WO2020227404A1 - Lignes de production de pièces moulées en fibres à haut rendement et à temps de cycle réduit - Google Patents

Lignes de production de pièces moulées en fibres à haut rendement et à temps de cycle réduit Download PDF

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Publication number
WO2020227404A1
WO2020227404A1 PCT/US2020/031667 US2020031667W WO2020227404A1 WO 2020227404 A1 WO2020227404 A1 WO 2020227404A1 US 2020031667 W US2020031667 W US 2020031667W WO 2020227404 A1 WO2020227404 A1 WO 2020227404A1
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WO
WIPO (PCT)
Prior art keywords
fiber part
molded fiber
press
shuttle
station
Prior art date
Application number
PCT/US2020/031667
Other languages
English (en)
Inventor
Pablo Gonzalez
Rick BONTRAGER
Original Assignee
Zume, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zume, Inc. filed Critical Zume, Inc.
Publication of WO2020227404A1 publication Critical patent/WO2020227404A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds

Definitions

  • PRODUCTS are hereby incorporated by reference herein in their entireties.
  • molded paper pulp also referred to as molded fiber
  • Paper pulp can be produced from recycled materials such as old newsprint and corrugated boxes or directly from tree and other plant fibers.
  • Today, molded pulp packaging is widely used for electronics, household goods, automotive parts and medical products.
  • Molds are made by machining a metal tool in the shape of a mirror image, if you will, of the finished part. Holes are drilled through the tool and then a screen is attached to its surface. The vacuum is drawn through the holes while the screen prevents the pulp from clogging the holes.
  • the mold is immersed into a slurry of fiber and a pressure gradient is applied and water is drawn through the holes in the mold. Fiber from the slurry is collected on the screen and, after the fiber layer is formed to a desired thickness, the mold with the molded fiber part is removed from the slurry. The molded fiber part is then disengaged from the mold and may be subjected to subsequent processing (e.g., forming, heating, drying, top coating, and the like).
  • Molded fiber packaging products can be biodegradable and compostable.
  • the technology relates to a molded fiber part production line including: a forming mold; a transfer shuttle for removing a partially -formed fiber part from the forming station; a plurality of press station sub-lines, wherein each of the plurality of press station sub-lines includes: a press station including an entrance side and an exit side; and a press station shuttle; a distribution shuttle for distributing the partially- formed fiber part from the transfer gantry to at least one of the plurality of press station shuttles, wherein the distribution gantry is disposed on the entrance side of the press station; a trim-waste station disposed on the exit side of the press station; and an exit conveyor disposed opposite the trim-waste station from the press station.
  • At least one of the transfer shuttle, the distribution shuttle, and the press station shuttle include a part retention feature.
  • the part retention feature includes a part retention mold.
  • the part retention mold defines a plurality of vacuum channels.
  • the press station shuttle includes the part retention feature, and wherein the part retention feature defines a first plurality of vacuum channels and a second plurality of vacuum channels discrete from the first plurality of vacuum channels.
  • the press station shuttle is configured to enter the entrance side of the press station and exit the exit side of the press station.
  • the molded fiber part production line includes a press station shuttle gantry disposed at least partially in a volume defined by the press station, wherein the press station shuttle is configured to travel along the press station shuttle gantry.
  • the press station shuttle is configured to trav el from the entrance side of the press station to the exit side of the press station along the press station shuttle gantry.
  • the molded fiber part production line includes a gantry for each of the transfer shuttle, the distribution shuttle, and the press station shuttle.
  • the transfer station shuttle gantry and the press station shuttle gantry are disposed in a north-south orientation, and wherein the distribution gantry is disposed in an east-west orientation.
  • the distribution shuttle includes a plurality of parallel distribution shuttles.
  • the exit conveyor includes a registration feature.
  • the press station includes a trimmer.
  • the technolog ⁇ ⁇ relates to a method of manufacturing a molded fiber part, the method including: drawing a fiber slurry onto a forming mold to form a partially -formed molded fiber part; inserting the partially -formed molded fiber part into an entrance side of a press, wherein the press includes a heating element; applying a compressive pressure to the partially-formed molded fiber part with the press; applying an elevated temperature to the partially -formed molded fiber part with the heating element, wherein application of the compressive pressure and the elevated temperature substantially solidifies the partially -formed molded fiber part into the molded fiber part; and removing the molded fiber part from an exit side of the press, wherein the exit side is discrete from the entrance side.
  • the method includes removing the partially-formed molded fiber part from the forming mold. In another example, the method further includes transferring the partially -formed molded fiber part to a first distribution shuttle. In yet another example, the method includes distributing the partially -formed molded fiber part to at least one of a plurality of press station shuttles, wherein the at least one of the plurality of press station shuttles inserts the partially-formed molded fiber part into the press. In still another example, the at least one of the plurality of press station shuttles removes the molded fiber part from the press.
  • the method further includes trimming the molded fiber part to produce a waste trim.
  • the method further includes removing the waste trim from the exit side of the press.
  • removing the molded fiber part includes applying a part vacuum to the molded fiber part to separate the molded fiber part from the press, and wherein removing the waste trim includes applying a waste trim vacuum to the waste trim to separate the waste trim from the press, wherein the part vacuum is discrete from the waste trim.
  • inserting the partially -formed molded fiber part into the press and removing the molded fiber part from the press is performed with a press shuttle comprising a part transfer feature.
  • the method includes terminating application of the waste trim vacuum at a waste trim station disposed between the exit side of the press and an exit conveyor.
  • the method includes returning an empty second distribution shuttle from a distribution location towards a transfer location, substantially simultaneously with transferring the partially-formed molded fiber part to the first distribution shuttle.
  • the method includes applying a vacuum pressure to the partially -formed molded fiber part during application of the compressive pressure and the elevated temperature.
  • the technolog ⁇ ⁇ relates to a method of manufacturing a molded fiber part, the method including: drawing a fiber slurry onto a forming mold to form a partially -formed molded fiber part; removing the partially-formed molded fiber part from the forming mold; transferring the partially -formed molded fiber part to a first distribution shuttle; identifying a first available press station sub-line of a plurality of press station sub lines; transferring the partially-formed molded fiber part to a first press shuttle associated with the first available press station sub-line; transferring the partially-formed molded fiber part to a first available press station associated with the first available press station sub-line; forming the partially -formed molded fiber part into the molded fiber part with the first available press station; substantially simultaneously with forming the molded fiber part, separating a waste trim from the molded fiber part; transferring the molded fiber part and the waste trim to the first press shuttle; and releasing the waste trim from the first press shuttle while retaining the molded fiber part
  • the method includes returning a second distribution shuttle towards the forming mold substantially simultaneously with at least one of transferring the partially-formed molded fiber part to the first distribution shuttle and transferring the partially -formed molded fiber part to the first press shuttle.
  • the plurality of press station sub-lines include the first available press station sub-line and a second press station sub-line.
  • the method includes forming an additional partially-formed molded fiber part into an additional molded fiber part with a second press station of the second press station sub-line, at least partially simultaneously with forming the partially-formed molded fiber part into the molded fiber part with the first available press station.
  • the method includes transferring the molded fiber part from the first press shuttle to an exit conveyor.
  • the technolog ⁇ ' relates to a system including: at least one processor; and memory, operatively connected to the at least one processor and storing instructions that, when executed by the at least one processor, cause the system to perform a set of operations, the set of operations including: drawing a fiber slurry onto a forming mold to form a partially -formed molded fiber part; removing the partially -formed molded fiber part from the forming mold; transferring the partially-formed molded fiber part to a first distribution shuttle; identifying a first available press station sub-line of a plurality' of press station sub-lines; transferring the partially -formed molded fiber part to a first press shuttle associated with the first available press station sub-line; transferring the partially- formed molded fiber part to a first available press station associated with the first available press station sub-line; forming the partially -formed molded fiber part into the molded fiber part with the first available press station; substantially simultaneously with forming the molded fiber part, separating a waste trim from the set of operations, the set of operations
  • the set of operations further includes returning a second distribution shuttle towards the forming mold substantially simultaneously with at least one of transferring the partially -formed molded fiber part to the first distribution shuttle and transferring the partially -formed molded fiber part to the first press shuttle.
  • the set of operations further includes forming an additional partially -formed molded fiber part into an additional molded fiber part with a second press station of a second press station subline, at least partially simultaneously with forming the partially -formed molded fiber part into the molded fiber part with the first available press station.
  • the set of operations further includes transferring the molded fiber part from the first press shuttle to an exit conveyor.
  • FIG. 1 depicts a schematic of an example molded fiber part production line.
  • FIG. 2 depicts a partial perspective view of an example of the production line of FIG. 1, in a linear layout configuration.
  • FIG. 2A depicts a partial perspective view of the production line of FIG. 2, with multiple parallel press and trim sublines.
  • FIG. 3 depicts an example of a forming station.
  • FIG. 4 depicts a partial schematic view of a forming station and part transfer system in mating engagement.
