WO2021105133A1

WO2021105133A1 - Apparatus and method for pressure moulding

Info

Publication number: WO2021105133A1
Application number: PCT/EP2020/083234
Authority: WO
Inventors: Gunnar Edvardsson; Mikael Lundgren
Original assignee: Södra Skogsägarna Ekonomisk Förening
Priority date: 2019-11-25
Filing date: 2020-11-24
Publication date: 2021-06-03
Also published as: SE1951346A1

Abstract

A method and an apparatus for pressure moulding for providing products from a fibre base material are disclosed. According to the invention, the apparatus comprises an upper part having a circulating carrier system with first moulds; and a lower part having a circulating carrier system with second moulds that fit to said first moulds. The upper and lower parts form a pressure

Description

APPARATUS AND METHOD FOR PRESSURE MOULDING FIELD OF THE INVENTION

The present inventive concept relates to a pressure moulding apparatus for providing products from a fibre base material. The present inventive concept further relates to a method providing products from such pressure moulding apparatus.

BACKGROUND

Fibre base products have experienced an increased usage during the past years and especially those made of cellulose. One of the reasons is the environmental aspect which has led to plastic material being gradually forced out by the consumers and the industry and replaced by cellulose fibre base materials.

A fibre base product is typically produced by feeding a fibre base web to a pressure moulding apparatus, also known as a compression moulding apparatus or dry forming apparatus. The characteristics of the final products are dependent on the pressure time, temperature, and pressure. Examples of documents that relate to this kind of apparatus and methods are US 2010/0190020 which describes manufacturing of three layered packaging products, and WO 2017/160217 which describes a method and apparatus for manufacturing a cellulose product.

Many apparatuses or methods of the prior art have in common that they are adapted for a continuous process for providing fibre base products. However, although the apparatus is adapted for a continuous process, a break in the process is inevitable since the fibre base web is intermittently fed to the pressure moulding. Furthermore, the overall process rate is dependent on the pressure time of one product at a time. A drawback with the current state of the art is thus that the feeding of the web to the pressure mould is not made continuously which makes the overall process time-consuming. The present inventive concept seeks to provide a pressure moulding apparatus for providing products from a fibre base material with higher effectivity and shorter process time compared to prior art solutions.

SUMMARY

An object of the inventive concept is to overcome the above problems, and to provide a pressure moulding apparatus which, at least to some extent, has higher effectivity than prior art solutions. This, and other objects, which will become apparent in the following, are accomplished by a pressure moulding apparatus and method as defined in the accompanying claims.

The present inventive concept is based on the insight that the pressure moulding apparatus can be made more effective, and be more flexible to use, if the pressure moulding apparatus comprises a circulating carrier system having first and second moulds which provides for continuous feed of the fibre base web into the pressure section.

According to at least a first aspect of the present inventive concept, a pressure moulding apparatus for providing products from a fibre base material is provided. The pressure moulding apparatus comprises an upper part having a circulating carrier system with first moulds; a lower part having a circulating carrier system with second moulds that fit to said first moulds; and wherein said upper and lower parts form a pressure section in which said first and second moulds are pressed against each other.

It should be noted that the circulating carrier system of the upper part and the circulating carrier system of the lower part are two separate units. However, the circulating carrier system of the upper part is similar in construction and function to the circulating carrier system of the lower part, except that the circulating carrier system of the upper part is carrying first moulds and the circulating carrier system of the lower part is carrying second moulds, although the first and second moulds are exchangeable. The circulating carrier system of the upper part and the circulating carrier system of the lower part are described as one unit hereto forth. In other words, the pressure moulding apparatus could be described to comprise an upper part having a first circulating carrier system with first moulds and a lower part having a second circulating carrier system with second moulds that fit to said first moulds.

It should be noted that the pressure section does not comprise the entire upper and lower parts but merely a section of the upper and lower parts where the first and second moulds are pressed together. The pressure section is thus a section of the pressure moulding apparatus where the products are produced.

The first and second moulds are allowed to circulate at the same time as the products are produced. In use, this means that the first and second moulds are in substantially constant motion. Hence, the circulating carrier system allows for a continuous feed of the fibre base material into the pressure section, and a continuous output of products. This is advantageous since the pressure moulding apparatus allows for a faster production rate compared to a pressure moulding apparatus that does not have a circulating carrier system. On the contrary, a pressure moulding apparatus which does not have a circulating carrier system is limited to an intermittent feed of fibre base material to the pressure section, and consequently an intermittent output of products, which is time-consuming. The production rate according to prior art solutions is thus dependant on the pressure time for one single product.

