JP6788061B2 - Tools or tool parts, devices containing tools or tool parts, methods of manufacturing tools or tool parts, and methods of molding products from pulp slurry - Google Patents

Description

The present disclosure relates to tools or tool parts used to mold products from slurries. The present disclosure also relates to methods of making such tools and various uses of such tools or tool parts.

It is known that a product is formed from a pulp slurry by immersing the porous mold in the pulp slurry, subsequently drying it, and possibly pressing the product thus formed. Examples of such products are egg cartons, shock absorbing packaging inserts and paper trays, paper cups, beverage delivery trays, mushroom and strawberry boxes and other forms of industrial, agricultural and consumer packaging.

Porous pulp molding dies are made of wire cloth material that is stretched and woven to fit the mold surface. Such molds have some drawbacks with respect to the amount of strain or elongation that allows the wire cloth to fit the mold surface. Further, as a further drawback, the wire cloth tends to be torn easily. The use of wire cloth is also related to some limitations regarding the complexity of the products that can be molded. In particular, when a wire cloth is formed in the mold, the mesh (pore) of the wire cloth is deformed and the distribution of openings cannot be controlled.

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

For example, according to US Pat. No. 30,67470, it is known to provide a porous pulp molding die from small spheres that are sintered together to provide a porous body. Such porous bodies can be made from polymeric materials as disclosed in US Pat. No. 30,67470. However, this type of mold not only has a disadvantage in terms of strength, but also limits the usable temperature range. In addition, these molds suffer from the trade-off between surface quality and pressure drop (pressure loss). That is, the smaller the particles used on the surface, the smaller the flow path and the greater the pressure loss.

International Publication No. 2011059391A1 discloses a method for producing a pulp molding die by sintering particles of a metal material such as bronze. While such molds can withstand higher temperatures than polymer-based molds, their manufacture requires higher temperatures, leading to more difficult sintering processes. Moreover, the finished mold has the same advantages as those made of polymeric materials.

For this reason, some problems remain regarding the molding of products from pulp. That is, it is possible to provide a smoother surface structure, reduce energy consumption, provide a cheaper process for manufacturing molds, provide molds that are durable and can be exposed to high temperatures. It is desired. It is also required to improve the quality control of the forming process.

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

The present invention is defined by the attached independent claims, the embodiments being described in the attached dependent claims, the following description and drawings.

According to the first aspect, a tool or tool component for use in the process of molding a product from pulp slurry is provided. The tool or tool component includes a self-supporting tool wall having a product surface for contact with the product and a back surface opposite the wall to the product surface. The tool wall exhibits holes provided by a plurality of channels that extend from the surface of the product to the back through the tool wall. The flow path is straight or curved, and the curved one has only one inflection point.

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

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

The product surface may be either the molding surface of the slurry pickup tool, the contact surface of the transfer tool, or the molding surface of a male or female press tool.

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

A tool or tool part according to the concept of the present invention provides efficient removal, transfer or evaporation of the pulp or molded product used while reducing the energy for vacuum generation compared to prior art. Can be done.

A tool or tool component can have a product surface that exhibits a flat surface portion and a convex surface portion.

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

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

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

Therefore, a vacuum is provided as needed.

The product surface can exhibit a flat surface portion and a concave surface portion.

The flat surface portion can have a larger porosity than the concave surface portion.

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

The product surface is a substantially flat surface and can have a pair of surface portions that are at an angle of 45 ° to 135 ° to each other and show the maximum angle to the horizontal plane during the main movement of the tool or tool part The surface portion exhibits a larger porosity than the other surface portions.

"The main movement of a tool" is understood as part of the movement of a tool and performs its main function with respect to the product being molded during that movement. Therefore, in the case of a pick-up tool, the main function is performed at the position where the pulp is taken out by the applied vacuum. Also, in the case of a transfer tool, the main operation is performed when the pulp is transferred from the pickup tool to the transfer tool. Further, in the case of a press tool, the main operation is a pressure press operation.

