SE1851631A1

SE1851631A1 - Forming mould system and method for forming cellulose products

Info

Publication number: SE1851631A1
Application number: SE1851631A
Authority: SE
Inventors: Jonsson Felix Sjöstrand; Olle Högblom
Original assignee: Pulpac AB
Priority date: 2018-12-20
Filing date: 2018-12-20
Publication date: 2020-06-21
Also published as: SE544079C2

Abstract

A forming mould system (1) for forming three-dimensional cellulose products (2) from an air-formed cellulose blank (3), comprising a forming mould (4) having a first mould part (5a), a second mould part (5b), a forming cavity (6), and a deformation element (7), wherein the first mould part (5a) and the second mould part (5b) are movable in relation to each other in a pressing direction (DP) and arranged to be pressed in relation towards each other during forming of the cellulose products (2), wherein the forming cavity (6) is formed and enclosed by the first mould part (5a) and the second mould part (5b) during forming of the cellulose products (2), and wherein the deformation element (7) during forming of the cellulose products (2) is arranged in the forming cavity (6) and is exerting a forming pressure (P) on the cellulose blank (3), wherein the forming mould (4) further comprises one or more hole punch rods (8) arranged to form one or more apertures (10) in the cellulose blank (3) during forming of the cellulose products (2), wherein each of the one or more hole punch rods (8) is attached to the first mould part (5a) and/or the second mould part (5b).

Description

FORMING MOULD SYSTEM AND METHOD FOR FORMING CELLULOSEPRODUCTS TECHNICAL FIELD The present disclosure relates to a forming mould system for forming celluloseproducts from an air-formed cellulose blank, comprising a forming mouldhaving a first mould part, a second mould part, a forming cavity, and adeformation element. The deformation element is during forming of thecellulose products arranged to exert a forming pressure on the cellulose blank.The disclosure further relates to a method for forming cellulose products from an air-formed cellulose blank.

BACKGROUND Cellulose fibres are often used as raw material for producing or manufacturingproducts. Products formed of cellulose fibres can be used in many differentsituations where there is a need for having sustainable products. A wide rangeof products can be produced from cellulose fibres and a few examples aredisposable plates and cups, blank structures and packaging materials.Packages produced from cellulose fibres may for example be used forpackaging of liquids, dry materials and other types of goods, where thepackaging may be made in a three-dimensional shape or formed into a three- dimensional shape from a two-dimensional sheet material.

Forming moulds are commonly used when manufacturing cellulose productsfrom raw materials including cellulose fibres, and traditionally the celluloseproducts have been produced with wet-forming techniques. A materialcommonly used for cellulose fibre products is moulded pulp. Moulded pulp hasthe advantage of being considered as a sustainable packaging material, sinceit is produced from biomaterials and can be recycled after use. Consequently, moulded pulp has been quickly increasing in popularity for differentapplications. Moulded pulp articles are generally formed by immersing asuction forming mould into a liquid or semi liquid pulp suspension or slurrycomprising cellulose fibres, and when suction is applied, a body of pulp isformed with the shape of the desired product by fibre deposition onto theforming mould. With all wet-forming techniques, there is a need for drying ofthe moulded product, which is a time and energy consuming production step.The demands on aesthetical, chemical and mechanical properties of celluloseproducts are increasing, and due to the properties of wet-formed celluloseproducts, the mechanical strength, flexibility, and chemical properties arelimited. lt is also difficult in wet-forming processes to control the mechanicalproperties of the products with high precision.

One development in the field of producing cellulose products is the forming ofcellulose fibres without using wet-forming techniques. lnstead of forming thecellulose products from a liquid or semi liquid pulp suspension or slurry, an air-formed cellulose blank is used. The air-formed cellulose blank is inserted intoa forming mould comprising a deformation element and during the forming ofthe cellulose products the cellulose blank is subjected to a high formingpressure and a high forming temperature. For cellulose products havingapertures, cutouts, or holes in the construction, these apertures, cutouts, orholes are often produced after the forming of the cellulose products. The highforming pressure used is demanding specific tolerances when constructing theforming mould, which makes it difficult to produce the apertures, cutouts, orholes during the forming step. When the deformation element is exerting thehigh forming pressure on the cellulose blank, there is a risk that thedeformation element is damaged or that the pressure distribution on thecellulose blank is uneven, which could result in products with poor quality.

There is thus a need for an improved forming mould system and method forforming cellulose products with a deformation element in a forming mould, where the cellulose products are having apertures, cutouts, or holes, and are produced from an air-formed cellulose blank. There is a further need tomanufacture products with high precision and with a high quality, where the production is cost-efficient and rational.

SUMMARY An object of the present disc|osure is to provide a forming mould system anda method for forming cellulose products from an air-formed cellulose blankwhere the previously mentioned problems are avoided. This object is at leastpartly achieved by the features of the independent claims. The dependent claims contain further developments of the forming mould system.

The disc|osure concerns a forming mould system for forming three-dimensional cellulose products from an air-formed cellulose blank, comprisinga forming mould having a first mould part, a second mould part, a formingcavity, and a deformation element. The first mould part and the second mouldpart are movable in relation to each other in a pressing direction and arrangedto be pressed in relation towards each other during forming of the celluloseproducts. The forming cavity is formed and enclosed by the first mould partand the second mould part during forming of the cellulose products, and thedeformation element is during forming of the cellulose products arranged inthe forming cavity and exerting a forming pressure on the cellulose blank. Theforming mould further comprises one or more hole punch rods arranged toform one or more apertures in the cellulose blank during forming of thecellulose products, wherein each of the one or more hole punch rods isattached to the first mould part and/or the second mould part.

Advantages with these features are that an efficient forming of the celluloseproducts can be achieved with the forming mould system, where apertures canbe formed in the cellulose blank directly in the forming process of the celluloseproducts. The high forming pressure used during the forming process isdemanding specific tolerances when constructing the forming mould, and through the construction with one or more hole punch rods apertures, cutouts,or holes can in an efficient way be produced during the forming step. Throughthe use of hole punch rods arranged in the forming mould, the celluloseproducts can be manufactured with high precision and with a high quality, in a cost-efficient and rational way.

According to an aspect of the disclosure, each of the one or more hole punchrods is arranged to cooperate with the other of the first mould part and/or thesecond mould part during the forming of the cellulose products. Thecooperation between the one or more hole punch rods and the mould part isestablishing an efficient cutting function in the forming mould, and theapertures can in this way easily be formed in the cellulose blank.

According to another aspect of the disclosure, the forming mould furthercomprises one or more corresponding openings for each hole punch rod. Theopenings are arranged in the other of the first mould part and/or the secondmould part, and the hole punch rods are extending at least partly into the oneor more openings during forming of the cellulose products. The one or moreopenings are designed to cooperate with the one or more hole punch rods foran efficient aperture forming process. When the hole punch rods are extendinginto the openings, the deformation element can be efficiently deformed to exertthe forming pressure on the cellulose blank.

According to an aspect of the disclosure, a gap is formed between the holepunch rod and the opening during forming of the cellulose products. Thesystem further comprises a seal, and the seal is sealing the gap between thehole punch rod and the opening during forming of the cellulose products.Through the arrangement with a gap and a seal that is sealing the gap, anefficient pressure distribution can be achieved in the forming mould during theforming of the cellulose products. The pressure distribution is important forachieving cellulose products with high quality.

According to another aspect of the disclosure, the gap has an extension in adirection perpendicular to the pressing direction between an outer wall sectionof the hole punch rod and an inner wall section of the opening during formingof the cellulose products. The gap is thus formed between the first hole punchrod and the opening in a direction perpendicular to the pressing direction,which is providing a design of the forming mould where it is possible to have agap with small dimensions in order to achieve an efficient forming of thecellulose products with desired temperatures and pressure levels.

According to a further aspect of the disclosure, the gap has an extension in adirection perpendicular to the pressing direction with a smallest width in therange 0.0005-0.9 mm, preferably 0.01-0.09 mm. With these smallestdimensions an efficient forming of the cellulose products is achieved.