Further, the circulating carrier system makes it possible to continuously press a plurality of products with less space consumption compared to a stationary pressure moulding apparatus. The pressure moulding apparatus can therefore be made less bulky than prior art solutions.

The pressure moulding apparatus may be driven by one or more synchronised engines.

The fibre base material may be in the form of a web, formed for example by the air laid or wet laid processes that is continuously fed into the pressure moulding apparatus. The web can be continuously fed as a coherent web or continuously fed as separate segments following each other. The term “fibre base web” described herein is also referred to as “web” or “web of fibre base material”.

The circulating carrier system of the pressure moulding apparatus may comprise multiple solid carriages, which are articulatedely coupled to each other, and wherein said first and second moulds are releasably arranged on said carriages.

Stated differently, the plurality of articulatedely coupled solid carriages is interlinked to each other in such a way that they are able to pivot. The number of solid carriages may be in the interval between 5-34, and preferably between 13-20. Having the multiple solid carriages articulatedely coupled to each other is advantageous since it provides the circulating carrier system having a chainlike structure. This allows for a smooth circulation of the circulating carrier system.

The number of moulds arranged on each carriage may be in the interval of from 1-10, and preferably between 2-4. To have the first and second moulds releasably arranged on the solid carriages is advantageous since this provides the possiblity to exchange the first and second moulds to other types of moulds. Hereby, the pressure moulding apparatus may produce a large variety of different products with regards to shape and/or mechanical properties. Further advantages of having the first and second moulds releasably arranged on the circulating carrier system is the possibility to change places of the first and second moulds. Hereby, it is possible to achieve an effect of drape of the web of fibre base material around the first or second mould.

According to one example embodiment, each first and second mould comprises a pressure surface.

According to one example embodiment, the pressure moulding apparatus further comprises a pre-pressure section in which said first and second moulds are arranged to approach each other, and wherein said pressure surfaces of said first and second moulds are parallelly aligned.

According to one example embodiment, a pressure moulding apparatus is provided, wherein said carriages in said upper and lower parts are arranged to move in a substantially vertical direction towards each other when circulating into the pressure section and are arranged to move in a substantially vertical direction away from each other when circulating out of the pressure section.

In other words, the first and second moulds are arranged to move both in a vertical direction and in a horizontal direction. This should be understood as the first and second moulds are arranged to move in a horizontal direction when the fibre base web is under pressure and the first and second moulds are clamped, and a vertical direction right before or after the fibre base web is pressure moulded, i.e. when the moulds approach each other or release from each other. Hence, the products are not only pressed between two vertically movable moulds. They are also transported along the horizontal axis of the pressure moulding apparatus. This is advantageous as it allows for a constant outflow of products from the pressure moulding apparatus and a high production rate.

This could also be expressed as the first and second moulds are transported via the upper and lower circulating carrier system, wherein the upper and lower circulating carrier system function as a rotating track. Once the upper and the lower moulds are vertically aligned before the pressure section, they approaches each other vertically and the pressure mould cycle starts.

Stated differently, the first and second moulds are arranged to appoach each other in a substanially aligned configuration. Hereby, the pressure force applied to the fibre base web is substantially uniform along the vertical axis. This is an advantageous as it allows for symmetrical properties of the final products. It should be understood that the direction of the moulds when approaching the pressure section is dependant on the arrangment of the pressure moulding apparatus. Stated differently, a pressure moulding apparatus located with the first circulating carrier system above the second carrier system has the moulds arranged in a horizontal direction when approaching the pressure section, while a pressure moulding apparatus located such that the the first and second carrier systems are arranged parallell has the moulds arranged vertically when approaching the pressure section.

According to one example embodiment, said carriages comprises heating elements for providing heat to said first moulds and/or said second moulds.

It should be understood that heating elements may be provided to either of the first or the second moulds. Heating elements may also be provided to both of the first and second moulds. The temperature of the first mould may be different from the temperature of the second mould. For example, the temperature of the first moulds may be higher than the temperature of the second moulds, or vice versa. The temperature of the first and second moulds may also be the same.

It should be noted that the heating elements may be located on the carriages and/or somewhere else on the pressure moulding apparatus. The term “heating elements” should be interpreted as one or more heating elements.

According to one example embodiment, the pressure moulding apparatus further comprises means for recycling leftover fibre base material arranged downstream of said pressure section.

