CA2165902A1 - Composite hollow moulded panels and methods of manufacture - Google Patents
Composite hollow moulded panels and methods of manufactureInfo
- Publication number
- CA2165902A1 CA2165902A1 CA 2165902 CA2165902A CA2165902A1 CA 2165902 A1 CA2165902 A1 CA 2165902A1 CA 2165902 CA2165902 CA 2165902 CA 2165902 A CA2165902 A CA 2165902A CA 2165902 A1 CA2165902 A1 CA 2165902A1
- Authority
- CA
- Canada
- Prior art keywords
- moulded
- face
- panel
- elements
- wet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Abstract
A unique method of producing a moulded sheet or an external moulded element of a composite hollow panel comprised of at least two co-extensive elements, said external element thereof or said moulded sheet having one continuously planar face and having a plurality of thickened areas which provide a corresponding plurality of prominences directed outwardly of the other face, said prominences having predetermined shapes, locations and dimensions to serve as reinforced areas for said sheet or external element and, where required, to serve as gluing surfaces for joining to another one of said at least two co-extensive elements.
Description
COMPOSITE HOLLOW MOULDED PANELS AND METHODS OF MANUFACTURE
Field of the Invention This invention relates to composite hollow moulded panels and their elt~m~ontc, and the methods of m~nllfa- tllring and combining said elements into said composite panels.
Brief Description of the Prior Art Composite hollow panels are already known and in common use, such as the famili~r co~ hler board comprised of a diaphragm of corrugated ~ap.lLoald glued between two flat sheets of paperboard to form the strong but lightweight wall of a folding container, and a structural panel, used in Australia. made up from a diaphragm comprised of a continuous layer made from a multiplicity of moulded pulp egg trays (30 egg type) glued between two panels of plywood or pulpboard. The recent development of a hollow panel comprised of two ribbed elernPntc is described in U.S. Patent Number 4,702,870, and an earlier development of a hollow panel, comprised of a single element formed by means of a multiplicity of moulding dies used in combination is described in U.S. Patent Number 3,053,728 awarded to Emery in 1962.
The deeply ribbed hollow panel of U.S. Patent Number 3,053,728 was coln~lised of a plurality of tubular preforms pressed together while still supported on the forming moulds and still immersed in the slurry of cement asbestos moulding ll~al~lials. But the succescful development ~_ 2165902 .
project was abandoned when the dangers of wolhing with asbestos became known.
The concept of a deeply ribbed composite hollow moulded pulp panel described in U.S. Patent Number 4,702,870 provides for a ,..~ h;ng network of deep ribs p~ojee~ g from one face of each of the two co-extensive moulded pulp elements of which it is colllplised, said e1PmPntC
being glued together internally of said hollow panel along the facing outer edges of said m~ hing rib networks. The co,l~ c,.;ial success of this eol,cept awaits the discove~y and development of a practical and economical method of m~nnfa~tllre.
Back~round of the ~nvention In a radically dirfelellt concept to the earlier inventions described above, it is the object of this invention to create a series of composite hollow moulded panels mo~ Pd from fibrous pulps such as wood pulps which will allow the ~cccc~rul use of lower grade molllrling materials, such as waste papers or paper mill slud_e, becd.lse of the greater ~ lh which can be achieved in the design of said panels and their elemPntc. Instead of the deep thin ribs of the previous inventions described above, the special advantages of this invention lie in the greater slle~ll and improved gluing surfaces inherent in the design of at least one extt~ l elem~nt of said panel, moulded with a plurality of wide ~hirk~Pd areas pr~je-;ling from one face of said at least one element, to provide an increased total combined area of ,~i~ol~e,l~ l over the entire extent of said element, and a plurality of wide and secure gluing faces to bind said external elemlont together with the immP~ tely ~dj~renr elem~nt of said panel.
- ' 2165902 It is well known in the industry that the wall thickness conveniently produced at high speed in a moulded fibre product such as an egg tray is limited by the character of the raw materials used. Thus the limit for the typical short fibres found in the sludge from paper mills, in which the fibres are sometimes mixed with clay particles, may be a sheet or wall thi~n~ss in the order of three millim~res or less, while a sheet of 10 or 15 millimetres in thickness or even more will be available in products made from the longer fibres found in pulps made from other recycled products such as old corrugated containers. When consolidated following the preform stage by hot press drying between heated pressing dies, the final thickness may be reduced to one half these thickn.ocses or even less. This invention supplies the means to produce thickened areas in such elements beyond the limits of thi~kn~ss which can be produced in a simple sheet of a particular pulp type when produced by high speed pulping methods.
The practical success of this invention is ensured by the use of known and widely used wet vacuum moulding and hot press drying methods, supplemented by the use of a unique method of producing thickened reinforcing areas at one face of a panel element. The use of a new method of hot press drying a wet preform at considerably higher speeds, as described in U.S.
Patent Number 5,174,863, will add to the commercial practicality and area of application of this invention.
Summary of the Invention A novel method of producing a thickened reinforcing portion in limited areas of one or more - " 2165902 elements of such a sheet or wall of a moulded panel is made co~ ially practical by the employment of a series of releasable mounted and freely transferable and rotatable groups of transfer or pressing dies such as described in said U.S. Patent 5,174,863, by means of which a plurality of ribs or conical projections, or a series of such ribs or conical projections vertically imposed, one upon the other, have first been formed in a wet pl~follll. Said ribs or conical projections may be collapsed and densified in one or a series of wet pressing stages under vacuum, using carefully designed wet pressing dies to define and control the shape and volume to which the collapsed material is reduced at each of these interm~di~te wet pressing stages, in order to control the thicknto5~ location, shape, and lateral tlimpn~ions of the thickened reinforced area produced in the final hot press drying stage of the process, at the same time creating a continuously planar surface of at least 80% ullirO~ density, or such greater uniformity of density as may be required for a printing surface on the opposite side of the sheet or wall, where a soft or depressed area may have existed in the wet preform as first moulded. The use of multiple pressing stages to achieve a desired final moulded shape by the hot press drying process after first using intermediate pressing stages, was exemplified in the m~nllfartnre of moulded fibre shell cases on special moulding m~ in~ry design~l1 and supplied by Emery to the Brunswick Corporation for the U.S. Air Force, as recounted but not described for military secrecy reasons, in the article "A Small C~n~ n company has opened the door on a new technology" by Suzanne Marr, published in the C~n~ n Con~--ltin~ F.nginPer, June, 1974. The usual shape of ribs or conical elements projecting from a moulded fibre sheet or wall is shown in the drawings of U.S. l)esign Patent DES229,608 issued to Reifer, December, 1973.
