EP4045712A1 - Procédé de production de pièces moulées en matériau fibreux, ledit matériau fibreux étant dégradable d'une manière respectueuse de l'environnement - Google Patents

Procédé de production de pièces moulées en matériau fibreux, ledit matériau fibreux étant dégradable d'une manière respectueuse de l'environnement

Info

Publication number
EP4045712A1
EP4045712A1 EP20803081.7A EP20803081A EP4045712A1 EP 4045712 A1 EP4045712 A1 EP 4045712A1 EP 20803081 A EP20803081 A EP 20803081A EP 4045712 A1 EP4045712 A1 EP 4045712A1
Authority
EP
European Patent Office
Prior art keywords
molded part
suction
pressing
tool
pulp
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
EP20803081.7A
Other languages
German (de)
English (en)
Inventor
Gerhard Wieser
Richard Hagenauer
Matthias Hausmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kiefel GmbH
Original Assignee
Kiefel GmbH
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 Kiefel GmbH filed Critical Kiefel GmbH
Publication of EP4045712A1 publication Critical patent/EP4045712A1/fr
Pending legal-status Critical Current

Links

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

  • the invention relates to a method for producing molded parts from environmentally degradable fiber material by means of a fiber molding process in a fiber molding plant, such a fiber molding plant for carrying out the above method and a molding produced with such a fiber molding plant or with such a method.
  • the raw material basis here is pulp.
  • the pulp consists of water, natural fibers and a binding agent such as industrial starch (potato starch) and has a pulpy consistency.
  • the invention is based on the object of providing a production method for environmentally compatible molded parts made of natural fibers and a corresponding machine with which these products (molded parts) can be produced in an effective, flexible and reproducible manner with good quality.
  • the object of the invention is achieved by a method for the production of molded parts from environmentally compatible degradable fiber material by means of a fiber molding process in a fiber molding plant, comprising the following steps:
  • the suction tool comprising a suction head with a three-dimensionally shaped suction head suction side, the shape of which is adapted to a contour of the later molded part;
  • the term "environmentally compatible degradable fiber material” refers to fiber materials that decompose under environmental influences such as moisture, temperature and / or light The decomposition process takes place in the short term, for example in the range of days, weeks or a few months.
  • the “environmentally compatible degradable fiber material” is also sometimes referred to as “fiber material” in the following. In this case, neither the fiber material nor the decomposition products should pose an environmental hazard or contamination.
  • Fiber materials, which in the sense of the present invention represent an environmentally compatible degradable fiber material are for example natural fibers obtained from cellulose, paper, cardboard, wood, grass, plant fibers, sugar cane residues, hemp etc. or from their components or parts thereof and / or appropriately recycled material.
  • An environmentally compatible, degradable fiber material can also designate artificially produced fibers such as PLA (polylactide) etc., which correspond to the above fiber materials or have their properties.
  • the environmentally compatible degradable fiber material is compostable.
  • the environmentally compatible, degradable fiber material and the containers made from it are preferably suitable for introduction into the recycling of materials in the German biowaste bin and as a resource for biogas plants.
  • the fiber materials and the containers made from them are preferably biodegradable in accordance with EU standard EN 13432.
  • the term “pulp” refers to fluid masses that contain fibers, in this case the environmentally friendly degradable fiber material.
  • liquid here denotes the physical state of the pulp, the liquid pulp comprising the environmentally compatible, degradable fiber material in the form of fibers.
  • the fibers can be present as individual fibers, as a fiber structure or fiber group consisting of several connected fibers.
  • the fibers represent the fiber material regardless of whether they are in the pulp as individual fibers, fiber structures or fiber groups.
  • the fibers are dissolved in the liquid solution in such a way that they float in the liquid solution with the same concentration as possible, regardless of location, for example as a mixture or suspension of liquid solution and fiber material.
  • the pulp can be appropriately tempered and / or circulated in some embodiments.
  • the pulp preferably has a low consistency, ie a proportion of fiber material less than 8%.
  • a pulp with a proportion of environmentally compatible degradable fiber material of less than 5%, preferably less than 2%, particularly preferably between 0.5% and 1.0%, is used in the process according to the invention.
  • This low proportion of fiber material can, among other things, prevent the fiber material from clumping together in the liquid solution, so that the fiber material can still be molded to the suction tool with good quality.
  • the liquid solution can be any solution suitable for the fiber molding process.
  • the pulp can be an aqueous solution with the environmentally friendly degradable fiber material.
  • An aqueous solution is, among other things, an easy-to-use solution.
  • the fiber molding process refers to the process steps that are involved in the formation of the molded part starting with the provision of the pulp, the molding of the molded part in the suction tool from the fiber material from the pulp, the pre-pressing of the molded part, the hot pressing of the molded part and, if necessary, the coating of the molded part with functional layers, whereby the coating can be arranged at any point in the fiber molding process that is suitable for the respective layer to be applied.
  • the molded parts can have any shape, also referred to here as a contour, provided that this shape (or contour) can be produced in the method according to the invention or the method is suitable for producing this shape (or contour).
  • the components used for the fiber molding process can be adapted to the respective shape (or contour) of the molded part.
  • different appropriately adapted components such as the suction tool, the suction head, the pre-pressing station, the hot press station etc. can be used.
  • End-formed molded parts can represent a wide variety of products, for example cups, containers, vessels, lids, bowls, portion containers, envelopes or containers for a wide variety of purposes.