  • FIG. 5 depicts a perspective view of a press station.
  • FIG. 6 depicts a partial schematic view of a two molds of a press station in mating engagement.
  • FIGS. 7 A and 7B depict a perspective view and a partial enlarged perspective view, respectively, of an upper mold for a press station.
  • FIG. 8 depicts a partial schematic view of a press/trim station mold and a removal system in mating engagement.
  • FIG. 9 illustrates an alternative example of a production line in which the parts are moved between various stations via multiple shuttle systems.
  • FIG. 10 illustrates an alternative example of a production line including two parallel configurations of the production line depicted in FIG. 9.
  • FIG. 11 illustrates a process flow diagram and example cycle times for the production line of FIG. 9.
  • FIG. 12 illustrates an alternative example of a production line including two parallel configurations.
  • FIG. 13 depicts a method of forming a molded fiber part.
  • FIG. 13A depicts a press station sub-line operational method.
  • FIGS. 14A and 14B depict another method of forming a molded fiber part.
  • FIG. 15 illustrates one example of a suitable operating environment in which one or more of the present examples may be implemented.
  • FIG. 16 is an example of a network in which the various systems and methods disclosed herein may operate.
  • Various embodiments of the technology described below relate to the manufacture of fiber-based or pulp-based products for use both within and outside of the food and beverage industry.
  • the present disclosure relates to the automated, efficient, high-speed production of fiber-based containers.
  • the fiber-based products are adapted to replace their plastic counterparts in a wide variety of applications such as, for example: frozen, refrigerated, and non-refrigerated foods;
  • microwavable food containers beverages; comestible and non-comestible liquids; substances which liberate water, oil, and/or water vapor during storage, shipment, and preparation (e.g., cooking); horticultural applications including consumable and landscaping/gardening plants, flowers, herbs, shrubs, and trees; single-use or disposable storage and dispensing apparatuses (e.g., paint trays, food trays, brush handles, protective covers for shipping); produce (including human and animal foodstuffs such as fruits and vegetables); salads; prepared foods; packaging for meat, poultry, and fish; lids; cups; bottles; guides and separators for processing and displaying the foregoing; edge and comer pieces for packing, storing, and shipping electronics, mirrors, fine art, and other fragile components; buckets; tubes; industrial, automotive, marine, aerospace and military components such as gaskets, spacers, seals, cushions, and the like; and associated molds, wire mesh forms, recipes, processes, chemical formulae, tooling, s
  • The‘438 application” describes generally a forming station that includes a former that creates a wet part by dipping a first mold into a tank of fiber slurry, drawing fiber onto the mold until a desired amount of fiber is collected on the screen, and then removing the mold with the attached fiber layer from the slurry.
  • the forming station also subjects the wet part to a forming operation in which the first mold with the attached layer of fiber is pressed into a second mold after it is removed from the slurry. This forming operation removes some water from the wet part and contours the surface of the wet part opposite the first mold.
  • the pressing station may be a plurality of pressing stations, operating in parallel. In one example of the‘438 application, four pressing stations are utilized. Each of the four pressing stations in the‘438 application includes a single press. Parts are sent to a stacking station after pressing.
  • the forming station, pressing stations, and stacking station are arranged in a circle around a centrally located robot controlling an extendable robotic arm.
  • the robot and robotic arm are configured to remove formed parts from the forming station and transfer them to any one of the four pressing stations.
  • the robotic arm is further configured to remove pressed parts from any the pressing stations and transfer them to either a different one of the pressing stations or to the stacking station.
  • FIG. 1 depicts a schematic of an example molded fiber part production line 100.
  • the line 100 is depicted having a number of stations and systems for moving partially - formed and formed parts between various stations of the line 100.
  • the various stations and systems, as well as particular configurations of the line 100 itself, are described further herein.
  • a forming station 102 includes generally a forming mold, a slurry tank, and an actuation system that moves the forming mold relative to the slurry tank (typically by lowering the mold into the slurry tank).
  • Forming stations are available, for example, fromNanya Pulp Molding Equipment Co., Ltd., of Guangzhou, China.
  • the slurry tank includes a fiber slurry that includes wood fibers in a liquid.
  • the forming mold itself includes a number of vacuum channels that are connected to a vacuum source.
  • the forming mold may have a number of discrete molds for making, typically, a plurality of identical fiber parts, although forming molds that are used to form different parts are also contemplated.
  • the forming mold may include a mold body or plate that includes the required contours, features, etc., for a particular product.
  • the vacuum channels of the mold body may have deliberate paths or layouts within the mold body, or may be formed randomly therein as part of the mold manufacturing process.
  • Some mold bodies may include thereon a screen or mesh that forms the surface upon wftich the fibers are drawn during the forming process.
  • the actuation system In use, the actuation system lowers the forming mold into the slurry tank and the associated vacuum source is activated. This draws the slurry liquid into the vacuum channels, thereby leaving fibers disposed on the surface of the forming mold or the mesh, if present. When a desired amount of fibers are drawn onto the surface or mesh, the actuation system raises the forming mold from the slurry. At this point in the process the fibers disposed on the forming mold are referred to herein as a partially -molded fiber part, in that it includes the general contours and features of a finished molded fiber part, but does not display the performance characteristics of a finished part.
  • the partially -formed molded fiber part may then be removed from the forming mold for further processing.
  • This operation may be performed by a part transfer system 104 including a part transfer feature that may be a part transfer mold that substantially corresponds to or is compatible with the forming mold.
  • the part transfer mold also performs a function of forming surfaces of the partially-molded fiber part disposed opposite the surfaces of the partially -molded fiber part that contact the forming mold.
  • the part transfer mold may also include or define a number of vacuum channels (as described above in the context of the forming mold) that are connected to a vacuum source. In use, the part transfer mold is positioned so as to contact the partially -formed molded fiber part. This contact forms the opposite surface of the partially-formed molded fiber part.
  • the part transfer system 104 includes a conveyance system that moves the part transfer mold from the forming station 102 to a downstream station, in this case, a press station 106.
  • the forming station 102 and the press station 106 may form the terminal ends of a range of motion of the part transfer system 104, which in examples may be referred to as a first position and a second position, respectively.
  • the second position may be an intermediate wait station where the part transfer feature may be positioned to wait for the press station 106 to become available.
  • the production line 100 includes a press station 106 and a trim station 108, or in examples, a combination press/trim station 110 (depicted by the dashed line in FIG. 1).
  • the press station 106 utilizes a combination of compressive pressure and elevated temperature to substantially solidify the partially-formed molded fiber part into the molded fiber part (which meets the general performance requirements to be used).
  • the trim station 108 removes excess material that is formed as part of the pressing operation.
  • the part transfer system 104 may transfer the partially-formed fiber part to the press station 106 (as depicted by arrow 112a) or may transfer the partially -formed fiber part to the combination press/trim station 110 (as depicted by arrow 112b).
  • the discrete press station 106 includes two molds, referred to generally as a core mold and a corresponding and compatible cavity mold. Regardless of terminology used, the core mold and cavity mold form the two generally opposing surfaces of a formed fiber part.
  • the transfer 112a may occur by the part transfer feature of the part transfer system 104 substantially mating with either of the core mold or the cavity mold.
  • Vacuum channels may be formed in either or both of the core mold and cavity mold and connected to a dedicated vacuum source.
  • the vacuum source for the mold in engagement with the transfer feature during transfer 112a may be activated so as to transfer the partially-molded fiber part to the appropriate mold of the press.
  • Heating elements may be disposed in either or both of the core mold and cavity mold.
  • the core mold and cavity mold are moved relative to each other by a press actuation system that in examples is a hydraulic press.
  • the increased compressive pressure helps form the part into the molded fiber part.
  • the increased compressive pressure squeezes additional liquid from the partially -formed fiber part, which may be removed from the press station by one of more vacuum sources connected to the vacuum channels present in either or both of the core mold and the cavity mold.
  • the elevated temperature generated by the heating elements helps to further form and dry the partially -formed fiber part until a part more consistent with the formed fiber part is produced therefrom.
  • a removal system 114 removes the molded fiber parts from the press station 106.
  • the removal system may include a removal feature that includes a plurality of vacuum channels. If the line 100 includes discrete press 106 and trim 108 stations, the plurality of vacuum channels in the removal feature may be utilized to remove the part from the press station 106.
  • the removal feature may be in the form of a removal mold configured to be compatible with the either of the core mold and the cavity mold. The vacuum channels, in that case are in communication with one or more ports on the surface of the removal mold such that vacuum pressure may draw the formed fiber part off of the core mold or cavity mold.
  • the removal feature may be a plurality' of vacuum cups connected to the vacuum channels.
  • Vacuum pressure applied to the channels by the vacuum source may also remove the formed fiber part from the core mold or the cavity mold.