Non limited examples of means for recycling leftover fibre base material are suction or blowing of leftover materials into a collection funnel. Hereby, the leftover materials can be used in the same process cycle without interuption of the production speed. An advantage with this is that the spill of raw material is limited which makes the pressure moulding apparatus suitable for process which is both economical and environmentally friendly.

According to one example embodiment, the pressure moulding apparatus further comprises a laminate layer applicator arranged upstream of said pressure section and a laminate layer collector arranged downstreams of said pressure section.

Hereby, a laminate layer may be pressure moulded together with and simultaneously with the fibre base material. Hence, the laminate layer will become a part of the final product. An advantage with this is that the properties of the products can be tailored with respect to the properties of the laminate layer.

It should be understood that a laminate layer should be interpreted as at least one laminate layer. The laminate layer could be positioned on top of the fibre base material and/or on the bottom of the fibre base material.

In one example embodiment the laminate layer applicator is adapted to align the laminate layer with the fibre base material.

The laminate layer collector is advantageous in that it makes it possible to collect leftover laminate layer after the pressure moulding. Hereby, the leftover laminate layer is separated from the leftover fibre base material. This makes it possible to recycle leftover fibre base material and leftover laminate layer seperately.

In one example embodiment, the laminate layer applicator and the laminate layer collector respectively is a reeling device.

According to one example embodiment, the pressure moulding apparatus further comprises applicator means upstreams of said pressure section, said applicator means being adapted for application of one or more of water, steam, and additives into/onto the fibre base material.

It should be understood that the applicator means can be arranged such that water, steam or other additives are applied directly to the fibre base material when it is in the form of a web. The applicator means could also be arranged to apply water, steam or other additives to the fibre base material before it is formed into a web, for example in a fluff state.

The applicator means may for example be a spray applicator or a pad applicator.

Non limiting examples of additives are modified natural resins, e.g. pine resins, syntethic adhesives, e.g. Alkyl ketene dimer (AKD) and Alkenyl succinic anhydride (ASA), and wax dispersions.

According to one example embodiment, the pressure moulding apparatus further comprises a preheating section arranged upstream of said pressure section.

Hereby, the fibre base material can be preheated before entering into the pressure section. Preheating is advantageous as it may improve the properties of the final product. Other advantages with a preheating section are that the pressure time, pressure force, and pressure temperature can be lowered.

The preheating section is advantagous if the fibre base material comprises thermoset or thermoplastic fibres, such as PLA. The fibre base material may also comprise additives in the form of powders or particles, made of for instance waxes, such as Alkyl ketene dimer (AKD). AKD is advantageous in that it provides hydrophobic properties to the product. When these powders and/or particles are present it may be beneficial to have a preheating section.

According to one example embodiment, one of said first and second moulds comprises a puncher cutter boarder, and the other one of said first and second moulds comprises an abutment surface for said puncher cutter boarder.

Hereby, the pressure moulding apparatus is advantageous since it allows for products to be punched out upon leaving the pressure section.

It should be noted that a puncher cutter boarder should be understood as at least one puncher cutter boarder.

According to one example embodiment said carriages comprise a chassis having a plurality of wheels, and an attachment portion for holding said first moulds and/or said second moulds, and wherein said chassis and said attachment portion are pivotally connected to each other.

According to one example embodiment each one of said upper and lower part further comprises a guiding rail and wherein said carriages further comprise a guiding member adapted to run within said guiding rail.

According to one example embodiment each one of said upper and lower part comprises a track, and wherein said carriages are adapted to run on said track.

According to at least a second aspect of the present inventive concept, a method for providing products is provided. The method comprises the following steps: i) providing a fibre base material in the form of a web; and ii) continuously feeding said web into a pressure section of a pressure moulding apparatus comprising an upper part having a circulating carrier system with first moulds; and a lower part having a circulating carrier system with second moulds that fit to said first moulds; and wherein said upper and lower parts form a pressure section in which said first and second moulds are pressed against each other, and in which said pressure section the products are produced from the web; wherein a velocity of circulation of the upper and lower parts is synchronised with a feeding velocity of the web.

Thus, the present invention provides for an alternative pressure moulding technique for fibre base material. This method is advantageous since it allows for a larger quantity of products to be produced per time unit than for a conventional method. This is because the feeding velocity of the web can be kept constant. The method for providing a fibre base product according to the inventive concept can thus be made more effective compared to prior art methods which not have a continuous feed of the web into the pressure section.