According to an aspect of the disclosure, the outer wall section of at least anouter end of the hole punch rod and the inner wall section of the opening havecorresponding peripheral shapes in a plane perpendicular to the pressingdirection. With this configuration, a simple construction of the forming mould isachieved, where the hole punch rod and the opening are designed with cooperating shapes for an efficient forming process.

According to another aspect of the disclosure, the system further comprisesthe cellulose blank, and during forming of the cellulose products the seal isformed by the cellulose blank arranged in the forming cavity. The celluloseblank can in this way seal the gap during the forming process and establish anefficient sealing function so that a high pressure forming operation is achieved.To use the cellulose blank as the seal, a simple and efficient sealing functionis achieved with the cellulose blank material being present in the forming operation.

According to an aspect of the disclosure, the cellulose blank has a materialcomposition of 70-99.9% dry wt cellulose fibres and 0.1-30% dry wt of one ormore additives, preferably 80-99.9% dry wt cellulose fibres and 0.1-20% dry wt of one or more additives, more preferably 90-99.9% dry wt cellulose fibresand 0.1 -10% dry vvt of one or more additives. These material compositions areproviding an efficient sealing function in the forming mould.

According to another aspect of the disclosure, during forming of the celluloseproducts the seal is formed by the deformation element arranged in the formingcavity. The deformation element is when being deformed sealing the gap,wherein a high pressure forming can be achieved. To use the deformationelement as the seal, a simple and efficient construction of the forming mouldsystem is achieved.

According to a further aspect of the disclosure, during forming of the celluloseproducts the seal is formed by a sealing element. The sealing element isestablishing a seal between the hole punch rod and the opening during formingof the cellulose products, wherein the gap is efficiently sealed.

According to an aspect of the disclosure, the sealing element is made of anelastomeric material. The elastomeric material is establishing an efficient sealbetween the mould parts.

According to another aspect of the disclosure, the hole punch rod comprises afirst cutting edge and the opening comprises a second cutting edge, and thefirst cutting edge and the second cutting edge are arranged to cooperate duringthe forming of the cellulose products. The cutting edges are providing anefficient way of cutting the cellulose blank into a desired shape during theforming process. With this arrangement, the cellulose blank may have anyshape when being arranged in the forming mould. When being pushed into theforming mould, the cellulose blank is cut into a shape suitable for the celluloseproducts to be produced. The cellulose product can be cut into a desired shape directly in the forming process from the cellulose blank.

According to a further aspect of the disclosure, the system further comprisesa suction device connected to the first mould part and/or the second mouldpart. The suction device is arranged to remove residual cellulose from the forming mould after forming of the one or more apertures in the cellulose blank.The suction device is connected to one or more of the hole punch rods and/orone or more of the openings via one or more suction channels arranged in thefirst mould part and/or the second mould part. The suction device is thus used for an efficient removal of residual cellulose from the cellulose blank.

According to an aspect of the disclosure, the deformation element is providedwith one or more recesses arranged to receive the one or more hole punchrods. The one or more hole punch rods are extending into the one or morerecesses through the deformation element. Through the construction of theone or more hole punch rods extending into the recesses of the deformationelement, the risk of damaging the deformation element when exerting the highforming pressure on the cellulose blank is minimized. Further, this constructionis ensuring an even pressure distribution on the cellulose blank during the forming process, wherein cellulose products with high quality can be achieved.

According to another aspect of the disclosure, each of the one or more holepunch rods is releasably attached to the first mould part and/or the secondmould part. The releasable attachment of the hole punch rods is providing an simple and efficient way to change the hole punch rods when needed.

According to an aspect of the disclosure, the one or more hole punch rods arehaving an elongated shape with an extension in the pressing direction. Theelongated shape is efficient when forming the cellulose products and used formatching the hole punch rods with the corresponding openings. This shapealso simplifies the construction, where the hole punch rods are extendingthrough the deformation element.

According to another aspect of the disclosure, one or more of the hole punchrods are having a hollow configuration with an inner wall section surroundinga channel formed in the hole punch rod. The hollow configuration can be usedfor a more lightweight construction, and to achieve an efficient hole punching operation, or for collecting the cellulose blank residues after the cellulose blankhas been cut.

According to a further aspect of the disclosure, one or more of the hole punchrods comprise a tapered outer end arranged to separate the fibres in thecellulose blank during forming of the cellulose products. The tapered outer endin simplifying the separation of the cellulose fibres when the mould parts aremoved in relation to each other. The tapered outer end can efficiently separatethe cellulose fibres when meeting and penetrating the cellulose blank duringthe forming process.

According to an aspect of the disclosure, the deformation element duringforming of the cellulose products is exerting an isostatic forming pressure onthe cellulose blank. The isostatic pressure from the deformation element isestablishing a uniform pressure in all directions in the forming mould on thecellulose blank. ln this way an efficient forming of the cellulose products isachieved, and the cellulose products can be produced with high quality.

According to another aspect of the disclosure, during forming of the celluloseproducts the deformation element is through deformation establishing auniform pressure in all directions in the forming mould on the cellulose blank,and the deformation element is during forming of the cellulose productsexerting an isostatic forming pressure on the cellulose blank in the range 1-100 MPa. This pressure range is with the isostatic forming pressure providing an efficient forming of the cellulose products.

The disclosure further concerns a method for forming three-dimensionalcellulose products from an air-formed cellulose blank in a forming mouldsystem. The system comprises a forming mould having a first mould part, asecond mould part, a forming cavity, a deformation element, and one or morehole punch rods. The method comprises the steps: arranging a cellulose blankin the forming mould between the first mould part and the second mould part;moving the first mould part and the second mould part in relation to each other in a pressing direction; forming one or more apertures in the cellulose blankwith the one or more hole punch rods; exerting a forming pressure on thecellulose blank by the deformation element during forming of the celluloseproducts.

BRIEF DESCRIPTION OF DRAWINGS The disclosure will be described in greater detail in the following, with referenceto the attached drawings, in which Fig. 1 shows schematically, a forming mould system in a perspective view according to the disclosure, Fig. 2 show schematically, a first mould part and a second mould part in a perspective view according to the disclosure, Fig.3a-d show schematically, cross-sectional side views of a firstembodiment of a forming mould with a hole punch rod according to the disclosure, Fig. 4a-b show schematically, a view from above and a cross-sectional viewfrom above of the first embodiment of the forming mould according to the disclosure, Fig.5a-c show schematically, cross-sectional side views of a secondembodiment of the forming mould with hole punch rods according to the disclosure, Fig. 6a-b show schematically, cross-sectional side views of alternative embodiments of the hole punch rod according to the disclosure, Fig. 7a-d show schematically, cross-sectional side views of alternativeembodiments of the forming mould with a suction device according to the disclosure, and Fig. 8 shows schematically, a cross-sectional side view of the formingmould with a gap according to the disclosure.

DESCRIPTION OF EXAMPLE EMBODIMENTS Various aspects of the disclosure will hereinafter be described in conjunctionwith the appended drawings to illustrate and not to limit the disclosure, whereinlike designations denote like elements, and variations of the described aspectsare not restricted to the specifically shown embodiments, but are applicable on other variations of the disclosure.

Figure 1 schematically shows in a perspective view a forming mould system 1forforming three-dimensional cellulose products 2 from an air-formed celluloseblank. The forming mould system comprises a forming mould 4, and in figure2 forming mould parts of a first embodiment of the forming mould 4 is shown.