  • the suction tool here refers to the tool in which the suction head (s) for forming the molded part are arranged. In the case of a single suction head, this is also the suction tool. In the case of several simultaneously operated suction heads, these are all arranged in the common suction tool, so that when the suction tool is moved, the individual suction heads in the suction tool are moved along with it. The media supply of the suction tool with several suction heads is guided in a suitable manner in the suction tool to the individual suction heads.
  • Placing the suction tool on the pulp refers to touching the pulp with all suction heads located in the suction tool, which are provided for the molding of molded parts, in such a way that the fiber material is sucked out of the pulp due to the negative pressure applied to the pulp with the suction tool or the pulp with the fiber material dissolved therein is sucked in.
  • the suction tool is not only placed on the pulp, but dipped into it.
  • the depth of immersion of the suction tool in the pulp depends on the respective application and the respective fiber molding process and can differ depending on the application and, if applicable, the molded part to be molded.
  • Partial immersion of the suction head or the suction tool is advantageous because the pulp level in the reservoir could fluctuate due to the movements of the suction head / suction tool and if the pulp surface is uneven due to wave movements, a mere placement could result in locally inadequate suction.
  • the suction head can have a so-called negative shape.
  • a negative shape is a shape where the suction side of the suction head, i.e. the side where the fiber material is deposited due to the suction effect of the suction head and thus forms the molded part, is on the inside of the suction head, so that this inside is located on the Pulp or dipping the suction head into the pulp Forms cavity into which the pulp with the fiber material is sucked (as shown in Fig. 2).
  • the outside of the later molded part is directed towards the inside of the suction head. After molding, the molded part therefore sits on the inside on the inside of the suction head.
  • the suction head can alternatively also have a so-called positive shape.
  • a positive form is a form where the suction side of the suction head, i.e. the side where the fiber material is deposited due to the suction effect of the suction head and thus forms the molded part, is on the outside of the suction head, so that this outside is located on the Pulp or immersion of the suction head in the pulp does not form a cavity (as shown in Fig. 3).
  • the inside of the later molded part is directed towards the outside of the suction head. After molding, the molded part therefore sits on the outside of the suction head.
  • the forming of the molded part denotes a first pre-forming of the molded part, this being formed from fiber material previously randomly distributed in the pulp by means of the attachment of the fiber material to the contour of the suction head with the corresponding contour.
  • the molded part still has a large proportion, for example 70% -80%, of liquid solution, for example water, and is therefore not yet stable in terms of shape.
  • the pre-pressing of the molded part significantly reduces the proportion of the liquid solution in the molded part, for example to 55% - 65%, so that the contour of the molded part is now much more stable.
  • the molded part With the hot pressing of the pre-pressed molded part with a hot press pressure, the molded part is finally shaped with a further reduction of the proportion of the liquid solution in the molded part, for example to below 10%, preferably to about 7%, after which it is then stable and dimensionally stable.
  • the output of the finished molded part refers to the release of the molded part for further transport or further processing, for example to cutting, labeling, printing and / or packing stations.
  • a molded part is produced in a simple manner from a fiber material which, depending on the configuration of the contour of the suction head, can deliver molded parts with a wide variety of contours.
  • the ratio of width or diameter to height of the molded part does not represent a limiting or critical parameter for the quality of the production of the respective molded parts.
  • the molding, pre-pressing and hot pressing steps the molded parts can be very reproducible and with great accuracy and quality in terms of shape and the layer thickness of the individual molded part sections can be produced.
  • the manufacturing process is able to process fibers of the most varied types, provided that they can be brought into solution in such a way that greater clumping of the fibers in the liquid solution can be avoided before processing.
  • stable molded parts can be produced easily, effectively and flexibly from environmentally friendly degradable fiber material with good quality and good reproducibility in this way.
  • the method according to the invention thus represents a production method for environmentally compatible molded parts made of natural fibers and a corresponding machine with which these products (molded parts) can be produced in an effective, flexible and reproducible manner with good quality.
  • the pulp does not comprise an organic binder, preferably likewise no non-organic binder.
  • the molded parts produced from originally environmentally degradable fiber material can still be degraded in an environmentally compatible manner, since no environmentally critical binder, preferably no binder at all, is used.
  • the elimination of binders is made possible by the combination of the molding, pre-pressing and hot pressing steps, which in their entirety ensure good mechanical interlinking of the individual fibers with one another in the fiber material of the molded part.
  • the mechanical linkage is so strong that binders can be dispensed with for dimensional stability of the molded part.
  • the environmentally compatible degradable fiber material consists essentially of fibers with a fiber length of less than 5 mm. With fibers of this length one obtains, among other things, a good homogeneous solution of the fiber material in the liquid solution, so that the degree of clumping of the fibers in the pulp is sufficiently low for a good reproducible fiber molding process for the molded part.
  • the pulp is provided with a temperature of less than or equal to 80 ° C., preferably less than or equal to 50 ° C., particularly preferably room temperature. These low temperatures allow, among other things, simple process management, in particular at room temperature.
  • the pulp comprises dopants or constituents which are introduced into the fiber material via the pulp at the start of the molding process.
  • doping can be, for example, fragrances, flavorings, active ingredients, minerals, nutritional and care additives, etc., which diffuse out of the fiber material due to the later use and the then prevailing conditions, are dissolved or are left behind when the molded part is broken down in an environmentally friendly way.
  • the suction head is completely immersed in the pulp for contacting.
  • Complete immersion is particularly suitable for a suction head as a positive form, since, in contrast to a negative form, there is no inner cavity in the suction head in which a negative pressure can be generated between the pulp and the suction surface for sucking the fiber material.
  • a positive mold it is advantageous in the case of a positive mold to immerse the suction head completely into the pulp.