  • the removal system 114 includes a conveyance mechanism that moves the removal feature from the position in engagement with the particular mold of the press station to a downstream station. If discrete press 106 and trim 108 stations are utilized, the removal system 114 moves the removal feature (carrying the formed fiber product) to the trim station 108, along path 120a.
  • the pressing of the partially-formed fiber part in the press station 106 may result in at least a portion of the partially-formed fiber part being expelled from a perimeter edge of core mold and/or the cavity mold. This excess material must be removed for aesthetic and/or functional purposes.
  • the trim station may be a fixed blade trim station, for example, where a perimeter blade is lowered or otherwise brought into contact with the molded fiber part to remove portions of the part typically proximate an edge thereon.
  • the trim station may include a mold or other registration feature that ensure the molded fiber part is properly positioned thereon, prior to trimming the part with the trimmer. When the removal feature of the removal system 114 is engaged with the registration feature of the trim station 108, the trimming operation may be performed.
  • the removal feature may engage with the registration feature so as to deposit the molded fiber part for subsequent trimming.
  • the trimmer may be a fixed blade (e.g., in the form of a ring-shaped projection extending from the registration feature).
  • the trimmer may be fixed relative to the location of the registration feature, e.g., and located about the perimeter of where the registration feature will locate the molded fiber part.
  • the trimmer blade and the registration feature may be unitary' part.
  • Removed portions of the molded fiber part may be referred to herein as“trim” or“waste trim.”
  • the removal system 114 may again move the molded fiber part from the tnm station to a downstream station.
  • Downstream stations in this context may be one or more of a waste station 118, a print station 122, a quality control station 124, and a stacking station 126, each of which are described below.
  • An integrated press/trim station 110 may include a core mold or cavity mold having a trimmer thereon, for example in the form of a fixed trim blade typically used at a discrete trim station.
  • the trimmer may be in the form of a ring-shaped projection that extends from the respective mold, for example, proximate a perimeter thereof.
  • the trimmer blade may be an element fixed relative to the associated mold, or may move relative thereto, for example, with a dedicated actuation system. If fixed to the mold, it may be advantageous for the trimmer to form a unitary part with the mold.
  • a trimmer blade made from a material different than that of the mold may expand and/or contract at different rates, which may cause improper performance.
  • the removal system 114 may be utilized to remove both the molded fiber part, as well as any trim from the press, to prevent trim material from potentially interfering with a subsequent pressing operation.
  • a removal feature having two systems of vacuum channels may be utilized.
  • the removal system may include one or more part vacuum channels and one or more trim vacuum channels, each of which may be served by a discrete vacuum source.
  • a transfer feature in the form of a transfer mold is utilized, appropriately positioned ports (typically within the portion of the mold corresponding to the location of the finished molded fiber part) in the surface of the mold may be communicatively coupled to the part vacuum channels and part vacuum source; ports in surface of the mold that do not correspond to the location of the finished molded fiber part may be communicatively coupled to the trim vacuum channels and trim vacuum source.
  • both the molded fiber part and trim may be removed simultaneously from the press/trim station 110 by the removal feature 114.
  • vacuum cups dedicated to the molded fiber part and to the trim may be appropriately located.
  • the removal system 114 may be the same system as the part transfer system 104. Such configurations are depicted below.
  • a waste station 118 is downstream of the removal system 114.
  • the waste station 118 may include a system for capturing trim from the removal system and reintroducing the trim into the slurry system.
  • the waste station may be a bin, chute, or other structure into which the trim may be released from the removal system 114.
  • the trim vacuum source may be turned off or terminated, so that the trim may disengage from or otherwise fall from the removal feature.
  • Appropriate positioning may correspond to physical engagement between the removal feature and the waste station, or the position of the removal feature may be detected relative to the waste station, via proximity, optical, or other sensors.
  • Part vacuum pressure is maintained at the waste station 118, such that the molded fiber parts are not released into the waste station 118. In certain configurations, however, part vacuum pressure may be released to discard damaged or otherwise undesirable parts to the waste station 118.
  • the molded fiber part is considered generally sufficiently formed for use.
  • other downstream stations may be utilized to add graphics, logos, or other visual information to each molded fiber part, check the quality of the finished parts, or stack or otherwise pack the molded fiber parts for delivery.
  • a downstream print station 122, a quality control station 124, and a stacking station 126 are depicted. These optional stations are described in further detail below.
  • the entire production line 100 may be automated and controlled by a control system 128 as shown.
  • the control system 128 may be connected to, and control the operation of, each station and even subcomponents of each station, as well as the transfer and removal systems (in the form of conveyors, robots and other devices, as described elsewhere herein).
  • the control system 128 may monitor the operation and conditions on the production line 100 continuously and adjust operation to ensure proper functioning and quality of the final parts.
  • Control of all operational parameters is anticipated to improve the quality of the formed fiber parts and increase yield of the production line 100.
  • a sensor network throughout the production line 100 is contemplated.
  • various sensors are provided at each station and on each conveyance system to monitor any pertinent parameter of the operation of the production line 100.
  • the temperature control of the heated molds of the press station is one example of such monitoring.
  • the press station 106 may be dynamically controlled based on sensors in the station 106. That is, the press station 106 may be operated until a desired state in the formed fiber part is obtained.
  • one of the molds in the press station 106 may be provided with one or more sensors that monitor, directly or indirectly, a state of the formed fiber part.
  • a temperature sensor on the surface of the mold could be provided to monitor a temperature of the formed part at a location where it contacts the mold.
  • a pressure sensor, a humidity sensor, a light emitter/sensor pair, a conductance sensor, an electrode or electrodes monitoring the flow of current through the formed part, or any other such monitoring device or devices could be provided at one or more locations on the mold. Based on the output of the sensors, the time allotted to press the formed part could be dynamically controlled by the control system 128. For example, upon reaching a desired temperature (e.g., a predetermined temperature threshold) as determined by a temperature sensor, the pressing operation may be terminated.
  • a desired temperature e.g., a predetermined temperature threshold
  • Such monitoring sensors are not limited to being located in or on the press station 106 and could be located at any place in the production line 100.
  • white water flow associated with the forming station 102 could be monitored via one or more flow sensors. This allows the flowrate and quantity of white water removed from the partially -formed fiber part to be monitored over time throughout the various stations of the entire production line 100. This allows, e g., the press station, to be controlled based on the quantity and flow rate of water observed during the operation.
  • the pressing operation may be terminated regardless of how long the operation has taken.
  • a predetermined threshold e.g., the flow rate has dropped by 90% since the start of the operation, or after collecting 10 ml of water from the part during a pressing operation
  • Such monitoring data could also be used to do more than simply control how long the press station 106 or any other component operates.
  • the press station 106 could increase or decrease pressure dynamically based on the data collected.
  • any controlled operational parameter e.g., press operation time, press pressure, mold temperature, slurry temperature, vacuum pressure, slurry flow rate, slurry quality, mix tank temperature, conveyor speed or temperature, dryer temperature, ink flow rate, or any other operational setting related to time, temperature, pressure, or movement of a component of the production line
  • any controlled operational parameter e.g., press operation time, press pressure, mold temperature, slurry temperature, vacuum pressure, slurry flow rate, slurry quality, mix tank temperature, conveyor speed or temperature, dryer temperature, ink flow rate, or any other operational setting related to time, temperature, pressure, or movement of a component of the production line
  • the production line 100 in FIG. 1 may be operated in a continuous mode.
  • the various stations and part transfer systems may be continuously moving and parts on the production line 100 are pressed, trimmed, printed, and dried while in motion.
  • the quality control station may be a simple pass through station through which a conveyor passes while the parts are tested, as described herein.
  • the printing station may be one or more movable or fixed print heads that print onto the part as the part passes under the print heads.
  • a semi-continuous configuration could be provided in which one or more of the stations removes the part from the production line 100 for some period of time and then replaces it when a subsequent station’s operation is complete.
  • the part transfer system 104 may operate in a stop-start mode in which, on a prescribed schedule, the part transfer system 104 moves a predetermined distance and stops. In this way, each part is moved between stations over time.
  • one or more of the part transfer system 104 and removal system 114 may have part transfer features in the form of molds, such as core molds as described herein, incorporated into the appropriate system 102, 114. The molds may provide positive retention of the parts during movement thereof. The press stations could then have the outside mold which receives the part when it reaches the station.
  • the production line 100 in FIG. 1 has several advantages. It has inherent expandability in that multiple parallel press stations 106, trim stations 108, waste stations 118 may be operated simultaneously, with a part transfer system 104 and a removal system 114 serving the various stations. In such parallel configurations, each of the parallel portions may be referred to as“sub-lines.” In another example, each of the parallel sub-lines may be dedicated to a different customer having different printing requirements, finished part requirements (thus different pressing and/or drying requirements). Further, as another example, multiple stacking stations 126 would allow for the different customer parts to be stacked separately in an easily automated fashion.