At least some of the channels can exhibit a channel opening region on the product surface that is smaller than the corresponding channel opening region on the back.

This reduces the risk of clogging.

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

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

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

The product surface may have first and second juxtaposed surface portions, and the central axis of the flow path opened at the first surface portion is a second surface with respect to the product surface of the surface portion. It may extend at an angle different from the central axis of the flow path that opens at the portion.

The void capacity inside the tool or tool component 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 component.

The void capacity is a volume created by voids (voids) rather than cavities, that is, heaters or supports.

Therefore, an enhanced distribution of vacuum is achieved with respect to the product surface and the need for vacuum force is reduced.

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

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

At least some of the channels 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 can be formed as a homogeneous piece of material with less than 95%, preferably less than 99% or less than 99.9% voids between the flow paths.

The tool or tool component can be formed with sufficient material and wall thickness for the tool or tool component to self-support during operation.

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

The tool or tool part may form part of a tool selected from the following groups:
A pick-up tool for removing pulp from pulp slurry,
A transfer tool for receiving a certain amount of pulp from other tools,
A press tool that pressurizes a certain amount of pulp to form a molded product.

The tool or tool component can include at least two tool walls that are interconnectable and preferably movably interconnectable.

According to the second aspect, an apparatus for forming a product from a pulp slurry, wherein at least one tool or tool component as described above, a means for applying pulp to the product surface, vacuuming, and A device having / or means for applying a pressure greater than the atmospheric pressure on the back surface is provided.

The device of the present invention may further have a heating element that is located on the back side of the tool wall and is configured to supply heat to the tool wall.

The heating element may be arranged in a heater portion arranged at a distance from the tool wall portion.

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

The heater portion can be formed by a separate part (separate part) that contacts the tool wall portion 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 formed integrally with the tool wall portion or the heater portion. The spacer element is preferably arranged so that none of the flow paths is blocked. This is facilitated by forming a spacer element on the back of the tool wall.

Instead of this, the heating element may be integrated with the tool wall.

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

According to a third aspect, it is a method of manufacturing a tool or a tool part for forming a product from a pulp slurry, in which particles of a material on which the tool or the tool part is formed are prepared and a plurality of layers of the particles are prepared. At the location of each distribution layer of particles on the target surface corresponding to the cross section of the tool or tool part manufactured in it so that the powder particles are fused and the particles come together. Methods are provided that include directing the energy source.

The method of the present invention further comprises forming a tool wall portion having holes provided by a plurality of flow paths extending from the product surface to the back surface through the tool wall portion, and the flow paths are straight or one or less. It is a curved shape with a bending point of.

According to a fourth aspect, a method of molding a product from pulp slurry is provided. The method of the present invention includes preparing a mold as described above, applying a vacuum to the back surface of the mold, and supplying pulp slurry to the product surface 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 invention further comprises using a mold that pressurizes the pulp slurry to form a product, whereby at least some solvent is removed from the pulp slurry.

FIG. 1a is a schematic view showing an outline of a method for forming a product from a pulp slurry. FIG. 1b is a schematic diagram showing an outline of a method for forming a product from a pulp slurry. FIG. 1c is a schematic diagram showing an outline of a method for forming a product from a pulp slurry. FIG. 1d is a schematic view showing an outline of a method for forming a product from a pulp slurry. FIG. 2a is a schematic diagram showing a mold wall portion having a different flow path design. FIG. 2b is a schematic diagram showing a mold wall portion having a different flow path design. FIG. 2c is a schematic diagram showing a mold wall portion having a different flow path design. FIG. 2d is a schematic diagram showing a mold wall portion having a different flow path design. FIG. 2e is a schematic diagram showing a mold wall portion having a different flow path design. FIG. 3 is a schematic view showing a portion of the 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. 1a schematically shows a pickup tool 10 partially immersed in a container 1 holding a pulp slurry 2. The pick-up tool is attached to the tool holder 11 and defines the vacuum chamber 12 connected to the pressure regulator P1 together with the pick-up tool. The pressure regulator can have the ability to selectively generate at least a partial vacuum (ie, air pressure below atmospheric pressure) and / or air pressure above atmospheric pressure.