With a cellulose blank is meant a fibre web structure produced from cellulosefibres. With air-forming of the cellulose blank is meant the formation of acellulose blank in a dry-forming process in which cellulose fibres are air-formedto produce the cellulose blank. When forming the cellulose blank in the air-forming process, the cellulose fibres are carried and formed to the fibre blankstructure by air as carrying medium. This is different from a normalpapermaking process or a traditional wet-forming process, where water is usedas carrying medium for the cellulose fibres when forming the paper or fibrestructure. ln the air-forming process, small amounts of water or othersubstances may if desired be added to the cellulose fibres in order to changethe properties of the cellulose product, but air is still used as carrying mediumin the forming process. The cellulose blank may have a dryness that is mainlycorresponding to the ambient humidity in the atmosphere surrounding the dry- formed cellulose blank. 11 As shown in the figures, the forming mould system 1 comprises the formingmould 4, where the forming mould 4 is having a first mould part 5a, a secondmould part 5b, a forming cavity 6, and a deformation element 7. Thedeformation element 7 is during forming of the cellulose products 2 arrangedto exert a forming pressure PF on the cellulose blank 3. During the forming, thedeformation element 7 is deformed to exert a pressure on the cellulose blank3 and through the deformation an even pressure distribution is achieved in theforming mould 4, even if the cellulose products 2 are having complex three-dimensional shapes or if the cellulose blank 3 is having a varied thickness.

The cellulose blank 3 may be formed of cellulose fibres in a conventional dry-forming process and be configured in different ways. For example, thecellulose blank 3 may have a composition where the fibres are of the sameorigin or alternatively contain a mix of two or more types of cellulose fibres,depending on the desired properties of the cellulose products 2. The cellulosefibres used in the cellulose blank 3 are during the forming of the celluloseproducts 2 strongly bonded to each other with hydrogen bonds. The cellulosefibres may be mixed with other substances or compounds to a certain amountas will be further described below. With cellulose fibres is meant any type ofcellulose fibres, such as natural cellulose fibres or manufactured cellulosefibres.

The cellulose blank 3 may comprise one or more additives that are altering themechanical, hydrophobic, and/or oleophobic properties of the celluloseproducts 2. Tests have shown that if the cellulose blank 3 contains at least70% of cellulose fibres, desired mechanical properties of the cellulose product2 can be achieved. ln order to achieve the desired properties of the formedcellulose products 2, the cellulose fibres should be strongly bonded to eachother through fibril aggregation in a way so that the resulting cellulose products2 will have good mechanical properties. The additives used may therefore notimpact the bonding of the cellulose fibres during the forming process to a high extent. 12 As a non-limiting example, the cellulose blank 3 may have a materialcomposition of 70-99.9% dry wt cellulose fibres and 0.1 -30% dry wt of the oneor more additives. ln another embodiment, the cellulose blank 3 may have amaterial composition of 80-99.9% dry wt cellulose fibres and 0.1-20% dry wtof the one or more additives. ln a further embodiment, the cellulose blank 3may have a material composition of 90-99.9% dry wt cellulose fibres and 0.1-10% dry vvt of the one or more additives. Depending on the amount of cellulosefibres and additives used in the cellulose blank 3, the cellulose products 2 can have different properties.

The one or more additives of the cellulose blank 3 may be, as a non-limitingexample, starch compounds, rosin compounds, butanetetracarboxylic acid,gelatin compounds, alkyl ketene dimer (AKD), Alkenyl Succinic Anhydride(ASA), and/or flourocarbons. These additives are commonly used in theforming of cellulose products and are therefore not described in detail. Starchcompounds, gelatin compounds, butanetetracarboxylic acid, andfluorocarbons may for example be used for altering the mechanical properties,such as strength or stiffness, of the cellulose product. Rosin compounds, alkylketene dimer (AKD), Alkenyl Succinic Anhydride (ASA), and fluorocarbonsmay for example be used for altering the hydrophobic properties of thecellulose products. Fluorocarbons may for example be used also for alteringthe oleophobic properties of the cellulose product. The one or more additivesof the cellulose blank 3 may be added to the cellulose blank 3 before forming the cellulose products, for example when dry-forming the cellulose blank 3.

The cellulose blank 3 may have a single-layer or a multi-layer structure. Acellulose blank 3 having a single-layer structure is referring to a cellulose blankstructure that is formed of one layer containing cellulose fibres. A celluloseblank 3 having a multi-layer structure is referring to a cellulose blank structurethat is formed of two or more layers containing cellulose fibres, where thelayers may have the same or different compositions or configurations. 13 ln order to form the cellulose products 2, the cellulose blank 3 is arranged inthe forming mould 4, where the cellulose blank 3 is heated to a specific formingtemperature TF and pressed with a specific forming pressure PF in the formingcavity 6 of the forming mould 4. When forming the cellulose products 2, a forceF is applied to the first forming mould part 5a and/or the second forming mouldpart 5b, as i||ustrated in the figures. The applied force F is during the formingprocess establishing the forming pressure PF in the forming cavity 6 exertedon the cellulose blank 3. According to the disclosure, when forming thecellulose blank 3 in the forming mould 4, a forming pressure PF in the range 1-100 MPa and a forming temperature TF in the range of 100°C to 300°C areapplied to the cellulose blank 3. The cellulose fibres in the cellulose blank 3will in the forming process be bonded to each other in a way so that theresulting cellulose products 2 will have good mechanical properties. Testshave shown that higher forming temperatures will give stronger bondingbetween the cellulose fibres when being pressed at a specific formingpressure. With forming temperatures above 100°C together with a formingpressure of at least 1 MPa, the cellulose fibres will be strongly bonded to eachother with hydrogen bonds. A higherforming temperature will increase the fibrilaggregation, water resistance, Young's modulus and the mechanicalproperties of the final cellulose product. The high pressure is important for fibrilaggregation between the cellulose fibres in the cellulose products 2. Attemperatures higher than 300°C, the cellulose fibres will be thermallydegraded and therefore temperatures above 300°C should be avoided. Theforming pressure and the forming temperature may be chosen to be suitablefor the specific cellulose products 2 to be produced.

Tests have shown that when forming the cellulose products 2 from celluloseblanks 3, suitable forming pressure levels are, as described above, in therange of 1-100 MPa, and suitable forming temperature levels are in the rangeof 100°C to 300°C. However, pressure levels in the range of 4-20 MPa, andtemperature levels in the range of 140°C to 200°C are often sufficient in order to achieve cellulose products 2 with desired properties. 14 The cellulose products 2 may be formed in the forming mould 4 during aforming time period in a range of 0.001 to 20 seconds. As an alternative, theforming time period may be in a range of 0.01 to 15.0 seconds or in a range of0.1 to 10.0 seconds. The time period is chosen so that the desired propertiesof the cellulose products 2 are achieved. Longer forming time periods can beneeded if the multi-layer cellulose blank 3 is heated in the forming mould 4,compared to a pre-heated cellulose blank 3.

By holding a specific forming pressure at a specific forming temperature for acertain period of time, the fibril aggregation in the cellulose fibres of thecellulose blank 3 will form the cellulose products 2, with a cellulose fibrestructure having mechanical properties similar to thermoplastic materials. lf asa non-limiting example, the forming pressure is 4 MPa, the formingtemperature is 150°C, and the forming time period is 5 seconds, celluloseproducts 2 with a fibre structure with mechanical properties close tothermoplastic materials can be achieved. The forming time period may asdescribed above for example range from 0.001 seconds to several seconds,depending on the forming temperature of the cellulose blank 3 and the formingpressure applied to the cellulose blank 3 in the forming mould 4.

The dry forming of the cellulose blank 3 may take place as a separate processstep, in which the cellulose blank 3 may be stacked in sheets or arranged asa rolled web, before forming of the cellulose products 2. As an alternative, thedry forming of the cellulose blank 3 may be part of a continuous process, inwhich the cellulose products 2 are formed in the forming mould 4. The dryforming of the cellulose blank 3 will then be an initial process step before arranging, heating, and pressing the cellulose blank 3 in the forming mould 4.

The heating of the cellulose blank 3 may take place before the pressing in theforming mould 4 or at least partly before the pressing in the forming mould 4.As an alternative, the heating of the cellulose blank 3 may take place in theforming mould 4 when being pressed. The heating of the cellulose blank 3 mayfor example be accomplished through heating the forming mould 4 before pressing the cellulose blank 3. The pressure may also be applied beforeheating the cellulose blank 3, and for example the heating of the cellulose blank 3 may take place in the forming mould 4 during pressing.