  • the parallel configuration of multiple sub-lines adds resilience to the production line 100 in that any one station in the sub-lines could fail without bringing the entire production line 100 to a stop. Further resilience could be provided by including a second forming station 102. At any given time, different sub-lines may be taken out of operation without affecting the operation of the other sub-lines. Thus, a sub-line dedicated to a specific product may be inoperative until that product is needed, meaning that retooling time can be eliminated.
  • FIG. 2 depicts a partial perspective view of an example of a production line 200, in a linear layout configuration.
  • the production line 200 includes a forming station 202.
  • the forming station 202 includes a forming mold 202a, and an actuation system 202b that lowers the forming mold 202a into a slurry tank 202c.
  • a part transfer system 204 in the form of a shuttle 204a is mounted on a linear gantry or frame 204b located above the forming station 202.
  • the shuttle gantry 204b may extend along a considerable distance or may be modularized so as to be expandable to support larger production lines.
  • the shuttle frame 204b extends linearly from either side of the forming station 202, allowing the forming station 202 to be centrally located within the production line 200.
  • the shuttle 204a also includes a part transfer feature in the form of a part transfer mold 204c that may engage with the forming mold 202a to enable forming the partially -formed fiber parts, and transferring those parts to the press station 206.
  • the part transfer system 204 also includes a press shuttle 204d that removes the parts from the shuttle 204a and deposits them at the press station 206. Multiple press stations 206 may be disposed along the shuttle gantry 204b, but only a single press station 206 is depicted in FIG. 2 for clarity.
  • the shuttle 204a moves along the shuttle gantry 204b from a location above and proximate the forming station 202 and receives from the forming station 202 a partially-formed fiber part (again, typically, multiple partially- formed fiber parts). The shuttle 204a then moves until it is adjacent the pressing station 206, where the partially-formed fiber parts are transferred to the press shuttle 204d, which then delivers the partially-formed fiber parts to the press 206.
  • Additional shuttles may be utilized as required or desired for a particular production line to transfer the partially -formed fiber parts.
  • the central shuttle 204a simply moves back and forth on the central shuttle gantry 204b between the forming station 202 and the pressing station 206. When aligned with the pressing station 206, the central shuttle 204a releases its payload of molded products to a transfer shuttle 204e.
  • the transfer shuttle 204e moves the partially -molded fiber parts to the press shuttle 204d, which carries the partially-molded fiber parts to the press station 206.
  • These multiple shuttles 204a, 204d, and 204e maintain orientation of the partially-molded fiber parts.
  • the press station 206 is depicted schematically for clarity. After a pressing operation performed at the press station 206, the formed fiber parts are left in place on the press station 206.
  • a combination press/trim station may also be utilized.
  • the removal system 214 removes the formed fiber parts and the trim, then deposits the trim at a waste station 218. In this configuration, the removal shuttle 214a may move beyond the waste station 218 to other downstream stations, not depicted.
  • the press shuttle 204d and the removal shuttle 214a are movable along the same gantry 215, though this is not required.
  • the various gantries 204b, 215 depicted may include both upper and lower frame rails to surround casters or wheels upon which the shuttles 204a, 204d, 214a roll during movement. Other frame configurations are also contemplated. Further, unlike the systems that utilize rotating robotic arms as described herein, the linear movements of the various shuttles are easier to program, trouble shoot, and maintain, and likely involve lower initial capital investment.
  • FIG. 2A depicts a partial perspective view of the production line 200 of FIG. 2, with multiple parallel press and trim sublines 207a-d.
  • a single former 202 serves the four sub-lines 207a-d, each of which are also served by a single central shuttle 204a that travels along a single gantry 204b.
  • Each of the four two-stage pressing station may be configured as depicted in FIG. 2, above. In other examples, the length of the frame 204b may be extended so as to accommodate more than the four sub-lines 207a-d. Further, one or more sub-lines 207a-d may be disposed on an opposite side of the gantry 204b from where the four sublines 207a-d are depicted.
  • Other systems and components of the production line 200 are depicted above in FIG. 2, or with regard to FIG. 1.
  • FIG. 3 depicts an example of a forming station 300.
  • the forming station 300 includes a frame 311 on which a lower portion 312 and an upper portion 313 are provided.
  • the upper portion 313 includes a shuttle 331
  • a cylindrical rotating shaft 323 is rotatably connected to the middle of the frame 311 between the lower portion 312 and the upper portion 313 via a rack mount 328.
  • the shaft 323 has a rotation angle of less than 360° and the cylindrical rotating shaft 323 rotates back and forth.
  • At both ends of the cylindrical rotating shaft 323 is an elbow 326.
  • the two ends of the rotating shaft 323 are fixed on the frame by the rotating shaft seat, and the gears 327 are respectively sleeved on both ends of the cylindrical rotating shaft 323, and the two sides of the middle portion of the frame 311 are provided with a translational connection with the gears 327.
  • Attached to the cylindrical rotating shaft 323 are two opposing, symmetrical forming molds 324a, 324b.
  • the two molds 324a, 324b include mold plates 330 (only visible on the upper portion 313) having core molds formed thereon and provided with screens onto which the fiber is drawn when the molds are in the lower forming chamber 321, or slurry tank.
  • the lower mold 324b is in the slurry tank 321, referred to as the forming position, and the oppositely located upper mold 324a is facing upwards towards the shuttle 331 and the transfer mold (a cavity mold) 332 carried thereon.
  • the two core molds 324a, 324b are rigidly connected to the rotating shaft 323 by several tubes 325. These tubes 325 and hollow shaft 323 are connected to a vacuum pump system. The tubes are further connected to the penetrations in the molds 324a, 324b.
  • the vacuum pump system creates the pressure differential that pulls the slurry towards the mold 324, thus causing the fiber to build up on the screened surface of the mold.
  • the two core molds 324a, 324b are symmetrical. This allows them to be rotated about the axis of rotating shaft 323 by rotating the shaft 323, thus quickly moving the molds between the lower portion 312 and an upper portion 313.
  • the fiber slurry bath is contained in the slurry tank 321.
  • the fiber is deposited on the mold 324 as the slurry is draw n through the mold 324 by the vacuum pump system, thus creating the partially -formed fiber part (not shown) on the mold 324.
  • the slurr tank 321 is lowered from the mold 324 by an actuation system in the form of a vertical lift 322, freeing the mold 324 to be moved to the upper portion 313 position.
  • the mold 324 and partially- formed fiber part can then be rotated to the upper portion 313 position.
  • the upper portion 313 includes transfer mold 332 attached to the actuation mechanism 333.
  • the mechanism 333 causes the transfer mold 332 to press against the upward-facing lower mold 324a.
  • the mechanism 333 may include one or more of a hydraulic cylinder, a servomotor, a gas cylinder or any other known lifting device.
  • water may be driven out of the partially-formed fiber part and collected through the inner mold 324 via the shaft 323.
  • a suction is applied to the partially -formed fiber part through penetrations in the mold 332, and the mold 332 is retracted by the mechanism 333 onto the shuttle 331 for movement to a downstream station. This frees the mold 324 to be rotated to the lower portion 312 for the entire forming process to be repeated.
  • the press operation performed by the transfer mold 332 is operated at a selected pressure for a fixed period of time that is equal to the time that is taken for the formed part to be drawn onto the mold at the lower portion 312.
  • the pressing time is dynamically controlled based on monitoring data from sensors at one or more locations on the upper portion 313.
  • the slurry tank 321 may also include a movable outer mold (not shown) in the tank 321. In this embodiment, after the fibers from the slurry are drawn onto the mold 324, this outer mold may be pressed against the mold 324 while in the slurry tank 321.
  • the shuttle 331 transfers it to another station in production line.
  • the transfer mold 332 may be located at the end of a robotic arm that extends into the upper portion 313 and receives the part when the transfer mold’s 332 suction on the partially -formed fiber part is activated. This is but one example of how the transfer of parts via the robotic arm may be effected. Many such methods and systems are known in the art and any suitable method and mechanism may be used in the forming station 300, the robotic arm or any other component of the production lines described herein.
  • FIG. 4 depicts a partial schematic view of a forming station and part transfer system in mating engagement 400.
  • the forming station 402 includes a forming mold 404, in this case in a core mold configuration.
  • the term“core mold” means a mold having features that substantially project away from the mold plate so as to form a “core” about which the fiber part 406 is at least partially surrounded.
  • the part transfer system 408 includes a part transfer feature, in this case, in the form of a part transfer mold having a cavity mold configuration.
  • the term“cavity mold” means a mold having features that substantially project inward into the mold plate so as to form a “cavity” into which the fiber part 406 and core mold extend.
  • Each of the forming mold 404 and the part transfer mold 410 define at least one (but usually a plurality) of vacuum channels 412.
  • the vacuum channels 412 are each connected to a dedicated vacuum source 414, the function of which is described above. It should be noted that a similar mating engagement is utilized when a removal system (described above) engages with a mold of a press station.
  • FIG. 5 depicts a perspective view of a press station 500.
  • the station 500 includes a press mechanism 502 that includes an upper mold 506 and a mating lower mold 508.
