WO2024039387A1 - Produit de pâte composite multicouche, et système et procédé de fabrication de celui-ci - Google Patents

Produit de pâte composite multicouche, et système et procédé de fabrication de celui-ci Download PDF

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Publication number
WO2024039387A1
WO2024039387A1 PCT/US2022/049630 US2022049630W WO2024039387A1 WO 2024039387 A1 WO2024039387 A1 WO 2024039387A1 US 2022049630 W US2022049630 W US 2022049630W WO 2024039387 A1 WO2024039387 A1 WO 2024039387A1
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WIPO (PCT)
Prior art keywords
layer
pulp
reinforcement
pattern
product
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PCT/US2022/049630
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English (en)
Inventor
Paul Zhang
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Paul Zhang
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Publication of WO2024039387A1 publication Critical patent/WO2024039387A1/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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D19/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D19/0004—Rigid pallets without side walls
    • B65D19/0053—Rigid pallets without side walls the load supporting surface being made of more than one element
    • B65D19/0077—Rigid pallets without side walls the load supporting surface being made of more than one element forming discontinuous or non-planar contact surfaces
    • B65D19/0089—Rigid pallets without side walls the load supporting surface being made of more than one element forming discontinuous or non-planar contact surfaces the base surface being made of more than one element
    • B65D19/0093—Rigid pallets without side walls the load supporting surface being made of more than one element forming discontinuous or non-planar contact surfaces the base surface being made of more than one element forming discontinuous or non-planar contact surfaces
    • B65D19/0097—Rigid pallets without side walls the load supporting surface being made of more than one element forming discontinuous or non-planar contact surfaces the base surface being made of more than one element forming discontinuous or non-planar contact surfaces and each contact surface having a discrete foot-like shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00014—Materials for the load supporting surface
    • B65D2519/00019—Paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00014—Materials for the load supporting surface
    • B65D2519/00039—Agglomerates, i.e. different materials mixed together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00049—Materials for the base surface
    • B65D2519/00054—Paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00049—Materials for the base surface
    • B65D2519/00074—Agglomerates, i.e. different materials mixed together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00119—Materials for the construction of the reinforcements
    • B65D2519/00129—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00009—Materials
    • B65D2519/00119—Materials for the construction of the reinforcements
    • B65D2519/00139—Plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00263—Overall construction of the pallet
    • B65D2519/00273—Overall construction of the pallet made of more than one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00283—Overall construction of the load supporting surface
    • B65D2519/00293—Overall construction of the load supporting surface made of more than one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00313—Overall construction of the base surface
    • B65D2519/00323—Overall construction of the base surface made of more than one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00313—Overall construction of the base surface
    • B65D2519/00328—Overall construction of the base surface shape of the contact surface of the base
    • B65D2519/00338—Overall construction of the base surface shape of the contact surface of the base contact surface having a discrete foot-like shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00398—Overall construction reinforcements
    • B65D2519/00402—Integral, e.g. ribs
    • B65D2519/00407—Integral, e.g. ribs on the load supporting surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00398—Overall construction reinforcements
    • B65D2519/00462—Applied in mold, e.g. bi-injection molded reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00398—Overall construction reinforcements
    • B65D2519/00462—Applied in mold, e.g. bi-injection molded reinforcement
    • B65D2519/00467—Applied in mold, e.g. bi-injection molded reinforcement on or in the load supporting surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00398—Overall construction reinforcements
    • B65D2519/00462—Applied in mold, e.g. bi-injection molded reinforcement
    • B65D2519/00472—Applied in mold, e.g. bi-injection molded reinforcement on or in the base surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00547—Connections
    • B65D2519/00552—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer
    • B65D2519/00557—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer without separate auxiliary elements
    • B65D2519/00562—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer without separate auxiliary elements chemical connection, e.g. glued, welded, sealed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00736—Details
    • B65D2519/00935—Details with special means for nesting or stacking
    • B65D2519/0094—Details with special means for nesting or stacking nestable

Definitions

  • the present disclosure relates to pulp molded products, and the systems and processes by which they are manufactured.