While the pickup tool is immersed in the pulp slurry 2, the pressure regulator P1 creates a vacuum to attach the pulp fibers 3 to the product surface of the pickup tool 10.

FIG. 1b schematically shows a pickup tool 10 that transfers the pulp fiber 3 to the transfer tool 20. The transfer tool may be connected to a second pressure regulator P2 capable of generating vacuum or pneumatic pressure. The transfer tool may be attached to the transfer tool holder 21 so as to define a vacuum chamber 22 connected to a second pressure regulator.

During the transfer of the pulp fibers 3 from the pickup 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 pickup tool.

Alternatively, or as an aid thereof, a vacuum is created by the second pressure regulator P2 and the pulp fibers are received by the transfer tool 20.

FIG. 1c schematically shows a drying device having a heating device 5 and an energy supply source E. This drying device can be used to remove a sufficient amount of water from pulp 3 and prepare it for further treatment and / or complete the formation of product 3'.

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

One or both of the press tools may be provided with heating elements 33, 43 urged by the energy supply sources E1 and E2 and, in some cases, controlled by the control device C. Heating can be achieved by an electric heating element, hot air or liquid or induction.

The press tools and their associated tool holders are relatively movable between the open position and the pressurized position where the partially formed pulp product can be inserted, the press tools are pressed against each other and the product 3 ″ Formed on the product surface of each tool 30, 40.

When in the pressurized position, heat can 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 that helps discharge the water vapor coming out of the product 3 ″.

As an alternative, 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).

Note that two or more continuous pressurization steps may be employed. In such a continuous pressurization step, for example, all or part of product 3 ″ can be gradually formed and / or additional features such as coating and decoration can be added to the product.

In one embodiment, the steps are performed as described with respect to FIGS. 1a, 1b and 1d.

In one embodiment, the pickup tool 10 can deliver the pulp fibers directly to the drying device. Such direct transfer may be assisted by the first pressure regulator P1 generating air pressure greater than atmospheric pressure. Therefore, in this embodiment, the steps are performed as described only with respect to FIGS. 1a and 1c.

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

2a-2e schematically show mold wall portions with different flow path designs. All mold walls have a product surface Fp and a back surface Fb. The product surface Fp is the face surface of the mold that comes into contact with the product, and the back surface Fb is the facing surface of the mold wall. The back surface 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 depends on 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 path may be smaller than the back opening area of the flow path, 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 to the product surface.

The flow path exhibits a central axis that can be defined as a straight line or curve passing through the center of gravity of each flow path cross section taken parallel to the product surface 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 first flow path portion having a constant flow path cross section and a second flow path portion having a tapered cross section.

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

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

FIG. 2c schematically shows a pulp mold wall portion having a flow path whose central axis extends at an angle other than a right angle to the product surface Fp. This angle can be between 20 and 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 cross-sectional area that decreases toward the product surface Fp.

The mold wall can exhibit flow paths that extend at different angles within the spacing.

FIG. 2d schematically shows a pulp mold wall portion having a curved flow path. Specifically, such a curved flow path may be curved in one plane or in two orthogonal planes as shown.

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

FIG. 2e schematically shows a pulp mold wall portion having a curved flow path having one bending point. Such a curved flow path 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 cross-sectional area that decreases toward the product surface Fp.

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

With reference to FIGS. 2d and 2e, the bend radius of the flow path is greater than 1/2 of the wall thickness of the flow path, preferably greater than 3/4 of the thickness of the flow path, or of the wall thickness of the flow path. 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. Channels include quadrilaterals, triangles, pentagons, hexagons, heptagons, octagons, quintuplets, quadrilaterals, elevens, dodecagons, or other polygons with internal angles from 60 ° to 180 °. At least a portion having a circular, oval or polygonal cross section can be presented.