Field of the Invention This invention relates to composite hollow moulded panels and their elt~m~ontc, and the methods of m~nllfa- tllring and combining said elements into said composite panels.
Brief Description of the Prior Art Composite hollow panels are already known and in common use, such as the famili~r co~ hler board comprised of a diaphragm of corrugated ~ap.lLoald glued between two flat sheets of paperboard to form the strong but lightweight wall of a folding container, and a structural panel, used in Australia. made up from a diaphragm comprised of a continuous layer made from a multiplicity of moulded pulp egg trays (30 egg type) glued between two panels of plywood or pulpboard. The recent development of a hollow panel comprised of two ribbed elernPntc is described in U.S. Patent Number 4,702,870, and an earlier development of a hollow panel, comprised of a single element formed by means of a multiplicity of moulding dies used in combination is described in U.S. Patent Number 3,053,728 awarded to Emery in 1962.
The deeply ribbed hollow panel of U.S. Patent Number 3,053,728 was coln~lised of a plurality of tubular preforms pressed together while still supported on the forming moulds and still immersed in the slurry of cement asbestos moulding ll~al~lials. But the succescful development ~_ 2165902 .
project was abandoned when the dangers of wolhing with asbestos became known.
The concept of a deeply ribbed composite hollow moulded pulp panel described in U.S. Patent Number 4,702,870 provides for a ,..~ h;ng network of deep ribs p~ojee~ g from one face of each of the two co-extensive moulded pulp elements of which it is colllplised, said e1PmPntC
being glued together internally of said hollow panel along the facing outer edges of said m~ hing rib networks. The co,l~ c,.;ial success of this eol,cept awaits the discove~y and development of a practical and economical method of m~nnfa~tllre.
Back~round of the ~nvention In a radically dirfelellt concept to the earlier inventions described above, it is the object of this invention to create a series of composite hollow moulded panels mo~ Pd from fibrous pulps such as wood pulps which will allow the ~cccc~rul use of lower grade molllrling materials, such as waste papers or paper mill slud_e, becd.lse of the greater ~ lh which can be achieved in the design of said panels and their elemPntc. Instead of the deep thin ribs of the previous inventions described above, the special advantages of this invention lie in the greater slle~ll and improved gluing surfaces inherent in the design of at least one extt~ l elem~nt of said panel, moulded with a plurality of wide ~hirk~Pd areas pr~je-;ling from one face of said at least one element, to provide an increased total combined area of ,~i~ol~e,l~ l over the entire extent of said element, and a plurality of wide and secure gluing faces to bind said external elemlont together with the immP~ tely ~dj~renr elem~nt of said panel.
- ' 2165902 It is well known in the industry that the wall thickness conveniently produced at high speed in a moulded fibre product such as an egg tray is limited by the character of the raw materials used. Thus the limit for the typical short fibres found in the sludge from paper mills, in which the fibres are sometimes mixed with clay particles, may be a sheet or wall thi~n~ss in the order of three millim~res or less, while a sheet of 10 or 15 millimetres in thickness or even more will be available in products made from the longer fibres found in pulps made from other recycled products such as old corrugated containers. When consolidated following the preform stage by hot press drying between heated pressing dies, the final thickness may be reduced to one half these thickn.ocses or even less. This invention supplies the means to produce thickened areas in such elements beyond the limits of thi~kn~ss which can be produced in a simple sheet of a particular pulp type when produced by high speed pulping methods.
The practical success of this invention is ensured by the use of known and widely used wet vacuum moulding and hot press drying methods, supplemented by the use of a unique method of producing thickened reinforcing areas at one face of a panel element. The use of a new method of hot press drying a wet preform at considerably higher speeds, as described in U.S.
Patent Number 5,174,863, will add to the commercial practicality and area of application of this invention.
Summary of the Invention A novel method of producing a thickened reinforcing portion in limited areas of one or more - " 2165902 elements of such a sheet or wall of a moulded panel is made co~ ially practical by the employment of a series of releasable mounted and freely transferable and rotatable groups of transfer or pressing dies such as described in said U.S. Patent 5,174,863, by means of which a plurality of ribs or conical projections, or a series of such ribs or conical projections vertically imposed, one upon the other, have first been formed in a wet pl~follll. Said ribs or conical projections may be collapsed and densified in one or a series of wet pressing stages under vacuum, using carefully designed wet pressing dies to define and control the shape and volume to which the collapsed material is reduced at each of these interm~di~te wet pressing stages, in order to control the thicknto5~ location, shape, and lateral tlimpn~ions of the thickened reinforced area produced in the final hot press drying stage of the process, at the same time creating a continuously planar surface of at least 80% ullirO~ density, or such greater uniformity of density as may be required for a printing surface on the opposite side of the sheet or wall, where a soft or depressed area may have existed in the wet preform as first moulded. The use of multiple pressing stages to achieve a desired final moulded shape by the hot press drying process after first using intermediate pressing stages, was exemplified in the m~nllfartnre of moulded fibre shell cases on special moulding m~ in~ry design~l1 and supplied by Emery to the Brunswick Corporation for the U.S. Air Force, as recounted but not described for military secrecy reasons, in the article "A Small C~n~ n company has opened the door on a new technology" by Suzanne Marr, published in the C~n~ n Con~--ltin~ F.nginPer, June, 1974. The usual shape of ribs or conical elements projecting from a moulded fibre sheet or wall is shown in the drawings of U.S. l)esign Patent DES229,608 issued to Reifer, December, 1973.
The thickness, shape, area and spacing of the thickened portions of the moulded elements formed in this manner will be determined by the requirements and structural design of the composite panel of which it forms a part, at the same time regulating the span of the surrounding unreinforced unthickened rem~ining area of the sheet or wall of the moulded element on which they are formed. Such an element may also be designed and m~mlf~rtnred for use as an uncombined single sheet or wall of a moulded product.