The cellulose blank 3 may be arranged into the forming mould 4 in any suitableway, and as an example, the cellulose blank 3 may be manually arranged inthe forming mould 4. Another alternative is to arrange a feeding device for thecellulose blank 3, which is transporting the cellulose blank 3 to the formingmould 4. The feeding device could for example be a conveyor belt, an industrialrobot, or any other suitable manufacturing equipment. lf the dry forming of thecellulose blank 3 is part of a continuous manufacturing process in which thecellulose products are produced, the cellulose blank 3 may be fed to theforming mould 4 from a dry forming unit. More specifically, the cellulose blank3 could be intermittently fed to the forming mould 4 by a feeding unit if desired.

The first mould part 5a and the second mould part 5b are movably arranged inrelation to each other in a pressing direction Dp and further arranged to bepressed in relation towards each other during forming of the cellulose products2 with the force F. The force F may vary during the forming process anddepend on the type of cellulose products 2 formed and the forming equipmentused. When forming the cellulose products 2, the cellulose blank 3 is arrangedin the forming mould 4 when the forming mould is in an open state betweenthe first mould part 5a and the second mould part 5b. The forming cavity 6 maybe arranged with a shape that is corresponding to the final shape of thecellulose products 2 that are formed in the forming mould 4. The celluloseblank 3 is arranged in a way in the forming mould 4 so that during the formingprocess the forming cavity 6 is fully or partly covered by the cellulose blank 3.When the cellulose blank 3 has been arranged in the forming mould 4, the firstmould part 5a and the second mould part 5b are moved in relation to eachother during the forming process.

The forming mould system 1 can for example be constructed so that the first mould part 5a or the second mould part 5b is movable and arranged to move 16 towards the other mould part during the forming process, where the othermould part is stationary or non-movably arranged. ln an alternative solution,both the first mould part 5a and the second mould part 5b are movablyarranged, where the first mould part 5a and the second mould part 5b aredisplaced in directions towards each other during the forming process. Themoving mould part or alternatively moving mould parts may be displaced witha suitable actuator, such as a hydraulic, pneumatic, or electric actuator. Acombination of different actuators may also be used. The relative speedbetween the first mould part 5a and the second mould part 5b during theforming process is chosen so that the cellulose blank 3 is evenly distributed inthe forming cavity 6 during the forming process. The actuator or actuators usedfor moving the first mould part 5a, or alternatively the second mould part 5b,or both mould parts may for example be pressure controlled, wherein therelative movement of the first mould part 5a in relation to the second mouldpart 5b is stopped when the correct forming pressure is established in the forming mould.

The forming mould 4 of the forming mould system 1 further comprises one ormore hole punch rods 8 arranged to form one or more apertures 10 in thecellulose blank 3 during forming of the cellulose products 2. Each of the oneor more hole punch rods 8 is attached to the first mould part 5a and/or thesecond mould part 5b. Each of the one or more hole punch rods 8 is arrangedto cooperate with the other of the first mould part 5a and/or the second mouldpart 5b during the forming of the cellulose products 2. The forming mould 4further comprises one or more corresponding openings 11 for each hole punchrod 8, where the one or more openings 11 are arranged in the other of the firstmould part 5a and/or the second mould part 5b. The one or more hole punchrods 8 are extending at least partly into the one or more openings 11 duringforming of the cellulose products 2, as illustrated in figure 3d.

The one or more hole punch rods 8 are having essentially elongated shapes extending in the pressing direction Dp. The one or more corresponding 17 openings 11 are having hollow or channel-like configurations extending in thepressing direction Dp. When forming the cellulose products 2, the one or morehole punch rods 8 are forming the one or more apertures 10 in the celluloseproducts 2. An outer end 8c of the hole punch rod 8 may be provided with afirst cutting edge 13 that is cooperating with a second cutting edge 14 arrangedin connection to the corresponding opening 11. The one or more apertures 10are formed in the cellulose blank 3 when the one or more hole punch rods 8are pushed into the corresponding opening 11 during movement of the firstmould part 5a in relation to the second mould part 5b during the formingprocess, where the cutting edges are cooperating to form the apertures. Thecross-sectional shapes and dimensions of the one or more hole punch rods 8may vary along the extension in the pressing direction Dp. The one or morehole punch rods 8 may for example be wider where they are attached to the first mould part 5a or the second mould part 5b for a more stable connection.

A gap may be formed between each of the one or more hole punch rods 8 andthe corresponding one or more openings 11 during the forming of the celluloseproducts 2, which gap may be sealed by the cellulose blank, the deformation element, or by a separate sealing element. ln figures 3a-d and figures 4a-b, a first embodiment of the forming mould 4 ofthe forming mould system 1 is shown. ln figures 3a-d, the forming mould 4 isshown in cross-sectional side views of different forming steps of the formingprocess. ln figure 4a, the forming mould 4 of the first embodiment is shown ina view from above, and in figure 4b, the forming mould 4 of the firstembodiment is shown in a cross-sectional view from above along a plane P indicated in figure 3d. ln the first embodiment, as illustrated in figures 3a-d and figures 4a-b, theforming mould system 1 for forming three-dimensional cellulose products 2from an air-formed cellulose blank 3 comprises a forming mould 4 having afirst mould part 5a, a second mould part 5b, a forming cavity 6, and a deformation element 7. The forming cavity 6 is formed and enclosed by the 18 first mould part 5a and the second mould part 5b during the forming of thecellulose products 2, as shown in figure 3d. During forming of the celluloseproducts 2, the deformation element 7 is arranged in the forming cavity 6 andexerting a forming pressure PF on the cellulose blank 3. The forming mould 4in the first embodiment further comprises one hole punch rod 8 arranged toform one aperture 10 in the cellulose blank 3 during forming of the celluloseproducts 2. The hole punch rod 8 is attached to the first mould part 5a. Thehole punch rod 8 is arranged to cooperate with the second mould part 5bduring the forming process, as further described below.

The forming mould 4 in the first embodiment further comprises onecorresponding opening 11 for the hole punch rod 8. The opening 11 isarranged in the second mould part 5b, and has a hollow or channel-likeconfiguration extending in the pressing direction Dp. ln the shown embodiment,the opening 11 is extending into the second mould part 5b in the pressingdirection Dp, wherein the opening 11 is forming a cavity for receiving the holepunch rod 8. During forming of the cellulose products 2, the hole punch rod 8is extending at least partly into the opening 11, as shown in figure 3d. ln the first embodiment, as shown in figure 3a, the first mould part 5acomprises a first side wall 19a, an upper surface 19b, and a lower surface 19c.The first side wall 19a is surrounding the first mould part 5a. The deformationelement 7 is attached to the lower surface 19c of the first mould part 5a withsuitable attachment means, such as for example glue or mechanical fasteningmembers. The hole punch rod 8 is attached to the first mould part 5a andextending downwards in the pressing direction from the lower surface 19cthrough the deformation element 7.

As shown in figure 3a, the second mould part 5b comprises a second side wall20a and a bottom wall 20b. The opening 11 is arranged in the bottom wall 20band extending as a channel structure into the bottom wall 20b. ln thisembodiment, the forming cavity 6 is arranged in the second mould part 5b and delimited by the second side wall 20a and the bottom wall 20b. 19 The hole punch rod 8 has an elongated shape with an extension in the pressingdirection Dp, and when forming the cellulose products 2, the hole punch rod 8is forming the aperture 10 in the cellulose products 2. To cut out the aperture10, the hole punch rod 8 comprises a first cutting edge 13 and the opening 11comprises a second cutting edge 14, where the first cutting edge 13 and thesecond cutting edge 14 are arranged to cooperate during the forming of thecellulose products 2. ln the first embodiment shown, the outer end 8c of thehole punch rod 8 comprises the first cutting edge 13, where the first cuttingedge 13 is arranged around the periphery of the outer end 8c. The first cuttingedge 13 is cooperating with the second cutting edge 14, where the secondcutting edge 14 is arranged around the periphery of an inner end 11c of thecorresponding opening 11. The aperture 10 is formed in the cellulose blank 3when the hole punch rod 8 is pushed into the corresponding opening 11 duringmovement of the first mould part 5a in relation to the second mould part 5bduring the forming process. When the first cutting edge 13 and the secondcutting edge 14 meet, as indicated in figure 3c, they are cooperating to cut outthe aperture 10 in the cellulose products 2. To establish the cutting function, atleast an outer wall section 8a of an outer end 8c of the hole punch rod 8 andthe inner wall section 11a of the opening 11 have corresponding peripheralshapes in a plane P perpendicular to the pressing direction Dp. A gap G isformed between the hole punch rod 8 and the corresponding opening 11 duringthe forming of the cellulose products 2. The first cutting edge 13 and thesecond cutting edge 14 are thus when meeting each other during themovement of the mould parts relative to each other cooperating to cut thecellulose blank 3. The outer end 8c of the hole punch rod 8 may have aninclined or other shaped bottom surface for an efficient cutting of the aperture10.