FIG. 3 schematically shows a part of a mold wall in which the product surface faces upward / right and the back surface faces downward / left.

The mold wall portion of FIG. 3 is a horizontal mold wall portion Ph, i.e. +/- 45 °, preferably +/- 30 ° or +/- 15 ° to the horizontal during the main operating phase of the mold. It may exhibit a mold wall portion. Such a horizontal mold wall portion Ph may be flat or substantially flat. For example, such a substantially flat mold wall portion Ph may be curved to deviate from the surface by less than 10%, preferably 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.

Note that the convex mold wall portions may be convex in one or two directions orthogonal to each other.

Also, the mold wall portion is a vertical mold wall portion Pv, i.e., a mold wall at +/- 45 °, preferably +/- 30 ° or +/- 15 ° to the vertical during the main operating phase of the mold. It may present a portion. Such vertical mold wall portions may be flat or substantially flat. For example, a substantially flat molded wall portion may be curved to deviate from the surface by less than 10%, preferably less than 5%, along any direction in the plane.

Further, 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 purposes of the present disclosure, the term "porosity" is defined as the ratio of the channel opening area to the total wall area (including the channel opening) of a given wall portion.

The pore openings on the product surface can have an outer diameter of 0.25 mm to 2 mm. The pore openings on the back surface can have an outer diameter of 0.3-4 mm.

Therefore, the pore openings on the product surface Fp can have an opening 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.

Further, the pore opening on 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 .

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

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

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 portion Ph can have a porosity of 20% to 75%, preferably 30% to 55%.

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

The mold described above can be manufactured by an additive manufacturing process such as a 3D printing method. Such an additive manufacturing process may include selective sintering of powder 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 a laser beam or an electron beam.

The material for making the mold may be either a metal or an 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 molding process, a well-defined flow path connecting the product surface Fp to the back surface Fb is presented and the material between these flow paths is homogeneous, at least 95%, preferably 99% or 99.9. It is possible to achieve a porous mold with no% voids.

It should be noted that with reference to FIGS. 1a-1d above, one or more of the tools 10, 20, 30, 40 may be formed as disclosed herein.

Further note, for example, the pick-up tool 10 and / or the transfer tool 20 may be made of a material having a thinner wall and / or a lower melting point than the press tools 30 and 40.

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

Further, the tool can be formed as a pair of tool parts having a hinge mechanism for connecting the tool parts. The tool thus formed can enable the production of more complex products.

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

The pressure mold provides a mold wall 101 having a recess 1015 in which the heating element 33 is located. The mold wall 101 provides a flow path 102 that can be formed according to any of FIGS. 2a-3.

The recess and heating element can be formed by elongated leads for resistance heating or guiding channels to guide the heated liquid or gas. As an alternative, the recess can accept a magnetic material that can be induced heated. Such magnetic materials can be formed as individually separated islands or as one or more elongated rods.

The recess and heating element can cover all or part of the back surface. The recesses and sections of the heating element can be separated from each other as necessary.

The recess 1015 can be extended into the mold wall from its back surface. A non-limiting example of the distance 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 needed.

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

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

The pressure mold includes an outer portion 1011 and a heater portion 1013, and a gap 1021 is provided between them. The spacer 1012 extends between the heater portion 1013 and the outer portion 1011 and straddles the gap 1021.

The flow path 102 of the outer portion 1011 connects the product surface Fp to the back surface Fb. These channels can be formed according to the disclosure of any of FIGS. 2a-3.

A recess 1015 may be present in the back surface Fb2 of the heater section 1013, in which the heating element 33 may be arranged according to any of the options described in connection with FIG.

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

The manifold flow path 1022 also communicates the gap 1021 with the back surface Fb2 of the heater unit 1013. These manifold channels have a larger cross section than the channels 102, the number of which is less than the number of channels 102. For example, the main width of the manifold flow path 1022 may be on the order of 10 to 1000 times the width of the flow path 102.