Brief Description of the Drawin~s In drawings which illustrate example embodiments of panels and panel elements constructed in accordance with this invention;
Figure 1 is a cross sectional view of a portion of a panel element shown in both a wet preform state and final pressed and dried state;
Figure 2A is a cross sectional view of a portion of another panel element in a wet preform state;
Figure 2B is a cross sectional view of a portion of the panel element of Figure 2A shown both in a wet preform state and final pressed and dried state;
Figure 3 is a cross sectional view through a portion of a composite panel;
- ' 21fi5902 Figure 4 is a cross sectional view through a portion of another composite panel;
Figure 5A is a cross sectional view through a portion of a primary panel element in a wet preform state, with three supplementary wet preforms superimposed thereon;
Figure 5B is a cross sectional view through a portion of the panel elements of Figure SA, shown in an intermediate pressed state;
Figure SC is a cross sectional view of a portion of a panel element in its final state, formed from the wet preforms shown in Figures SA and 5B;
Figure 6 is a cross sectional view through a portion of another composite panel, formed by combining two of the final elements shown in Figure 5C.
Figure 7 is a cross sectional view through a portion of yet another composite panel formed by combining one each of the finished elements shown in Figure 1 and Figure 5C;
Figure 8 is a cross sectional view through a portion of another panel element shown in the traditional egg tray form, shown in both an initial wet preform state and a final state;
Figure 9 is a cross sectional view through a portion of a panel formed from two of the panel elements 31 of Figure 2B and one of the panel element 40X of Figure 8;
Figure 10 is a plan view of another panel suitable for use as an acoustic ceiling panel;
Figure llA is an edge view of the panel of Figure 10;
Figure llB is an enlarged edge view of a portion of the panel shown in Figure 11A;
Figure 12 is a plan view of a panel adapted to be folded into a container;
Figure 13 is a cross sectional view of a portion of the panel of Figure 12 along A - A;
Figure 14 is a cross sectional view of a portion of the panel of Figure 12 along B - B;
Figure 15 is a cross sectional view similar to that of Figure 14, folded at 90~;
Figure 16 is a diagram showing the general form of a pulp moulding m~rhinP with hot press drying equipment which can be used to m~mlfa~ture the moulded panel element of Figure 2B.
Figure 17 is plan view of a portion of one side of a moulded element showing one of the variety of arrangements of thickened areas available.
Figure 18 is a plan of a portion of one side of a moulded element showing another one of the variety of arrangements of thickened areas available.
'~ (: 216 5 9 0 2 f Figure 19 is a plan view of a portion of one side of a moulded elem~t showing a third one of the variety of arrangements of thick~Pd areas available.
Figure 20 is a plan view of the planar side of a single sheet with thi~on~d rc;hlfolced areas, adapted to be folded into a container.
Figure 21 is a cross sectional view of sheet 401 along A - A.
Figure 22 is a cross sectional view of the sheet 401 along B - B.
Figure 23 is a cross sectional view of the sheet 401 along either A - A or B - B, folded at 900 ., Detailed Description of ~lef~ ,d Embo-lim~ontc - In the drawings, Figure 1 is a cross section through a portion of a wet moulded pl-fo 30, showing the outlines 10 and 11 of said preform 30, and the outlines 12 and 11 of a final form 30X into which it can be cG~ ,;,sed, for example, into one half its original thi~kn~ss~ by using a mating hot press forming die with a moulding face in the shape of line 12, in any form of the well known hot press drying and finiching system.
- Figure 2A is a cross section through a portion of the wet pl~foll-l 30 of Figure 1, but 2165902 1 ' with the surface along line 11 directed upwards, ready to present the smaller ribs or conical projections to the final hot press die with a moulding face in the shape of line 13 of Figure 2B;
- Figure 2B is a cross section of the portion of the wet preform 30 shown in Figure 2A, showing the final shape and reduced volume of the finichP~ element 31 into which said wet preform 30 may be transformed, by transfer into a pair of hot press drying dies, the first of said dies having a planar moulding face to produce the planar surface shown in profile along line 15, and the second of said dies having a moulding face as shown in profile along line 13, and in this example as shown, the volume of wet preform material included in and under each of said ribs or conical projections is designed to be compressed and densified to approximately one half the net vclume contained in said rib or conical projection and the material immPdi~tely thereunder from which it was formed, with the rem~ining unthickened portions of said wall of said fini.chP~ element 31 being compressed to one half the wall thi~knpss and volume of the related portions of said wet preform, thus assuring an approximately uniform density throughout the entirety of said finichPd element 31.
- Figure 3 is a cross section through a portion of a composite hollow moulded panel 33, comprised of one element 30X and one element 31 glued together between the prominent surfaces of said ribs or conical projections along line 11 of said element 31, thus providing one uninterrupted planar outer surface and one ribbed or indented opposite surface to said panel 33.
Figure 4 is a cross section through a portion of a composite hollow moulded panel 34, comprised of two elements 31, glued together at the mating prominent surfaces of their respective mating thickened areas along the lines 13 of each of said elements, thus providing uninterrupted planar surfaces on the two outer faces of said panel 34, along the lines 15 of said elements.
Figure SA is a cross section through a portion of a wet prefo~ 35 showing additional wet preforms 36 superimposed upon the upwardly directed ribs or conical projections along line 20 of said preform 35 in a l~min~ting process.
Figure 5B is a cross section showing the wet preforms 35 and 36 in their interm~ te wet pressed forms 35X and 36X as in-lic~ted in profile along lines 17 and 18, said interrnediate pressing operation having been made between a pair of intermP(li~te wet pressing dies, with the first of said dies having a moulding surface to retain the shape of one surface of said element 35X along line 19, and the second of said dies having moulding surfaces conforming to lines 17 on partly colll~lcssed preforms 36X and ret~ining the existing planar form of the rem~ining areas along line 20 of the preform 35X, thus tending to reduce the sideward spread of the upwardly directed projections now partly densified as intlic~t~cl in profile along lines 18.