  • the lower mold 508 in this case is referred to as a core mold because of the presence of projecting features 516 that form the forming core of the molded fiber part.
  • the upper mold 506, in contrast, is referred to as a cavity mold because of a cavity formed therein to receive the projecting features 516 and the molded fiber part during press operations. In other examples, the location of the core and cavity molds may be reversed.
  • the upper mold 506 and lower mold 508 may include one or more individual plates that are used to form the particular formed packaging product.
  • a press station 500 has six plates, although one, two, four, eight, ten, or more plates may be used. While odd numbers of plates may be used, even numbers of plates are more typical. This increases the throughput for a press station 500 (as well as other stations within the production line) within only an incremental increase in the cost of the equipment.
  • the press mechanism 502 is supported on a fixed base 510.
  • the press mechanism 502 includes a movable plate 512. to which is secured to the upper mold 506.
  • This movable plate 512 is configured to slide along a plurality of rails 515, when actuated by a piston 516. Actuation of the piston 516 drives the movable plate 512 (with the upper mold 506 located thereon) towards the base 510.
  • a single pressurized fluid chamber 518 may be connected by pipes 520, valves, and other known elements to the piston 516.
  • a controller 522 may be programmable and communicatively coupled to a controller for the robot (not shown) or shuttles that form a part of the production line (not shown) so as to control the station 500 as required or desired for a particular application.
  • a controller for the robot not shown
  • shuttles that form a part of the production line (not shown) so as to control the station 500 as required or desired for a particular application.
  • either or both of the upper mold 506 and lower mold 508 may be heated so as to properly form the molded fiber products. Such heating elements are described elsewhere within the present application.
  • FIG. 6 depicts a partial schematic view of a two molds of a press station 600 in mating engagement.
  • the press station 600 includes a low er mold 602, in this case in a core mold configuration.
  • An upper mold 604 is in the form of a part transfer mold having a cavity configuration.
  • the terms“core mold” and“cavity mold” are described above.
  • a fiber part 606 is disposed between the lower mold 602 and the upper mold 604.
  • Each of the lower mold 602 and the upper mold 604 define at least one (but usually a plurality of) vacuum channels 608.
  • the vacuum channels 608 are each connected to a dedicated vacuum source 610, the function of which is described above.
  • Each of the lower mold 602 and the upper mold 604 each include a heating element 612.
  • a combination press/trim station 600a may be utilized in certain examples of a production line.
  • elements 602-1012 are still utilized, but a trimmer 614 may also be used in conjunction with either or both of the lower mold 602 and the upper mold 604.
  • the trimmer 614 may be a discrete element, as in the depicted example. As the low3 ⁇ 4r mold 602 and the lower mold 604 are brought into compressive contact, the trimmer 614 may cut or press through any material disposed outside of a predetermined portion of the molds 602, 604. This separates waste trim from the molded fiber part 606.
  • each mold 602, 604 is provided with an internal heating element 612.
  • the element 612 may be a simple internal passage through which a heated fluid may flow.
  • a resistive heater may be built into each mold 602, 604. Heating elements 612 are known in the art and any suitable heating technology, now known or later developed, may be used. Examples of a heated mold 602, 604 may be further provided with one or more temperature sensors T. The temperature sensors T may monitor the temperature in the mold 602, 604, of the surface of the mold 602, 604, of the fiber part 606, or at any other location in, on, or near the mold 602, 604.
  • a mold 602, 604 may be divided into multiple segments, or sectors, and the temperature of each segment may be independently monitored and controlled.
  • a circular mold such as depicted in FIGS. 7A-7B, for a making a molded fiber part may be divided into two, four, or more, segments.
  • Each segment may be provided with one or more temperature sensors and one or more internal heating elements. By monitoring and controlling each sector’s temperature, it is believed the performance of the mold may be further improved.
  • FIGS. 7A and 7B depict a perspective view and a partial enlarged perspective view, respectively, of an upper mold 700 for a press station.
  • FIGS. 7A and 7B are described concurrently and the mesh covering is not depicted for clarity.
  • the upper forming mold 700 (depicted inverted in FIGS. 7 A and 7B) is formed from a machined unitary part 702.
  • the unitary part 702 has formed therein a cavity mold 704 that, in the depicted example, includes an integral trimmer 706 that defines an outermost extent of a molded fiber product (not shown) formed with the mold 700.
  • the integral trimmer may be formed as part of a lower mold, described above.
  • one or more vacuum channels formed in the part 702 may be communicatively coupled to ports 710 on the surface of the cavity 704 to draw liquid, under vacuum, from the partially-formed fiber part during pressing operations.
  • FIG. 8 depicts a partial schematic view of a press/trim station 802 and a removal system 808 in mating engagement 800.
  • the press/trim station 802 includes a lower mold 804, in this case in a core mold configuration.
  • the removal system 808 includes a removal feature, in this case, in the form of a removal mold 810 having a cavity mold configuration into which a fiber part 806 and core mold extend.
  • Each of the lower mold 804 and the part transfer mold 810 define at least one (but usually a plurality) of vacuum channels 812.
  • the vacuum channels 812 are each connected to a dedicated vacuum source 814, the function of which is described herein. Vacuum channel 812a is described above in the context of FIGS. 6-7B.
  • Vacuum channel 812b operates to remove the formed fiber part 806 from the press station 802.
  • vacuum channel 812c operates to remove trim cut during the press/trim operation.
  • the ports connected to vacuum channel 812c are disposed outside of the position 816 where the trimmer would be located.
  • the production lines depicted generally in FIGS. 1-2 A display significant improvements over production lines that utilize a centrally-located robotic arm, e.g., as described in the‘438 application, referenced above.
  • the production lines having shuttle travelling on linear gantries may occupy greater floor space than production lines that utilize a centrally-located robotic arm
  • shuttle-based systems are typically easier to program, less costly to maintain, and can display limited downtimes.
  • shuttle-based production lines are also scalable, allowing the production lines to be expanded as needed to accommodate increased production needs.
  • portions of such production lines may be taken off-line as required or desired for maintenance or other purposes.
  • Linear systems may also benefit from parallel sub-lines and systems, which can greatly increase throughput and cycle time.
  • Production lines that are based upon those shuttle-based production lines depicted in FIGS. 1-2A, as well as the components and systems depicted in more detail in FIGS. 3-6, are described further below.
  • FIG. 9 illustrates an alternative example of a production line 900 in which the molded fiber parts are moved between various stations via multiple shuttle systems.
  • the production line 900 includes a former 902, such as the former depicted herein or a former of another configuration.
  • the former 902 may also include a single press, having one, two, four, six, eight, or more molds for forming products from a fiber slurry such as described herein. Typically, even numbers of molds are utilized.
  • a former transfer Tx gantry 904 includes one or more alignment features that maintain a position of the products removed from the mold of the former 902.
  • the various shuttles described herein may all utilize alignment features that allow the products moved thereby to maintain the required position for subsequent delivery to a downstream system component.
  • the transfer Tx gantry 904 includes a single shuttle that travels along a rail or other structure to transfer the parts to a shuttle of the mainline (or distribution) gantry 7 906.
  • the transfer Tx gantr 904 may also include mechanical or hydraulic lifts or elevators that can raise and lower all or a portion of the shuttle that travels linearly thereon. This would allow the transfer Tx gantry 904 to transfer the formed products from the former 902 to a mainline gantry 906.
  • the shuttle of the transfer Tx gantry 904 may include the lift or elevator components to bring all or a portion of the transfer Tx gantry 904 proximate the distribution gantry 906 for product transfer.
  • the distribution gantry 906 is configured to include two shuttles thereon.
  • One shuttle may be configured for movement along an upper rail system, and a second shuttle may be configured for movement along a lower rail system.
  • the two shuttles have sufficient clearance therebetween to prevent inadvertent contact between the shuttles themselves, or the molded products or parts being transported thereon.
  • the two shuttles of the distribution gantry 906 may be disposed parallel to each other, and at a similar or same elevation (e.g., not disposed one above the other).
  • This configuration may necessitate a simplified control system, since the shuttle of the distribution gantry 906 may move along their entire linear range of motion without potential interference from the shuttle of the former transfer Tx gantry 904 or a shuttle of a hot press transfer Tx load gantry 908a, b, c, which may be removing formed products from the other of the two shuttles of the distribution gantry 906, or otherwise moving along a path that might interfere with the shuttles of the distribution gantry 906.
  • Each hot press 910a, b, c is served by a dedicated hot press transfer Tx load gantry 908a, b, c (respectively) and a dedicated hot press transfer Tx unload gantry 912a, b, c (respectively).
  • each hot press 810, hot press transfer Tx load gantry 908, and hot press Tx unload gantry 912 may be referred to as being part of the same press station sub-line. Multiple parallel sub-lines are depicted.
  • each hot press transfer Tx load gantry 908a, b, c includes a single shuttle that is configured to remove products from the mainline gantry 906 and deliver those products to the respective hot press 910a, b, c.