The first cutting edge 13 may be formed by an angled sharp transition at theouter end 8c of the outer wall section 8a. The second cutting edge 14 isarranged in connection to the opening 11 where the inner wall section 11a ofthe opening 11 meets the inner surface of the bottom wall 20b of the second mould part 5b. The second cutting edge 14 may be formed by an angled sharptransition between the inner wall section 11a and the inner surface of thebottom wall 20b. The cutting edges may have any suitable shape orconfiguration for efficiently cutting the cellulose blank 3.

As described above, the hole punch rod 8 is extending through the deformationelement 7, and the deformation element 7 is provided with a recess 12arranged to receive the hole punch rod 8. ln this way, the hole punch rod 8 isextending into the recess 12 through the deformation element 7. The recess12 may have a tubular-like or channel-like configuration receiving the holepunch rod 8, wherein the hole punch rod 8 is surrounded by the deformationelement 7. The outer end 8c of the hole punch rod 8 is extending below thedeformation element 7 in the pressing direction Dp, as shown in figures 3a-d.

As described above, the gap G is formed between the hole punch rod 8 andthe opening 11 during forming of the cellulose products 2, as illustrated infigure 3d and in figure 8. The gap G has an extension in a directionperpendicular to the pressing direction Dp between an outer wall section 8a ofthe hole punch rod 8 and an inner wall section 11a of the opening 11 duringforming of the cellulose products 2. The outer wall section 8a and the innerwall section 11a are during forming of the cellulose products 2 arranged to atleast partly overlap each other, establishing an overlapping section So in thepressing direction Dp, as shown in figure 8. The outer wall section 8a and theinner wall section 11a have in the overlapping section S0 correspondingperipheral shapes in directions parallel to any plane P perpendicular to thepressing direction Dp. ln this way, the gap G is established in the overlappingsection S0 between the peripheries of the outer wall section 8a and the innerwall section 11a. The gap G has an extension in a direction perpendicular tothe pressing direction Dp between the outer wall section 8a and the inner wallsection 11a in the overlapping section So.

The gap G may be arranged with a constant or essentially constant smallest dimension between the outer wall section 8a of the hole punch rod 8 and the 21 inner wall section 11a of the opening 11. The extension of the gap G in thedirection perpendicular to the pressing direction Dp may vary depending on thetype of cellulose products that are formed in the forming mould system 1. Testshave shown that a suitable size of the gap G for an efficient cutting function iswhen the gap G has an extension in a direction perpendicular to the pressingdirection Dp with a smallest width in the range 0.0005-0.9 mm, preferably 0.01-0.09 mm. With a smallest dimension is meant the smallest distance in adirection perpendicular to the pressing direction Dp between the outer wallsection 8a and the inner wall section 11a in any point along the peripheries ofthe of the outer wall section 8a and the inner wall section 11a in any plane Pin the overlapping section S0. ln the embodiment shown in figures 3a-d andfigure 8, the outer wall section 8a and the inner wall section 11a are arrangedparallel or essentially parallel to each other. ln alternative configurations, theouter wall section 8a and the inner wall section 11a may be arranged non-parallel to each other or alternatively have curved or other non-linear shapes.The hole punch rod 8 and the opening 11 may have any suitable cross-sectional shapes in a plane perpendicular to the pressing direction Dpcorresponding to the shape of the aperture 10 to be formed in the celluloseproducts 2.

The forming mould system 1 further comprises a seal 9, wherein the seal 9 issealing the gap G between the hole punch rod 8 and the opening 11 duringforming of the cellulose products 2. The seal 9 can be arranged in differentways depending on the type of cellulose products 2 formed in the formingmould 4, and further depending on the design of the forming mould 4.

The seal 9 is sealing the gap G. The gap G is, as described above, having anextension in a direction perpendicular to the pressing direction Dp in theoverlapping section S0 between the peripheries of the outer wall section 8a ofthe hole punch rod 8 and the inner wall section 11a of the opening 11. Asshown in figures 3a-d and figure 8, the forming mould system 1 further comprises the cellulose blank 3, and during forming of the cellulose products 22 2 the seal 9 is formed by the cellulose blank 3, where the cellulose blank 3 isarranged in the forming cavity 6 between the first mould part 5a and the secondmould part 5b. The use of the cellulose blank 3 as the seal 9 is a highly efficientway of providing the sealing function. During the forming of the celluloseproducts 2 in the forming mould 4, the cellulose blank 3 is positioned in theforming mould 4 so that the gap G is covered by the cellulose blank 3, asshown in figure 3d and in figure 8. The cellulose blank 3 can in this way sealthe gap G during the forming process and establish an efficient sealing functionso that a high pressure forming operation is achieved. To use the celluloseblank 3 as the seal 9, a simple and efficient sealing function is accomplished,where the cellulose blank 3 if forming part of the forming mould system 1.

The first mould part 5a and the second mould part 5b are movable in relationto each other in a pressing direction Dp and arranged to be pressed in relationtowards each other during forming of the cellulose products 2. ln the firstembodiment, the first mould part 5a is movably arranged in the pressingdirection Dp and the second mould part 5b is stationary. The first mould part5a and the second mould part 5b may be arranged in a suitable stand or framestructure to hold the mould parts, as shown schematically in figure 1, and anactuator arrangement may be used for moving the first mould part 5a. Whenforming the cellulose products 2, the cellulose blank 3 is arranged between thefirst mould part 5a and the second mould part 5b when the forming mould is inan open state, as shown in figure 3a. The cellulose blank 3 is in thisembodiment arranged in a way between the first mould part 5a and the secondmould part 5b so that the forming cavity 6 is covered by the cellulose blank 3.When the cellulose blank 3 is arranged in the forming mould 4 as describedabove, the first mould part 5a and the second mould part 5b are ready to bemoved in relation to each other during the forming process. ln the forming stepwhen the first mould part 5a is moving in the pressing direction Dp towards thesecond mould part 5b, the deformation element 7 is pushing the cellulose blank3 into the forming cavity 6, as illustrated in figure 3b. The hole punch rod 8 ismoving in the pressing direction Dp with the first mould part 5a. When the hole 23 punch rod 8 meets the opening 11, the aperture 10 is formed in the celluloseblank 3 with the hole punch rod 8, as shown in figure 3c. When the first mouldpart 5a is moving further into the forming cavity 6 and pushing the celluloseblank 3 towards the bottom wall 20b, the deformation element 7 is configuredso that it is deformed when meeting the bottom wall 20b. The cellulose blankis arranged between the deformation element 7 and the bottom wall 20b, asillustrated in figure 3c. The deformation element 7 may also be designed andconfigured to deform in other ways if desired. The deformation element 7 is inthe forming step exerting a forming pressure PF on the cellulose blank 3 during forming of the cellulose products 2, as shown in figure 3d. ln figures 3b and 3c intermediate steps in the forming process are shown,where the cellulose blank 3 is pushed into the forming cavity 6 by thedeformation element 7. When the deformation element 7 is fully deformed, asshown in figure 3d, the forming of the cellulose product is taking place and themovement of the first mould part 5a in the pressing direction Dp towards thesecond mould part 5b is being stopped. When the forming of the celluloseproduct 2 from the cellulose blank 3 is completed, the first mould part 5a ismoved in a direction away from the second mould part 5b, opposite thepressing direction Dp. When the forming mould 4 is moved into the open state,the formed cellulose product 2 is removed from the forming mould 4. Theresidues of the cellulose blank 10 from the cut out aperture 10 may be removed from the opening 11 with suitable removal means.