The feeding velocity of the web is correlating with the velocity of the circulating carrier system. For example, a constant velocity of the circulating carrier system provides for a constant feeding velocity of the web into the pressure section. Further, the press time for each product may be regulated by the velocity of the circulating carrier system. A high velocity of the circulating carrier system provides for a short press time and vice versa. The velocity of the circulating carrier system may for example be in the interval of 35- 1400 mm/sec.

The method is advantageous in that it makes it possible to continuously provide the fibre base material in the form of a web.

It should be understood that the fibre base material may be provided as a discontinues fibre base web arranged on a continuous carrier. The discontinuous fibre base web may be a fibre base web cut in portions, such as islands of continuous fibre base web. The continuous carrier may for instance be a tissue.

According to one example embodiment, the web is heated in said pressure section.

For example, the web may be heated in temperature between 25 to

250 °C. According to one example embodiment, the method further comprises a step of recycling leftover material from the web after step ii) back to step i).

This is advantageous since this step prohibits leftover material to be left in the pressure section or anywhere else in the pressure moulding apparatus. Further, waste of material is avoided. Hence, the method is made economical.

According to one example embodiment, the method further comprises a step of providing a laminate layer to be aligned with said provided web before entering step ii), and also fed at the same velocity as the web.

Hereby, the properties of the product can be adjusted according to specific end use. The laminate layer may comprise of for example a plastic film, a tissue or a liner, and may provide anyone of the following properties; hydrophobicity, stiffness, glaze, lustre, oxygen barrier, moisture barrier or fat barrier. The laminate layer may further comprise a multi-layer plastic film or sheet. Furthermore, the laminate layer may provide a logo or specific design to the products. It should be understood that a laminate layer should be interpreted as at least one laminate layer.

According to one example embodiment, the method further comprises a step of application of one or more of water, steam, and additives to the fibre material during step i) and/or to the web between step i) and ii).

Hereby, the fibres of the fibre base may bind better to each other in the final product.

According to one example embodiment, the method further comprises a step of heating the web between step i) and ii).

This step may be an advantage in that the fibres of the fibre base material may bind better to each other due to increased fibril aggregation. Further water resistance and increased mechanical properties of the final product may also be achieved by preheating. According to one example embodiment, the fibre base material comprises one or more materials selected from the group of textile fibre, plant fibre, pulp fibre, recycled fibre, and other cellulosic fibre.

The fibre base material may further comprise cellulosic fibre obtained from bark, wood, leaves of plants; natural cellulose fibres such as cotton, linen, or bamboo; or regenerated fibre such as rayon, viscose or lyocell.

It should be understood that both short and/or long fibres are included in the inventive concept.

According to at least a third aspect of the present inventive concept, a product obtainable by the above disclosed method is provided. Preferably, the product is in the form of an interior component for buildings or vehicles, a clamshell, or a component of an inner or outer package, an embossed sheet, a construction detail, such as a protective cover, a rigid carrying structure for a hygiene product, or a container, most preferred in the form of a tray, bowl or plate.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in more detail with reference to the appended schematic drawings, which show an example of a presently preferred embodiment of the invention.

Fig. 1 is a perspective view of a pressure moulding apparatus according to at least one example embodiment of the inventive concept;

Fig. 2 is an exploded view of a first and second carriage, a first and second pair of moulds, and a product.

Fig. 3 is a perspective view of a pressure moulding apparatus according to at least one example embodiment of the inventive concept;

Fig. 4 is a side view of the pressure moulding apparatus of Fig. 3; Fig. 5 is a detailed view of Fig. 4 illustrating a pre-pressure section and a pressure section of the pressure moulding apparatus;

Fig. 6 is a perspective view of a pair of complementing carriages illustrated in Fig. 3; Fig. 7 is an partly exploded view of the carriages in Fig.3;

Fig. 8a-b are side views of the carriage illustrated in Fig. 3-5 or 7.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and to fully convey the scope of the invention to the skilled addressee. Like reference characters refer to like elements throughout.

Fig. 1 illustrates in perspective view of a pressure moulding apparatus 1 for producing products 10 from a fibre base material. The pressure moulding apparatus 1 comprises an upper part 40 and a lower part 60 driven by one or more engines. Each one of the upper 40 and lower part 60 comprises a circulating carrier system 50 having a plurality of moulds 42, 62. The circulating carrier system 50 of the upper part 40 comprises a plurality of first moulds 42 and the circulating carrier system 50 of the lower part 60 comprises a plurality of second moulds 62 that are compatible with the first moulds 42. The upper part 40 and the lower part 60 together form a pressure section 20 into which a web 30 is fed, and in which the first moulds 42 and the second moulds 62 are pressed against each other with the fibre base web 30 pressed in between.