~- 2165902 - Figure SC is a cross section of a portion of element 37 in the final finished form and reduced volume into which it can be compressed from the partially compressed wet preforms 35X and 36X by transfer into a pair of hot press drying dies, the first of said dies having an unill~ellu~Led planar surface to form the planar surface in-lic~ted in profile along line 24, and the second of said dies having a moulding surface ap~lopliate for forming the final shape of the other surface of said element 37, as in-licate~l in profile along line 25, the net combined volumes of one of said elemPnt~ 36, one of the upwardly directed projections along line 20 of said preform 35, and the material directly thereunder being compressed along line 20 to approximately one half of said volume in the related thickened area long line 25 of fini~h~cl element 37, and the rem~ining planar areas of said preform 35 along line 20 being compressed to one half their thi~l~n~s~ and volume between lines 25 and 24 of said finished element 37.
- Figure 6 is a cross section of a portion of a composite hollow moulded panel 38, comprised of two of the fini~hecl elements 37 of Figure SC, glued together at the mating prominent surfaces of their respective thickened areas along the lines 25 of each of said elements 37, thus providing uninterrupted planar surfaces on each of the two outer faces of said panel 38, as shown in profile along lines 24 of said elements 37.
- Figure 7 is a cross section of a composite hollow moulded panel 39, comprised of one element 30 of Figure 1 and one element 37 of Figure SC, glued together at the ribs or conical projections along line 11 of said element 30, and the mating prominent surfaces ~ 2165902 -of the thickened areas along line 25 of element 37, thus providing one uninterrupted planar surface on one outer face of said panel 39 along line 24 of said element 37.
- Figure 8 is a cross section of a portion of a wet preform 40 of the traditional egg tray shape, having projections above side 21 and projections below side 23, showing the final shape and reduced thicknPss as defined by lines 22 and 23 of the fini~h~d element 40X
into which said preform 40 may be compressed and densified by the well known hot press drying process.
- Figure 9 is a cross section of a portion of a composite hollow moulded panel 41, comprised of one element 40 of Figure 8 serving as a diaphragm7 and two elements 31 of Figure 23 serving as the outer elements of said panel 41, the flrst of said elements 31 being glued along the projecting thieken~d areas of line 13 to the projecting surfaces along line 22 of said element 40, and the second of said elen e~ts 31 being glued along the projecting thickened areas of line 13 to the projecting surfaces along line 23 of said element 40, thus creating a panel with an unin~ellu~ted planar surface at each outer face.
- Figure 10 is a plan view of a composite hollow moulded panel 100, suitable for use as an acoustic ceiling panel or a drawer bottom comprised of two moulded elements glued together, with a reguiar pattern of indentions 49 on one face, as shown.
- Figure 11A is an edge view of said panel 100 showing the internal construction formed - ( ~
by the two moulded elements of which it is comprised, element 30X of Figure 1, and ~ element 31 of Figure 2, said indentations 49 of said element 30X being formed as the reverse side of the conical projections, instead of the optional alternative ribs.
- Figure 11B is a cross section through a portion of the panel 100 taken at line AA, showing said indentations 49 formed along line 12 of said element 30X, and the related conical projections along side 11 of said element 30X glued to the prominent surfaces along line 14 of the mating thickened areas of said element 31.
- Figure 12 is a plan view of a composite hollow moulded panel 101, similar to panel type 34 of Figure 4, with the two elements 31 moulded complete with the cutouts 52 and fold lines 51 required to form a folding container when said two- elements 31 are glued together at the matching elongated prominences formed by the thickened areas on the inwardly directed faces of each of said elements 31. In use, a first end wall 56 is hingedly connPcte(l at two parallel edges and fold lines 51 to the adjacent first edge of a first side wall 55, and at the adjacent first edge of a second side wall 55, and a second end wall 56 is hingedly connected at a first edge and a fold line 51 to a second edge of said first side wall 55, and at a second edge and fold line 51 is hingedly connPct~d to a flap 58, which may be stapled or glued to the free end of the second of said second side wall 55 thereby to form the complete perimeter of said container, which is then closed by first folding in the four top and bottom walls 57, which are hingedly connected to the upper and lower edges of said end walls 56, at fold lines 50, and then folding in the four top and bottom walls 54, which in turn are hingedly connected at their edges to the upper --~~ and lower edges of said side walls 55, at fold lines 53.
- Figure 13 is a cross section through a portion of a side wall 55 and of an end wall 56 of said panel 101 of Figure 12, along AA, showing the thickened areas of the two elements 31 glued together at the glue lines 59, and details at the fold line 51.
- Figure 14 is a cross section through a portion of a side wall 55 and a top wall 54 of said panel 101 of Figure 12, along BB, showing the glue line between two elongated thickened areas of said elements 31, and details of the fold line 50.
- Figure 15 is a cross section through a portion of a side wall SS and a top wall 54 of said panel 101 showing details at fold line 53 when said panel is folded there at an angle of 90~ between said side wall 55 and said top wall 54.
- Figure 16 is a diagram showing an example of a general arrangement of the locations for the moulding, transfer and pressing dies, and of the rotors by means of which said dies and the moulded items which they contain are transported in order to wet mould, collapse, densify and press dry the preform 30 of Figure 2A into the fini.ch~l element 31 of Figure 2B. As shown in the diagram the wet forming dies 251 are transported on rotor 201 through the wet moulding process, and the wet preforms are transferred to the transfer dies 252, and from there transported on rotor 202 to be transferred to the flat ~- ' 2165902 faced pressing dies 253 releasably mounted on rotor 203. Said flat faced pressing dies, still cont~ining the unchanged wet preforms, are then transferred by rotor 204 from said rotor 203 to rotor 205, where said flat faced dies 253, still cont~ining the unchanged wet preforms, are locked into mated pressing position with heated pressing dies 254 which conform in shape to the outline 13 of the element 31 of Figure 2A. The heated pressing dies 254 are then pressed against the wet preform 30 and towards the flat faced die 253, thus collapsing the wet moulded material projecting from side 11 of said element 30 and condensing the total material of said wet preform 30 into the final form of said fini~hPcl element 31.
After the final product has rem~in~l between said pressing dies 253 and 254 for the required drying time, the said flat faced pressing dies 253 are unlocked and transferred from the mating position with said heated pressing dies 254 on rotor 206 and thence to rotor 203, from whence said fini~h~(l products 31 are discharged from said flat faced pressing dies 253 and said empty dies 253 are then rotated on said rotor 203 to transfer position with said transfer dies 252 on rotor 202, to receive a new supply of said wet moulded preforms 30.