As shown in figure 3d, the forming cavity 6 is formed and enclosed by the firstmould part 5a and the second mould part 5b during forming of the celluloseproducts 2. As described above, the forming cavity 6 is in this embodimentarranged in the second mould part 5b and delimited by the second side wall20a and the bottom wall 20b. During the forming process, the forming cavity 6is further delimited by the lower surface 19c of the first mould part 5a, whereinthe forming cavity 6 is arranged as an enclosed volume in which the deformation element 7 is deformed, as shown in figure 3d. Thus, during 24 forming of the cellulose products 2 the deformation element 7 is arranged inthe forming cavity 6 and exerting a forming pressure PF on the cellulose blank3. ln figure 4a, the forming mould 4 is shown in a view from above and in figure4b, a cross-sectional view from above of the forming mould 4 is shown. ln theschematically shown embodiment, the forming cavity 6, the first mould part 5a,and the second mould part 5b are having rectangular-Iike shapes. However,the forming cavity 6 and mould parts may have any desired shapes, such ascircular, oval, or other regular or other non-regular shapes, depending on theshape of the cellulose products 2 produced. lt should be understood that the forming mould 4 may have other designs andconstructions compared to the ones described in the first embodiment above.The forming mould 4 may also for example be arranged with a cutting device,wherein the cellulose blank 3 is cut into a desired shape in the forming mould4 during the forming process. ln figures 5a-c a second embodiment of the forming mould 4 with two holepunch rods 8 is shown. ln this embodiment, the deformation element 7 isinstead attached to the second mould part 5b. As shown in figures 5a-c, thedeformation element 7 is attached to the bottom wall 20b and the second sidewall 20a. The deformation element 7 may be attached to the second mouldpart 5b with suitable attachment means, such as for example glue ormechanical fastening members. The first mould part 5a has in this embodimenta step-like cross-sectional configuration corresponding to the shape of thecellulose products 2. ln the second embodiment, the hole punch rods 8 may have the sameconfigurations as described above in the first embodiment of the formingmould, and the forming process may take place in the same way. The holepunch rods 8 are in the second embodiment attached to the second mould part5b. The forming mould 4 comprises two corresponding openings 11 for the hole punch rods 8. The openings 11 are arranged in the first mould part 5a,and have hollow or channel-like configurations extending in the pressingdirection Dp. ln the shown embodiment, the openings 11 are extending into thefirst mould part 5a in the pressing direction Dp, wherein the openings 11 areforming cavities for receiving the hole punch rods 8. During forming of thecellulose products 2, the hole punch rods 8 are extending at least partly intothe corresponding openings 11, as shown in figure 5c.

The hole punch rods 8 are attached to the second mould part 5b and extendingupwards in the pressing direction from the bottom wall 20b through recesses12 in the deformation element 7. The openings 11 are arranged in the firstmould part 5a and are extending as a channel structures into the first mouldpart 5a. ln the same way as described in the first embodiment above, the holepunch rods 8 may each comprise a first cutting edge 13 and the openings 11may each comprise a second cutting edge 14, where the first cutting edges 13and the second cutting edges 14 are arranged to cooperate during the formingof the cellulose products 2. The aperture 10 is formed in the cellulose blank 3when the hole punch rod 8 is pushed into the corresponding opening 11 duringmovement of the first mould part 5a in relation to the second mould part 5bduring the forming process, as shown in figures 5b-c. Further, a gap G isformed between the hole punch rod 8 and the corresponding opening 11 duringthe forming of the cellulose products 2 in the same way as described in relationto the first embodiment. The hole punch rods 8 are extending through thedeformation element 7, and the deformation element 7 is provided with therecesses 12 arranged to receive the hole punch rods 8.

As shown in figures 5a-c, the forming mould system 1 further comprises thecellulose blank 3, and during forming of the cellulose products 2 the seal 9 isformed by the cellulose blank 3, where the cellulose blank 3 is arranged in theforming cavity 6 between the first mould part 5a and the second mould part 5b. ln the different embodiments described above, the hole punch rods 8 are formed as elongated bodies, and may be made of steel, aluminium or other 26 suitable metals or combinations ofdifferent metals. The hole punch rods 8 mayalternatively be made from other suitable materials such as plastic materials,composite materials or combinations of different materials, where the firstcutting edge 13 may be formed of metal. One or more of the hole punch rods 8 may have solid bodies.

The one or more hole punch rods 8 may be releasably attached to the firstmould part 5a or the second mould part 5b, through for example a threadedconnection where an inner end 8d of the one or more hole punch rods 8comprises threads. The threads of the one or more hole punch rods 8 are inengagement with corresponding threads arranged in the first mould part 5a orthe second mould part 5b. The inner ends 8d of the one or more hole punchrods 8 may also be attached to the first mould part 5a or the second mouldpart 5b with other suitable fastening means, such as screws or rivets, oralternatively through welding. The one or more hole punch rods 8 may also bearranged as an integrated structure of the first mould part 5a or the secondmould part 5b if desired.

As an alternative to solid hole punch rods 8, one or more of the hole punchrods 8 may have hollow configurations with an outer wall section 8a and aninner wall section 8b, where the inner wall section 8b is surrounding a channel 8e formed in the hole punch rod 8, as schematically shown in figure 6a.

As a further alternative shown in figure 6b, one or more of the hole punch rods8 may comprise a tapered outer end 8c arranged to separate the fibres in thecellulose blank 3 during forming of the cellulose product 2. With the taperedouter end 8c, the hole punch rod 8 has a pointed or needle-like shape, wherethe tapered outer end is pushing away the fibres in the cellulose blank 3 whenthe first mould part 5a is moving in relation to the second mould part 5b duringthe forming process. This may be used as an alternative to cutting edges, andwith this configuration, no or little residual material is left behind after the forming of the cellulose products 2. 27 The system 1 may, as illustrated in figures 7a-d, further comprise a suctiondevice 15 connected to the first mould part 5a and/or the second mould part5b, where the suction device 15 is arranged to remove residual cellulose fromthe forming mould 4 after forming of the one or more apertures 10 in thecellulose blank 3. The suction device 15 may be connected to one or more ofthe hole punch rods 8 and/or one or more of the openings 11 via one or moresuction channels 16 arranged in the first mould part 5a and/or the secondmould part 5b. As an alternative, a blower may instead be arranged to blow away residual cellulose from the forming mould 4.

The suction device 15 may be connected to one or more of the hole punchrods 8 via one or more suction channels 16 arranged in the first mould part 5aor the second mould part 5b. The suction device 15 may be connected to theone or more suction channels 16 with pipes, hoses or other suitable connectionmeans for removal of residues. With the hollow configuration of the hole punchrods 8 described above, the residual cellulose after forming of the one or moreapertures 10 can be removed by the suction device 15 through the channels8e of the one or more hole punch rods 8 and the one or more suction channels16. ln the embodiment shown in figure 7a, the suction channel 16 is extendingin the pressing direction Dp, and in the embodiment shown in figure 7b, thesuction channel 16 has an angular configuration.

The suction device 15 may be arranged to remove residual cellulose from theforming mould 4 through the one or more of the openings 11. One or more ofthe openings 11 may be configured to extend through the forming mould partin the pressing direction Dp, or one or more of the openings 11 may beconnected to one or more suction channels 16 arranged in the first mould part5a or the second mould part 5b. The suction device 15 may be connected tothe one or more openings 11 or suction channels 16 with pipes, hoses or othersuitable connection means for removal of residues. ln the embodiment shownin figure 7c, the opening 11 extending in the pressing direction DP may constitute the suction channel 16, or an outer end 11b of the opening 11 may 28 be connected to the suction channel 16. ln the embodiment shown in figure7d, the suction channel 16 is extending from the outer end 11b of the opening 11 in an angular configuration. ln the different embodiments described above, the deformation element 7 isbeing deformed during the forming process, and the deformation element 7 isduring forming of the cellulose products 2 arranged to exert a forming pressurePF on the cellulose blank 3. To exert a required forming pressure PF on thecellulose blank 3, the deformation element 7 is made of a material that can bedeformed when a force or pressure is applied. For example, the deformationelement 7 can be made of an elastic material capable of recovering size andshape after deformation. The deformation element 7 may further be made of amaterial with suitable properties that is withstanding the high forming pressureand temperature levels used when forming the cellulose products 2 in the forming mould 4.