The circulating carrier system 50 is advantageous since it provides for a continuous feed of the web 30 into the pressure section 20. Hereby, the method for making products 10 is not interrupted during the mould cycle time. The circulating carrier system 50 may circulate continuously or stepwise.

The circulating carrier system 50 is arranged to circulate with a velocity of circulation which is dependent on, and adjusted to, the length of the pressure section 20 and the mould cycle time. A long pressure section 20 has the advantage that is allows for a higher velocity of circulation and a larger number of products 10 may be pressure moulded simultaneously. A short pressure section 20 is advantageous since it can make the pressure moulding 1 apparatus less space consuming.

The feeding velocity of the web 30 into the pressure section 20 is preferably adjusted and synchronised with the velocity of circulation of the circulation carrier system 50.

The circulating carrier system 50 is made up by a plurality of solid carriages 52 that are articulated coupled to each other and on which the first 42 and/or second moulds 62 are releasable arranged. Each one of the solid carriages 52 may have one or more moulds 42, 62 releasable arranged on it. One of the reasons for having the moulds 42, 62 releasable arranged on the solid carriages 52 is that different types of moulds can be used in the pressure moulding apparatus 1 and consequently different types and forms of products 10 may be produced.

The solid carriages 52 are provided with heating elements for providing heat to the first 42 and/or second moulds 62.

Before the solid carriages 52 enter the pressure section 20, they are horizontally arranged. This is advantageous since the mould cycle time for each product 10 can be held the same in the horizontal plane and the pressure force applied between the first and second moulds 42, 62 can be kept constant over the horizontal plane. The solid carriages 52 of the upper 40 and lower part 60 then start to approach each other until contact and the web 30 is pressure moulded. This should be understood as the first 42 and second moulds 62 simultaneously move in a vertical direction towards each other when they are arranged horizontally; the first moulds 42 move downwards and the second moulds 62 move upwards. The vertical distance the first 42 and the second moulds 62 move when horizontally arranged may thus be the same. Alternatively, when horizontally arranged, only the first moulds 42 move in a vertical direction downwards while the second moulds 62 are kept in constant position vertically, and vice versa. Hereby, it is possible to let the first 42 and second moulds 62 move in different lengths vertically compared to each other when horizontally arranged.

The circulating carrier system 50 allows the first 42 and second moulds 62 to move in a horizontal direction when the first 42 and second moulds 62 are clamped to each other and the products 10 are produced. In Fig. 1 , three pairs of first 42 and second moulds 62 are clamped in the pressure section 20. The number of pairs of first and second moulds to be clamped simultaneously in the pressure section 20 may vary from 1 to 10, preferably between 2-4.

It is also possible to let the first 42 and second moulds 62 move in a vertical direction when the first 42 and second moulds 62 are clamped and the products 10 are produced.

Arranged downstream of the pressure section 20 is a recycling suck 70. The recycling suck is an example of means 70 for recycling leftover fibre base material 35. The recycling suck recycles leftover fibre base materials back to a previous step of preparing the continuous fibre base web 30. Located below the pressure section 20 is another example of means 70 for recycling leftover fibre base material 35, in the form of a conveyor belt. Arranged upwards of the pressure section 20 is a laminate layer applicator 80 for application of a laminate layer 85, a preheating section 100, and a spray applicator. The latter is a form of applicator means 90 that is advantageous since it can provide at least one of steam, water or additives to the continuous fibre base web 30 before it enters the pressure section 20. The spray applicator is preferably located upstream of the preheating section 100 which is advantageous since an under pressure of the preheating section 100 helps to uniformly distribute the water, steam and/or other additives applied to/into the continuous fibre base web 30.

Fig. 2 illustrates an exploded view of a pair of complementing solid carriages 52, a first 42 and a second mould 62, a continuous fibre base web 30, and a final product 10. The first mould 42 has a puncher cutter boarder 44 and the second mould 62 has an abutment surface 64 for the puncher cutter boarder 44. Hereby, the products 10 can be punched from the web 30 at the same time as these are in the pressure section 20. As mentioned above, the solid carriages 52 are provided with heating elements 54 for providing heat to the first 42 and/or second moulds 62.

Fig. 3 illustrates in perspective view a pressure moulding apparatus 1 for producing products 10 from a fibre base material 30 comprising cellulose. The fibre base material is in the form of a web.