  • the suction head suction side of the suction head is formed from a porous screen, on whose pulp side facing the pulp the environmentally degradable fiber adheres due to the suction for forming the molded part.
  • the sieve must have a porosity so that the pulp including the fiber material can be sucked through the sieve and the liquid solution of the pulp can pass through the sieve can. Nevertheless, the porosity of the screen must not be too great so that the fiber material can adhere to the pulp side.
  • the liquid pulp solution passing through the sieve is removed from the suction tool during the molding.
  • the content of the liquid solution in the molded fiber material is already reduced by, for example, approx. 20% - 30% compared to the pulp.
  • This liquid solution passes through the sieve into the suction head. So that the suction head does not have to store the liquid solution temporarily, it is removed from the suction head and thus also from the suction tool.
  • the discharged liquid solution can be fed back into a pulp processor and reused in the fiber molding process.
  • the suction head comprises, on its end face facing the pulp, a collecting ring for receiving the liquid solution to be discharged, to which a discharge channel for the liquid solution is connected.
  • the suction tool comprises a plurality of suction channels distributed around the screen on its side opposite the pulp side.
  • the large number of suction channels makes it possible, among other things, to suck in pulp with fiber material over the entire surface of the screen so that the molded part can be formed flat on the screen.
  • the suction channels are distributed and arranged around the sieve and a structure of the sieve is designed such that an essentially identical suction power is applied in all areas of the pulp side of the sieve.
  • the term “essentially” here denotes a homogeneity of the suction power that is sufficient to produce a uniformly molded part without any significant variations in layer thickness at the corners and edges of the molded part as well as over the surfaces of the molded part.
  • the resulting end-formed molded part has a variation in the layer thickness of less than 7% to the desired layer thickness.
  • the suction channels for this purpose have an uneven distribution below the screen, with around 50% fewer suction channels per unit area being arranged in the area of (negative shapes or inner edge) edges in the molded part. In the case of positive or outside edges, the number of suction channels is increased by approx. 20% per unit area.
  • This lower density of suction channels in the area of edges here refers to all corners and edges, depressions and other major contour changes in the molded part) means that excess material or material deficits in the area of the edges are avoided relative to other material thicknesses on surfaces without edges.
  • the suction tool is a multi-tool with a plurality of suction heads.
  • a multi-tool With a multi-tool, a large number of molded parts can be formed simultaneously from a common pulp bath according to the number of suction heads, which increases the throughput of the fiber molding system and thus allows the fiber molding system to be produced more economically.
  • the suction head suction surface is designed either as a negative shape on the inside of the suction head or as a positive shape on the outside of the suction head.
  • negative form and “positive form”, reference is made to the explanations given above.
  • negative shapes or positive shapes of the suction head can be advantageous.
  • the molded part remains on the suction tool for pre-pressing. Since the molded part is still relatively moist when it is molded in the suction head and therefore not dimensionally stable, it is advantageous for an error-free and high-quality process to leave the molded part in the suction head at least until the pre-pressing is complete, in order to avoid any mold-damaging tool changes for the molded part.
  • the pre-press station comprises a pre-press lower tool to which the suction tool with the molded part is attached so that it is arranged between the pre-press lower tool and the suction tool and the suction tool is pressed onto the pre-press lower tool with the pre-press pressure.
  • the suction tool is designed to be suitable for exerting the pre-compression pressure on the pre-compression lower tool.
  • the suction tool can be pressed onto a stationary pre-press lower tool or the pre-press lower tool is pressed onto a stationary suction tool.
  • the term “apply” only refers to the relative movement of the suction tool to the pre-press lower tool.
  • the suction tool represents the upper pre-press tool of the pre-press station.
  • the suction tool is placed on the lower pre-press tool and pressed onto the lower pre-press tool by means of a separate pressing unit, preferably a piston rod.
  • the suction tool can also be attached to a robot arm, which exerts the pre-compression pressure itself via the suction tool on the pre-compression lower tool.
  • the pre-compression lower tool can also be designed as a multi-tool in order to apply the pre-compression pressure to all molded parts of the suction tool simultaneously and thus to carry out pre-compression for all molded parts simultaneously.
  • the suction tool with a negative shape as a suction head suction surface is placed on the pre-press lower tool (with a corresponding positive mold) or inserted with a positive shape as a suction head suction surface in the pre-press lower tool (as a corresponding negative mold).
  • the pre-press lower tool has a pressing surface facing the molded part, which has a lower surface roughness than the screen. This exerts a homogeneous pressure on the molded part.
  • the adhesion between the pre-press lower tool and the molded part is less than with structured surfaces of the pre-pressed lower tool, which ensures that the pre-pressed molded parts can be passed on to the hot-pressing station without any additional equipment Measures remain in the suction tool and not on the pre-press lower tool, which would cause a disruption in the production process.
  • the suction tool can generate a suitable negative pressure in the suction tool for the transfer of the pre-pressed molded parts to the hot-pressing station in order to improve the adhesion of the molded parts to the suction tool.
  • the pre-press lower tool is made of metal or at least partially made of an elastomer, preferably made of silicone.
  • Pre-pressing lower tools made of metal are particularly suitable for cases where a temperature greater than room temperature or a particularly high pre-pressing pressure is to be applied during pre-pressing.
  • Prepress lower tools made from an elastomer or at least partially from the elastomer are advantageous for multi-tools as suction tools and pre-press lower tools, since the elastomer can still be easily deformed under pressure and thus flexibly adapts to a multi-suction tool that may bend under the prepress pressure and This improves the homogeneity of the shaping of the various molded parts in the multi-suction tool.