  • Load-bearing plates are very important tools for modem industrial and commercial production, transportation, storage and packaging. With the development of the logistics industry, more and more load-bearing plates are used for storing goods and moving goods. Take the common pallet as an example, which are most typically made of a single, homogeneous material such as wood, steel, plastic or pulp.
  • a multi-layer composite pulp pallet in accordance with the present disclosure is quite different from the traditional pulp pallet.
  • a multi-layer composite pulp pallet may be composed of multi-layer pulp molding material. The number of layers of pulp molding material can be determined according to the loads anticipated to be sustained by the pallet during its use.
  • a high strength ductile material e.g., prefabricated
  • the reinforcement layer may be fused to the pulp layers adjacent to opposing sides of the reinforcement layer, so as to greatly increase the thickness and strength of the pulp molded pallet.
  • the shape of the high strength ductile material and the shape of the pulp molding are configured to fit each other.
  • High strength ductile materials may include, for example, plastic (e.g., recycled plastic), metal mesh, sheet metal, high strength fiber, some combination thereof or the like.
  • FIG. 1 is a diagrammatic perspective view of one non-limiting example of a multi-layer composite pulp product, in the form of a pallet;
  • FIG. 2 is a further diagrammatic perspective view of the example multilayer composite pulp product of FIG. 1;
  • FIG. 3 is a diagrammatic top view of the example multi-layer composite pulp product of FIG. 1;
  • FIG. 4 is a diagrammatic cross-sectional view taken along lines 4-4 of FIG. 3;
  • FIG. 5 is a magnified view of detail 5 in FIG. 4;
  • FIG. 6 is a diagrammatic exploded cross-sectional view of the example multi-layer composite pulp product of FIG. 1, taken along lines 4-4 of FIG. 3;
  • FIG. 7 is a diagrammatic view of one non-limiting system for manufacturing a multi-layer composite pulp product, shown prior to implementation of the system;
  • FIG. 8 is a diagrammatic view of the manufacturing system of FIG. 7, but wherein an example reinforcement layer fabrication subsystem is shown fabricating an example reinforcement layer, and a quantity of fluid pulp is shown applied to an example forming mold;
  • FIG. 9 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 8, wherein the reinforcement layer has now been removed from the fabrication subsystem, and a formed soggy first pulp layer now resides on the forming mold ready for transfer;
  • FIG. 10 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 9, wherein the transfer mold has now received the formed soggy first pulp layer from the forming mold;
  • FIG. 11 is a diagrammatic view of the manufacturing system of FIG. 7, but showing steps subsequent to those shown in FIG. 10, wherein the transfer mold and the lower hot press mold have moved into alignment with one another;
  • FIG. 12 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 11, wherein the soggy first pulp layer has now been released from the transfer mold and onto the lower hot press mold;
  • FIG. 13 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 12, wherein the reinforcement layer is being placed onto the soggy first pulp layer residing on the lower hot press mold, and the transfer mold has returned to alignment with the forming mold;
  • FIG. 14 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 13, wherein the transfer mold has now received a formed soggy second pulp layer from the forming mold;
  • FIG. 15 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 14, wherein the transfer mold with the soggy second pulp layer has returned into alignment with the lower hot press mold;
  • FIG. 16 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 15, wherein the soggy second pulp layer has now been released from the transfer mold and positioned onto the reinforcement layer, thereby completing formation of an example wet precursor composite;
  • FIG. 17 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 16, wherein the lower hot press mold with the wet precursor composite has now moved into alignment with a corresponding upper hot press mold;
  • FIG. 18 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 17, wherein the precursor wet composite is now being dried under compression between the upper and lower hot press molds;
  • FIG. 19 is a diagrammatic view of the manufacturing system of FIG. 7, but showing manufacturing steps subsequent to those shown in FIG. 18, wherein the multi-layer composite pulp product is now released (e.g., ejected) from the upper and lower hot press molds;