Further, the number of manifold flow paths 1022 may be about 1/10 to 1/10000 of the number of flow paths 102. The total flow cross section of the manifold flow path 1022 can be equal to or larger than the total flow cross section of the flow path 102. For example, the total flow cross section of the manifold flow path 1022 can be about 100 to 300% of the total flow cross section of the flow path 102.

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

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

In the embodiment of FIG. 6, the heater portion 1013'and optionally the spacer 1012 are formed from a separate piece of material and a material different from the outer portion 1011. A heating element may be arranged 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 portion 1013. In any case, the manifold flow path 1022 may penetrate the heater portion 1013'by the method described in relation to FIG.

The heater portion 1013'may include a main body made of a metal material.

An insulator 1014 may be provided on the rear side of the heater portion 1013'. The insulator 1014 may be in contact with the heater section 1013'or may be in contact with the heater section 1013' to allow vacuum distribution from the inlet flow path 1024 extending through the insulator 1014 to the manifold flow path 1022. It may be slightly separated from.

The insulator 1014 can be formed from 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) can be provided with insulators. In such cases, the insulator can substantially surround the mold so that energy loss is reduced when the molds are put together in the molding position. A gap may be provided at the place where the molds meet to allow steam to escape. Alternatively or additionally, through holes for letting out vapor can be provided in one or both insulators.

In embodiments where the additional body is located near the back of the mold, as in the case where heaters 1013, 1013'are provided, the spacer transfers a portion of the pressure applied to the product surface to the additional body. Can be sent to.

Typically, less than 95% of the pressure applied to the product surface is preferably transmitted to the additional body less than 90%, less than 80%, less than 70%, less than 50%, less than 30% or less than 10%. Can be done. The non-transmitting portion of the pressure may be absorbed by the mold due to its own rigidity.