The pressure moulding apparatus 1 comprises an upper part 40 and a lower part 60, driven by one or more synchronised engines. Each one of the upper 40 and lower part 60 comprises a circulating carrier system 50, such as a conveyer. The circulating carrier 50 has a plurality of moulds 42, 62 attached thereto. The circulating carrier system 50 of the upper part 40 comprises a plurality of first moulds 42 and the circulating carrier system 50 of the lower part 60 comprises a plurality of second moulds 62, compatible with the first moulds 42. The circulating carrier systems 50 of the upper part 40 and the lower part 60, respectively, are separated from each other. The circulating carrier system 50 and the moulds 42, 62, travel along a continuous elliptical path, wherein the first 42 and second moulds 62 to move in a horizontal direction while being clamped to each other and the products 10 are produced. This action is performed in the pressure section of the pressure moulding apparatus 1 , as will be described further down.

A laminate layer applicator 80, a preheating section 100, and a spray applicator are arranged upstream of the pressure section 20. The latter is a form of applicator means 90 that is advantageous since it can provide at least one of steam, water or additives to the fibre base web 30 before it enters the pressure section 20. The location of the spray applicator upstream of the preheating section 100 is advantageous since an under pressure of the preheating section 100 helps to uniformly distribute and apply water, steam and/or other additives to/into the fibre base material 30.

A laminate layer collector 82 and a conveyor belt are located downstream of the pressure section 20. The latter is an example of means 70 for recycling leftover fibre base material 35. Other examples of means 70 for recycling leftover fibre base material 35 is a recycling suck. The recycling suck and the conveyor belt are advantageous because it makes it possible to recycle leftover fibre base material 35 back to a previous step of preparing the fibre base web 30.

The circulating carrier system 50 may circulate continuously or stepwise. This is beneficial since it allows a continuous feed of the web 30 into the pressure section 20. The method for making products 10 is thus not interrupted during or between the mould cycle for each product 10.

Fig. 4 and 5 illustrate a circulating carrier system 50 made up by a plurality of solid carriages 52 that are articulated coupled to each other, and on which the first 42 and/or second moulds 62 are releasably arranged. The carriages 52 are adapted to run on a track 24 located in each one of the upper and lower parts. Each one of the upper and lower part further comprises a drive gear 5 which promotes the circulation of the carriages 52, and a guiding rail 22 which runs outside the track 24. The guiding rail 22 is adapted to control the inclination level of the pressure surfaces 43, 63 of the first and second mould, as will be explained further down.

In Fig. 5 a detailed view of the pressure section 20 and the pre-pressure section 21 is illustrated. As stated above, the pressure section 20 is a section of the pressure moulding apparatus 1 where the first moulds 42 and the second moulds 62 are pressed against each other and where the products 10 are produced. In the pressure section 20, the track 24 and the guiding rail 22 of the upper and lower parts run parallelly aligned to each other. However, in the pre pressure section 21 which is arranged upstream of the pressure section, is the track 24 and the guiding rail 22 at least in parts inclined toward the intersection of the upper part 40 and lower part 60. Hereby, when the carriages 52 are positioned in the pre-pressure section 21 , the front wheels 57 and the back wheels 57 of the carriages 52 are positioned at different levels along the z-axis. The chassis 56 of the carriages 52 is thus inclined (see Fig. 8b). Still, the pressure surface 43, 63 of the first 42 and second moulds 62 remain non- inclined and parallelly aligned, as illustrated in Fig. 8b. This is advantageous because it allows for a plane parallel configuration of the pressure surfaces 43, 63 of the moulds 42, 62 when entering the pressure section. The distance between the pressure surfaces 43, 63 of the first and second moulds 42, 62 when being parallelly aligned is at least 50 mm and remains parallelly aligned as the distance between the first and second moulds 42, 62 gradually decreases until they are clamped. This is advantageous for example when deep 3D moulds are used. As illustrated in Fig. 5, the pressure surfaces 43, 63 of the moulds 42, 62 remain parallelly aligned also when the first and seconds moulds 42, 62 exit the pressure section.

Fig. 6 and 7 illustrate a pair of complementing carriages 52 with first and second moulds 42, 62. The upper carriage is adapted to be located in the circulating carrier system 50 of the upper part 40 and the lower carriage is adapted to be located in the circulating carrier system 50 of the lower part 60. Note, in Fig. 6 the location of the first and second moulds 42, 62 is changed compared to the carriages 52 of Fig. 7 such that a protruding mould is attached to carriage located in the lower part 60 of the pressure moulding apparatus. This may be advantageous since it allows the web of fiber base material 30 to drape around the mould before pressure. Flereby, the web of fiber base material is less prone to break when it is clamped between the first 42 and second moulds 62.