  • FIG. 20 is a diagrammatic side view of an example multi-layer composite pulp product in the form of a pallet, wherein the pallet is shown supporting a load above a local substrate’
  • FIG. 21 is a diagrammatic top view of a second non-limiting example of a multi-layer composite pulp product in the form of a pallet;
  • FIG. 22 is a diagrammatic cross-sectional view taken along lines 22-22 of FIG. 21;
  • FIG. 23 is a diagrammatic magnified view of detail 23 in FIG. 22;
  • FIG. 24 is a diagrammatic exploded cross-sectional view of the example multi-layer composite pulp product of FIG. 21, taken along lines 22-22 of FIG. 21;
  • FIG. 25 is a diagrammatic view of one non-limiting example of a step of fabricating a reinforcement layer from a plastic sheet, for example by way of vacuum forming or stamping operation;
  • FIG. 26 is a diagrammatic view of a second non-limiting system for manufacturing a multi-layer composite pulp product, showing a formed pulp layer retained on an upper hot press mold, and a first reinforcement layer placed on a lower hot press mold;
  • FIG. 27 is a diagrammatic view of the manufacturing system of FIG. 26, but wherein the lower hot press mold is moved into alignment with the upper hot press mold;
  • FIG. 28 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 27, wherein the upper hot press mold and the lower hot press mold are moved toward one another to compress the pulp layer and first reinforcement layer together with heat and pressure;
  • FIG. 29 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 28, wherein the upper and lower hot press molds are separated, the lower hot press mold is moved out of alignment with the upper hot press mold, and a second reinforcement layer is placed on the pulp layer;
  • FIG. 30 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 29, wherein the lower hot press mold is moved back into alignment with the upper hot press mold;;
  • FIG. 31 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 30, wherein the upper hot press mold and the lower hot press mold are moved toward one another to press the second reinforcement layer, the pulp layer and the first reinforcement layer together with heat and pressure;
  • FIG. 32 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 31, wherein the upper and lower hot press molds are separated, the lower hot press mold is moved out of alignment with the upper hot press mold, and the manufactured multi-layer composite pulp product is retained on the upper hot press mold; and
  • FIG. 33 is a diagrammatic view of the manufacturing system of FIG. 26, but showing manufacturing steps subsequent to those shown in FIG. 32, wherein the manufactured multi-layer composite pulp product is shown being ejected from the upper hot press mold.
  • a multi-layer composite pulp product is shown generally at 100.
  • a multi-layer composite pulp product 100 may be in the form of a pallet.
  • a multi-layer composite pulp product 100 may comprise a first pulp layer 102, a second pulp layer 104 and a reinforcement layer 106 disposed (e.g., fused) between the first pulp layer 102 and the second pulp layer 104.
  • the product 100 may be shaped to have a pattern of opposingly-disposed cavities 110 and protrusions 112.
  • Such cavities 110 and protrusions 112 may take the form of, for example, stiffener channels 130 or pallet feet 132.
  • the first pulp layer 102 may have a first pattern 108a of opposingly-defined cavities 110a and protrusions 112a; the second pulp layer 104 may have a second pattern 108b of opposingly-defined cavities 110b and protrusions 112b; and the reinforcement layer 106 may have a reinforcement pattern 108c of opposingly-defined cavities 110c and protrusions 112c.
  • the reinforcement pattern 108c is aligned with the first pattern 108a and the second pattern 108b.
  • the product 100 may extend in generally planar fashion radially of a main axis 114.
  • the alignment of respective cavities and protrusions is preferably in a direction parallel to the main axis.
  • One or more of the various layers described herein may preferably be formed with a uniform wall thickness.
  • the first pulp layer 102 may have a uniform wall thickness 116
  • the second pulp layer 104 may have a uniform wall thickness 118
  • the reinforcement layer 106 may have a uniform wall thickness 120.
  • the uniform wall thickness 120 of the reinforcement layer 106 may be different from the uniform wall thickness (116, 118) of both the first pulp layer 102 and the second pulp layer 104.