During the forming process, the deformation element 7 is deformed to exertthe forming pressure PF on the cellulose blank 3. Through the deformation aneven pressure distribution can be achieved in the forming mould 4, even if thecellulose products 2 are having complex three-dimensional shapes withcutouts, apertures and holes, or if the cellulose blank 3 used is having varyingdensity, thickness, or grammage levels.

Certain elastic or deformable materials have fluid-like properties when beingexposed to high pressure levels. lf the deformation element 7 is made of sucha material, an even pressure distribution in the forming mould 4 can beachieved in the forming process, where the pressure exerted on the celluloseblank 3 from the deformation element 7 is equal or essentially equal in alldirections in the forming mould 4. When the deformation element 7 duringpressure is in its fluid-like state, a uniform fluid-like pressure distribution isachieved in the forming mould 4. The forming pressure is with such a materialthus applied to the cellulose blank 3 from all directions, and the deformation element 7 is in this way during the forming of the cellulose products 2 exerting 29 an isostatic forming pressure PF on the cellulose blank 3. The isostatic formingpressure PF from the deformation element 7 is establishing a uniform pressurein all directions in the forming mould 4 on the cellulose blank 3. The isostaticforming pressure PF is providing an efficient forming process of the celluloseproducts 2 in the forming mould 4, and the cellulose products 2 can be produced with high quality even if having complex shapes.

The deformation element 7 may be made of a suitable structure of elastomericmaterial, where the material has the ability to establish a uniform pressure onthe cellulose blank 3 in the forming mould 4 during the forming process. As anexample, the deformation element 7 is made of a massive structure or anessentially massive structure of silicone rubber, polyurethane,polychloroprene, or rubber with a hardness in the range 20-90 Shore A. Othermaterials for the deformation element 7 may for example be suitable gel materials, liquid crystal elastomers, and MR fluids.

As described above, the deformation element 7 is through deformation duringforming of the cellulose products 2 establishing a uniform pressure in alldirections in the forming mould 4 on the cellulose blank 3. The deformationelement 7 is during forming of the cellulose products 2 exerting an isostaticforming pressure PF on the cellulose blank 3. A suitable isostatic formingpressure PF when forming the cellulose products 2 is within the range 1-100MPa. ln the different embodiments described above, the deformation element 7 maybe releasably attached to the first mould part 5a or the second mould part 5b.The deformation element 7 is shaped into a shape suitable for the formingmould 4 with the hole punch rod 8, wherein the deformation element 7 duringthe forming of the cellulose product 2 is enabling an efficient pressuredistribution on the cellulose blank 3. ln an alternative embodiment, the deformation element 7 instead comprises aflexible membrane and a pressure media. With this construction, the deformation element 7 during the forming of the cellulose product 2 is enablingan efficient pressure distribution on the cellulose blank 3. The deformationelement 7 may for example be arranged in connection to the first mould part5a and the pressure media may for example be hydraulic oil exerting apressure on the ﬂexible membrane during the forming of the cellulose products2. An outer part of the ﬂexible membrane may for example be attached to thelower surface 19c of the first mould part 5a, wherein a sealed volume is formedbetween the flexible membrane, the one or more hole punch rods 8, and thelower surface 19c. The pressure media may be arranged to flow into and outfrom the sealed volume through a flow channel arranged in the first mould part5a. Through the pressure media, the deformation element is exerting a formingpressure on the cellulose blank. During the forming process, the pressuremedia is allowed to flow into the sealed volume. ln this way, the flexiblemembrane is exerting the forming pressure on the cellulose blank 3 arrangedin the forming cavity 6 of the forming mould 4 when being deformed. Asdescribed above, a suitable forming pressure PF when forming the celluloseproducts 2 is within the range 1-100 MPa. By applying a suitable pressure onthe cellulose blank 3 with the flexible membrane, the cellulose fibres in thecellulose blank 3 are compressed in the forming mould 4. The applied pressureon the cellulose blank 3 from the pressure media and the flexible membranemay be isostatic in order to compress the cellulose fibres evenly regardless oftheir relative position on the forming mould 4 and regardless of the actual localamount of fibres. The isostatic pressure from the deformation element 7 isestablishing a uniform pressure in all directions in the forming mould 4 on thecellulose blank 3. ln this way, an efficient forming of the cellulose products 2 isachieved, and the cellulose products 2 can be produced with high quality. Thepressure media and/or the forming mould parts may be heated to establish a suitable forming temperature.

The forming mould system 1 may comprise a fluid control device for thepressure media, and the fluid control device may be an actuator or similararrangement compressing and transporting the pressure media into the sealed 31 volume, and also transporting the pressure media out from the sealed volumeafter the forming process. The pressure media used in the forming processmay be any suitable fluid, such as for example hydraulic oil, water and air.

As an alternative to use the cellulose blank 3 as the seal 9 described above,the seal 9 may instead during forming of the cellulose products 2 be formed bythe deformation element 7 arranged in the forming cavity 6. When thedeformation element 7 is compressed during the forming of the celluloseproducts 2, the deformation element 7 is floating out and sealing the gap G.The same function can be achieved in the other mould configurations descnbed. ln a further alternative embodiment, the seal 9 may be formed by a separatesealing element, where during forming of the cellulose products 2 the sealingelement is arranged between the hole punch rod 8 and the opening 11. Thesealing element is during the forming of the cellulose products 2 sealing thegap. The sealing element may have any suitable configuration and be madeof a suitable elastomeric material, such as for example silicone materials,rubber materials, polyurethane, or other elastic or elastomeric materials. Thesealing element may have a shape corresponding to the peripheries of theouter wall section 8a of the hole punch rod 8 and the inner wall section 11a ofthe opening 11. The sealing element may further have a suitable cross-sectional shape, such as for example a flat, round, rectangular, oval, or otherregular and irregular shapes. The sealing element may be attached to the holepunch rod 8 or the opening 11 depending on the design of the forming mould.The hole punch rod 8 or the opening 11 may be provided with a groove or othersuitable means for holding the sealing element to the respective part. Further,as an alternative, two or more sealing elements may be attached to the holepunch rod 8 or the opening 11 to establish the sealing function.

The forming mould system 1 in the different embodiments described above isfurther comprising a heating device 17 arranged in relation to the first mould part 5a and/or the second mould part 5b. During forming of the cellulose 32 products 2 the first mould part 5a and/or the second mould part 5b is heatedto a forming mould temperature in the range 100-500°C to establish theforming temperature TF in the range of 100°C to 300°C that needs to be appliedto the cellulose blank 3. The heating device may be integrated in the first mouldpart 5a and/or the second mould part 5b, and suitable heating devices 17 aree.g. an electrical heater or a fluid heater in which a heated fluid medium isflowing in channels in the forming mould parts. Other suitable heat sourcesmay also be used.

The forming mould system 1 in the different embodiments described above isfurther comprising a pressing unit 18 arranged to apply a pressure on the firstmould part 5a and/or the second mould part 5b. Du during forming of thecellulose products 2 the deformation element 7 is exerting a forming pressurePF on the cellulose blank 3 in the range 1-100 MPa. The pressing unit mayalso be used for displacing the first mould part 5a and/or the second mouldpart 5b. The moving mould part or alternatively moving mould parts may bedisplaced with a suitable pressing actuator, such as a hydraulic, pneumatic, orelectric actuator. lt will be appreciated that the above description is merely exemplary in natureand is not intended to limit the present disclosure, its application or uses. Whilespecific examples have been described in the specification and illustrated inthe drawings, it will be understood by those of ordinary skill in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the present disclosureas defined in the claims. Furthermore, modifications may be made to adapt aparticular situation or material to the teachings of the present disclosurewithout departing from the essential scope thereof. Therefore, it is intendedthat the present disclosure not be limited to the particular examples illustratedby the drawings and described in the specification as the best mode presentlycontemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within 33 the foregoing description and the appended claims. Reference signsmentioned in the claims should not be seen as limiting the extent of the matterprotected by the claims, and their sole function is to make claims easier to understand.