  • Each hot press 910a, b, c may be a single- or multi-platen hot press, described elsewhere herein, that utilizes pressure and elevated temperature to form the products into a finished state (e.g., before trimming, painting, label application, etc ).
  • the formed products may be removed from the hot press 910a, b, c by a shuttle on a dedicated hot press transfer Tx unload gantry 912a, b, c.
  • the hot press transfer Tx unload gantry 912a, b, c (and the shuttle thereon) may be configured similarly to the hot press transfer Tx load gantry 908a, b, c (and shuttle).
  • each hot press transfer Tx unload gantry 912a, b, c may include larger or more robust frames that enable the shuttle associated with the hot press transfer Tx unload gantry 912a, b, c to remove the molds from the a particular hot press 910a, b, c.
  • the frame of the hot press transfer Tx unload gantry 912a, b, c may have greater load-bearing capabilities, due to increased frame gauge or size. To accommodate the shuttles lifting and moving the heavy molds, more robust bracing of the frame may also be utilized. Additionally, the shuttles themselves may include larger wheels, rollers, or casters, as well as motors that may drive the shuttle alone the frame. Grippers, latches, hooks, or other features that enable the shuttle to separate and lift the molds from the platens of the hot press 910a, b, c may also be utilized.
  • the hot press transfer Tx unload gantry 912a, b, c transfers molded fiber parts or products from the hot press to the trimmer gantry 914.
  • the trimmer gantry 914 may be configured similarly to the distribution gantry 906, in that it may dual shuttles and is configured to move product to a further downstream process, in this case, delivering those products to a trim station or trimmer 918.
  • the products are transferred from the trimmer gantry 914 to the trimmer 918 via a trimmer transfer Tx load gantry 916, which may include a single shuttle.
  • the single shuttle removes part or products from the trimmer gantry 914 and includes registration features similar to those on other shuttles that align the molded products for delivery to the trimmer 918.
  • the trimmer 918 may include or more movable knives, blades, or other mechanical cutting implements to trim excess product from the molded material. In other examples, the trimmer 918 may include a static blade. After trimming, the products are removed from the trimmer 918 by the trimmer transfer Tx unload gantry 920, which includes a single shuttle.
  • the products may then be delivered to an exit gantry 922, which may include a single or dual shuttle, which may remove the finished product from the manufacturing system 900 and deliver them to further stations for further processing (e.g., printing, stacking, boxing/packaging, etc.).
  • an exit gantry 922 which may include a single or dual shuttle, which may remove the finished product from the manufacturing system 900 and deliver them to further stations for further processing (e.g., printing, stacking, boxing/packaging, etc.).
  • the system 900 provides parallel shuttles on longer gantries (e.g., distribution gantry 906 and the trimmer gantry 914). This allows the system 900 to maintain high operational throughputs, since the shuttles of those gantries may operate simultaneously, reducing idle time of the gantries as the shuttles move between the former transfer Tx gantry 904 and the three hot press transfer Tx load gantries 908a, b, c (as well as the hot press transfer Tx unload gantries 912a, b, c and the trimmer transfer Tx load gantry 916).
  • gantries e.g., distribution gantry 906 and the trimmer gantry 914. This allows the system 900 to maintain high operational throughputs, since the shuttles of those gantries may operate simultaneously, reducing idle time of the gantries as the shuttles move between the former transfer Tx gantry 904 and the three hot press transfer Tx load gantries 908a, b, c (as well as the hot
  • the parallel dual shuttles on these gantries 906, 914 allow one shuttle to be down for maintenance, service, or due to failure, while the system 900 operates at a reduced throughout.
  • Linear movement of all the gantries reduces or eliminates the complexities associated with robotic arms that may move products from one component to another. For example, redundancies of robotics arms are difficult, if not impossible, to implement, given the complex movement geometries of such arms.
  • systems that utilize robotic arms may have smaller, more condensed footprints than the system gantry systems depicted in FIG. 9, the movements of the shuttles on the various gantries are move predictable and contained, thus allowing system operators access near and to the various components thereof during operation.
  • the system 900 depicted in FIG. 9 is also scalable.
  • four or more hot presses 910 may be utilized, though a significant increase may make desirable an increase in the number of shuttles on either or both of the mainline gantry 906 and/or the trimmer gantry 914.
  • two parallel mainline gantries 906 and/or trimmer gantries 914 having any number of shuttles may also be utilized.
  • a person of skill in the art would recognize that certain variations to or replications of certain gantries 906, 914 may necessitate modifications to the various transfer Tx gantries 904, 908, 912, 916 in a system.
  • Such modification may include lengthening of the linear range of motion of the transfer Tx gantries 904, 908, 912, 916, increasing the lifiting/lowering range of motion of the shuttles disposed thereon, etc. Changes in controls would be desirable as well.
  • FIG. 10 illustrates an alternative example of a production line 1000 including two parallel line 1002, 1004 configurations of the production line depicted in FIG. 9.
  • the various gantries, presses, and other components are described above and would be apparent to a person of skill in the art.
  • Each of the mainline (distribution) gantries and trimmer gantries utilize dual shuttle configurations.
  • the various transfer Tx gantries utilize single shuttles.
  • a single former is used for each of the parallel production lines 1002, 1004. In other examples, however, a single former may be utilized for both production lines 1002, 1004. Such formers may enable forming multiple sets of formed products simultaneously while balancing loads associated therewith.
  • the two parallel distribution gantries may be combined into a single gantry, having multiple parallel shuttles operating thereon.
  • four shuttles each with a linear range of movement along the entire mainline gantry, may be utilized, although two parallel gantries (as depicted) may be more desirable for redundancy and maintenance.
  • the two parallel exit gantries may be combined into a single gantry with multiple shuttles.
  • Other configurations of components in the production lines are also contemplated. For example, four, five, or more hot presses may be utilized in either of the parallel production lines 1002, 1004, although this may necessitate modifications to either or both of the mainline gantry and the trimmer gantry.
  • FIG. 11 illustrates a process flow diagram 1100 and example cycle times for the production line of FIG. 9.
  • the process 1100 begins with activating a load transfer tool, operation 1102, which is utilized subsequent to operation 1104 (described below) to remove partially-formed fiber parts from the former.
  • the former preforms the product, which contemplates the initial forming of the product to draw fiber onto a forming mold, to remove excess water, compress the fibers, and generally set the product into an initial configuration that may be moved to the subsequent steps in the process 1100.
  • the product is transferred via the transfer tool (e.g., former transfer Tx gantry 904 and shuttle thereon) to a shuttle of the mainline gantry 906 (referred to in FIG.
  • the transfer tool e.g., former transfer Tx gantry 904 and shuttle thereon
  • operation 1108 the product is moved along the mainline gantry 906 to one of the hot presses.
  • operation 1110a, b, c one of the three hot press transfer Tx load gantries 908a, b, c moves the product from the mainline gantry 906 to an associated hot press 910a, b, c, where part forming occurs in operations 1112a, b, c.
  • operations 1102-1108 would be performed serially, followed by operations 1110a, 1112b.
  • operations 1102-1108 again would be performed serially, followed by operations 1110b, 1112b.
  • operations 1102-1108 again would be performed serially, followed by operations 1110c, 1112c.
  • operations 1110c, 1112c As such, as there are now three sets of parts or products being moved through the subsequent stages of the production line 900, three serial sets of the subsequent operations are depicted.
  • parts After the pressing operations 1112a, b, c, parts are moved from a hot press via an associated hot press unload transfer Tx gantry 912a, b, c to the trimmer gantry 914 (described in FIG. 11 as“Gantry 2”), operations 1114a, b, c.
  • the parts or products Once the parts or products are delivered to the trimmer gantry 914, they are moved, in operation 1116, toward the trimmer 918.
  • the parts or products are transferred to the trimmer 904 (referred to as“Tl” in FIG. 11) by the trimmer transfer Tx load gantry 916.
  • the parts are trimmed.
  • the finished parts or products are transferred via the trimmer transfer Tx unload gantry 920 to the exit gantry 922 (referred to in FIG. 11 as“Gantry 3”). Subsequent printing, packing, stacking, etc. may be performed downstream thereof.
  • the amounts of time the products or parts are disposed or processed at the various stations may vary as required or desired for a particular application. In an example, of stage times in the system depicted in FIG.
  • operation 1104 may be performed in about 5 sec. Transfer from the former to Gantry 1, operation 1106) may be performed in about 5 sec. In the depicted example, Gantry 1 may move at about 52 in/sec. In other examples, Gantry 1 may move at about 55 in/sec. or 57 in/sec. As such, depending on the length of Gantry 1, transfer time to the first press station sub-line (indicated by operation 1110a) may be about 3 sec.; transfer time to the second (farther) press station sub-line (indicated by operation 1110b) may be about 5 sec.; transfer time to the third (farther) press station sub-line (indicated by operation 1110c) may be about 7 sec.