  • the reinforcement layer 106 may preferably be comprised of a plastic (e.g., recycled plastic), a metallic mesh, a metallic sheet (e.g., metal board), some combination thereof or the like.
  • the pulp layers (102, 104) may comprise raw material such as recycled paper and/or corrugated boxes.
  • the pulp layers may comprise chemical fibers such as waste carpet, at a concentration of, for example, 2-5% of the overall weight of the dried pulp layer.
  • the first pulp layer 102 and the second pulp layer 104 may comprise alkyl ketene dimer (AKD) sizing agent, or the like.
  • FIGS. 7-19 diagrammatically illustrate a system 200 for manufacturing a multi-layer composite pulp product 100, as the system 200 proceeds through the sequence of the manufacturing process.
  • the manufacturing process may comprise fabricating a reinforcement layer 106.
  • This fabrication may be by way of, for example, a reinforcement layer fabrication subsystem 202.
  • the subsystem 202 may comprise, for example, a first fabrication element 204 and a second fabrication element 206.
  • the fabrication elements may be, for example, complementary injection molding tools, metal stamping tools, or the like.
  • the fabrication elements may represent injection molding core/cavity tooling for forming the reinforcement layer 106 into the requisite shape.
  • the fabrication elements (204, 206) may represent complimentary metal stamping (e.g., pressing) tooling for forming the reinforcement layer 106 into the requisite shape.
  • the manufacturing process may comprise forming a soggy first pulp layer 102.
  • a pulp reservoir 208 may be provided with fluid pulp 210.
  • the fluid pulp may have a pulp concentration of, for example, 1.5% to 4% pulp.
  • a forming mold 212 may be partially or entirely submerged into the fluid pulp 210, where a quantity 220 of fluid pulp is applied to the forming mold 212.
  • the quantity of fluid pulp may then be dehydrated (e.g., by way of vacuum dehydration) on the forming mold 212 for a set time for forming and dehydration.
  • Such forming and dehydration may preferably leave the first pulp layer 102 formed in shape, but still soggy (i.e., not fully dehydrated).
  • the soggy first pulp layer 102 may be transferred onto a lower hot press mold 216 by way of a transfer mold 214. More particularly, referring to FIG. 10, the transfer mold 214 may drop and absorb the formed soggy first pulp layer 102. Referring to FIG. 11, the transfer mold 214 may then move up and slide over the top of the lower hot press mold 216. Referring to FIG. 12, the soggy first pulp layer 102 may be dropped, or blown via compressed air, into the lower hot press mold 216.
  • the reinforcement layer may be placed the on the soggy first pulp layer 102, either by manual or machine operation.
  • a soggy second pulp layer 104 may be formed and transferred in a manner similarly or identical to that of the soggy first pulp layer 102.
  • the soggy second pulp layer 104 may be dropped, or blown via compressed air, into positioning on the reinforcement layer.
  • a precursor wet composite 222 may be defined by the soggy first pulp layer 102, the reinforcement layer 106, and the soggy second pulp layer 104 being in a stacked configuration on the lower hot press mold 216.
  • the fabricated reinforcement layer 106 may have a reinforcement pattern 108c of opposingly-defined cavities 110c and protrusions 112c.
  • the formed soggy first pulp layer 102 may have a first pattern 108a of opposingly- defined cavities 110a and protrusions 112a.
  • the formed soggy second pulp layer 104 may have a second pattern 108b of opposingly-defined cavities 110b and protrusions 112b.
  • the reinforcement pattern 108c is preferably in alignment with the first pattern 108a and the second pattern 108b.
  • the precursor wet composite 222 may be dried at a selected heating temperature and under a selected pressure.
  • the lower hot press mold 216 may slide directly under a corresponding upper hot press mold 218.
  • the step of drying may then involve compression of the precursor wet composite 222 between the lower hot press mold 216 and an upper hot press mold 218 at the selected temperature and pressure for a set time.
  • the heating temperature may be, for example, from 150 to 260 degrees Celsius.
  • the selected pressure may be, for example, from 19-29 PSI.