The pressure applied to the mold surface can be on 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 back surface may be surface treated, for example, by grinding, polishing, anodizing, or providing a surface coating. Such surface treatments can be used, for example, to reduce the risk of corrosion compared to the materials used to make the mold. Surface treatments or coatings can provide alternative or additional anti-adhesion properties. Such anti-adhesion properties can be imparted, for example, with a material that is more hydrophobic than the material from which the mold is made. Yet another option, the surface treatment or coating can provide a surface with increased hardness compared to the molding material.
Hereinafter, the inventions described in the claims of the original application of the present application will be added.
[1] A tool or tool component used in the process of molding a product from a pulp slurry, which is a self-standing tool wall having a product surface in contact with the product and a back surface opposite to the product surface. A portion and a tool wall portion that exhibits holes provided by a plurality of flow paths extending from the product surface to the back surface through the tool wall portion, wherein the flow path is straight or one or less. A tool or tool component characterized by being curved at an inflection point.
[2] The tool or tool component according to [1], wherein the product surface exhibits a flat surface portion and a convex surface portion.
[3] The tool or tool component according to [2], wherein the convex surface portion is preferably 30 to 70% smaller or 40 to 60% smaller than the flat surface portion in terms of the tool wall thickness.
[4] The tool or tool component according to any one of [2] and [3], wherein the convex surface 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 exhibits 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 surface portion.
[7] The product surface is substantially flat, has a pair of surface portions at an angle of 45 ° to 135 ° to each other, and has a maximum angle with respect to a horizontal plane during the main operation of the tool or tool part. The tool or tool component according to any one of [1] to [6], wherein one of the surface portions exhibiting the above surface has a porosity larger than that of the other surface portion.
[8] The description in any one of [1] to [7], wherein at least some of the flow paths exhibit a flow path opening area smaller than the corresponding flow path opening area on the back surface on the product surface. 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 paths have a cross section that tapers toward the product surface.
[10] The tool or tool according to any one of [1] to [9], wherein at least some of the flow paths exhibit a central axis 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 paths exhibit a curved central axis.
[12] The product surface has first and second juxtaposed surface portions, and the central axis of the flow path that opens to the first surface portion is the second surface portion with respect to the product surface of the surface portion. The tool or tool component according to any one of [1] to [11], which extends at an angle different from the central axis of the flow path that opens in the surface portion of the above.
[13] The void volume inside the tool or tool component is at least 20%, preferably at least 40%, at least 60% or at least 80% of the total volume spanning the tool or tool component [1]. ] To [12]. 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 path has a length exceeding the thickness of the wall in the vicinity of the flow path.
[15] The tool or tool according to any one of [1] to [14], wherein at least some of the product surface openings of the flow path have a cross section having a maximum width of 0.1 to 2 mm. parts.
[16] The tool or tool according to any one of [1] to [15], wherein at least some of the channels have at least one branch located between the product surface and the back surface. Tool parts.
[17] Any of [1] to [16], wherein the tool wall has a thickness of 0.2 to 20 mm, preferably 0.3 to 15 mm or 0.5 to 10 mm. Tools or tool parts described in.
[18] The tool wall portion is characterized in that the voids between the flow paths are formed as a homogeneous material piece having a void of less than 95%, preferably less than 99% or less than 99.9% [1] to [1]. 17] The tool or tool component according to any one of.
[19] The tool or tool component according to any one of [1] to [18], characterized in that the tool or tool component is formed of a material and wall thickness sufficient for self-supporting during operation. Tools or tool parts.
[20] The back of the tool is characterized by exposure to at least 50%, preferably at least 70% or at least 90% of the chamber adapted to provide air pressure other than atmospheric pressure [1]. The tool or tool component according to any one of [19].
[21] Tools or tool parts include a pick-up tool for removing pulp from a pulp slurry, a transfer tool for receiving a certain amount of pulp from another tool, and a press for pressurizing a certain amount of pulp to form a molded product. The tool or tool component 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], wherein the tool or tool component includes at least two tool walls that are interconnectable and preferably movably interconnectable. Or tool parts.
[23] An apparatus for molding a product from a pulp slurry, wherein at least one tool or tool component according to any one of [1] to [22], means for applying pulp to the product surface, and vacuuming. A product molding apparatus comprising: and / or means for applying a pressure greater than the atmospheric pressure on the back surface.
[24] The molding apparatus according to [23], which is arranged on the back surface side of the tool wall portion (101) and further has a heating element (33) for supplying heat to the tool wall portion.
[25] The molding apparatus according to [24], wherein the heating element is arranged in a heater portion arranged at a distance from the tool wall portion.
[26] The molding apparatus according to [25], wherein the heater portion is integrally formed with the tool wall portion.
[27] The molding apparatus according to [25], wherein the heater portion is formed of a separate component that comes into contact with the tool wall portion via at least one spacer element.
[28] The molding apparatus according to [24], wherein the heating element is integrated with the tool wall portion.