  • Transfer to the hot press may take about 5 sec., while part forming in the hot press (operations 1112a, b, c) may take about 30 sec.
  • Transfer of the formed fiber parts from the hot press to Gantry 2 may take about 5 sec.
  • the speed of the Gantry 2 may be dependent on the length over which it must travel. As such, speeds such as 41 in/sec., 49 in/sec., or 52 in/sec. are contemplated.
  • Molded fiber parts may be transferred to the trimmer (operation 1118) in about 5 sec., and the trimming operation itself (operation 1120) may take about 5 sec. Finally, parts are removed from the trimmer and transferred to the Gantry 3 (operation 1122) in about 5 sec. Other times are contemplated.
  • FIG. 12 illustrates an alternative example of a molded fiber part production system or line 1200 including two parallel lines 1202, 1204.
  • Each line 1202, 1204 is configured as a mirror image of the other, with generally identical components arranged similarly.
  • a single forming station 1206 serves the production system 1200.
  • the single forming station 1206 is shared between the two parallel lines 1202, 1204 of the production line 1200 of FIG. 12; in other examples, a dedicated forming station 1206 may be used for each of the two parallel lines 1202, 1204.
  • a transfer shuttle 1208 is configured to remove a partially-formed fiber part from the forming mold of the forming station 1206, as described elsewhere herein. In other examples, a single transfer shuttle 1208 may serve both of the parallel lines 1202, 1204.
  • the transfer shuttle 1208 moves linearly along a transfer shuttle gantry 1210, which is generally arranged in a north-south orientation.
  • the transfer shuttle gantry 1210 extends between a tool loading zone 1212 and a pick-up location 1214.
  • the tool loading zone 1212 is an area proximate a first side of the forming station 1206 where forming molds may be loaded onto the forming station, and where part transfer features may be loaded onto the transfer shuttle 1208.
  • Either or both of the forming mold and the part transfer mold located on the transfer shuttle may be particularly massive, due to the metal and other robust materials from which those components are manufactured (either by tooling or forming). As such, clear access to the forming station 1206 and the transfer shuttle 1208 is advantageous so the molds disposed thereon may be accessed, loaded, and unloaded easily.
  • Partially-formed fiber parts are removed from the forming station 1206 by the transfer shuttle 1208.
  • the transfer shuttle 1208 then positions itself on the transfer shuttle gantry 1210, in a location where it may engage with a distribution shuttle 1216, e.g., at the pick-up location 1214.
  • the distribution shuttle 1216 is configured to move in an east-west orientation along a distribution shuttle gantry 1218.
  • the distribution shuttle gantr 1218 is, in the depicted example, a two-tiered distribution shuttle gantry 1218, with a first distribution shuttle 1216 on an upper tier of the distribution shuttle gantry 1218, and a lower distribution shuttle (not depicted for clarity) on a lower tier.
  • the two distribution shuttles may move in opposite directions as the production line 1200 is in operation.
  • the first distribution shuttle 1216 may be removing partially- formed fiber parts from the forming station 1206, while the second distribution shuttle may be moving towards the pick-up location, having recently distributed its own load of partially-formed fiber parts to one of three press station sub-lines 1220.
  • Each press station sub-line 1220a includes a press station 1222, which is served by a single press station shuttle 1224, only one of which is depicted in FIG. 12 for clarity.
  • the press station shuttle 1224 is configured to move in a north-south direction on a press station shuttle gantry 1226 to receive partially -formed molded fiber parts from the distribution shuttle 1216 and deliver those parts to the press station 1222.
  • the press station shuttle gantry 1226 is configured so as to pass through the volume of the press station 1222 so as to deliver or move parts therefrom.
  • the rails of the gantry 1226 are arranged so as to not interfere with the pressing action of the press station 1226, which allows for increased speed and throughput of the production line 1200.
  • the press station shuttle 1224 enters the volume of the press station 1222 via an entrance side disposed proximate the distribution shuttle gantry 1218.
  • the partially -formed molded fiber parts are then transferred to the press station mold consistent with processes described herein.
  • the press station shuttle 1224 may leave the volume of the press station 1222 (either via the exit side, near a trim-waste station 1228, or via the entrance side).
  • the pressing operation is then performed and the press station shuttle 1224 returns to the volume of the press station 1222 to retrieve the molded fiber parts.
  • the press station shuttle 1224 is configured to remove both molded fiber parts and waste trim from the press station 1222, e.g., as described in the context of FIG. 8.
  • the press station shuttle gantry 1226 extends beyond the exit area of the press station 1222 such that the press station shuttle 1224 passes over the trim- waste stab on 1228.
  • the trim- waste station 1228 may be in the form of a dry chute, a wet chute (e.g., with water or other liquid to be incorporated into the fiber slurry used for part manufacture), a wet tank, etc. Regardless, the trim-waste station 1228 collects the pieces of trim waste removed from the molded fiber part during the pressing process at the press station 1222 that includes the trimmer. To do so, trim vacuum pressure may be terminated at the trim-waste station, allowing the pieces to fall therefrom.
  • the press station shuttle gantry 122 extends to a location above an exit conveyor 1230, to deposit the molded fiber parts thereon. The molded fiber parts may be moved on to downstream printing, quality control, stacking, and/or shipping stations.
  • FIG. 13 depicts a method 1300 of forming a molded fiber part.
  • the method 1300 begins with drawing a fiber slurry onto a forming mold to form a partially -formed molded fiber part, operation 1302. Once a sufficient amount of fiber has been drawn onto the mold, operation 1304, removing the partially -formed molded fiber part from the forming mold, may be performed. In an example, this removal may be performed by a transfer shuttle, as described above. Operation 1306, transferring the partially-formed molded fiber part to a first distribution shuttle, may next be performed. Once on the distribution shuttle, the partially -formed molded fiber parts may be distributed to at least one of a plurality of press station shuttles, operation 1308.
  • the press station shuttle will insert the partially-formed molded fiber part into the press station, which occurs at operation 1310.
  • the press station includes a heating element.
  • Operation 1312 contemplates applying a compressive pressure to the partially- formed molded fiber part with the press, while operation 1314 includes applying an elevated temperature to the partially -formed molded fiber part with the heating element.
  • Operations 1312 and 1314 which may be performed substantially simultaneously, substantially solidifies the partially -formed molded fiber part into the molded fiber part.
  • operation 1316 removing the molded fiber part from an exit side of the press, wherein the exit side is discrete from the entrance side, is performed. Operation 1316 may be performed by the press station transfer shuttle that performed operation 1310.
  • This press station shuttle may include a part transfer feature capable of transferring the partially-formed fiber part, as well as the molded fiber part.
  • the method 1300 contemplates operations 1306 and 1308 being performed by a single distribution shuttle.
  • One described advantage of the present method 1300, however, as explained in the context of FIG. 12, is that multiple distribution shuttles may operate in a single production line.
  • operation 1318 returning an empty second distribution shuttle from a distribution location towards a transfer location, may also be performed to increase throughput.
  • This operation 1318 may be performed substantially simultaneously with transferring the partially-formed molded fiber part to the first distribution shuttle, operation 1308.
  • Operations 1310-1316 are typically performed at each press station sub-line. As such, further operations performed by those sub-lines are described below in the context of FIG. 13 A, as a press station sub-line operational method 1300a of the manufacturing method 1300 of FIG. 13. Operations 1310, 1312, 1314, and 1316 are already described above.
  • the press station sub-line operational method 1300a further includes operation
  • the method 1300a further includes operation 1320, trimming the molded fiber part to produce a waste trim. Once trimmed, removing the waste trim from the exit side of the press may be performed. As this is performed by the press station shuttle, operation 1322 may be performed substantially simultaneously with operation
  • Operation 1316 This substantially simultaneous operation is depicted in operation 1324, where removing the molded fiber part comprises applying a part vacuum to the molded fiber part to separate the molded fiber part from the press, and removing the waste trim comprises applying a waste trim vacuum to the waste trim to separate the waste trim from the press. As depicted in FIG. 8, the part vacuum is discrete from the waste trim. Operation 1326 includes terminating application of the waste trim vacuum at a waste trim station disposed between the exit side of the press and an exit conveyor.
  • FIGS. 14A and 14B depict another method 1400 of forming a molded fiber part.
  • the method begins with operation 1402, drawing a fiber slurry onto a forming mold to form a partially-formed molded fiber part. As indicated elsewhere herein, this may be performed by placing a forming mold into a slurry tank. Once a predetermined amount of slurry is drawn onto the mold (e.g., by vacuum), the forming mold is removed from the slurry tank and operation 1404, removing the partially-formed molded fiber part from the forming mold, is performed. Operation 1406 includes transferring the partially-formed molded fiber part to a first distribution shuttle.
  • the method 1400 includes optional operation 1408, returning a second distribution shuttle towards the forming mold. This may occur substantially simultaneously with operation 1406, transferring the partially -formed molded fiber part to the first distribution shuttle.