  • a quantitative waterproof preservative may be added to the fluid pulp 210 to avoid the influencing the strength of the product/pallet in wet operational environment.
  • the fluid pulp 210 may have alkyl ketene dimer (AKD) sizing agent (e.g., 0.8% to 2%) added.
  • the soggy first pulp layer 102 and the soggy second pulp layer 104 may comprise a percentage of alkyl ketene dimer (AKD) sizing agent.
  • the upper hot press mold 218 and lower hot press mold 216 may be separated, and the dried multi-layer pulp product 100 removing therefrom.
  • the dried multi-layer pulp composite product 100 may be removed to complete the processing.
  • the product 300 may comprise a pulp layer 302 and an upper reinforcement layer 306.
  • the pulp layer 302 may have a lower face 322 and an upper face 324 disposed oppositely of one another.
  • the pulp layer 302 may have a core pattern 308a of opposingly-defined cavities 310a and protrusions 312a.
  • the upper reinforcement layer 306 may be comprised of molded plastic sheet and may have an upper reinforcement pattern 308c of opposingly- defined cavities and protrusions.
  • the upper reinforcement layer may preferably be affixed to the upper face 324 with the upper reinforcement pattern 308c being aligned with the core pattern 308a.
  • particular embodiments of the product 300 may further comprise a lower reinforcement layer 304 comprised of molded plastic sheet and having a lower reinforcement pattern 308b of opposingly-defined cavities and protrusions.
  • the lower reinforcement layer 304 may preferably be affixed to the lower face 322 with the lower reinforcement pattern 308b being aligned with the core pattern 308a.
  • the product 300 may extend in generally planar fashion radially of a main axis 314 so as to form, for example, a pallet shape.
  • the alignments of the agreement patters are preferably in a direction parallel to the main axis 314.
  • the pulp layer 302 may have a uniform wall thickness 316
  • the lower reinforcement layer 304 may have a uniform wall thickness 318
  • the upper reinforcement layer 306 may have a uniform wall thickness 320.
  • the uniform wall thicknesses of the reinforcement layers (304, 306) may be different from the uniform wall thickness of the pulp layer 302.
  • the reinforcement layers may be comprised of a recycled plastic.
  • FIGS. 25- 33 Certain example implementations of a process for manufacturing a multilayer composite pulp product 300 are represented by the sequence illustrated in FIGS. 25- 33.
  • FIGS. 26-33 diagrammatically illustrate one example of a system 400 for manufacturing a multi-layer composite pulp product 300, as the system 400 proceeds through the sequence of the manufacturing process.
  • one or more plastic sheets 326 may be obtained.
  • the plastic sheets 326 may preferably be comprised of a recycled plastic.
  • a lower reinforcement layer 304 may be fabricated from a first plastic sheet 326 so as to have a lower reinforcement pattern 308b of opposingly-defined cavities and protrusions.
  • an upper reinforcement layer 306 may be fabricated from a second plastic sheet so as to have an upper reinforcement pattern 308c of opposingly-defined cavities and protrusions. This fabrication may preferably involve, for example, vacuum forming, stamping, or the like.
  • a pulp layer 302 may be formed so as to have a core pattern 308a of opposingly-defined cavities and protrusions.
  • the formed pulp layer 302 may initially be retained on an upper hot press mold 402.
  • the lower reinforcement layer 304 may be placed on a lower hot press mold 404.
  • the pulp layer 302 may be placed on the lower reinforcement layer 304.
  • the upper reinforcement layer 306 may then be placed on the pulp layer 302, for example after the lower hot press mold 404 is moved out of alignment with the upper hot press mold 402.
  • the upper reinforcement layer 306, the pulp layer 302 and the lower reinforcement layer 304 may be pressed together, for example by way of mutual engagement between the upper hot press mold 402 and the lower hot press mold 404, with the lower and upper reinforcement patterns being aligned with the core pattern.
  • This step of pressing may be at a first selected heating temperature and under a first selected pressure.