[29] A method of manufacturing a tool or tool component for molding a product from a pulp slurry, wherein particles of the material on which the tool or tool component is to be formed are supplied, and a plurality of layers of the particles are provided on a target surface. An energy source is placed at the location of each distribution layer of particles on the target surface that corresponds to the cross section of the tool or tool part to be manufactured therein so that the powder particles are continuously distributed and fused together. A method of manufacturing a tool or tool part, characterized in that it is directed or included.
[30] Further having a step of forming the tool wall portion having pores defined by a plurality of flow paths extending from the product surface to the back surface through the tool wall portion, the flow path is straight or 1 The manufacturing method according to [29], wherein the tool is curved at a bending point equal to or less than a point.
[31] A method for molding a product from a pulp slurry, wherein the mold according to any one of [1] to [22] is prepared, a vacuum is applied to the back surface of the mold, and pulp is applied to the product surface of the mold. A method for molding a product, which comprises applying a slurry.
[32] The molding method according to [31], further comprising a step of using the mold to take out the pulp slurry from the slurry container.
[33] It further comprises the step of 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 according to any one of [32].
(1) A self-supporting tool wall that is a tool or tool component used in the process of molding a product from a pulp slurry and has a product surface in contact with the product and a back surface opposite the wall to the product surface. The self-supporting tool wall portion is provided with a portion and a hole provided by a plurality of flow paths extending from the product surface to the back surface through the self-supporting tool wall portion, and the flow path is straight. The product surface is substantially flat and has a pair of surface portions that are at an angle of 45 ° to 135 ° to each other and is the main part of the tool or tool part, which is curved at one or less inflection points. One of the surface portions, which shows the maximum angle with respect to the horizontal plane during normal operation, has a larger porosity than the other surface portion, and at least some of the flow paths are walls in the vicinity of the flow path. At least one recess for the heating element is formed in the self-supporting tool wall portion so as to have a length exceeding the thickness of the self-supporting tool wall portion and extend into the self-supporting tool wall portion. Characterizing tools or tool parts.
(2) The tool or tool component according to (1), wherein the product surface exhibits a flat surface portion and a convex surface portion.
(3) The tool or tool component according to (2), wherein the convex surface portion has a smaller tool wall thickness than the flat surface portion.
(4) The tool or tool component according to (2), wherein the convex surface portion exhibits a porosity larger than that of the flat surface portion.
(5) The tool or tool component according to (1), wherein the product surface exhibits 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 surface portion.
(7) The flow path according to (1), wherein at least some of the flow paths have a flow path opening area on the product surface that is smaller than the corresponding flow path opening area on the back surface of the self-supporting tool wall portion. A tool or tool part.
(8) The tool or tool component according to (1), wherein at least some of the flow paths have a central axis extending at an angle of 40 to 90 degrees with respect to the product surface.
(9) The product surface has first and second juxtaposed surface portions, and the central axis of the flow path opened in the first surface portion is the second surface portion with respect to the product surface of the surface portion. The tool or tool component according to (1), wherein the tool or tool component extends at an angle different from the central axis of the flow path that opens in the surface portion of the tool.
(10) The distance that the at least one recess extends from the back surface of the self-supporting tool wall portion into the self-supporting tool wall portion is about 75% of the tool wall portion thickness of the corresponding self-supporting tool wall portion, or The tool or tool component according to (1), characterized in that it is about 50% or about 25%.
(11) A self-supporting tool wall that is a tool or tool component used in the process of molding a product from pulp slurry and has a product surface in contact with the product and a back surface opposite the wall to the product surface. The self-supporting tool wall portion is provided with a portion and a hole provided by a plurality of flow paths extending from the product surface to the back surface through the self-supporting tool wall portion, and the flow path is straight. The product surface is substantially flat, has a pair of surface portions at an angle of 45 ° to 135 ° to each other, and is a major part of the tool or tool part. A tool or tool component, characterized in that one of the surface portions, which exhibits the maximum angle with respect to a horizontal plane during normal operation, has a larger porosity than the other surface portion.
(12) A self-supporting tool wall that is a tool or tool component used in the process of molding a product from pulp slurry and has a product surface in contact with the product and a back surface opposite the wall to the product surface. The self-supporting tool wall portion is provided with a portion and a hole provided by a plurality of flow paths extending from the product surface to the back surface through the self-supporting tool wall portion, and the flow path is straight. A tool or tool component that is curved at one or less inflection points and that at least a portion of the flow path has a length that exceeds the thickness of the wall in the vicinity of the flow path.
(13) A self-supporting tool wall that is a tool or tool component used in the process of molding a product from pulp slurry and has a product surface in contact with the product and a back surface opposite the wall to the product surface. The self-supporting tool wall portion is provided with a portion and a hole provided by a plurality of flow paths extending from the product surface to the back surface through the self-supporting tool wall portion, and the flow path is straight. At least one recess for the heating element is formed in the tool wall so that it is curved at one or less inflection points and extends into it from the back surface of the tool wall. Tools or tool parts.