The carriages 52 comprise a chassis 56, with a plurality of wheels 57. The number of wheels 57 in Fig. 6 and 7 are four. The chassis 56 further comprises a connecting member 59, pivotally connected to an axle tree 61 of the wheels 57. The function of the connecting member 59 is to interlink the carriages 52 of the circulating carrier system 50 to one another in a chain like structure.

The chassis 56 is pivotally connected to an attachment portion 58, along a pivot axle 26. The pivot connection is advantageous because it allows the attachment portion 58 to align in a different angle compared to the track 24 on which the carriage is travelling. Flerby, the pressure surfaces 43, 63 of the first 42 and second mould 62, respectively, may be vertical aligned even though the track 24 is inclined. This is advantageous as it allows parallel pressing of the moulds 42, 62. The web of fiber base material is thus less prone to break when it is clamped between the first 42 and second moulds 62.

A heating plate comprising heating elements 54 is located between the attachment portion 58 and the first or second mould. The function of the heating plate is dual; it is adapted to provide heat to the mould and to provide flexibility in the x-y plane to the carriage. The flexibility of the heating plate enhances the pressure surfaces 43, 63 to align in a plan parallel configuration. This is made possible by a flexibility plate which is free to move and located within the heating plate. In Fig. 7 the heating elements 54 have been separated from the heating plate for easier view of the construction. A guiding member 23 is attached to a front side of respective attachment portion 58 and extends in line with the attachment portion 58. The guiding member 23 is thus aligned with the attachment portion 58. The guiding member 23 comprises a protruding wheel 25 adapted to run within the guiding rail 22, as illustrated in Fig. 3-5. The function of the guiding member 23 and its protruding wheel 25 is to decide the inclination angle of the attachment portion 58 and the mould attached thereto. The guiding member 23 comprised in the upper part 40 and the guiding member 23 comprised in the lower part 60 are located on the same side of respective carriage.

In Fig. 8a and 8b it is illustrated that the pressure surface of the first or second mould can remain horisontal aligned when the track 24 is inclined. Fig. 8a illustrates the configuration of the wheels 57 of a carriage 52 when located on a planar section of the track 24. That is for example when the carriage 52 is located within the pressure section 20. In this configuration, the x-y plane of the guiding member 23 (represented by dotted line A) is parallel with the track 24. Same goes for the x-y plane of the pressure surface 63 (represented by dotted line A’). The attachement portion 58, the x-y plane of wheel axises 61 , and the pressure surface 63 are thus all paralell aligned with the guiding member 23. Fig. 8b, on the contrary, illustrates the configuration of the wheels 57 of a carriage 52 when located on an inclined section of the track 24. That is for instance when the carriage 52 is located within the pre-pressure section 21 . In this instance, the wheel axises 61 of the front and back wheels 57 don’t lie within the same plane x-y plane, i.e. there is an inclination angle between the two of them in relation to the x-y plane of the guiding member 23 (dotted line A). Additionaly, the connecting members 59 are inclined in comparison to the x-y plane (dotted line A) of the guiding member 23 (see dotted line B). Flowever, the attachment portion 58 and the pressure surface 63 are paralell aligened with the guiding member 23. This is due to the attachment portion 58 being pivotally connected to the chassis 56 and to the guiding member 23 being guided by guiding rail 22. The guiding member 23 and the configuration of the guiding rail 22 steer the inclination level of the attachment portion 58 and the pressure surface 63 such that it remains in a horizontal position when located within the pre-pressure section 21 and in the pressure section. Hereby, the attachment portions 58 remain in a straight configuration which allows for a plane parallel configuration of the pressure surface 63 when the carriages 52 enter pressing mode. This is advantageous because when the carriages 52 are in the pre-pressure section 21 , the attachment portion 58 and the mould attached thereto is configured in a substantially non-inclined position until and throughout the time when the carriages 52 exit the pressure section 20. The skilled person realises that a number of modifications of the embodiments described herein are possible without departing from the scope of the invention, which is defined in the appended claims.

Claims

1. A pressure moulding apparatus (1) for providing products (10) from a fibre base material (30), comprising an upper part (40) having a circulating carrier system (50) with first moulds (42); a lower part (60) having a circulating carrier system (50) with second moulds (62) that fit to said first moulds (42); and wherein said upper and lower parts (40, 60) form a pressure section (20) in which said first and second moulds (42, 62) are pressed against each other.

