It may be slightly separated from

  Insulator 1014 can be formed of a rigid insulating material, such as a ceramic material. The insulator 1014 may be surrounded by a casing, for example to protect it from damage.

  Both pressure molds (eg, male and female molds) can be provided with an insulator. In such cases, the insulator can substantially surround the mold such that energy loss is reduced when the mold is brought together in the molding position. Where molds meet, gap gaps may be provided for the escape of steam. Alternatively or additionally, through holes can be provided in one or both of the insulators for the escape of steam.

  In the embodiment where the additional body is located close to the back of the mold, as in the case where the heater 1013, 1013 'is provided, the spacer adds some of the pressure applied to the product surface to the additional body. It can be sent to you.

  Typically, less than 95%, preferably less than 90%, less than 80%, less than 70%, less than 50%, less than 30% or less than 10% of the pressure applied to the product surface is transmitted to the additional body It is possible to The non-transferred part of the pressure may be absorbed by the mold for its own stiffness.

  The pressure applied to the mold surface can be of the order of at least 100 kPa, at least 25 kPa, at least 450 kPa, at least 800 kPa or at least 1 mPa, depending on the application during the pressing process.

The product surface and / or the back surface may be subjected to a surface treatment such as, for example, grinding, polishing, anodizing, or providing a surface coating. Such surface treatments can be used, for example, to reduce the risk of corrosion as compared to the material from which the mold is made. The surface treatment or coating may alternatively or additionally provide anti-stick properties. Such anti-stick properties can be imparted, for example, with a material that is more hydrophobic than the material from which the mold is made. As yet another option, the surface treatment or coating can provide a surface with increased hardness as compared to the mold making material.
In the following, the invention described in the original claims of the present application is appended.
[1] A tool or tool component used in a process of forming a product from pulp slurry, wherein the freestanding tool wall has a product surface in contact with the product and a back surface opposite to the wall with respect to the product surface And a tool wall exhibiting holes provided by a plurality of channels extending from the product surface to the back through the tool wall, the channels being straight or less than one Tool or tool part characterized in that it is curved at a bending point.
[2] The tool or tool component according to [1], wherein the product surface exhibits a flat surface and a convex surface.
[3] The tool or tool part according to [2], wherein the tool wall thickness is preferably 30 to 70% smaller or 40 to 60% smaller in the convex portion than the flat surface portion.
[4] The tool or tool component according to any one of [2] or [3], wherein the convex portion exhibits a porosity larger than that of the flat surface portion.
[5] The tool or tool component according to any one of [1] to [4], wherein the product surface presents a flat surface portion and a concave surface portion.
[6] The tool or tool component according to [5], wherein the flat surface portion exhibits a porosity larger than that of the concave portion.
[7] The product surface is substantially flat and has a pair of surface portions that are at an angle of 45 ° to 135 ° with respect to one another, and the largest angle with respect to the horizontal plane during main operation of the tool or tool part The tool or the tool component according to any one of [1] to [6], wherein one of the surface portions exhibiting a higher porosity has a porosity higher than that of the other of the surface portions.
[8] At least some of the flow channels exhibit a flow channel opening area smaller than the corresponding flow channel opening area of the back surface on the product surface, according to any one of [1] to [7]. Tools or tool parts.
[9] The tool or tool component according to any one of [1] to [8], wherein at least some of the flow channels have a cross section that tapers toward the product surface.
[10] The tool according to any one of [1] to [9], wherein at least some of the flow paths exhibit central axes extending at an angle of 40 to 90 degrees with respect to the product surface. Tool parts.
[11] The tool or tool component according to any one of [1] to [10], wherein at least some of the flow channels exhibit a curved central axis.
[12] The product surface has first and second juxtaposed surface portions, and the central axis of the flow passage opened in the first surface portion is the second surface relative to the product surface of the surface portion. The tool or the tool part according to any one of [1] to [11], which extends at an angle different from the central axis of the flow path opening in the surface portion of
[13] The internal void volume of the tool or tool part is characterized by at least 20%, preferably at least 40%, at least 60% or at least 80% of the total volume spanning the tool or tool part [1 ] The tool or tool component according to any one of [12].
[14] The tool or tool component according to any one of [1] to [13], wherein at least a part of the flow passage has a length exceeding a thickness of a wall near the flow passage.
[15] The tool or the tool according to any one of [1] to [14], wherein the product surface opening of at least some of the flow channels has a cross section having a maximum width of 0.1 to 2 mm. parts.
[16] The tool according to any one of [1] to [15], wherein at least some of the flow channels have at least one branch located between the product surface and the back surface. Tool parts.
[17] The tool wall has a thickness of 0.2 to 20 mm, preferably 0.3 to 15 mm or 0.5 to 10 mm. [1] to [16] Tools or tool parts as described in.
[18] The tool wall portion is characterized in that it is formed as a homogeneous piece of material having a void between the flow channels of less than 95%, preferably less than 99% or less than 99.9%. The tool or tool part according to any one of 17].
[19] The tool or tool part is formed of a material and wall thickness sufficient for the tool or tool part to be self-supporting in operation. [1] Tools or tool parts.
[20] The back of the tool is characterized in that at least 50%, preferably at least 70% or at least 90%, is exposed to a chamber adapted to provide an air pressure other than atmospheric pressure [1] Tool or tool part according to any of [19].
[21] A tool or tool part is a pick-up tool for removing pulp from pulp slurry, a transfer tool for receiving an amount of pulp from another tool, and a press for pressing an amount of pulp to form a shaped article The tool or tool part according to any one of [1] to [20], which forms a part of a tool selected from the group consisting of tools.
[22] The tool according to any one of [1] to [21], characterized in that the tool or the tool part comprises at least two tool walls which can be interconnected, preferably movably interconnected. Or tool parts.
[23] An apparatus for forming a product from pulp slurry, comprising at least one tool or tool component according to any one of [1] to [22], means for applying pulp to the product surface, and vacuum suction And / or means for applying a pressure greater than the atmospheric pressure of said back surface.
[24] The forming apparatus according to [23], further including a heating element (33) disposed on the back side of the tool wall (101) to supply heat to the tool wall.
[25] The forming apparatus according to [24], wherein the heating element is disposed in a heater portion spaced from the tool wall portion.
[26] The forming apparatus according to [25], wherein the heater portion is integrally formed with the tool wall portion.
[27] The forming apparatus according to [25], wherein the heater unit is formed by a separate part that contacts the tool wall via at least one spacer element.
[28] The forming apparatus according to [24], wherein the heating element is integrated with the tool wall.
[29] A method of manufacturing a tool or tool part for forming a product from a pulp slurry, wherein the tool or tool part supplies particles of material to be formed, and a plurality of layers of said particles on the target surface. An energy source is provided at the location of each distribution layer of particles on the target surface corresponding to the cross section of the tool or tool part to be manufactured therein, so as to continuously dispense and fuse the powder particles together. A method of manufacturing a tool or tool part, characterized in that it comprises directing.
[30] The method further includes the step of forming the tool wall having pores defined by a plurality of channels extending from the product surface to the back through the tool wall, the channels being straight or 1 The manufacturing method according to [29], characterized in that it is curved at a bending point below the point.
[31] A method for molding a product from pulp slurry, wherein the mold according to any one of [1] to [22] is prepared, vacuum is applied to the back of the mold, and pulp is applied to the product surface of the mold A method of forming a product, comprising applying a slurry.
[32] The molding method according to [31], further comprising the step of using the mold to take out the pulp slurry from the slurry container.
[33] further comprising using the mold to pressurize the pulp slurry to form a product, whereby at least some solvent is removed from the pulp slurry [31] or The molding method as described in any one of [32].