  • particular implementations of a process for manufacturing a multi-layer composite pulp product 300 may further comprise, after the step of positioning the pulp layer 302 on the lower reinforcement layer 304, compressing the pulp layer 302 and lower reinforcement layer together 304. This step of compressing may be at a second selected heating temperature and under a second selected pressure.
  • the heating temperatures may preferably from 150 to 260 degrees Celsius.
  • the selected pressures may preferably be 19-29 PSI.
  • the first selected heating temperature may preferably be different from the second selected heating temperature.
  • the first selected pressure may be different from the second selected pressure.
  • 128 substrate e.g., ground, floor or storage shelf
  • first fabrication element e.g., stamping or injection molding core/cavity tool
  • second fabrication element e.g., stamping or injection molding core/cavity tool

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Des exemples de modes de réalisation de l'invention concernent un produit de pâte composite multicouche comprenant une ou plusieurs couches de pâte, et une ou plusieurs couches de renforcement disposées entre celles-ci. Chacune de ces couches comprend de préférence un motif respectif de cavités et de parties saillantes définies de manière opposée, la disposition mutuelle des couches conduisant à l'alignement axial de leurs motifs les uns avec les autres. Les couches de renforcement peuvent être constituées d'un plastique recyclé, d'un treillis métallique ou d'une feuille métallique. Un exemple de procédé pour fabriquer un produit de pâte composite multicouche peut comprendre la fabrication d'une couche de renforcement, la formation d'une première couche de pâte détrempée, le placement d'une couche de renforcement sur la première couche de pâte détrempée, la formation d'une deuxième couche de pâte détrempée et le positionnement de la deuxième couche de pâte détrempée sur la couche de renforcement. Un composite humide précurseur peut ainsi être formé, et peut être séché à une température de chauffage sélectionnée et sous une pression sélectionnée.
PCT/US2022/049630 2022-08-19 2022-11-10 Produit de pâte composite multicouche, et système et procédé de fabrication de celui-ci WO2024039387A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4221751A (en) * 1979-03-07 1980-09-09 Board Of Control Of Michigan Technological University Articles molded from papermill sludge
US4790966A (en) * 1986-06-30 1988-12-13 Board Of Control Of Michigan Technological University Method for forming a pallet with deep drawn legs
US5246772A (en) * 1990-10-12 1993-09-21 James River Corporation Of Virginia Wetlaid biocomponent web reinforcement of airlaid nonwovens
US5435954A (en) * 1993-10-08 1995-07-25 Riverwood International Corporation Method for forming articles of reinforced composite material
US5769001A (en) * 1994-05-04 1998-06-23 Viessmann; Hans Load-carrying pallet
JP2001058375A (ja) * 1999-08-20 2001-03-06 Dainippon Printing Co Ltd 壁装用シート
US20160368659A1 (en) * 2015-06-22 2016-12-22 Bastian Solutions, Llc Composite concrete pallet
US20170073902A1 (en) * 2014-04-23 2017-03-16 Hewlett-Packard Development Company, L.P. Packaging material and method for making the same

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4221751A (en) * 1979-03-07 1980-09-09 Board Of Control Of Michigan Technological University Articles molded from papermill sludge
US4790966A (en) * 1986-06-30 1988-12-13 Board Of Control Of Michigan Technological University Method for forming a pallet with deep drawn legs
US5246772A (en) * 1990-10-12 1993-09-21 James River Corporation Of Virginia Wetlaid biocomponent web reinforcement of airlaid nonwovens
US5435954A (en) * 1993-10-08 1995-07-25 Riverwood International Corporation Method for forming articles of reinforced composite material
US5769001A (en) * 1994-05-04 1998-06-23 Viessmann; Hans Load-carrying pallet
JP2001058375A (ja) * 1999-08-20 2001-03-06 Dainippon Printing Co Ltd 壁装用シート
US20170073902A1 (en) * 2014-04-23 2017-03-16 Hewlett-Packard Development Company, L.P. Packaging material and method for making the same
US20160368659A1 (en) * 2015-06-22 2016-12-22 Bastian Solutions, Llc Composite concrete pallet

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