- Figure 17 is a plan view of a portion of one face of the moulded external element 31 of the panel 100 of Figure 10, with a plurality of isolated but regularly shaped promin~nres 214, and intervening nnthirkrn~ areas 215 on the inwardly directed face thereof, in one of the variety of arrangements available for use with said panel 100.
- Figure 18 is a plan view of a portion of one face of a moulded external element 51 of ~ the panel 101 of Figure 12, with a plurality of closely spaced parallel and elongated prominences 315 thereon, intel-upt~d by a narrow unthiekenPIl area at the fold line 353, conn~cted together at larger intervals with transverse plo~ np~ es 314, and with intervening unthickened spaces 316 on the inwardly directed face thereof, in one of the variety of arrangements available for use with said panel 101 - Figure 19 is a plan view of a portion of a moulded sheet or element 431, which sheet may be used as an alternative to the moulded element 31 of panel 101 of Figure 12, or as the single moulded sheet 431 of the panel 401 of Figure 20. Said sheet or element has on one face thereof a network of prominences 414 and intervening unthickened areas 416, said network being interrupted by a continuous elongated ~Inthiekened area at each fold line such as shown at fold line 453, said network providing stability in both vertical and horizontal directions in the side wall or end wall of a container.
- Figure 20 is a plan view of the continuously planar surface of one face of the moulded sheet 431 of the folding container panel 401, said sheet 431 having a net work of reinforcing prominences on its other face, similar to that shown in Figure 19. Said sheet 431 of said container panel 401 who has been moulded complete with the required perimeter cutouts 452, and fold lines 450, 451 and 453 required to form a container. In use, a first end wall 456 is hingedly conn.octed at two parallel edges and two fold lines 451 to the adjacent first edge of a first side wall 455 and the adjacent first edge of a second side wall 455, and a second end wall 456 is hingedly comle~ted at a first edge and a fold line 451 to a second edge of said first side wall 455, and at a second edge and fold line 451 is conn~oct~d to the adj~cerlt edge of a flap 438, which may be glued or stapled to the free end of said second side wall 455, lhe.eb~ to form the complete folded perimeter of said container, which is then closed by first folding in the four top and bottom walls 457 which are hingedly conn~cted to the upper and lower edges of said end walls 456 at fold lines 450, and then folding in the four top and bottom walls 454, which are hingedly conn.qcted to said side walls 455 at their top and bottom edges and at fold lines 453.
- Figure 21 is a cross section view along BB of portions of a side wall 455 and an end wall 456 of said sheet 431 of Figure 12, hinge~ly conl-Pc~ together at fold line 451.
- Figure 22 is a cross section view of portions of a side wall 455 and a top wall 454 of Figure 20 along AA hingedly conn~cte~ together at fold line 453.
- Figure 23 is a cross section view of portions of a side wall 455 and a top wall 454 of Figure 12 along BB hingedly conn.octetl together and folded at 90~ to each other at fold line 450, and showing details of the completed fold at said fold line 450.
Brief Description of the Drawin~s In drawings which illustrate example embodiments of panels and panel elements constructed in accordance with this invention;
Figure 1 is a cross sectional view of a portion of a panel element shown in both a wet preform state and final pressed and dried state;
Figure 2A is a cross sectional view of a portion of another panel element in a wet preform state;
Figure 2B is a cross sectional view of a portion of the panel element of Figure 2A shown both in a wet preform state and final pressed and dried state;
Figure 3 is a cross sectional view through a portion of a composite panel;
- ' 21fi5902 Figure 4 is a cross sectional view through a portion of another composite panel;
Figure 5A is a cross sectional view through a portion of a primary panel element in a wet preform state, with three supplementary wet preforms superimposed thereon;
Figure 5B is a cross sectional view through a portion of the panel elements of Figure SA, shown in an intermediate pressed state;
Figure SC is a cross sectional view of a portion of a panel element in its final state, formed from the wet preforms shown in Figures SA and 5B;
Figure 6 is a cross sectional view through a portion of another composite panel, formed by combining two of the final elements shown in Figure 5C.
Figure 7 is a cross sectional view through a portion of yet another composite panel formed by combining one each of the finished elements shown in Figure 1 and Figure 5C;
Figure 8 is a cross sectional view through a portion of another panel element shown in the traditional egg tray form, shown in both an initial wet preform state and a final state;
Figure 9 is a cross sectional view through a portion of a panel formed from two of the panel elements 31 of Figure 2B and one of the panel element 40X of Figure 8;
Figure 10 is a plan view of another panel suitable for use as an acoustic ceiling panel;
Figure llA is an edge view of the panel of Figure 10;
Figure llB is an enlarged edge view of a portion of the panel shown in Figure 11A;
Figure 12 is a plan view of a panel adapted to be folded into a container;
Figure 13 is a cross sectional view of a portion of the panel of Figure 12 along A - A;
Figure 14 is a cross sectional view of a portion of the panel of Figure 12 along B - B;
Figure 15 is a cross sectional view similar to that of Figure 14, folded at 90~;
Figure 16 is a diagram showing the general form of a pulp moulding m~rhinP with hot press drying equipment which can be used to m~mlfa~ture the moulded panel element of Figure 2B.
Figure 17 is plan view of a portion of one side of a moulded element showing one of the variety of arrangements of thickened areas available.
Figure 18 is a plan of a portion of one side of a moulded element showing another one of the variety of arrangements of thickened areas available.
'~ (: 216 5 9 0 2 f Figure 19 is a plan view of a portion of one side of a moulded elem~t showing a third one of the variety of arrangements of thick~Pd areas available.
Figure 20 is a plan view of the planar side of a single sheet with thi~on~d rc;hlfolced areas, adapted to be folded into a container.
Figure 21 is a cross sectional view of sheet 401 along A - A.
Figure 22 is a cross sectional view of the sheet 401 along B - B.