  • the control sy stem of the production line then identifies, in operation 1410, a first available press station sub-line of a plurality of press station sub-lines. “Availability” in one example is used to describe the condition where a press sub-line is available to transfer the partially -formed molded fiber parts thereto, or will be available to transfer.
  • Operation 1412 includes transferring the partially-formed molded fiber part to the first press shuttle associated with the first available press station sub-line. It should be noted that operation 1408 may also be performed substantially simultaneously with operation 1412, in order to increase throughput.
  • operation 1414 depicted in FIG. 14B, which includes transferring the partially -formed molded fiber part to a first available press station associated with the first available press station sub-line.
  • operation 1416 includes forming the partially-formed molded fiber part into the molded fiber part with the first available press station. Since the production lines described herein include multiple parallel press station sub-lines, the method 1400 may also include operation 1418, forming an additional partially-formed molded fiber part into an additional molded fiber part with a second press station of the second press station sub- line. In examples, this may be performed at least partially simultaneously with forming the partially -formed molded fiber part into the molded fiber part with the first available press station.
  • the method 1400 may include, substantially simultaneously with forming the molded fiber part, separating a waste trim from the molded fiber part, operation 1420.
  • the first press station shuttle returns to the press/trim station, and operation 1422, transferring the molded fiber part and the waste trim to the first press shuttle is performed. This clears both the molded fiber part and the waste trim from the press/trim station, which prepares the trim station for a repeat of operation 1414.
  • Operation 1424 includes releasing the waste trim from the first press shuttle while retaining the molded fiber part on the first press shuttle. This occurs, for example, at a waste trim station downstream from the exit area of the press station.
  • FIG. 15 illustrates one example of a suitable operating environment 1500 in which one or more of the present examples may be implemented.
  • This is only one example of a suitable operating environment and is not intended to suggest any limitation as to the scope of use or functionality.
  • Other well-known computing systems, environments, and/or configurations that may be suitable for use include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smart phones, network PCs, minicomputers, mainframe computers, smartphones, tablets, distributed computing environments that include any of the above systems or devices, and the like.
  • the computing system may include one or more product manufacturing management systems, which may be a single unit dedicated to all stations, systems, and subsystems of the examples of productions lines described herein.
  • the computing system may be a network of individual computing systems (e.g., one or more discrete computing systems for each station, system, and subsystem).
  • operating environment 1500 typically includes at least one processing unit 1502 and memory 1504.
  • memory 1504 may be volatile (such as RAM), non volatile (such as ROM, flash memory, etc ), or some combination of the two.
  • This most basic configuration is illustrated in FIG. 15 by dashed line 1506.
  • environment 1500 may also include storage devices (removable, 1508, and/or non-removable, 1510) including, but not limited to, magnetic or optical disks or tape.
  • environment 1500 may also have input device(s) 1514 such as touch screens, keyboard, mouse, pen, voice input, etc. and/or output device(s) 1516 such as a display, speakers, printer, etc.
  • Also included in the environment may be one or more communication connections, 1512, such as LAN, WAN, point to point, Bluetooth, RF, etc.
  • communication connections such as LAN, WAN, point to point, Bluetooth, RF, etc.
  • Operating environment 1500 typically includes at least some form of computer readable media.
  • Computer readable media can be any available media that can be accessed by processing unit 1502 or other devices utilizing the operating environment.
  • Computer readable media may include computer storage media and communication media.
  • Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data.
  • Computer storage media includes, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, solid state storage, or any other medium which can be used to store the desired information.
  • Communication media embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media.
  • modulated data signal means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.
  • communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media.
  • the operating environment 1500 may be a single computer operating in a networked environment using logical connections to one or more remote computers.
  • the remote computer may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above as well as others not so mentioned.
  • the logical connections may include any method supported by available communications media.
  • Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
  • the components described herein include such modules or instructions executable by computer system 1500 that may be stored on computer storage medium and other tangible mediums and transmitted in communication media.
  • Computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Combinations of any of the above should also be included within the scope of readable media.
  • computer system 1500 is part of a network that stores data in remote storage media for use by the computer system 1500.
  • FIG. 16 is an embodiment of a network 1600 in which the various systems and methods disclosed herein may operate.
  • portable device such as client device 1602 may communicate with one or more servers, such as servers 1604 and 1606, via a network 1608.
  • a client device may be a laptop, a tablet, a personal computer, a smart phone, a PDA, a netbook, or any other type of computing device, including individual controllers for various components of the packing system, and the computing device in FIG. 15.
  • servers 1604 and 1606 may be any type of computing device, such as the computing device illustrated in FIG. 15.
  • Network 1608 may be any type of network capable of facilitating communications between the client device and one or more servers 1604 and 1606. Examples of such networks include, but are not limited to, LANs, WANs, cellular networks, and/or the Internet.
  • the various systems and methods disclosed herein may be performed by one or more server devices.
  • a single server such as server 1604 may be employed to perform the systems and methods disclosed herein.
  • Portable device 1602 may interact with server 1604 via network 1608 in send testing results from the device being tested for analysis or storage.
  • the portable device 1602 may also perform functionality disclosed herein, such as by collecting and analyzing testing data.
  • the methods and systems disclosed herein may be performed using a distributed computing network, or a cloud netw ork. In such embodiments, the methods and systems disclosed herein may be performed by two or more servers, such as servers 1604 and 1606. Although a particular network embodiment is disclosed herein, one of skill in the art will appreciate that the systems and methods disclosed herein may be performed using other types of networks and/or network configurations.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

L'invention concerne une ligne de production de pièces moulées en fibres comprenant un moule de formage, une navette de transfert pour retirer une pièce en fibres partiellement formée de la station de formage, et une pluralité de sous-lignes de station de pressage. Chacune de la pluralité de sous-lignes de station de pressage comprend une station de pressage dotée d'un côté d'entrée et d'un côté de sortie, et une navette de station de pressage. Le système comprend une navette de distribution pour distribuer la pièce en fibres partiellement formée de la navette de transfert à au moins l'une de la pluralité de navettes de station de pressage. Le portique de distribution se trouve sur le côté d'entrée de la station de pressage et une station de rebuts de rognures est située sur le côté de sortie de la station de pressage. Un convoyeur de sortie se trouve en face de la station de rebuts de rognures de la station de pressage.
PCT/US2020/031667 2019-05-06 2020-05-06 Lignes de production de pièces moulées en fibres à haut rendement et à temps de cycle réduit WO2020227404A1 (fr)

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US201962844044P 2019-05-06 2019-05-06
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US202062978643P 2020-02-19 2020-02-19
US62/978,643 2020-02-19

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US20220242015A1 (en) * 2019-05-06 2022-08-04 Zume, Inc. Systems and methods for producing molded fiber products

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WO1999022069A1 (fr) * 1997-10-25 1999-05-06 Px Technologies Ltd. Procede et appareil de formage d'articles a partir de pate a papier
EP1240975A1 (fr) * 2001-03-12 2002-09-18 FELSOMAT GmbH & Co. KG Système de fabrication à enchainement pour l'usinage de pièces
WO2005012640A1 (fr) * 2003-08-01 2005-02-10 Ecologico Packaging Sdn Bhd Dispositif et procede de fabrication pour produire des articles en fibres vegetales
WO2006057610A2 (fr) * 2004-11-26 2006-06-01 Pakit International Trading Company Inc Procede et machine de fabrication de produits fibreux a partir d'une composition de fabrication et nouveau type de produit fibreux
US20170197334A1 (en) * 2016-01-12 2017-07-13 Golden Arrow Priinting Co.,Ltd. Double molded pulp molding machine
CN107915044A (zh) * 2017-11-15 2018-04-17 浙江舒康科技有限公司 用于生产纸浆模塑产品的柔性生产线

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WO1999022069A1 (fr) * 1997-10-25 1999-05-06 Px Technologies Ltd. Procede et appareil de formage d'articles a partir de pate a papier
EP1240975A1 (fr) * 2001-03-12 2002-09-18 FELSOMAT GmbH & Co. KG Système de fabrication à enchainement pour l'usinage de pièces
WO2005012640A1 (fr) * 2003-08-01 2005-02-10 Ecologico Packaging Sdn Bhd Dispositif et procede de fabrication pour produire des articles en fibres vegetales
WO2006057610A2 (fr) * 2004-11-26 2006-06-01 Pakit International Trading Company Inc Procede et machine de fabrication de produits fibreux a partir d'une composition de fabrication et nouveau type de produit fibreux
US20170197334A1 (en) * 2016-01-12 2017-07-13 Golden Arrow Priinting Co.,Ltd. Double molded pulp molding machine
CN107915044A (zh) * 2017-11-15 2018-04-17 浙江舒康科技有限公司 用于生产纸浆模塑产品的柔性生产线

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Publication number Priority date Publication date Assignee Title
US20220242015A1 (en) * 2019-05-06 2022-08-04 Zume, Inc. Systems and methods for producing molded fiber products

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