1 ... container, 2 ... pulp slurry, 3 ... pulp fiber, 3', 3 "... product, 5 ... heating device, 10 ... pickup 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,
101 ... Mold wall (self-supporting tool wall), 102 ... Flow path, 1011 ... Outer part, 1012 ... Spacer, 1013, 1013' ... Heater part, 1014 ... Insulator, 1015 ... Indentation, 1021 ... Gap (gap) , 1022 ... Manifold flow path, 1024 ... Inlet flow path,
P1, P2, P3, P4 ... Pressure regulator, E, E1, E2 ... Energy supply source, C ... Control device,
Fp ... product side, Fb ... back side.

Claims (12)

A tool or tool part used in the process of molding a product from pulp slurry.
A self-supporting tool wall portion having a product surface in contact with the product and a back surface opposite to the wall with respect to the product surface, and the self-supporting tool wall portion through the self-supporting tool wall portion and the product surface. There are holes provided by a plurality of channels extending from to the back surface.
The flow path is straight or curved at one or less inflection points.
The product surface is substantially flat, has a pair of surface portions that are at an angle of 45 ° to 135 ° to each other, while having the maximum angle to the horizontal plane during the main movement of the tool or tool part. The surface portion of one has a larger porosity than the other surface portion of
At least some of the channels have a length that exceeds the thickness of the wall near the channels.
A tool or tool component characterized in that at least one recess for a heating element is formed within the self-supporting tool wall portion so as to extend into the self-supporting tool wall portion. The product surface, the tool or tool part according to claim 1, characterized in that it comprises a flat surface portion and the convex portion. The tool or tool component according to claim 2, wherein the tool wall thickness is smaller in the convex surface portion than in the flat surface portion. The convex portion, the tool or tool part according to claim 2, characterized in that it has a greater porosity than said flat surface portion. The product surface, the tool or tool part according to claim 1, characterized in that it comprises a flat surface portion and a concave portion. It said flat surface portions, the tool or tool part according to claim 5, characterized in that it has a greater porosity than said concave portion. The tool or tool according to claim 1, wherein at least some of the flow paths have a flow path opening area on the product surface that is smaller than the corresponding flow path opening area on the back surface of the self-supporting tool wall portion. parts. The tool or tool component according to claim 1, wherein at least some of the flow paths have a central axis extending at an angle of 40 to 90 degrees with respect to the product surface. The product surface has first and second juxtaposed surface portions, and the central axis of the flow path that opens to the first surface portion is the second surface portion with respect to the product surface of the surface portion. The tool or tool component according to claim 1, wherein the tool or tool component extends at an angle different from the central axis of the flow path that opens in. The distance that the at least one recess extends from the back surface of the self-supporting tool wall into it is about 75% or about 50% of the tool wall thickness of the corresponding self-supporting tool wall. The tool or tool component according to claim 1, wherein the tool or tool component is, or is about 25%. A tool or tool part used in the process of molding a product from pulp slurry.
A self-supporting tool wall having a product surface in contact with the product and a back surface opposite the wall to the product surface, and the self-supporting tool wall portion passing through the self-supporting tool wall portion to the product surface. There are holes provided by a plurality of channels extending from to the back surface.
The flow path is straight or curved at one or less inflection points.
The product surface is substantially flat, has a pair of surface portions at an angle of 45 ° to 135 ° to each other, while having the maximum angle to the horizontal plane during the main operation of the tool or tool part. A tool or tool component, wherein the surface portion of the tool has a larger porosity than the other surface portion. A tool or tool part used in the process of molding a product from pulp slurry.
A self-supporting tool wall having a product surface in contact with the product and a back surface opposite the wall to the product surface, and the self-supporting tool wall portion passing through the self-supporting tool wall portion to the product surface. There are holes provided by a plurality of channels extending from to the back surface.
The flow path is straight or curved at one or less inflection points.
A tool or tool component characterized in that at least one recess for a heating element is formed within the tool wall so as to extend into the tool wall from the back surface.

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