  • silicone for example, is also well suited as an elastomer as a temperature-resistant material in this area.
  • the pre-pressing is carried out as a membrane pressing.
  • Membrane pressing is particularly suitable for geometries of the molded part where pressure is to be exerted on a large area.
  • surfaces can also be simultaneously put under the same pressure, which are perpendicular to one another in any spatial orientation, since with membrane pressing the pre-compression pressure is generated by gas pressure, for example by means of compressed air, which acts on the membrane in any direction. This would not be possible with a plunger rod, for example.
  • the pre-press lower tool for membrane pressing is therefore designed as a flexible membrane and the pre-pressing pressure is applied to the membrane as gas pressure, which is then pressed onto the outer contour of the molded part.
  • the membrane is impermeable to gas and flexible in order to be able to adhere to the To be able to nestle the shape of the molded part.
  • Rubber membranes for example, can be used as membranes.
  • the membrane should have a contour accuracy of less than 20% and can be designed differently locally, for example with thinner and thicker walls and / or arranged closer to the contour or further away from it.
  • the pre-pressing is carried out at a temperature of the pre-pressing station of less than 80 ° C., preferably less than 50 ° C., particularly preferably at room temperature.
  • a temperature of the pre-pressing station of less than 80 ° C., preferably less than 50 ° C., particularly preferably at room temperature.
  • the pre-pressing is carried out at the pre-pressing pressure between 0.2 N / mm 2 and 0.3 N / mm 2 , preferably between 0.23 N / mm 2 and 0.27 N / mm 2 .
  • These moderate pressures which are lower than the hot pressing pressure, enable the molded part to solidify gently with moderate liquid reduction, which is advantageous for a low-reject hot pressing process.
  • the method comprises the step of transferring the pre-pressed molded part to the hot-pressing station by means of the suction tool, the molded part being removed from the suction tool for subsequent hot-pressing.
  • the transfer is advantageous in that the hot pressing is carried out at a high temperature with a significantly higher pressure. If the molded part were to remain in the suction tool without being transferred for hot pressing, the fiber material could get caught in the sieve of the suction tool and be removed from the suction tool only with difficulty, possibly only with damage after the hot pressing. In addition, the strainer could be damaged by the high pressure, so that the suction tool would then no longer be functional.
  • the hot press station comprises a hot press lower tool with a hot press side adapted to a contour of the molded part and a correspondingly shaped hot press upper tool Hot pressing the upper hot pressing tool is pressed onto the lower hot pressing tool with the molded part arranged in between.
  • the molded part is placed on the hot press lower tool (negative shape) or inserted (positive shape).
  • the hot-pressing side is the outside in the case of a negative mold and the inside of the hot-pressing lower tool in the case of a positive mold.
  • the hot-press upper tool is correspondingly complementary in shape.
  • the two hot-press upper and lower tools can work together to apply high pressures at high temperatures to the molded part in between.
  • at least the hot-pressing lower tool is made of metal for this purpose.
  • the hot-pressing lower tool comprises channels on its outside, with which the liquid solution can be at least partially removed during hot pressing.
  • the liquid solution can be at least partially removed during hot pressing.
  • the hot-press upper tool is adapted to the contour of the molded part at least with the side facing the molded part; the hot-press upper tool is preferably made of metal.
  • the hot press lower tool and the hot press upper tool have different temperatures during hot pressing, preferably the hot press upper tool has a higher temperature than the hot press lower tool. This gives the molded part, among other things, a better surface, especially on the warmer side.
  • the temperatures differ for this by at least 25 ° C, preferably not more than 60 ° C, particularly preferably by 50 ° C.
  • the hot pressing is carried out at a temperature greater than 150.degree. C., preferably between 180.degree. C. and 250.degree. This enables the liquid (or moisture) in the molded part to be reduced to less than 10%.
  • the hot pressing is carried out at the hot pressing pressure higher than the pre-pressing pressure. This enables the liquid (or moisture) in the molded part to be reduced to below 10%, in particular in combination with the above temperatures.
  • the hot pressing pressure is carried out between 0.5 N / mm 2 and 1.5 N / mm 2 , preferably between 0.8 N / mm 2 and 1.2 N / mm 2 .
  • the hot pressing pressure is applied for a pressing time of less than 20s, preferably more than 8s, particularly preferably between 10 and 14s, even more preferably 12s.
  • the liquid (or moisture) in the molded part can be reduced to below 10%, in particular in combination with the above temperatures and hot pressing pressures.
  • the contour of the molded part is designed in such a way that all surfaces of the molded part have an angle ⁇ of at least 3 degrees to the pressing direction during hot pressing. This ensures that the hot pressing pressure can be applied to all surfaces of the molded part. No pressure can be exerted on surfaces parallel to the direction of pressure during hot pressing.
  • the hot press pressure is, for example Hydraulically applied to the hot-pressing station via a piston rod, this piston rod pressing, for example, on the hot-pressing upper tool, which in turn presses on the stationary hot-pressing lower tool, with the molded part in between.
  • the arrangement could also be carried out the other way round.
  • the finished molded part is then output to further processing stations of the fiber molding system, for example for further transport or for further processing, for example in a cutting, labeling, printing and / or packing station.
  • the method comprises the additional step of coating the molded part, preferably the final molded part, with one or more functional layers.
  • Such functional layers can include additional functionalities such as moisture, aroma, odor or taste barriers.
  • the invention further relates to a fiber molding plant for the production of molded parts from environmentally compatible degradable fiber material by means of the method according to the invention
  • the output unit outputs the molded part for further transport or further processing, for example to subsequent cutting, labeling, printing and / or packing stations.
  • a molded part is easily produced from a fiber material, which is very flexible depending on the design of the contour of the suction head Can deliver molded parts with a wide variety of contours.
  • the ratio of width or diameter to height of the molded part is not a limiting or critical parameter for the quality of the production of the respective molded part.
  • the fiber molding plant according to the invention is able to process fibers of the most varied types, provided that they can be brought into solution in such a way that a major clumping of the fibers in the liquid solution can be avoided before processing.
  • stable molded parts can be produced simply, effectively and flexibly from environmentally friendly degradable fiber material with good quality and good reproducibility.
  • the fiber molding plant according to the invention thus makes it possible to produce environmentally compatible molded parts from natural fibers in an effective, flexible and reproducible manner with good quality.
  • the fiber molding plant comprises a control unit for controlling of the procedure carried out.
  • the control unit can be designed as a processor, separate computer system or web-based and is suitably connected to the components of the fiber molding plant to be controlled, for example via data cables or wirelessly by means of WLAN, radio or other wireless transmission means.
  • the fiber molding system additionally comprises a coating unit for applying one or more functional layers to the molded part.
  • a coating unit for applying one or more functional layers to the molded part.
  • additional functionalities such as moisture, aroma, odor or taste barriers can be applied to the molded part.
  • the coating unit can be arranged at any position suitable for the layer to be applied in the process sequence for producing the molded part.
  • the functional layer can be arranged in the suction process, after the pre-pressing or after the hot pressing.
  • the term “functional layer” here refers to any additional layer applied to the original fiber material, which is applied over the entire surface or in partial areas both on an inside and / or on an outside of the molded part.
  • the invention further relates to a molded part made of environmentally compatible degradable fiber material produced with the method according to the invention or the fiber molding plant according to the invention.
  • the molded part has a contour in which all surfaces of the molded part have an angle of at least 3 degrees to a pressing direction during hot pressing.
  • a minimally required hot pressing pressure can be applied to all surfaces in order, among other things, to reduce the content of liquid solvent in the fiber material to such an extent that the molded part is dimensionally stable
  • the environmentally compatible degradable fiber material does not comprise any organic binder, preferably likewise no non-organic binder. This achieves a particularly good environmentally compatible degradability of the molded part.
  • the world-compatible degradable fiber material consists essentially of fibers with a fiber length of less than 5 mm. As a result, on the one hand, the molded part can be manufactured with better quality. On the other hand, shorter fibers reduce the surface roughness and porosity of the molded part, so that any coatings are easier to apply to the molded part.
  • one or more functional layers are applied to the environmentally compatible degradable fiber material of the molded part.
  • Such functional layers can include additional functionalities such as moisture, water, aroma, odor or taste barriers or barriers against fats, oils, gases such as O2 and N2, light acids, all substances that contribute to the perishability of food , and / or have substances that are not suitable for use with food.
  • the fiber material of the molded part comprises dopants or constituents which, due to their concentration, application of the molded part, environmental conditions, dissolve out of the fiber material of the molded part in the desired manner in order to develop a supporting effect for the application of the molded part.
  • dopants or constituents can already be present in the pulp and get into the molded part with the fiber molding process.
  • doping can be additives, etc., for example fragrances, flavorings, active ingredients, minerals, nutritional and care products.
  • Fig.l a schematic representation of an embodiment of the method according to the invention.
  • FIG. 2 an embodiment of the suction head with a negative shape for the steps of contacting and molding as well as the transfer for pre-pressing in the method according to the invention
  • FIG. 3 shows an embodiment of the suction head with a positive form for the steps of contacting and molding and the transfer for pre-pressing in the method according to the invention
  • FIG. 4 an embodiment of the prepressing station in a lateral section of the fiber molding plant according to the invention
  • FIG. 5 a further embodiment of the prepressing station in a lateral section with a membrane as a prepress lower tool of the fiber molding system according to the invention
  • FIG. 6 an embodiment of the hot pressing station in a lateral section of the fiber molding plant according to the invention
  • FIG. 8 a further embodiment of the prepress station with a movement unit and pulp preparation and delivery unit of the fiber molding plant according to the invention
  • FIG. 9 an embodiment of the fiber molding plant according to the invention.
  • FIG. 10 a further embodiment of the fiber molding plant according to the invention.
  • Fig.l shows a schematic representation of an embodiment of the method 100 according to the invention for the production of molded parts 10 from environmentally friendly degradable fiber material 11 by means of a fiber molding process in a fiber molding plant 20 comprising the following steps.
  • a pulp 1 is provided 110 as a liquid solution with environmentally friendly degradable fiber material 11 so that a suction tool 2 contacts 120 the pulp 1 by placing it on or at least partially immersing it in the pulp 1, the suction tool 2 having a suction head 21 a three-dimensionally shaped suction head suction side 21 i, the shape of which is adapted to a contour of the later molded part 10, followed by molding 130 of the molded part 10 by sucking the environmentally compatible fiber material 11 onto the suction head suction side 21 i by means of negative pressure in the suction tool 2
  • the suction tool can contain a single suction head or it can be a multi-tool with a large number of suction heads.
  • the suction tool when there are already two suction heads 21 is referred to as a multi-tool.
  • the multi-tool can also comprise 10, 2030 or more suction heads 21.
  • the subsequent pre-pressing 140 of the molded-on molded part 10 takes place in a pre-pressing station 3 with a pre-pressing pressure VD to reduce a proportion of the liquid solution in the molded part 10.
  • the pre-compression station is adapted to the suction tool, possibly in the form of a multi-tool.
  • the pre-pressed molded part 10 can be transferred 170 to the hot-pressing station 4 by means of the suction tool 2, the molded part 10 being removed from the suction tool 2 for the subsequent hot-pressing 150.
  • the hot press station 4 comprises a hot press lower tool 41 with a hot press side 41a adapted to a contour 10i of the molded part 10 and a hot press upper tool 42, the molded part 10 being placed or inserted from the suction tool 2 onto the hot press lower tool 41 during transfer 170 and during hot pressing 150 the hot pressing upper tool 42 is pressed onto the hot pressing lower tool 41 with the molded part 10 arranged therebetween.
  • the pre-pressed molded part 10 is hot-pressed 150 with a hot-pressing pressure HD, the molded part 10 is finally shaped, with a further reduction in the proportion of the liquid solution in the molded part 10 in the corresponding hot-pressing station 4.
  • the method can also include the additional step of coating 180 the molded part 10, preferably the end-formed molded part 10, with one or more functional layers 15. At the end of the process, the finished molded part 10 is output 160 to further processing stations of the fiber molding system 20.
  • the suction head 21 shown here can be the only suction head 21 in the suction tool 2 or part of one Multi-tool with a multiplicity of suction heads 21, only one suction head 21 being shown here by way of example for reasons of clarity.
  • the pulp reservoir 30 for the manufacturing process is shown here schematically below the suction head 21 with the fiber material 11, indicated as “waves”.
  • a pulp 1 with a proportion of environmentally compatible degradable fiber material 11 of less than 5%, preferably less than 2%, particularly preferably between 0.5% and 1.0%, in a liquid solution, for example an aqueous solution can be used , in which.
  • the pulp 1 comprises with no organic binder, preferably no binder at all.
  • the environmentally compatible degradable fiber material 11 can essentially consist of fibers with a fiber length of less than 5 mm.
  • the pulp 1 is provided with a temperature of less than or equal to 80 ° C., preferably less than or equal to 50 ° C., particularly preferably room temperature.
  • the suction head suction side 21 i of the suction head 21 is formed from a porous sieve 22, on whose pulp side 22p facing the pulp 1 the environmentally compatible degradable fiber 11 adheres due to the suction for forming 130 of the molded part 10 (see molded part 10 in FIG. 2c ).
  • the suction tool 2 comprises a plurality of suction channels 23 distributed around the screen 22 on its side 22s opposite the pulp side 22p for sucking in the pulp 1.
  • the suction channels 23 are distributed and arranged around the screen 22 and a structure ( The shape of the surface, sieve size, pore size) of the sieve 22 is designed in such a way that essentially the same suction power is applied in all areas of the pulp side 22p of the sieve 22.
  • the suction channels 23 have, for example, an uneven distribution below the screen 23, with fewer suction channels 23 per unit area being arranged in the area of edges in the molded part 10.
  • the suction head only dips a little into the pulp 1 for shaping the molded part so that a closed cavity is formed in the interior 21 i of the suction head.
  • the suction head 21 could also be completely immersed in the pulp 1.
  • the liquid solution of the pulp 1 which passes through the sieve 22 during the molding 130 is discharged from the suction tool 2, for which the suction head 21 on its end face 21p facing the pulp 1 comprises a collecting ring 24 for receiving the liquid solution to be discharged, on which a discharge channel 25 for the liquid solution is connected.
  • the molded part 10 (gray inner layer in the suction head 21) is then placed onto the pre-press lower tool 31 with a pressing surface 31a as the outer surface of the pre-press lower tool 31 for pre-pressing.
  • FIG. 3 shows an embodiment of the suction head 21 with a positive form for the steps of contacting 120 and molding 130 as well as the transfer for pre-pressing 140 in the method 100 according to the invention.
  • the suction head 21 shown here can be the only suction head 21 in the suction tool 2 or be part of a multi-tool with a plurality of suction heads 21, only one suction head 21 being shown here by way of example for reasons of clarity.
  • the pulp reservoir 30 and the properties of the pulp 1 what has already been described for FIG. 2 also applies here.
  • the suction head suction surface 21p is designed here as a positive shape and forms the suction head outside 21a.
  • the structure of the suction head 21 with sieve 22 and suction channels 23 the same applies as described under FIG.
  • the suction head 21 In order to suck up the pulp 1 with fiber material 11, in the case of the positive form of the suction head suction surface 21p, the suction head 21 is completely immersed in the pulp 1 for contacting 120. As shown in Figure 3c, the molded part 10 (gray outer layer on the suction head 21) is then used for pre-pressing in the pre-pressing lower tool 31, which has a shape adapted to the positive shape of the suction head 21 with a pressing surface 31 as the inner surface of the pre-pressing Lower tool 31 has.
  • the pre-press station 3 comprises a pre-press lower tool 31 on which the suction tool 2 with the molded part 10 is placed so that it is arranged between the pre-press lower tool 31 and the suction tool 2 so that the suction tool 2 is pressed onto the pre-press lower tool 31 with the pre-press pressure VD can be so that the moisture is removed from the molded part and the fiber material is stabilized by the pre-pressing.
  • the lower pre-press tool 31 has a pressing surface 31a facing the molded part 10, which has a lower surface roughness than the screen 22.
  • the lower pre-press tool 31 can be made of metal or at least partially of an elastomer, for example silicone, The latter being designed as multi-tools for suction tools is advantageous.
  • the prepressing 140 is carried out at a temperature of the prepressing station 3 of less than 80 ° C., preferably less than 50 ° C., particularly preferably at room temperature, the prepressing pressure VD being between 0.2 N / mm 2 and 0.3 N / mm 2 , preferably between 0.23 N / mm 2 and 0.27 N / mm 2 .
  • FIG. 5 shows a further embodiment of the prepress station 3 in a lateral section with a membrane 32 as the prepress lower tool 31 of the fiber molding system 20 according to the invention for carrying out the prepress 140 as a membrane press.
  • the suction tool 2 is inserted here with a positive form as the suction head suction surface 21 s in the correspondingly shaped pre-press lower tool 31.
  • the membrane 32 is designed as a flexible membrane 32.
  • the pre-compression pressure VD is applied as gas pressure to the membrane 32, which is then pressed onto the outer contour 10a of the molded part 10.
  • pressure can also be exerted on surfaces of the molded part 10 which cannot be applied by means of hydraulic pressing, since the gas pressure applies the membrane to all surfaces with the same pressure regardless of direction.
  • the hot press station 4 comprises a hot press lower tool 41 with a hot press side 41a adapted to a contour 10i of the molded part 10 and a hot press upper tool 42, with the molded part 10 being placed or inserted from the suction tool 2 onto the hot press lower tool 41 during transfer 170 ( depending on whether a negative form is present or a positive form is used).
  • the hot pressing upper tool 42 is then pressed onto the hot pressing lower tool 41 with the molded part 10 arranged in between.
  • the hot press lower tool 41 can be made of metal.
  • the hot-pressing lower tool 41 also comprises channels 41k to its hot-pressing side 41a, with which the liquid solution during hot-pressing 150 can be at least partially removed.
  • the upper hot press tool 42 is adapted to the contour 10a of the molded part 10 at least with the side 42i facing the molded part; the upper hot press tool 42 is preferably also made of metal.
  • different temperatures can be used during hot pressing; the hot press upper tool 42 preferably has a higher temperature than the hot press tool.
  • the hot pressing can be carried out at a temperature greater than 150.degree. C., preferably between 180.degree. C. and 250.degree.
  • the hot pressing 140 is carried out at the hot pressing pressure HD higher than the pre-pressing pressure VD.
  • the hot pressing pressure HD can be between 0.5 N / mm 2 and 1.5 N / mm 2 , preferably between 0.8 N / mm 2 and 1.2 N / mm 2 , this being for a pressing time of less than 20s, preferably more than 8s, particularly preferably between 10 and 14s, even more preferably 12s.
  • the molded part 10 is very dimensionally stable and has a liquid content in the fiber material 11 of less than 8%.
  • the molded part is environmentally compatible and degradable.
  • the contour of the molded part 10 is designed such that all surfaces lOf of the molded part 10 have an angle ⁇ of at least 3 degrees to the pressing direction PR during hot pressing 150.
  • the environmentally compatible degradable fiber material 11 does not include an organic binder, preferably also no non-organic binder. It essentially consists of fibers with a fiber length of less than 5mm.
  • One or more functional layers 15 can be applied to the molded part 10.
  • the fiber material 11 of the molded part 10 can also be doped or constituents which, due to their concentration, an application of the molded part 10 and / or environmental conditions, dissolve out of the fiber material 11 of the molded part 11 in a desired manner in order to provide a suitable for the application of the Molding 11 to develop supporting effect.
  • dopings or constituents can be introduced into the fiber material via the pulp at the beginning of the molding process or be part of a subsequent coating with a functional layer, if the fiber molding process should not allow an earlier addition.
  • Such doping can be, for example, fragrances, aromatic substances, active ingredients, minerals, nutritional and care additives, etc., which due to the later use and the then prevailing conditions Diffuse out of the fiber material, be released or remain behind when the molded part is broken down in an environmentally friendly manner.
  • the environmental conditions promoting this can be, for example, differences in the concentration of certain materials, temperature, humidity and / or light irradiation.
  • the supporting manner could for example be in the care, taste modification, supply etc. of the molded part 10 or the goods transported with or in the molded part 10 or at least temporarily stored therein.
  • FIG. 8 shows a further embodiment of the prepress station 3 with pulp reservoir 30, movement unit 40 and pulp preparation and delivery unit 35 of the fiber molding system 20 according to the invention.
  • the suction tool 2 shown here is a multi-tool with 20 suction heads 21 Pre-press units on the pre-press lower tool 31 as a multi-tool.
  • FIG. 9 shows an embodiment of the fiber molding system 20 according to the invention for producing molded parts 10 from environmentally compatible degradable fiber material 11 by means of the method 100 according to the invention as shown in FIG. 1, comprising a reservoir 30 for providing 110 a pulp 1 as a liquid solution with environmentally compatible degradable fiber material 11, a suction tool 2 attached to a movement unit 40 with a suction head 21 with a three-dimensionally shaped suction head suction side 21 i, the shape of which is adapted to a contour of the later molded part 10, the movement unit 30 being designed to carry the suction tool 2 with the pulp 1 by placing it on or at least partially immersing it in the pulp 1 to contact 120.
  • the movement unit 40 is designed here as a robot.
  • a robot can carry out precise and reproducible movements in a confined space and is therefore particularly suitable for guiding the suction tool between the pulp reservoir 30 and the prepressing station 3.
  • the suction tool 2 is designed to apply the molded part 10 by sucking the environmentally compatible fiber material 11 onto the Suction head suction side 21 i to be molded 130 by means of negative pressure in the suction tool 2.
  • the pre-pressing station 3 is for pre-pressing 140 the molded-on molded part 10 with a pre-pressing pressure VD to reduce a Proportion of the liquid solution in the molded part 10 and provided for its shape stabilization.
  • the hot pressing station 4 is provided for hot pressing 150 the pre-pressed molded part 10 with a hot pressing pressure HD and thus for the final shaping of the molded part 10 and for further reducing the proportion of the liquid solution in the molded part 10.
  • the dispensing unit 50 then dispenses the finished molded part 10.
  • the fiber molding system 20 comprises a control unit 60 which is connected to the other components of the fiber molding system 20 in a suitable manner in order to control these components.
  • FIG. 10 shows a further embodiment of the fiber forming system 20 according to the invention, the provision of the pulp 1 and the prepressing taking place in the prepressing station 3 as already shown in FIG.
  • two separate system parts are operated in this embodiment, each with a hot pressing station 4, a coating unit 70 for applying one or more functional layers to the molded part 10, a printing unit 80 for printing the molded part and a stacking unit 90 for stacking the final molded parts 10
  • the molded parts are transported on a conveyor belt 95 between these stations.
  • the fiber molding machine could also comprise a cutting unit for post-processing or for separating the molded parts.
  • the prepress station can therefore supply at least two subsystems for the subsequent steps without this leading to a loss of time during hot pressing 150.
  • Hot press side of the hot press lower tool e.g. outside

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Abstract

L'invention concerne un procédé (100) de production de pièces moulées (10) en matériau fibreux (11) au moyen d'un procédé de moulage de fibres dans un système de moulage de fibres (20), ledit matériau fibreux étant dégradable d'une manière respectueuse de l'environnement, le procédé comprenant les étapes suivantes : la fourniture (110) d'une pâte à papier (1) en tant que solution liquide ayant un matériau fibreux qui est dégradable d'une manière respectueuse de l'environnement ; la mise en contact (120) d'un outil d'aspiration (2) avec la pâte à papier en plaçant l'outil d'aspiration sur la pâte à papier ou au moins en immergeant partiellement l'outil d'aspiration dans la pâte à papier, l'outil d'aspiration comprenant une tête d'aspiration (21) ayant un côté d'aspiration de tête d'aspiration de forme tridimensionnelle (21i), dont la forme est adaptée au contour de la partie moulée ultérieure ; le moulage (130) de la pièce moulée sur le côté d'aspiration de la tête d'aspiration (21i) par aspiration du matériau fibreux au moyen d'une pression négative dans l'outil d'aspiration ; le pré-pressage (140) de la pièce moulée moulée dans une station de pré-pressage (3) avec une pression de pré-pressage (VD) afin de réduire la proportion de la solution liquide dans la pièce moulée ; le pressage à chaud (150) de la pièce moulée pré-pressée présentant une pression de pressage à chaud (HD) dans une station de pressage à chaud (4) pour finalement mouler la pièce moulée et pour réduire davantage la proportion de la solution liquide dans la pièce moulée ; et la délivrance (160) de la pièce moulée (10) qui a été finalement moulée. L'invention concerne en outre un tel système de moulage de fibres pour la mise en œuvre du procédé ci-dessus et une pièce moulée produite au moyen d'un tel système de moulage de fibres ou au moyen d'un tel procédé.
EP20803081.7A 2019-10-14 2020-10-01 Procédé de production de pièces moulées en matériau fibreux, ledit matériau fibreux étant dégradable d'une manière respectueuse de l'environnement Pending EP4045712A1 (fr)

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DE102019127557.1A DE102019127557A1 (de) 2019-10-14 2019-10-14 Verfahren zur herstellung von formteilen aus umweltverträglich abbaubarem fasermaterial
PCT/DE2020/000227 WO2021073671A1 (fr) 2019-10-14 2020-10-01 Procédé de production de pièces moulées en matériau fibreux, ledit matériau fibreux étant dégradable d'une manière respectueuse de l'environnement

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EP4045712A1 true EP4045712A1 (fr) 2022-08-24

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EP (1) EP4045712A1 (fr)
CN (1) CN114585780A (fr)
DE (1) DE102019127557A1 (fr)
WO (1) WO2021073671A1 (fr)

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DE102019127562A1 (de) * 2019-10-14 2021-04-15 Kiefel Gmbh Faserformanlage zur herstellung von formteilen aus umweltverträglich abbaubarem fasermaterial
DE102022112313A1 (de) 2022-05-17 2023-11-23 Kiefel Gmbh Faserverarbeitungseinrichtung zum einsatz in einer faserverarbeitungsanlage, faserverarbeitungsanlage und verfahren zum steuern einer faserverarbeitungsanlage
DE102022124331A1 (de) 2022-09-22 2024-03-28 Kiefel Gmbh Wiegesystem, Herstellungsvorrichtung und Verfahren zum Betrieb einer Herstellungsvorrichtung für Werkstücke

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DE4008862C1 (fr) * 1990-03-20 1991-04-11 Friedrich 2807 Achim De Priehs
WO2000058556A1 (fr) * 1999-03-26 2000-10-05 Kao Corporation Forme a papier destinee a la production de pate moulee et procede et dispositif de production de pate moulee
JPWO2002032187A1 (ja) * 2000-10-06 2004-02-26 三菱電機株式会社 スピーカ装置並びにスピーカ装置の製造方法及びスピーカ装置の製造装置
SE528685C2 (sv) * 2004-11-26 2007-01-23 Pakit Int Trading Co Inc Metod och maskin för att tillverka fiberprodukter av mäld
US10113271B2 (en) * 2012-08-03 2018-10-30 Varden Process Pty Ltd Decoration and adornment methods for thermoformed pulp

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DE102019127557A1 (de) 2021-04-15
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