Figure 23 is a cross sectional view of the sheet 401 along either A - A or B - B, folded at 900 ., Detailed Description of ~lef~ ,d Embo-lim~ontc - In the drawings, Figure 1 is a cross section through a portion of a wet moulded pl-fo 30, showing the outlines 10 and 11 of said preform 30, and the outlines 12 and 11 of a final form 30X into which it can be cG~ ,;,sed, for example, into one half its original thi~kn~ss~ by using a mating hot press forming die with a moulding face in the shape of line 12, in any form of the well known hot press drying and finiching system.
- Figure 2A is a cross section through a portion of the wet pl~foll-l 30 of Figure 1, but 2165902 1 ' with the surface along line 11 directed upwards, ready to present the smaller ribs or conical projections to the final hot press die with a moulding face in the shape of line 13 of Figure 2B;
- Figure 2B is a cross section of the portion of the wet preform 30 shown in Figure 2A, showing the final shape and reduced volume of the finichP~ element 31 into which said wet preform 30 may be transformed, by transfer into a pair of hot press drying dies, the first of said dies having a planar moulding face to produce the planar surface shown in profile along line 15, and the second of said dies having a moulding face as shown in profile along line 13, and in this example as shown, the volume of wet preform material included in and under each of said ribs or conical projections is designed to be compressed and densified to approximately one half the net vclume contained in said rib or conical projection and the material immPdi~tely thereunder from which it was formed, with the rem~ining unthickened portions of said wall of said fini.chP~ element 31 being compressed to one half the wall thi~knpss and volume of the related portions of said wet preform, thus assuring an approximately uniform density throughout the entirety of said finichPd element 31.
- Figure 3 is a cross section through a portion of a composite hollow moulded panel 33, comprised of one element 30X and one element 31 glued together between the prominent surfaces of said ribs or conical projections along line 11 of said element 31, thus providing one uninterrupted planar outer surface and one ribbed or indented opposite surface to said panel 33.
Figure 4 is a cross section through a portion of a composite hollow moulded panel 34, comprised of two elements 31, glued together at the mating prominent surfaces of their respective mating thickened areas along the lines 13 of each of said elements, thus providing uninterrupted planar surfaces on the two outer faces of said panel 34, along the lines 15 of said elements.
Figure SA is a cross section through a portion of a wet prefo~ 35 showing additional wet preforms 36 superimposed upon the upwardly directed ribs or conical projections along line 20 of said preform 35 in a l~min~ting process.
Figure 5B is a cross section showing the wet preforms 35 and 36 in their interm~ te wet pressed forms 35X and 36X as in-lic~ted in profile along lines 17 and 18, said interrnediate pressing operation having been made between a pair of intermP(li~te wet pressing dies, with the first of said dies having a moulding surface to retain the shape of one surface of said element 35X along line 19, and the second of said dies having moulding surfaces conforming to lines 17 on partly colll~lcssed preforms 36X and ret~ining the existing planar form of the rem~ining areas along line 20 of the preform 35X, thus tending to reduce the sideward spread of the upwardly directed projections now partly densified as intlic~t~cl in profile along lines 18.
~- 2165902 - Figure SC is a cross section of a portion of element 37 in the final finished form and reduced volume into which it can be compressed from the partially compressed wet preforms 35X and 36X by transfer into a pair of hot press drying dies, the first of said dies having an unill~ellu~Led planar surface to form the planar surface in-lic~ted in profile along line 24, and the second of said dies having a moulding surface ap~lopliate for forming the final shape of the other surface of said element 37, as in-licate~l in profile along line 25, the net combined volumes of one of said elemPnt~ 36, one of the upwardly directed projections along line 20 of said preform 35, and the material directly thereunder being compressed along line 20 to approximately one half of said volume in the related thickened area long line 25 of fini~h~cl element 37, and the rem~ining planar areas of said preform 35 along line 20 being compressed to one half their thi~l~n~s~ and volume between lines 25 and 24 of said finished element 37.
- Figure 6 is a cross section of a portion of a composite hollow moulded panel 38, comprised of two of the fini~hecl elements 37 of Figure SC, glued together at the mating prominent surfaces of their respective thickened areas along the lines 25 of each of said elements 37, thus providing uninterrupted planar surfaces on each of the two outer faces of said panel 38, as shown in profile along lines 24 of said elements 37.
- Figure 7 is a cross section of a composite hollow moulded panel 39, comprised of one element 30 of Figure 1 and one element 37 of Figure SC, glued together at the ribs or conical projections along line 11 of said element 30, and the mating prominent surfaces ~ 2165902 -of the thickened areas along line 25 of element 37, thus providing one uninterrupted planar surface on one outer face of said panel 39 along line 24 of said element 37.
- Figure 8 is a cross section of a portion of a wet preform 40 of the traditional egg tray shape, having projections above side 21 and projections below side 23, showing the final shape and reduced thicknPss as defined by lines 22 and 23 of the fini~h~d element 40X
into which said preform 40 may be compressed and densified by the well known hot press drying process.
- Figure 9 is a cross section of a portion of a composite hollow moulded panel 41, comprised of one element 40 of Figure 8 serving as a diaphragm7 and two elements 31 of Figure 23 serving as the outer elements of said panel 41, the flrst of said elements 31 being glued along the projecting thieken~d areas of line 13 to the projecting surfaces along line 22 of said element 40, and the second of said elen e~ts 31 being glued along the projecting thickened areas of line 13 to the projecting surfaces along line 23 of said element 40, thus creating a panel with an unin~ellu~ted planar surface at each outer face.
- Figure 10 is a plan view of a composite hollow moulded panel 100, suitable for use as an acoustic ceiling panel or a drawer bottom comprised of two moulded elements glued together, with a reguiar pattern of indentions 49 on one face, as shown.
- Figure 11A is an edge view of said panel 100 showing the internal construction formed - ( ~
by the two moulded elements of which it is comprised, element 30X of Figure 1, and ~ element 31 of Figure 2, said indentations 49 of said element 30X being formed as the reverse side of the conical projections, instead of the optional alternative ribs.
- Figure 11B is a cross section through a portion of the panel 100 taken at line AA, showing said indentations 49 formed along line 12 of said element 30X, and the related conical projections along side 11 of said element 30X glued to the prominent surfaces along line 14 of the mating thickened areas of said element 31.