DESCRIPTION OF SYMBOLS 1 ... Container, 2 ... Pulp slurry, 3 ... Pulp fiber, 3 ', 3 "... manufacture, 5 ... Heating apparatus, 10 ... Pick-up tool, 11 ... Tool holder, 12, 22, 32, 42 ... Vacuum chamber, 20 ... Transfer tool, 21 ... Transfer tool holder, 30 ... Male press tool, 31, 41 ... Tool holder, 33, 43 ... Heater (heating element), 40 ... Female press tool,
DESCRIPTION OF SYMBOLS 101 ... Mold wall part (self-supporting tool wall part), 102 ... Flow path, 1011 ... Outer part, 1012 ... Spacer, 1013, 1013 '... Heater part, 1014 ... Insulator, 1015 ... Indentation, 1021 ... Gap (gap) , 1022 ... manifold flow channel, 1024 ... inlet flow channel,
P1, P2, P3, P4 ... pressure regulator, E, E1, E2 ... energy source, C ... controller
Fp: Product side, Fb: Back side.

Claims (15)

A method of manufacturing a porous mold, comprising
The porous mold comprises a tool wall having holes provided by a plurality of flow channels,
The flow path extends through the tool wall from the product side to the back side opposite the wall to the product side to contact a product;
The flow path is straight or curved at only one inflection point,
A method of manufacturing a porous mold comprising forming the flow path using an additive manufacturing process.   The method according to claim 1, wherein the additive manufacturing process is 3D printing.   Method according to any of the claims 1 or 2, characterized in that the porous mold is made of a powder material having particles of average size of 1 to 50 microns, preferably 5 to 30 microns.   A method according to any of the preceding claims, wherein the porous mold is made of a material which is a metal or an alloy.   The porous mold is made of a material which is titanium or titanium alloy, aluminum or aluminum alloy, copper or copper alloy, bronze, brass, cobalt or chromium alloy or stainless steel. The method according to any one of the preceding claims.   A method according to any of the preceding claims, wherein the porous mold is made of a material which is a polymeric material such as a plastic material.   A method according to any one of claims 3 to 6, wherein the material between the channels is homogeneous and at least 95%, preferably 99% or 99.9%, are void free. A method of manufacturing a porous tool or tool part for forming a product from a pulp slurry, comprising:
Said porous tool or tool part supplies particles of material to be formed;
Continuously distributing a plurality of layers of said particles on the target surface,
A source of energy is directed to the location of each distribution layer of particles of the target surface corresponding to the cross section of the porous tool or tool part to be produced therein, such that the powder particles fuse together.
A method of making a porous tool or tool component comprising:   The method may further comprise the step of forming the tool wall having a hole defined by a plurality of channels extending from the product surface to the back through the tool wall, the channels being straight or having only one bend. The method according to claim 8, characterized in that it is curved at a point.   Method according to claim 9, characterized in that the material between the channels is homogeneous and at least 95%, preferably 99% or 99.9%, are void free.   A method according to any one of claims 8 to 10, wherein the particles have an average size of 1 to 50 microns, preferably 5 to 30 microns. Directing an energy source to the location of each distribution layer of particles on the target surface corresponding to the cross section of the tool or tool part to be generated therein,
A method according to any one of claims 8 to 11, wherein the step comprises completely melting the powder material by applying energy by means of a laser beam or an electron beam.   The method according to any one of claims 8 to 12, wherein the material is a metal or an alloy.   14. The material according to any one of claims 8 to 13, wherein the material comprises titanium or titanium alloy, aluminum or aluminum alloy, copper or copper alloy, bronze, brass, cobalt or chromium alloy, or stainless steel. the method of.   13. A method according to any one of claims 8 to 12, wherein the material is a polymer material such as a plastic material.

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