2. The pressure moulding apparatus (1 ) according to claim 1 , wherein each first and second mould (42, 62) comprises a pressure surface (43, 63).

3. The pressure moulding apparatus (1 ) according to claim 2, said pressure moulding apparatus (1) further comprising a pre-pressure section (21 ) in which said first and second moulds (42, 62) are arranged to approach each other, such that said pressure surfaces (43, 63) of said first and second moulds (42, 62) are parallelly aligned in said pre-pressure section (21).

4. The pressure moulding apparatus (1 ) according to any one of claims 1 - 3, wherein said circulating carrier system (50) comprises multiple solid carriages (52), which are articulatedely coupled to each other, and wherein said first and second moulds (42, 62) are releasably arranged on said carriages (52).

5. The pressure moulding apparatus (1) according to claim 4, wherein each of said carriages (52) comprises a chassis (56) having a plurality of wheels, and an attachment portion (58) for holding said first moulds (42) or said second moulds (62), and wherein said chassis (56) and said attachment portion (58) are pivotally connected to each other.

6. The pressure moulding apparatus (1) according to claim 4 or 5, wherein said carriages (52) in said upper and lower parts (40, 60) are arranged to move in a substantially vertical direction towards each other when circulating into said pressure section (20) and are arranged to move in a substantially vertical direction away from each other when circulating out of said pressure section (20).

7. The pressure moulding apparatus (1 ) according to any one of claims 4- 6, wherein each one of said upper and lower part (40, 60) comprises a guiding rail (22) and wherein each of said carriages (52) comprises a guiding member (23) adapted to run within said guiding rail (22).

8. The pressure moulding apparatus (1) according to claim 4-7, wherein each one of said upper and lower part (40, 60) comprises a track (24), and wherein each of said carriages (52) is adapted to run on said track (24).

9. The pressure moulding apparatus (1 ) according to any one of claims 4- 8, wherein each of said carriages (52) comprises heating elements (54) for providing heat to said first moulds (42) and/or said second moulds (62).

10. The pressure moulding apparatus (1 ) according to any one of the preceding claims, further comprising means (70) for recycling leftover fibre base material (35), said means (70) for recycling being arranged downstream of said pressure section (20).

11. The pressure moulding apparatus (1 ) according to any one of the preceding claims, further comprising a laminate layer applicator (80) arranged upstream of said pressure section (20) and a laminate layer collector (82) arranged downstream of said pressure section (20).

12. The pressure moulding apparatus (1 ) according to any one of the preceding claims, further comprising applicator means (90) upstream of said pressure section (20), said applicator means (90) being adapted for application of one or more of water, steam, and additives into and/or onto said fibre base material (30).

13. The pressure moulding apparatus (1) according to any one of the preceding claims, wherein one of said first and second moulds (42, 62) comprises a puncher cutter boarder (44), and the other one of said first and second moulds (42, 62) comprises an abutment surface (64) for said puncher cutter boarder (44).

14. A method for providing products (10), said method comprising the following steps: i) providing a fibre base material (30) in the form of a web; and ii) continuously feeding said web of fiber base material (30) into a pressure section (20) of a pressure moulding apparatus (1) comprising an upper part (40) having a circulating carrier system (50) with first moulds (42); and a lower part (60) having a circulating carrier system (50) with second moulds (62) that fit to said first moulds (42); wherein said upper and lower parts (40, 60) form a pressure section (20) in which said first and second moulds (42, 62) are pressed against each other, and in which said pressure section (20) said products (10) are produced from said web of fibre base material (30); wherein a velocity of circulation of said upper and lower parts (40, 60) is synchronised with a feeding velocity of said web (30).

15. The method according to claim 14, wherein said web of fiber base material (30) is heated in said pressure section (20).

16. The method according to claim 14 or 15, further comprising a step of recycling leftover fiber base material (35) after step ii) back to step i).

17. The method according to any one of claims 14-16, further comprising a step of providing a laminate layer (85) to be aligned with said provided web of fiber base material (30) before entering step ii), and said laminate layer (85) also being fed at the same velocity as said web of fiber base material (30).

18. A method according to any one of claims 14-17, further comprising a step of application of one or more of water, steam, and additives to said fibre base material (30) during step i) and/or to said web of fiber base material (30) between step i) and ii).

19. A method according to any one of claims 14-18, further comprising a step of heating said web of fiber base material (30) between step i) and ii).

20. A method according to any one of claims 14-19, wherein said fibre base material (30) comprises one or more materials selected from the group of textile fibre, plant fibre, pulp fibre, recycled fibre, and other cellulosic fibre.