- Figure 12 is a plan view of a composite hollow moulded panel 101, similar to panel type 34 of Figure 4, with the two elements 31 moulded complete with the cutouts 52 and fold lines 51 required to form a folding container when said two- elements 31 are glued together at the matching elongated prominences formed by the thickened areas on the inwardly directed faces of each of said elements 31. In use, a first end wall 56 is hingedly connPcte(l at two parallel edges and fold lines 51 to the adjacent first edge of a first side wall 55, and at the adjacent first edge of a second side wall 55, and a second end wall 56 is hingedly connected at a first edge and a fold line 51 to a second edge of said first side wall 55, and at a second edge and fold line 51 is hingedly connPct~d to a flap 58, which may be stapled or glued to the free end of the second of said second side wall 55 thereby to form the complete perimeter of said container, which is then closed by first folding in the four top and bottom walls 57, which are hingedly connected to the upper and lower edges of said end walls 56, at fold lines 50, and then folding in the four top and bottom walls 54, which in turn are hingedly connected at their edges to the upper --~~ and lower edges of said side walls 55, at fold lines 53.
- Figure 13 is a cross section through a portion of a side wall 55 and of an end wall 56 of said panel 101 of Figure 12, along AA, showing the thickened areas of the two elements 31 glued together at the glue lines 59, and details at the fold line 51.
- Figure 14 is a cross section through a portion of a side wall 55 and a top wall 54 of said panel 101 of Figure 12, along BB, showing the glue line between two elongated thickened areas of said elements 31, and details of the fold line 50.
- Figure 15 is a cross section through a portion of a side wall SS and a top wall 54 of said panel 101 showing details at fold line 53 when said panel is folded there at an angle of 90~ between said side wall 55 and said top wall 54.
- Figure 16 is a diagram showing an example of a general arrangement of the locations for the moulding, transfer and pressing dies, and of the rotors by means of which said dies and the moulded items which they contain are transported in order to wet mould, collapse, densify and press dry the preform 30 of Figure 2A into the fini.ch~l element 31 of Figure 2B. As shown in the diagram the wet forming dies 251 are transported on rotor 201 through the wet moulding process, and the wet preforms are transferred to the transfer dies 252, and from there transported on rotor 202 to be transferred to the flat ~- ' 2165902 faced pressing dies 253 releasably mounted on rotor 203. Said flat faced pressing dies, still cont~ining the unchanged wet preforms, are then transferred by rotor 204 from said rotor 203 to rotor 205, where said flat faced dies 253, still cont~ining the unchanged wet preforms, are locked into mated pressing position with heated pressing dies 254 which conform in shape to the outline 13 of the element 31 of Figure 2A. The heated pressing dies 254 are then pressed against the wet preform 30 and towards the flat faced die 253, thus collapsing the wet moulded material projecting from side 11 of said element 30 and condensing the total material of said wet preform 30 into the final form of said fini~hPcl element 31.
After the final product has rem~in~l between said pressing dies 253 and 254 for the required drying time, the said flat faced pressing dies 253 are unlocked and transferred from the mating position with said heated pressing dies 254 on rotor 206 and thence to rotor 203, from whence said fini~h~(l products 31 are discharged from said flat faced pressing dies 253 and said empty dies 253 are then rotated on said rotor 203 to transfer position with said transfer dies 252 on rotor 202, to receive a new supply of said wet moulded preforms 30.
- Figure 17 is a plan view of a portion of one face of the moulded external element 31 of the panel 100 of Figure 10, with a plurality of isolated but regularly shaped promin~nres 214, and intervening nnthirkrn~ areas 215 on the inwardly directed face thereof, in one of the variety of arrangements available for use with said panel 100.
- Figure 18 is a plan view of a portion of one face of a moulded external element 51 of ~ the panel 101 of Figure 12, with a plurality of closely spaced parallel and elongated prominences 315 thereon, intel-upt~d by a narrow unthiekenPIl area at the fold line 353, conn~cted together at larger intervals with transverse plo~ np~ es 314, and with intervening unthickened spaces 316 on the inwardly directed face thereof, in one of the variety of arrangements available for use with said panel 101 - Figure 19 is a plan view of a portion of a moulded sheet or element 431, which sheet may be used as an alternative to the moulded element 31 of panel 101 of Figure 12, or as the single moulded sheet 431 of the panel 401 of Figure 20. Said sheet or element has on one face thereof a network of prominences 414 and intervening unthickened areas 416, said network being interrupted by a continuous elongated ~Inthiekened area at each fold line such as shown at fold line 453, said network providing stability in both vertical and horizontal directions in the side wall or end wall of a container.
- Figure 20 is a plan view of the continuously planar surface of one face of the moulded sheet 431 of the folding container panel 401, said sheet 431 having a net work of reinforcing prominences on its other face, similar to that shown in Figure 19. Said sheet 431 of said container panel 401 who has been moulded complete with the required perimeter cutouts 452, and fold lines 450, 451 and 453 required to form a container. In use, a first end wall 456 is hingedly conn.octed at two parallel edges and two fold lines 451 to the adjacent first edge of a first side wall 455 and the adjacent first edge of a second side wall 455, and a second end wall 456 is hingedly comle~ted at a first edge and a fold line 451 to a second edge of said first side wall 455, and at a second edge and fold line 451 is conn~oct~d to the adj~cerlt edge of a flap 438, which may be glued or stapled to the free end of said second side wall 455, lhe.eb~ to form the complete folded perimeter of said container, which is then closed by first folding in the four top and bottom walls 457 which are hingedly conn~cted to the upper and lower edges of said end walls 456 at fold lines 450, and then folding in the four top and bottom walls 454, which are hingedly conn.qcted to said side walls 455 at their top and bottom edges and at fold lines 453.
- Figure 21 is a cross section view along BB of portions of a side wall 455 and an end wall 456 of said sheet 431 of Figure 12, hinge~ly conl-Pc~ together at fold line 451.
- Figure 22 is a cross section view of portions of a side wall 455 and a top wall 454 of Figure 20 along AA hingedly conn~cte~ together at fold line 453.
- Figure 23 is a cross section view of portions of a side wall 455 and a top wall 454 of Figure 12 along BB hingedly conn.octetl together and folded at 90~ to each other at fold line 450, and showing details of the completed fold at said fold line 450.