REFERENCE SIGNS 1: Forming mould system 2: Celluiose products 3: Celluiose blank 4: Forming mould 5a: First mould part 5b: Second mould part Forming cavity7: Deformation elementHole punch rod 8a: Outer wall section, Hole punch rod8b: lnnerwall section, Hole punch rod8c: Outer end, Hole punch rod8d: lnner end, Hole punch rod8e: Channel, Hole punch rod 9: Seal : Aperture 11: Opening 11a: lnner wall section, Opening11b: Outer end, Opening 11c: lnner end, Opening 12: Recess, Deformation element13: First cutting edge 14: Second cutting edge : Suction device 16:17:18: 19a:19b:19c:20a:20b: 34 Suction channel Heating device Pressing unit First side wall, First mould partUpper surface, First mould partLower surface, First mould partSecond side wall, Second mould partBottom wall, Second mould part

Claims

1._ 1. A forming mould system (1) for forming three-dimensional celluloseproducts (2) from an air-formed cellulose blank (3), comprising a formingmould (4) having a first mould part (5a), a second mould part (5b), aforming cavity (6), and a deformation element (7), wherein the first mould part (5a) and the second mould part (5b)are movable in relation to each other in a pressing direction (Dp) andarranged to be pressed in relation towards each other during forming ofthe cellulose products (2), wherein the forming cavity (6) is formed and enclosed by the firstmould part (5a) and the second mould part (5b) during forming of thecellulose products (2), and wherein the deformation element (7) duringforming of the cellulose products (2) is arranged in the forming cavity (6)and is exerting a forming pressure (PF) on the cellulose blank (3), wherein the forming mould (4) further comprises one or more holepunch rods (8) arranged to form one or more apertures (10) in the celluloseblank (3) during forming of the cellulose products (2), wherein each of theone or more hole punch rods (8) is attached to the first mould part (5a)and/or the second mould part (5b).

2. A system (1) according to claim 1, wherein each of the one or more hole punch rods (8) is arrangedto cooperate with the other of the first mould part (5a) and/or the secondmould part (5b) during the forming of the cellulose products (2).

3. A system (1) according to claim 1 or 2, wherein the forming mould (4) further comprises one or morecorresponding openings (11) for each hole punch rod (8), where theopenings (11) are arranged in the other of the first mould part (5a) and/orthe second mould part (5b), wherein the hole punch rods (8) are extendingat least partly into the one or more openings (11) during forming of the cellulose products (2). 36

4. A system (1) according to claim 3, wherein a gap (G) is formed between the hole punch rod (8) andthe opening (11) during forming of the cellulose products (2), wherein the system (1) further comprises a seal (9), wherein theseal (9) is sealing the gap (G) between the hole punch rod (8) and theopening (11) during forming of the cellulose products (2).

5. A system (1) according to claim 4, wherein the gap (G) has an extension in a direction perpendicu|arto the pressing direction (Dp) between an outerwa|| section (8a) of the holepunch rod (8) and an inner wall section (11a) of the opening (11) duringforming of the cellulose products (2).

6. A system (1) according to claim 5, wherein the gap (G) has an extension in a direction perpendicu|arto the pressing direction (Dp) with a smallest width in the range 0.0005-0.9mm, preferably 0.01-0.09 mm.

7. A system (1) according to claim 5 or 6, wherein the outer wall section (8a) of at least an outer end (8c) ofthe hole punch rod (8) and the inner wall section (1 1a) of the opening (11)have corresponding peripheral shapes in a plane (P) perpendicu|ar to thepressing direction (Dp).

8. A system (1) according to any of claims 4-7, wherein the system (1 ) further comprises the cellulose blank (3),and wherein during forming of the cellulose products (2) the seal (9) isformed by the cellulose blank (3) arranged in the forming cavity (6).

9. A system (1) according to claim 8, 15. 37 wherein the cellulose blank (3) has a material composition of 70-99.9% dry wt cellulose fibres and 0.1-30% dry wt of one or more additives,preferably 80-99.9% dry wt cellulose fibres and 0.1-20% dry wt of one ormore additives, more preferably 90-99.9% dry wt cellulose fibres and 0.1- 10% dry wt of one or more additives. A system (1) according to any of claims 4-7,wherein during forming of the cellulose products (2) the seal (9) isformed by the deformation element (7) arranged in the forming cavity (6). A system (1) according to any of claims 4-7,wherein during forming of the cellulose products (2) the seal (9) is formed by a sea|ing element. A system (1) according to claim 11, wherein the sea|ing element is made of an elastomeric material. A system (1) according to any of claims 3-12, wherein the hole punch rod (8) comprises a first cutting edge (13)and the opening (11) comprises a second cutting edge (14), wherein thefirst cutting edge (13) and the second cutting edge (14) are arranged to cooperate during the forming of the cellulose products (2). A system (1) according to any of claims 3-13, wherein the system (1) further comprises a suction device (15)connected to the first mould part (5a) and/or the second mould part (5b),wherein the suction device (15) is arranged to remove residual cellulosefrom the forming mould (4) after forming of the one or more apertures (10) in the cellulose blank (3). A system (1) according to claim 14, 21. 38 wherein the suction device (15) is connected to one or more of thehole punch rods (8) and/or one or more of the openings (11) via one ormore suction channels (16) arranged in the first mould part (5a) and/or thesecond mould part (5b). A system (1) according to any of the preceding claims, wherein the deformation element (7) is provided with one or morerecesses (12) arranged to receive the one or more hole punch rods (8),wherein the one or more hole punch rods (8) are extending into the one or more recesses (12) through the deformation element (7). A system (1) according to any of the preceding claims,wherein each of the one or more hole punch rods (8) is releasably attached to the first mould part (5a) and/or the second mould part (5b). A system (1) according to any of the preceding claims,wherein the one or more hole punch rods (8) are having an elongated shape with an extension in the pressing direction (Dp). A system (1) according to any of the preceding claims,wherein one or more of the hole punch rods (8) are having ahollow configuration with an inner wall section (8b) surrounding a channel (8e) formed in the hole punch rod (8). A system (1) according to any of the preceding claims, wherein one or more of the hole punch rods (8) comprise atapered outer end (8c) arranged to separate the fibres in the celluloseblank (3) during forming of the cellulose product (2). A system (1) according to any of the preceding claims, 23. 39 wherein the deformation element (7) during forming of thecellulose products (2) is exerting an isostatic forming pressure (PF) on thecellulose blank (3). A system (1) according to any of the preceding claims, wherein during forming of the cellulose products (2) thedeformation element (7) through deformation is establishing a uniformpressure in all directions in the forming mould (4) on the cellulose blank(3), wherein the deformation element during forming of the celluloseproducts (2) is exerting an isostatic forming pressure (PF) on the celluloseblank (3) in the range 1-100 MPa. A method for forming three-dimensional cellulose products (2) from an air-formed cellulose blank (3) in a forming mould system (1) according to anyof claims 1-22, wherein the system (1) comprises a forming mould (4)having a first mould part (5a), a second mould part (5b), a forming cavity(6), a deformation element (7), and one or more hole punch rods (8),wherein the method comprises the steps: arranging a cellulose blank (3) in the forming mould (4) betweenthe first mould part (5a) and the second mould part (5b); moving the first mould part (5a) and the second mould part (5b) inrelation to each other in a pressing direction (Dp); forming one or more apertures (10) in the cellulose blank (3) withthe one or more hole punch rods (8); exerting a forming pressure (PF) on the cellulose blank (3) by the deformation element (7) during forming of the cellulose products (2).