Claims (7)
1. A method of forming a moulded pulp element with thickened areas from a wet preform, said wet preform having been moulded in a prior wet forming stage of the process from the raw materials of the final product, and finished by a hot press densification and drying process or, alternatively, finished by means of one or more intermediate wet pressing stages followed by said hot press densification and drying process, to collapse and densify a plurality of ribs or conical projections already formed on said moulded wet preform to form a corresponding plurality of thickened areas of predetermined shape and dimensions raised above a first face of said moulded pulp element and at the same time creating or maintaining a continuously planar surface on a second opposite face of said moulded pulp element, said continuously planar second face being of at least 80% uniform density to provide a printing surface, the volume of each of said ribs or conical projections already formed on said moulded wet preform being of sufficient quantity to provide the required volume and density in the corresponding thickened areas of said moulded pulp element.
2. A moulded pulp element made in accordance with the method of Claim 1 comprising a single moulded pulp sheet reinforced by thickened areas, said sheet having two faces, a first face and a second opposite face, said first face having a plurality of interconnected prominences of predetermined shape, dimensions and location formed by said thickened areas projecting from said first face, said reinforcing thicknesses and prominences being designed to strengthen and stabilize said moulded pulp element as a sheet sufficiently strong and stable to form the walls of a container, said second face having a continuously planar surface.
3. The single moulded pulp sheet of Claim 2, with dimension and details, including perimeter outline, fold lines and cutouts, suitable for folding into a form of a container.
4. A composite hollow moulded pulp panel comprised of at least two co-extensive press dried moulded pulp elements, including a first external element and a second element, said first external element being a moulded element produced by the method of Claim 1, reinforced at intervals by a plurality of thickened areas, said first external element having two faces, a first external face and second face, said first external face having a continuously planar surface of at least 80% uniform density when required for a printing surface, said second opposite face of said first external element having a plurality of prominences of predetermined shape and dimensions projecting from said second face, and corresponding in location to said thickened areas, said prominences having a series of co-planar surfaces, or such other surfaces as may be required for gluing or other purposes, providing that said second element of said composite hollow moulded panel may comprise a simple sheet with a continuously planar surface on each face, or a moulded shape having two faces, at least one of said two faces having a series of matching gluing surfaces for correspondence with said gluing surfaces of said second face of said first external element.
5. The composite hollow moulded panel of Claim 4 comprised of two or more of said co-extensive elements, said elements being finished in any one or a variety of thicknesses, shapes and densities and overall depths and scale for packaging or construction.
6. The hollow moulded pulp panel of Claim 4, said panel being comprised of two moulded and hot press dried co-extensive elements, each formed by the method of Claim 1, each of said elements having a continuously planar surface at one face, at least one of said two elements having said planar face of at least 80% uniform density, and each of said two elements having corresponding thickened portions projected as moulded reinforcing and gluing prominences of predetermined shape and dimensions and location on the opposite face thereof, said elements being glued together internally of said hollow moulded pulp panel, thus forming said panel with each of its two external faces continuously planar, at least one of said two external faces having a surface of at least 80% uniform density to form a printing face.
7. The composite hollow moulded panel of Claim 6, with dimensions and details including perimeter outline fold lines and cutouts, and with the moulded elements glued together, so as to be suitable for folding into a container to serve as an alternative to the familiar folding corrugated paperboard container.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US37052895A | 1995-01-09 | 1995-01-09 | |
| US08/370,528 | 1995-01-09 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2165902A1 true CA2165902A1 (en) | 1996-07-10 |
Family
ID=23460061
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2165902 Abandoned CA2165902A1 (en) | 1995-01-09 | 1995-12-21 | Composite hollow moulded panels and methods of manufacture |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2165902A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106149478A (en) * | 2015-04-02 | 2016-11-23 | 赖宗伸 | The manufacture method of layered product and finished product |
-
1995
- 1995-12-21 CA CA 2165902 patent/CA2165902A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106149478A (en) * | 2015-04-02 | 2016-11-23 | 赖宗伸 | The manufacture method of layered product and finished product |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP3450003B2 (en) | Method and apparatus for producing a lattice structure from fibers | |
| US5316828A (en) | Reinforced fluted medium and corrugated fiberboard made using the medium | |
| CA2570866C (en) | Dry-forming three-dimensional wood fiber webs | |
| US5900304A (en) | Molded wood fiber web and structural panels made utilizing the fiber web | |
| US20130266772A1 (en) | Three-dimensional wood fiber structural composites | |
| US5876835A (en) | Molded stressed-skin panels | |
| WO2007006046A1 (en) | Paper products and processes of producing them | |
| CA2140184A1 (en) | Composite hollow moulded panels and methods of manufacture | |
| JPH09504258A (en) | Pallets for transporting loads | |
| CA2165902A1 (en) | Composite hollow moulded panels and methods of manufacture | |
| JP2018519901A (en) | Large and light kite and method for its manufacture | |
| US5064504A (en) | Pulp molding press | |
| DK168020B1 (en) | PROCEDURE FOR THE PREPARATION OF FORM STABLE ARTICLES FROM A FLUIDIZED CELLULOSE FIBER MATERIAL | |
| DK166736B1 (en) | PROCEDURE FOR THE MANUFACTURE OF BEARING ELEMENTS, INCLUDING LOADS FROM A FLUIDIZED CELLULOSE FIBER MATERIAL | |
| CA2190565A1 (en) | Composite hollow moulded panels and methods of manufacture | |
| JP4339491B2 (en) | Mold board manufacturing method | |
| WO2014035290A1 (en) | Method for producing a foldable box blank and blank produced by said method (variants) | |
| CN109648659A (en) | A kind of preparation method of wooden corrugated composite board | |
| JPH0524290B2 (en) | ||
| Hunt et al. | 3-D fiber forming-A step toward engineered sandwich construction | |
| Coli et al. | Thermoformable Paperboard for Contouredautomotive Trim Foundation | |
| JPH03504621A (en) | Manufacturing method of dry molded fibrous material | |
| JP2001032200A (en) | Pulp-molded body | |
| ITGE940004U1 (en) | PLASTIC COMPOSITE PANEL. |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |