阅读说明：本技术 利用流体修整操作的模制纤维产品生产线 (Molded fiber product production line utilizing fluid trimming operations ) 是由 巴勃罗·冈萨雷斯 保罗·利曼 于 2020-11-11 设计创作，主要内容包括：本发明涉及利用流体修整操作的模制纤维产品生产线。一种模制纤维部件成型器,其包括第一成型模具,第一成型模具限定第一模具区域和至少一个流体入口。所述模制纤维部件成型器还包括壁,壁基本围绕所述第一模具区域。所述模制纤维部件成型器包括第一流体通道,第一流体通道邻接并且围绕所述壁,其中所述通道流体连接到所述至少一个流体入口并限定流体通道出口。(The present invention relates to a molded fiber product production line utilizing a fluid trimming operation. A molded fiber component former includes a first forming die defining a first die region and at least one fluid inlet. The molded fiber component former also includes a wall that substantially surrounds the first mold region. The molded fiber component former includes a first fluid channel adjacent to and surrounding the wall, wherein the channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet.)

1. A molded fiber component former, comprising:

a first forming die defining a first die region and at least one fluid inlet;

a wall substantially surrounding the first mold region; and

a first fluid channel adjacent to and surrounding the wall, wherein the channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet.

2. The molded fiber component former of claim 1, further comprising:

a sealing ring at least partially covering the fluid passage outlet, wherein the sealing ring is spaced apart from the wall to at least partially define a fluid groove between the sealing ring and the wall.

3. The molded fiber component former of claim 2, wherein the sealing ring is secured to the first mold component.

4. A molded fiber component former as claimed in claim 2 wherein the sealing ring is removably secured to the first mold component.

5. The molded fiber component former of claim 2, wherein the fluid channel defines a maximum channel width and the fluid slot defines a maximum slot width that is less than the maximum channel width.

6. A molded fiber component former as claimed in claim 2 wherein the fluid slot is configured to direct fluid flow in a direction substantially perpendicular to an uppermost extent of the wall.

7. The molded fiber component former of claim 1, further comprising a second forming mold defining a mating mold region configured to mate with the first mold region of the first forming mold.

8. A molded fiber component former as claimed in claim 7 wherein the second molding die comprises a rim surrounding the mating die region and wherein the rim is configured to deflect fluid streams ejected from the fluid channel in a direction away from the die region and the mating die region when the first die region and the mating die region are in a mated configuration.

9. The molded fiber component former of claim 7, wherein the outer edge is curved.

10. The molded fiber component former of claim 1, wherein the at least one fluid inlet comprises a plurality of fluid inlets.

11. The molded fiber component former of claim 10, wherein the plurality of fluid inlets are distributed around an outer edge of the first forming die.

12. The molded fiber component former of claim 10, wherein the plurality of fluid inlets are each fluidly connected to the fluid channel.

13. A method for making a molded fiber component, the method comprising:

disposing a first forming die in a bucket, the bucket comprising a plurality of fibers and a liquid, wherein the first forming die comprises a first die region, at least one fluid inlet, and a plurality of vacuum channels;

actuating a vacuum vessel communicatively attached to the plurality of vacuum channels to draw at least some of the plurality of fibers onto the forming mold to form a partially formed molded fiber component;

removing the first forming die from the bucket;

applying compressive pressure to the partially formed molded fibrous component with a second forming die;

separating the scrap trim from the partially formed molded fiber component substantially simultaneously with the application of the compressive pressure, an

After separating the scrap trim, transferring the partially formed molded fiber component to a downstream station.

14. The method of claim 13, wherein separating the scrap trim includes receiving fluid from the at least one fluid inlet and ejecting the fluid from a fluid outlet at least partially defined by the first forming die.

15. The method of claim 13, wherein the plurality of vacuum channels are fluidly connected to the first mold region, and wherein the at least one fluid inlet is fluidly connected to a fluid outlet located on the first forming mold remote from the first mold region.

16. The method of claim 14, further comprising directing the ejected fluid away from the first mold region.

17. The method of claim 13, further comprising grasping the scrap trim and the fluid.

18. The method of claim 17, further comprising reprocessing the waste trim and the fluid after grasping the waste trim and the fluid.

19. The method of claim 13, wherein separating the scrap trim comprises jetting fluid toward an edge of the partially formed molded fiber component.

20. The method of claim 19, wherein the fluid is ejected in a substantially annular flow.

21. A molded fiber component production line, comprising:

(a) a forming station, comprising:

a bucket configured to receive a fiber slurry comprising a plurality of fibers and a liquid;

a forming die comprising a die plate defining a plurality of vacuum channels and at least one fluid conditioning channel; and

a mold actuation system for adjusting a position of the mold plate relative to the bucket;

(b) a component transfer system, comprising:

a component transfer feature defining a plurality of component vacuum channels, an

A transfer mechanism for moving the component transfer feature from a first position engaged with the forming die to a second position;

(c) a press station, comprising:

a core mold;

a cavity mold mated with the core mold, an

A press actuation system for adjusting a position of the core mold relative to the cavity mold, wherein at least one of the core mold and the cavity mold defines a plurality of vacuum channels and at least one heating element, and wherein in the second position the component transfer feature is engaged with at least one of the core mold and the cavity mold, an

(d) A removal system, comprising:

a removal feature defining a plurality of component vacuum channels and a plurality of trim vacuum channels, an

A transport mechanism for moving the removal feature from a third position engaged with at least one of the core mold and the cavity mold to a fourth position.

22. A molded fiber component production line as set forth in claim 21 wherein said mold plate includes a first mold region and at least one fluid inlet, and a wall substantially surrounding said first mold region, wherein said fluid channel abuts and surrounds said wall, and wherein said at least one fluid trim channel is fluidly connected to said at least one fluid inlet and defines a fluid channel outlet.

23. The molded fiber component former of claim 21, wherein the forming station further comprises:

a sealing ring secured to the die plate and at least partially covering the at least one fluid trim channel outlet, wherein the sealing ring is spaced from the wall, thereby partially defining a fluid groove between the sealing ring and the wall.

24. The molded fiber component former of claim 23, wherein the sealing ring is removably secured to the mold plate.

25. The molded fiber component former of claim 23, wherein the at least one fluid trim channel defines a maximum channel width and the fluid slot defines a maximum slot width that is less than the maximum channel width.

26. A molded fiber component former as claimed in claim 23 wherein the fluid slot is configured to direct fluid flow in a direction substantially perpendicular to an uppermost extent of the wall.

27. A molded fiber component production line as claimed in claim 21, wherein the component transfer feature comprises a component transfer mold that mates with the forming mold.

28. A molded fiber component production line as set forth in claim 21 wherein said component transfer system transfer mechanism includes a robotic arm.

29. A molded fiber component production line as in claim 21 wherein said component transfer system transport mechanism comprises a shuttle positioned on a rack.

30. A molded fiber component production line as set forth in claim 29 wherein said frame extends in a first direction away from said forming die and an opposite second direction away from said forming die.

31. A molded fiber component production line as set forth in claim 21 wherein both of said core mold and said cavity mold define said plurality of vacuum channels.

32. A molded fiber component production line as set forth in claim 21 wherein said at least one heating element comprises a plurality of heating elements and wherein both said core mold and said cavity mold comprise at least one of said plurality of heating elements.

33. A molded fiber component production line as claimed in claim 21, wherein said removing features comprise removing molds.

34. The molded fiber component production line of claim 21, wherein the removal feature comprises a plurality of vacuum cups.

35. The molded fiber component production line of claim 21, wherein the removal system transfer mechanism comprises a robotic arm.

36. The molded fiber component production line of claim 21, wherein the removal system transport mechanism includes a shuttle placed on a rack.

37. A molded fiber component production line as claimed in claim 21, wherein said removal system is said component transfer system.

38. A molded fiber component production line as claimed in claim 21, further comprising a printing station, and wherein the removal feature is engaged with the printing station when in the fourth position.

39. A molded fiber component production line as claimed in claim 38, wherein the printing station includes a registration feature.

40. A molded fiber component production line as claimed in claim 39 wherein the printing station comprises at least one printing device.

41. A molded fiber component production line as claimed in claim 40, wherein said at least one printing device comprises at least one of a screen printer, a laser printer, an ink jet printer, and a pad printer.

42. A molded fiber component production line as set forth in claim 41 further comprising a stacking station.

43. A molded fiber component production line as claimed in claim 21 wherein at least one of said component transfer system and said removal system comprises at least one of a robotic arm, a shuttle, and a conveyor.

Technical Field

This application claims priority and benefit from U.S. provisional patent application serial No. 62/933,593 entitled "molded fiber product line with water trim operation" filed on 11/2019, the disclosure of which is incorporated herein by reference.

Background

Contamination by disposable plastic containers and packaging materials has now become a recognized problem worldwide. It has been proposed that replacing disposable packaging with biodegradable and compostable materials is one way to reduce plastic contamination. However, to succeed in a new environmentally friendly alternative, the alternative must compete in cost and performance with the existing plastic technology to be replaced.

As a brief background, molded pulp (also referred to as molded fiber) has been used in the past 1930's to make containers, trays and other packaging. The pulp can be made from recycled materials such as old newsprint and corrugated containers, or directly from trees and other plant fibers. Molded pulp packaging is now widely used in electronic products, household products, automotive parts, and medical products.

The mold is made by machining a metal tool that mirrors the shape of the finished part. Holes are drilled in the tool and then a net is attached to the surface of the tool. Vacuum is drawn through the holes while the mesh prevents the grout from plugging the holes. To manufacture a molded fiber component, a mold is immersed in the fiber slurry and a pressure gradient is applied and water is pumped through holes in the mold. The fibers from the pulp are collected on a web and, after forming the fibrous layer to a desired thickness, the mold with the molded fibrous component is removed from the pulp. The molded fiber component is then released from the mold and may be subjected to subsequent processing (e.g., shaping, heating, drying, surface coating, etc.).

The molded fibrous packaging product may be biodegradable and compostable. However, the currently known fiber technology is not well suited for use in food packaging, particularly meat and poultry containers, prepared foods, products, microwavable food containers, and lids and cups for beverage containers where food may come into contact with the packaging.

Disclosure of Invention

In one aspect, the technology relates to a molded fiber component former comprising: a first forming die defining a first die region and at least one fluid inlet; a wall substantially surrounding the first mold region; and a first fluid channel adjacent to and surrounding the wall, wherein the channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet. In one example, the molded fiber component former further comprises: a sealing ring at least partially covering the fluid passage outlet, wherein the sealing ring is spaced apart from the wall to at least partially define a fluid groove between the sealing ring and the wall. In another example, the sealing ring is secured to the first mold component. In yet another example, the sealing ring is removably secured to the first mold part. In yet another example, the fluid channel defines a maximum channel width, and the fluid slot defines a maximum slot width that is less than the maximum channel width.

In another example of the above aspect, the fluid slot is configured to direct fluid flow in a direction substantially perpendicular to an uppermost extent of the wall. In one example, the molded fiber component former further comprises: a second forming die defining a mating die region configured to mate with the first die region of the first forming die. In another example, the second forming die comprises a rim surrounding the mating die region, and wherein the rim is configured to deflect a fluid stream ejected from the fluid channel into a direction away from the die region and the mating die region when the first die region and the mating die region are in a mated configuration. In yet another example, the outer edge is curved. In yet another example, the at least one fluid inlet comprises a plurality of fluid inlets.

In another example of the above aspect, the plurality of fluid inlets are distributed around an outer edge of the first forming die. In one example, the plurality of fluid inlets are each fluidly connected to the fluid channel.

In another aspect, the technology relates to a method for manufacturing a molded fiber component, the method comprising: disposing a first forming die in a bucket, the bucket comprising a plurality of fibers and a liquid, wherein the first forming die comprises a first die region, at least one fluid inlet, and a plurality of vacuum channels; actuating a vacuum vessel communicatively attached to the plurality of vacuum channels to draw at least some of the plurality of fibers onto the forming mold to form a partially formed molded fiber component; removing the first forming die from the bucket; applying compressive pressure to the partially formed molded fibrous component with a second forming die; separating a scrap trim from the partially formed molded fibrous component substantially simultaneously with the application of the compressive pressure, and transferring the partially formed molded fibrous component to a downstream station after separating the scrap trim. In one example, separating the scrap trim includes receiving a fluid from the at least one fluid inlet and ejecting the fluid from a fluid outlet at least partially defined by the first forming die. In another example, separating the fertilizer trim includes ejecting fluid from a fluid outlet at least partially defining the second forming die. In yet another example, the plurality of vacuum channels are fluidly connected to the first mold region, and wherein the at least one fluid inlet is fluidly connected to a fluid outlet located on the first forming mold remote from the first mold region. In yet another example, the method further includes directing the ejected fluid away from the first mold region.

In another example of the above aspect, the method further comprises grasping the scrap trim and the fluid. In one example, the method further comprises reprocessing the waste trim and the fluid after grasping the waste trim and the fluid. In another example, separating the scrap trim includes ejecting fluid toward an edge of the partially formed molded fiber component. In yet another example, the fluid is ejected in a substantially annular flow.

In another aspect, the technology relates to a molded fiber component production line, comprising: (a) a forming station, comprising: a bucket configured to receive a fiber slurry comprising a plurality of fibers and a liquid; a forming die comprising a die plate defining a plurality of vacuum channels and at least one fluid conditioning channel; and a mold actuation system for adjusting the position of the mold plate relative to the bucket; (b) a component transfer system, comprising: a component transfer feature defining a plurality of component vacuum channels, and a transport mechanism for moving the component transfer feature from a first position engaged with the forming mold to a second position; (c) a press station, comprising: a core mold; a cavity mold mated with the core mold, and a press actuation system for adjusting a position of the core mold relative to the cavity mold, wherein at least one of the core mold and the cavity mold defines a plurality of vacuum channels and at least one heating element, and wherein in the second position the part transfer feature is engaged with at least one of the core mold and the cavity mold, and (d), a removal system comprising: a removal feature defining a plurality of part vacuum channels and a plurality of trim vacuum channels, and a transfer mechanism for moving the removal feature from a third position engaging at least one of the core mold and the cavity mold to a fourth position. In one example, the die plate includes a first die region and at least one fluid inlet, and a wall substantially surrounding the first die region, wherein the fluid channel abuts and surrounds the wall, and wherein the at least one fluid conditioning channel is fluidly connected to the at least one fluid inlet and defines a fluid channel outlet. In another example, the forming station further comprises: a sealing ring secured to the die plate and at least partially covering the at least one fluid trim channel outlet, wherein the sealing ring is spaced from the wall, thereby partially defining a fluid groove between the sealing ring and the wall. In yet another example, the seal ring is removably secured to the mold plate. In yet another example, the at least one fluid trimming channel defines a maximum channel width and the fluid slot defines a maximum slot width that is less than the maximum channel width.

In another example of the above aspect, the fluid slot is configured to direct fluid flow in a direction substantially perpendicular to an uppermost extent of the wall. In one example, the component transfer feature comprises a component transfer mold that mates with the forming mold. In another example, the component transfer system transfer mechanism includes a robotic arm. In yet another example, the component transfer system transport mechanism includes a shuttle disposed on the rack. In yet another example, the frame extends in a first direction away from the forming die and an opposite second direction away from the forming die.

In another example of the above aspect, both the core mold and the cavity mold define the plurality of vacuum channels. In one example, the at least one heating element comprises a plurality of heating elements, and wherein both the core mold and the cavity mold comprise at least one of the plurality of heating elements. In another example, the removing features includes removing a mold. In yet another example, the removal feature includes a plurality of vacuum cups. In yet another example, the removal system transfer mechanism includes a robotic arm. In yet another example, the removal system transport mechanism includes a shuttle disposed on the frame.

In another example of the above aspect, the removal system is the component transfer system. In one example, the molded fiber component production line further includes a printing station, and wherein the removal feature is engaged with the printing station when in the fourth position. In one example, the printing station includes an enrollment feature. In another example, the printing station includes at least one printing device. In yet another example, the at least one printing device includes at least one of a screen printer, a laser printer, an inkjet printer, and a pad printer. In yet another example, the molded fiber component production line further includes a stacking station.

In another example of the above aspect, at least one of the component transfer system and the removal system includes at least one of a robotic arm, a shuttle, and a conveyor.

Drawings

Various aspects of at least one example are discussed below with reference to the accompanying drawings, which are not intended to be drawn to scale. The accompanying drawings, which are included to provide an illustration and a further understanding of the various aspects and examples, are incorporated in and constitute a part of this specification, but are not intended as a definition of the limits of the particular examples. The drawings, as well as the remainder of the specification, serve to explain the principles and operations of the described and claimed aspects and examples. For purposes of clarity, not every component may be labeled in every drawing.

FIG. 1 depicts a schematic diagram of an exemplary molded fiber component production line.

Fig. 2 depicts an example of the production line of fig. 1 in a circular layout configuration.

Fig. 3 shows an example of a method for manufacturing a fibre pulp.

FIG. 4 is a schematic view of a pulp production line performing the method of FIG. 3.

Fig. 5 depicts an example of a forming and trimming station.

Fig. 6 depicts a partial schematic view of a forming and trimming station having a fluid grasping system.

FIG. 7 depicts an enlarged cross-sectional view of a portion of the mold of the forming and trimming station.

Fig. 8 shows a partial schematic view of two dies of a press station in mating engagement.

Fig. 9A and 9B show a perspective view and a partially enlarged perspective view of the upper molding and trimming mold, respectively.

Fig. 10A and 10B show a perspective view and a partial cross-sectional view, respectively, of an upper shaping and trimming die.

FIG. 11 depicts a method of producing a molded fiber component.

FIG. 12 illustrates an example of a suitable operating environment in which one or more of the present examples can be implemented.

Fig. 13 is an example of a network in which the various systems and methods disclosed herein may operate.

Detailed Description

Before a manufacturing line for producing molded fiber products is disclosed and described, it is to be understood that this disclosure is not limited to the particular structures, process steps, or materials disclosed herein, but extends to equivalents thereof as would be recognized by those skilled in the relevant art. It is also to be understood that the terminology employed herein is used for the purpose of describing particular examples of production lines and their components only, and is not intended to be limiting. It should be noted that, as used in this specification, the singular forms "a," "an," "the," and the like include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "an operation" can include multiple operations, reference to "a production" or "an article of manufacture" in reference to one operation or action, and not to all articles of manufacture.

Various examples of the technology described below relate to the manufacture of fiber-based or paper-based products for use inside and outside the food and beverage industry. By way of non-limiting example, the present disclosure relates to automated, efficient, high-speed production of fiber-based containers. Fiber-based products are suitable for replacing their plastic counterparts in various applications, such as: frozen, refrigerated and non-refrigerated food products; medical, pharmaceutical and biological applications; a microwavable food container; a beverage; edible and non-edible liquids; substances that release water, oil and/or water vapor during storage, transport and preparation (e.g., cooking); horticultural applications including consumables and landscape/horticultural plants, flowers, herbs, shrubs and trees; disposable or single-use storage and dispensing devices (e.g., paint trays, food trays, brush handles, shipping covers); agricultural products (including human and animal food, such as fruits and vegetables); salad; preparing a food; packaging of meat, poultry and fish; a cover; a cup; a bottle; agricultural products (including human and animal food, such as fruits and vegetables); salad; preparing a food; packaging of meat, poultry and fish; a cover; a cup; a bottle; guides and dividers for processing and displaying the aforementioned items; corner pieces for packaging, storing and transporting electronic devices, mirrors, art and other fragile parts; a tube; industrial, automotive, marine, aerospace and military components such as gaskets, seals, cushions, etc.; and associated molds, screen formats, formulations, processes, chemical formulations, tools, slurry dispensing, chemical monitoring, chemical pouring, and associated systems, apparatus, methods, and techniques for manufacturing the same.

One existing production line for making molded fiber components or products is described in chinese patent application No. 201711129438.X (hereinafter the '438' application "), entitled" flexible production line for producing pulp molded products, "which is hereby incorporated by reference in its entirety. The' 438 application generally describes a forming station that includes a former that creates a wet part by dipping a first mold into a fiber slurry tank, drawing the fibers onto the mold until the desired amount of fibers is collected on a screen, and then removing the mold with the attached fiber layer from the slurry. In the system described in the' 438 application, the forming station also performs a forming operation on the wet part in which the first mold with the attached fibrous layer is pressed into the second mold after it is removed from the slurry. The forming operation removes some of the water from the wet end and contours a surface of the wet end opposite the first mold. In the production line of the' 438 application, the formed fibrous components are formed by the forming station and then pressed in the pressing station. The pressing station may be a plurality of pressing stations operating in parallel. In one example of the' 438 application, four press stations are used. The four press stations in the' 438 application each include a press. After pressing, the components are sent to a stacking station. The forming station, the pressing station and the stacking station are arranged to: a circle is enclosed around the robot centered which controls the extendable mechanical arm. The robot and robotic arm are configured to remove the molded parts from the molding station and transfer them to any of the four pressing stations. The robotic arm is also configured to remove pressed components from any pressing station and transfer them to another of the different pressing stations or to a stacking station. Although this application describes many of the basic components and stations of a molded fiber component production line, it unfortunately presents a number of inefficiencies.

FIG. 1 depicts a schematic view of an exemplary molded fiber component production line 100. The depicted production line 100 has a plurality of stations and systems for moving partially formed and formed parts between the various stations of the production line 100. The specific configurations of the various stations and systems, as well as the production line 100 itself, are further described herein. The combined forming and trimming station 102 includes a forming die, a slurry tank, and an actuation system that moves the forming die relative to the slurry tank (typically by lowering the die into the slurry tank). The pulp tank comprises a fibre pulp comprising wood fibres in a liquid. The forming and trimming die itself includes a number of vacuum channels connected to a vacuum source that are used in the forming process. The forming and trimming die further includes a plurality of fluid channels defined therein that are used in the fluid trimming process described herein. The forming and trimming die may have a plurality of separate dies for making a plurality of identical fibrous components, although forming and trimming dies for forming different components are also contemplated. In one example, the forming and trimming mold may include a mold body or plate that includes contours, features, etc. as desired for a particular product. The vacuum channels of the mold body may have a deliberate path or layout within the mold body, or may be randomly formed therein as part of the mold manufacturing process. Some mold bodies may include a screen or mesh thereon that forms a surface onto which the fibers are drawn during the forming process. In use, the actuation system lowers the forming die into the mud pot and activates the associated vacuum source. This draws the slurry into the vacuum channels, thereby placing the fibers on the surface of the forming mold or screen (if present). When the desired amount of fibers is pulled onto the surface or screen, the actuating system lifts the forming die from the slurry. At this point in the process, the fiber placed on the forming die is referred to herein as a partially molded fiber component because it includes the general contours and features of the finished molded fiber component, but does not exhibit the performance characteristics of the finished component.

The part-forming molded fiber part may then be partially compressed and trimmed of scrap material. These operations may be performed in part by the forming and trimming station 102 in conjunction with the component transfer system 104. Component transfer system 104 includes component transfer features that may be component transfer molds that substantially correspond to or mate with forming and trimming molds. In this regard, the component transfer mold also performs the function of forming a surface of the partially molded fiber component that is disposed opposite the surface of the partially molded fiber component that is in contact with the forming mold. During this portion of the forming operation, a finishing operation such as that described herein may also be performed by the forming and finishing station 102. The part transfer mold may also include or define a plurality of vacuum channels connected to a vacuum source (as described above in the context of the forming mold). In use, the component transfer mold is positioned in contact with the partially formed molded fiber component. The contact forms opposing surfaces of the partially formed molded fiber component. Upon actuation of the vacuum source, the partially formed molded fiber component is removed from the forming mold. The component transfer system 104 includes a transport system that transfers the component transfer mold from the molding station 102 to a downstream station (in this case, the press station 106). In this regard, the forming station 102 and the pressing station 106 may form an end of the range of motion of the component transfer system 104, which in an example may be referred to as a first position and a second position, respectively. Depending on the cycle time of the forming station 102 and the pressing station 106, the second location may be an intermediate waiting station in which the component transfer feature may be positioned to wait for the pressing station 106 to become available.

The production line 100 includes a press station 106 that utilizes a combination of compression pressure and elevated temperature to substantially cure the partially formed molded fiber component into a molded fiber component (which meets the general performance requirements to be used). Component transfer system 104 can transfer the partially formed fibrous component to press station 106 (as indicated by arrow 112). The discrete pressing station 106 includes two molds, which are commonly referred to as a core mold and a corresponding and matching cavity mold. Regardless of the terminology used, the core mold and the cavity mold form two opposing surfaces of the formed fiber component. To form the partially formed filamentary members into formed filamentary members, the two dies are generally similar in construction to the forming and trimming dies and the transfer die described above, as desired. However, since the trimming operation is performed on the molding and trimming die, there is no need to allow a configuration for trimming in the die used in the pressing station 106. The transfer 112 may occur through a component transfer feature of the component transfer system 104 that substantially matches a core or cavity mold. The vacuum channels may be formed in one or both of the core and cavity molds and connected to a dedicated vacuum source. The vacuum source for the mold that engages the transfer feature during transfer 112 can be activated to transfer the partially molded fibrous component to the appropriate mold of the press. The heating element may be disposed in one or both of the core mold and the cavity mold. The core mold and cavity mold are moved relative to each other by a pressure actuated system, which in the example is a hydraulic press. Since the pressure actuation system reduces the separation distance between the core mold and the cavity mold (with the partially formed fibrous component therebetween), the increased compressive pressure helps form the portion into a molded fibrous component. The increased compression pressure forces additional liquid from the partially formed fibrous part, which can be removed from the pressing station by one of a plurality of vacuum sources connected to vacuum channels present in one or both of the core die and the cavity die. In addition, the elevated temperature generated by the heating element facilitates further forming and drying of the partially formed fibrous component until a component is produced therefrom that is more consistent with the formed fibrous component.

The removal system 114 removes the molded fiber component from the pressing station 106, for example, along a path 116. The removal system may include a removal feature including a plurality of vacuum channels. A plurality of vacuum channels in the removal feature may be used to remove the component from the pressing station 106. The removal feature may be in the form of a removal mold configured to mate with any one of the core mold and the cavity mold. In that case, the vacuum channels communicate with one or more ports on the surface of the removal mold so that the vacuum pressure can draw the formed fibrous part out of the core or cavity mold. In another example, the removal feature may be a plurality of vacuum cups connected to the vacuum channel. Vacuum pressure applied to the channels by the vacuum source may also remove the formed fibrous component from the core or cavity mold. The removal system 114 includes a transfer mechanism that moves the removal features from a position of engagement with a particular mold of the press station to a downstream station, for example, along a path 120. In this case, the downstream stations may be one or more of a waste station 118, a printing station 122, a quality control station 124, and a stacking station 126, each of which is described below. However, in general, a downstream station includes any station downstream of a particular identification station, and an upstream station includes any station upstream of a particular identification station.

The reject station 118 may be utilized to treat molded fiber products that are significantly defective or damaged prior to further downstream processing. The reject station 118 may include a system for reintroducing the damaged molded fiber product into the slurry system. In one example, the waste station may be a trash bin, chute, or other structure into which damaged products may be released from the removal system 114. When the removal system 114 is properly positioned relative to the scrap station 118, the vacuum source may be turned off or terminated such that the defective product may disengage or otherwise fall off of the removal feature. The appropriate positioning may correspond to a physical engagement between the removal feature and the scrap station 118, or the position of the removal feature relative to the scrap station 118 may be detected via proximity, optical, or other sensors. The partial vacuum pressure may be maintained by the reject station 118 so that acceptable molded fiber components are not released into the reject station 118, but are transported to a further downstream station.

After the scrap station 118, the molded fiber component is generally considered to be sufficiently formed for use. However, other downstream stations may be utilized to add graphics, logos, or other visual information to each molded fiber component, to check the quality of the final component, or to stack or package the molded fiber components for shipment. Thus, a downstream printing station 122, a quality control station 124, and a stacking station 126 are depicted. These optional stations will be described in further detail below.

As shown, the entire production line 100 may be automated and controlled by the control system 128. A control system 128 may be connected to each station, and even to the sub-assemblies and transfer and removal systems (in the form of conveyors, robots, and other equipment, as described elsewhere herein) of each station, and controls the operation of each station. As discussed further below, the control system 128 may continuously monitor operations and conditions on the production line 100 and adjust the operations to ensure proper function and quality of the final part.

Control, which anticipates all operating parameters, will improve the quality of the formed fibrous part and increase the throughput of the production line 100. To obtain such control, a network of sensors throughout the entire production line 100 is contemplated. In an example, various sensors are provided at each station and each conveyor system to monitor any relevant parameters of the operation of the production line 100. An example of such monitoring is a sensor that detects the presence of excess fiber to be trimmed from the partially formed fibrous component at the forming and trimming station; another example is the temperature control of heated moulds of a press station. Signals from these and other sensors may be sent to and processed by the control system 128. As another example, the forming and trimming or pressing stations 106 may be dynamically controlled based on sensors in the respective stations 102, 106. In an example, the trimming operation may be performed by the forming and trimming station until the sensor associated therewith no longer detects the presence of a trim that needs to be removed. In a more complex example, the pressing station 106 may be operated until a desired condition is obtained in the formed fibre component. In one example, one of the dies in the pressing station 106 may be provided with one or more sensors that directly or indirectly monitor the status of the formed fibrous component. For example, a temperature sensor may be provided on the surface of the mold to monitor the temperature of the molded part at the location where it contacts the mold. Similarly, a pressure sensor, a humidity sensor, a light emitter/sensor pair, a conductivity sensor, one or more electrodes monitoring the current through the mold part, or any other such monitoring device that may be disposed at one or more locations on the mold may be provided at one or more locations. Based on the output of the sensor, the time allotted to pressing the molded part may be dynamically controlled by the control system 128. For example, the pressing operation may be terminated when a desired temperature (e.g., a predetermined temperature threshold) determined by the temperature sensor is reached.

Such monitoring sensors are not limited to being located in or on the forming and trimming station 102 or the pressing station 106 and may be located anywhere in the production line 100. In an example, the white water flow rate associated with the forming and finishing station 102 can be monitored via one or more flow rate sensors. This allows the flow rate and amount of white water removed from the partially formed fibrous component to be monitored over time at various stations throughout the production line 100. This allows for example to control the pressing station based on the amount and flow rate of water observed during operation. When it is determined that the water flow rate or amount has reached a predetermined threshold (e.g., a 90% decrease in flow rate since the start of operation, or after 10ml of water has been collected from the component during a pressing operation), the pressing operation may be terminated regardless of how long the operation has been performed.

Such monitoring data may be used to do more things than simply controlling the runtime of the press station 106 or any other component. In one example, the compression station 106 may dynamically increase or decrease the pressure based on the collected data. In this manner, it is contemplated that any controlled operating parameter (e.g., press operating time, press pressure, mold temperature, slurry temperature, vacuum pressure, slurry flow rate, slurry quality, mix tank temperature, conveyor belt speed or temperature, dryer temperature, ink flow rate, or any other operating setting related to time, temperature, pressure, or movement of a line component) may be controlled in response to data obtained from one or more sensors.

The production line 100 in fig. 1 may be operated in a continuous mode. The various stations and component transfer systems may be continuously moving and in motion forming, trimming, pressing, printing and drying components on the production line 100. For example, in one example, the quality control station may be a simple pass-through station through which the conveyor belt passes as the parts are tested, as described herein. The printing station may be one or more removable or fixed print heads that print on the part as it passes under the print heads.

Other configurations are also possible. For example, a semi-continuous configuration may be provided in which one or more stations remove parts from the production line 100 for a period of time and then replace them after the operations at subsequent stations are completed. In a different semi-continuous configuration, component transfer system 104 may operate in a stop-start mode in which component transfer system 104 moves a predetermined distance and stops on a prescribed schedule. Thus, each part will move between workstations over time. In one example, one or more of the component transport system 104 and removal system 114 may have component transfer features incorporated into the appropriate system 102, 114 in the form of a mold (e.g., a core mold as described herein). The mould may provide a reliable retention of the component during its movement. The pressing station may then have an outer mould which receives the component as it arrives at the station.

The production line 100 of fig. 1 has several advantages. It is inherently scalable in that multiple parallel pressing stations 106 and scrap stations 118 can be operated simultaneously, with the component transport system 104 and removal system 114 provided for each station. In such a parallel configuration, each parallel portion may be referred to as a "child line". In another example, each parallel sub-line may be dedicated to different customers having different printing requirements, finishing requirements (and thus different pressing and/or drying requirements). Further, as another example, multiple stacking stations 126 would allow for different customer parts to be stacked individually in an easy, automated manner. The parallel configuration of multiple sub-lines adds flexibility to the production line 100 because a possible failure at any one station in a sub-line will not bring the entire production line 100 to a stop. Further flexibility may be provided by including a second forming station 102. At any given time, a different sub-line may exit the run without affecting the operation of the other sub-lines. Thus, the sub-line dedicated to a particular product may not function until the product is needed, which means that rework time can be saved.

Fig. 2 shows another example of a production line 200. Many of the components and their features have been described above with reference to fig. 1 and will not be described again. In this production line 200, the various stations are arranged in a circular configuration around a central component transfer system 204. Here, the part transfer system 204 includes an articulating robotic arm 205 having a maximum range of motion rotation generally corresponding to the depicted circle C. The component transfer system 204 moves a transfer feature 207 (in this case, a component transfer mold) located at one end of a robotic arm 205 from the forming and trimming station 202 to one of four press stations 206. The movement in this example will generally include removing the transfer feature 207 from the forming and trimming station 202 of the pressing station 206 (e.g., by retracting the robotic arm 205 and then rotating the robotic arm 205 to align the transfer feature with the entry region (generally facing the region of the part transfer feature 204)), and then extending the robotic arm 205 to insert the transfer feature 207 into the pressing station 206. During this movement, the component transfer system 204 also moves the partially formed fibrous component that is placed on the component transfer feature 207. Once the formed fibrous components are pressed, the component transfer system 204 moves the components (again placed on the transfer feature 207) in a substantially similar motion pattern from the pressing station 206 to the reject station 208, where significantly damaged or defective products may be discarded. Then, in this example, as described above in FIG. 1, component transfer system 204 also acts as a removal system. Although only the stacking station 226 is shown, acceptable formed fiber components may be transferred to one or more downstream stations after depositing an unacceptable product at the scrap station. A transfer system from waste station 208 to stacking station 226 may be required. For example, stacking system 226 may include a dedicated arm or other feature that removes the formed fiber components from component transfer system 204 and stacks them directly at stacking station 226. This enables acceptable shaped fiber components to move through scrap station 208 to stacking station 226. This may be performed by one or more conveyors, a second robotic arm, a servo shuttle, or a ramp.

Fig. 3 shows an example of a method for manufacturing a fibre pulp. The pulp production line 300 is sometimes referred to as "wet preparation" or "stock preparation," which produces fiber pulp from stock. Typical raw materials are wood or plant fibers, which are usually provided in the form of rolls or sheets; and water. In addition to the feedstock, malfunctions, damage or other unacceptable products from the waste stations described above may also be introduced with the feedstock. In some cases, chemical additives may also be used to enhance or modify the properties of the final fiber product (e.g., grease penetration resistance, water absorption, porosity, density, etc.). In the example shown, the incoming virgin dry fibers are conveyed to a grinder and cut to a predetermined size in a grinding operation 302. Sometimes also referred to as a pulper or hydropulper, the mill may be any conventional mill. Fiber grinding is known in the art and any conventional system or method now known or later developed may be used. In one example, as part of the milling operation 302, the fibers are mixed with at least some water and the output product is a liquid stream comprising the milled fibers and water mixture. This improves grinding efficiency and reduces fiber dust generated during operation.

In one embodiment, the grinding may be performed in multiple stages. For example, a first grinder may perform coarse grinding and convey the coarse ground fiber slurry to a second fine grinder, which produces a final grinding and outputs the ground fiber slurry. After milling, the milled fiber and water mixture is delivered to a first mixing tank where a first mixing operation 304 is performed. In a first mixing operation 304, additional water is added, if necessary. Chemical additives may also be added in the first mixing operation 304 if specific characteristics are required for the final fiber component to be manufactured. The quality of the slurry may be monitored periodically or continuously as part of the first mixing operation 304. The corresponding information obtained from the detection means can be used to control the addition of water, any additives and temperature. In one embodiment, the detection device may include the use of one or more sensors, such as a temperature sensor, a water quality sensor (e.g., a densitometer), a Total Dissolved Solids (TDS) sensor, a pH meter, a density meter, a dissolved oxygen sensor, a salinity meter, a resistivity meter, a conductivity meter, and the like. Many water quality sensors are known in the art, and any such monitoring device now known or later invented may be used to monitor the quality of the slurry therein or any operation in the slurry production process 300.

After the first mixing operation 304, an optional second mixing operation 306 may be performed. In this embodiment, the first mixing operation 304 may be considered a pre-mixing or preparatory operation that is controlled to bring the slurry within a certain range of slurry quality. The pulp properties are then adjusted to a finer quality range using a second mixing operation 306. For example, in the first mixing operation 304, the pulp may be controlled to be within +/-10% of the desired nominal pulp mass (e.g., if the desired pulp is at 10% of the fiber pulp weight, the stationary mixing tank is controlled to maintain the pulp within 9.0 to 11.0% of the fiber weight. then the second mixing operation 306 may be designed to maintain the pulp within a nominal range of +/-1%). the +/-10% and +/-1% ranges of the two operations 304, 306 are merely simple examples, and any suitable range may be used. For example, the first mixing operation 304 may maintain the slurry at nominally +/-0.5%, +/-1.0%, +/-1.5%, +/-2.0%, +/-2.5%, +/-3.0%, +/-3.5%, +/-4%, +/-4.5%, +/-5.0%, +/-7.5%, +/-10.0%, +/-15.0%, +/-20.0%, and the second mixing operation 306 may maintain the slurry at any small range near the nominal, such as +/-0.01%, +/-0.05%, +/-0.1%, +/-0.2%, +/-0.25%, +/-0.30%, +/-0.035%, +/-0.4%, +/-0.45%, +/-0.5%, +/-0.55%, +/-0.6%, +/-0.75%, +/-1.0%, +/-2.0%, +/-5.0% or more.

In an embodiment of the second mixing operation 306, the intermediate slurry from the first mixing operation 304 is analyzed and the stream is passed through an intermediate mixer where the addition of water and chemical additives (if any) is carefully controlled to achieve a better range of slurry quality. The intermediate mixer may be a mixing tank or a plug flow reactor or a combination thereof. The second mixing operation 306 may be a batch, semi-batch, or continuous operation. The second mixing operation 306 outputs a final fiber slurry stream that may then be stored in a storage tank in a storage operation 308 until used as described above or passed directly to a forming station for forming a formed part in a forming operation 310. As part of the forming operation 310, water is recovered from the slurry as it passes through the mesh on the forming die. The reclaimed water is referred to as "white water". By collecting the white water in the collecting operation 312, the white water can be reused in the pulp production method 300. The white water can include the finish obtained from the combined forming and finishing station described above and elsewhere herein, which typically has a moisture content that does not cause undesirable clumping of the finish in the white water, thus allowing it to be reintroduced without reprocessing. However, in other embodiments, the trim can be filtered or otherwise removed from the whitewater (at filtering operation 314) and reintroduced, for example, in grinding operation 302. The whitewater may then be returned and used as feedwater in any of the grinding operation 302, the first mixing operation 304, and/or the second mixing operation 306.

In one embodiment, the water used in the fiber slurry production method 300 is pre-treated to remove any unwanted organic or inorganic compounds. For example, in one embodiment, the water may be filtered to reduce the concentration of salt or Total Dissolved Solids (TDS). It is particularly economical to form a closed loop by the collecting operation 312 and return the white water to the pulp as a pulp if the raw water must be pre-treated before use in the pulp production method 300. In one embodiment, the water and the various intermediate and final pulps produced in the fiber pulp production method 300 are heated to maintain them at a desired temperature. In another embodiment, the final fiber slurry is heated as a final operation (not shown) before it is transferred to the forming station. For example, in one embodiment, the milled fiber slurry, the intermediate fiber slurry, and the final fiber slurry are all maintained within a predetermined temperature range. I.e. the temperature of the water and the pulp is controlled during the whole production process. The temperature range may be from 90 ° F to 200 ° F or from 100 ° F to 150 ° F. In one embodiment, the predetermined temperature range is a temperature range of +/-5 ° F selected from a nominal temperature of 90 ° F, 95 ° F, 100 ° F, 105 ° F, 110 ° F, 115 ° F, 120 ° F, 125 ° F, 130 ° F, 135 ° F, and 140 ° F.

FIG. 4 is a schematic diagram of a pulp production line 400 for performing the method of FIG. 3. In the schematic, a first mixing tank 406 follows the first grinder 402 and the second grinder 404. The grinders 402, 404 are described above. The first mixing tank 406 may be open or closed for exposure to or control by the atmosphere. While in the mixing tank 406, the slurry may be stirred. Any stirring method may be used, such as a mechanical stirrer (e.g., a blade stirrer, paddle or rotating screw) for removing and re-injecting the slurry to circulate the contents of the tank, or by sparging a gas (e.g., heated or ambient temperature air, nitrogen, argon, or other inert gas) in the tank to the slurry. The tank 406 may be temperature controlled by any suitable means known in the art (e.g., heated jackets, internal heating elements, heated gas streams, infrared radiation, etc.). A temperature sensor may be provided to continuously monitor the temperature of the tank 406.

A second mixer 408 will be provided to perform the second mixing operation 306. As noted above, the second mixer 408 need not be a tank, and may be a plug flow reactor (e.g., a pipe section with injection points for water and chemical additives and a sensor for monitoring slurry quality). Or it may be a second mixing tank 408 similar to the first mixing tank 406. A holding tank 410 is provided in the pulp line 400 for buffering the final fiber slurry before it is transferred to a forming and finishing station (shown elsewhere herein). As shown, the pulp line 400 also includes white water returned from the forming and finishing stations. A second holding tank 412 is provided for buffering the white water until water is needed in an earlier operation of the pulp production line 400. The trim from the forming and trimming station may be removed from the white water at filter 414 and may be reintroduced separately, for example at first grinder 402, although the trim may also be introduced to second grinder 404. Alternatively, the finish can be introduced as a component of the white water. In one embodiment, the pulp production line 400 forms a closed loop with little or no makeup water required after initial startup.

The schematic of fig. 4 does not include the fixtures and equipment of standard piping typically used for this operation, e.g., flow rate control valves between each component, safety valves, bypass valves, sampling ports, pumps needed to move the pulp between the components, conveyors or similar feeders for conveying the raw fibers to the muller, sensors, etc. The reader will understand that such fixtures and implements are contemplated and considered part of the production line 400, but are not shown in FIG. 4 for clarity. For example, in one embodiment, there is one pump between each component in the production line 400.

The pulp production line 400 may be configured for batch, semi-batch, or continuous operation. In continuous operation, one or more components may store enough fiber slurry to act as a flow buffer to allow switching out of the fiber source or to perform periodic (automatic or manual) fiber grinding operations. For example, in one embodiment, the first mixing tank 404 is sized to maintain a sufficient volume of slurry for eight hours of continuous operation when the fiber product manufacturing line 400 is in full operation. In this manner, a new batch of milled fiber slurry may be generated (either automatically or manually) and added to the first mixing tank 406 every few hours. The second mixing tank or mixer 408 may be significantly smaller or simply pass through to continuously feed the final fiber slurry to the forming station. In one embodiment, the pulp production line 400 may be fully automated and may be controlled by a central control system, in addition to reloading the raw fiber input material and maintenance activities. In another example, the raw fiber input is even automatically processed using autonomous robots to move and mount the raw fiber input port onto the feed system (e.g., inserting a new roll of raw fiber sheets into a roll feeder or placing bundles of fiber sheets into a feed hopper).

Fig. 5 depicts an exemplary view of a forming and trimming station 500. Specifically, as shown in fig. 5, the forming and trimming station 500 includes a frame 511 on which a lower portion 512 and an upper portion 513 are disposed. Upper portion 513 includes a shuttle 531 (in this case, corresponding to the component transfer system described above) having an actuation mechanism 533 that allows for raised and lowered transfer features, in this case transfer mold 532. The dedicated vacuum source fixed to shuttle 531 is not visible in the figure. A cylindrical rotating shaft 523 is rotatably connected to the middle of the frame 511 between the lower portion 512 and the upper portion 513 via a rack mount 528. The shaft 523 has a rotation angle of less than 360 °, and the cylindrical rotation shaft 523 rotates back and forth. At both ends of the cylindrical rotating shaft 523 are elbows 526. Two ends of the rotating shaft 523 are fixed on the frame through a rotating shaft seat, the gears 527 are respectively sleeved on two ends of the cylindrical rotating shaft 523, and two sides of the middle part of the frame 511 are connected with the gears 527 in a translation mode. Two symmetrically opposed molding dies 524a, 524b are attached to the cylindrical rotating shaft 523. In this embodiment, the two dies 524a, 524b comprise a die plate 530 (visible only on the upper part 513) on which the core die is formed and which is provided with a screen onto which the fibres are drawn when the dies are in the lower forming chamber 521 or the pulp tank. In fig. 5, the lower die 524b is in the mud pot 521, referred to as the molding position, and the oppositely positioned upper die 524a faces upwardly toward the shuttle 531 and is carried on the transfer die (cavity die) 532 at the shuttle.

The two core dies 524a, 524b are rigidly connected to a rotating shaft 523 by a plurality of conduits 525a, 525 b. Conduit 525a connects to a conduit within hollow shaft 523 which is connected to a fluid source (not shown) for the trimming operation described herein. The conduit 525b is connected to a conduit within a hollow shaft 523 that is connected to a vacuum pump system. The conduits 525a, 525b are further connected to perforations in the dies 524a, 524b, as described in more detail below. The vacuum pumping system creates a pressure differential that pulls the slurry toward the mold 524, causing the fibers to accumulate on the screen surface of the mold. As described above, the two core dies 524a, 524b are symmetrical. This allows them to be rotated about the axis of the rotating shaft 523 by the rotating shaft 523, thereby rapidly moving the mold between the lower portion 512 and the upper portion 513. The fibre pulp tank is accommodated in a pulp tank 521. As shown in fig. 5, when the die 524 is in the tank 521, the pulp is pumped through the die 524 by a vacuum pumping system, and the fibers will be deposited on the die 524, thereby creating a partially formed fibrous component (not shown) on the die 524. In one embodiment of the forming and trimming station 500, after an appropriate amount of fiber is drawn onto the die 524 to achieve the desired thickness, the pulp tank 521 is lowered from the die 524 by an actuation system in the form of a vertical lift 522, releasing the die 524 to move into position on the upper portion 513. The die 524 and partially formed filamentary members can then be rotated to the position of the upper portion 513. Upper portion 513 includes a transfer mold 532 attached to an actuating mechanism 533. Activation mechanism 533 presses transfer die 532 against upwardly facing lower die 524 a. Mechanism 533 may include one or more hydraulic cylinders, servo motors, gas cylinders, or any other known lifting device. By pressing the dies 524 and 532 together, water may be driven from the partially formed fibrous component and collected by the inner die 524 via the shaft 523. Substantially simultaneously with this pressing operation, pressurized fluid for the trimming operation may be delivered to die 524 through conduit 525a, excess material of the trim that may be extruded from die 524 during the pressing operation. The trimming operation serves to remove rough edges of the partially molded fiber product that are present as a result of the forming and pressing. In this context, when forming a molded fiber product, the significant pressing force used can cause the molded fibers to flow and be ejected from the mold. Such expelled fibrous material should be removed for aesthetic, performance, design tolerance, and other purposes. The trimming operation is performed substantially simultaneously with the pressing operation during forming, using jets of pressurized water or other fluid (e.g., white water, compressed air, etc.) to improve production time and reduce waste.

After the forming and trimming operations are completed, suction is applied to the partially formed fibrous component by infiltration in the die 532, and the die 532 is retracted by mechanism 533 onto shuttle 531 for movement to a downstream position. This releases the die 524 to rotate to the lower portion 512 for repeating the entire molding process. In one embodiment, the forming and trimming operations performed by transfer die 532 operate at a selected pressure for a fixed period of time equal to the time it takes to pull the formed part onto the die at lower portion 512. Alternative embodiments, described in more detail below, dynamically control the compression time based on monitored data from sensors at one or more locations of the upper portion 513. In an alternative embodiment of the forming and trimming station 500, the slurry tank 521 may also include a removable outer mold (not shown) in the tank 521. In this embodiment, after the fibers from the pulp are drawn onto the die 524, the outer die may be pressed against the die 524 while in the pulp tank 521. This provides an additional pressing operation on the partially formed fibrous part so that the part exiting the former 500 will be subjected to two pressing operations, rather than just one as in the previous example. Regardless, after the partially formed fibrous component is produced by transfer die 532 and removed from inner die 524, shuttle 531 transfers it to another station in the production line. In another embodiment, transfer mold 532 may be located at the end of a robotic arm that extends into upper portion 513 and receives the partially formed fibrous part when transfer mold 532 is activated, drawing on the part. This is just one example of how the transfer of parts is performed by a robotic arm. Many such methods and systems are known in the art, and any suitable method and mechanism may be used in the forming station 500, robotic arm, or any other component of a manufacturing line described herein.

Fig. 6 depicts a forming and trimming station 600 having a first forming die 604 and a mating engaged component transfer system 606. The forming and trimming station 600 includes a first forming die 604, in this case a cavity die structure. As used herein, the term "cavity mold" refers to a mold having features designed generally to project inwardly into the mold plate to form a "cavity" into which the fibrous component 608 and core mold extend. Part transfer system 606 includes part transfer features, in this case part transfer molds in the form of core mold structures. As used herein, the term "core mold" refers to a mold having features designed to project substantially away from the mold plate to form a "core" that is at least partially surrounded by the fiber component 608. Each of the forming mold 604 and the part transfer mold 606 defines at least one (but typically a plurality) of vacuum channels 613. The vacuum channels 613 are each connected to a dedicated vacuum source 615, which functions as described above. After the fibers are drawn onto first forming die 604 by applying vacuum through vacuum channel 613, component transfer system 606 is brought into mating contact with first forming die 604. This mating contact applies a slight pressure to the partially formed molded part, squeezing liquid therefrom, which can be captured by the vacuum source 615. As such, the component transfer feature 606 may also be referred to as a "second forming die," although it also performs the function of transferring the partially formed fibrous component to one or more stations downstream of the forming and trimming station 600.

In the depicted embodiment, the wet trim feature is a fluid jet ring 602 integrated with an upper forming die 604. The upper forming die 604 is shaped to cooperate with a lower forming die, such as a component transfer system 606, to form a shaped fiber component 608 therebetween. The fluid jet ring 602 substantially surrounds a portion of the upper forming die 604 that forms the outer extent of the formed fiber component 608. The fluid ejection ring 602 may be a curved pipe or other conduit that is manufactured separately from and obtained from the material of the upper molding die 604. The conduits forming the fluid ejection ring 602 may be substantially recessed within channels 610 formed in the upper forming die 604 that prevent excess ejected fibers (referred to as "flash" in some embodiments) from potentially clogging fluid outlets in the fluid ejection ring 602, prevent the fluid ejection ring 602 from being inadvertently damaged, and raise the fluid ejection ring 602 above the level of submersion of the upper forming die 604 (again, to prevent fluid outlet clogging). Channels 610 may also serve as guides for fluid jets 612 exiting fluid jet ring 602. In other embodiments, the outlet itself may direct and direct the fluid jet 612, but it should be understood that the direction of fluid flow may be directed and/or controlled in any suitable manner including dynamic direction/orientation/configuration. In an embodiment, it is desirable to discharge fluid jet 612 in a linear or fan-shaped configuration because it can be precisely directed to a particular location of the street forming and trimming station 600. Water, white water, or other fluid or liquids used to perform the trimming operation may be delivered to the fluid-ejecting ring 602 via one or more channels 613 connected to a fluid source 615, which may be a pressurized reservoir, pump, compressor, or other component.

In addition, other functions may be incorporated into the forming and trimming station 600 to control the output of the fluid ejection ring 612. For example, fluid ejection ring 612 may include a plurality of spaced nozzles, each of which may be independently controlled to direct fluid only when needed or desired. For example, only the nozzles disposed near the detection portion adjacent to the unnecessary discharge fibers may be activated, thereby reducing the fluid ejection volume utilized. The detector D may utilize image recognition or other techniques to detect the excess drain fibers to be removed. Certain nozzles can only be activated for certain molds, products or processes. The fluid jet 612 may also be operated at a fixed time or until the detector D or sensor indicates that the target burr has been removed. In addition, the fluid pressure, the direction of fluid ejection, and/or the ejection pattern configuration may be controlled individually. In one embodiment, higher pressure may be directed to discharge from a "thicker" product made from molds for both thick and thin products at the flash.

In an example, the fluid spray 612 is oriented substantially vertically (as in the case of the structure shown in fig. 6) to limit the possibility of fluid from infiltrating the space between the upper mold 604 and the lower mold 606, which may result in damage to the partially-formed fiber component 608. To further reduce this possibility, the outer portion 614 of the lower mold 606 may be angled to aid in the shedding of the resulting fluid spray 612. In an example, the outer portion 614 may be disposed at an angle of about 80 °, about 75 °, 70 °, 65 °, 60 °, or about 50 ° from horizontal. In other examples, the outer portion 614 may be substantially curved to smoothly redirect the fluid spray 612 away from the mold 606.

In operation, as the upper forming die 604 and the lower forming die 606 are pressed together, some of the fiber slurry may escape from the forming station through the outer edges of the forming station 600. Accordingly, a fluid spray 612 is ejected from fluid spray ring 602 to remove overflow slurry from forming station 600. Due to the precise discharge pattern of the fluid spray 612, only the overflow portion of the fibrous slurry is removed, leaving the clean edges of the partially formed fibrous component 608 intact. The fluid spray 612 and material removed as part of the wet trim operation may fall into a water collector 616, which water collector 616 may be disposed below the lower forming die 606. This mixing of materials may be handled by one or more processes (described generally in element 618, and described above in the context of fig. 3 and 4). In other examples, the mixture of materials may simply be reintroduced into the mud pot 620 into which the upper forming die 604 is introduced at the beginning of the forming process. Thus, the fluid conditioning operations shown and described also include the additional advantage that wet (relative to the pressing operation performed after the downstream pressing operation) slurry can be removed from the former. The wetted material is more easily re-added to the slurry than the dry material removed near the end of the manufacturing process. This reduces or even completely eliminates waste generated downstream in the production process. In another example, the fluid spray 612 may be emitted to trim portions prior to the molding operation (e.g., pressed together prior to the upper molding die 604 and the lower molding die 606), but in such an example, it may be difficult to maintain clean edges of the forming member 608. For example, fluid spray 612 may be injected at a pressure between 20psi and about 120 psi. Generally, standard potable water pressures from cities to typical commercial facilities can be employed without further pressurization. Pressures that may be employed include about 20psi, about 30psi, about 40psi, about 50psi, about 60psi, about 70psi, about 80psi, about 90psi, about 100psi, about 110psi, and desirably about 120 psi. Further pressurisation may be used if desired, for example by an additional fluid pump. In other examples, the fluid spray may be emitted from an outlet disposed on component transfer system 606.

It may also be advantageous to draw more slurry on a particular portion of the forming die in order to obtain a desired edge (e.g., by the precision fluid trim system and operations described herein). For example, it may be desirable to draw a greater amount of slurry near the outer edge of the forming die. This may help to ensure that the slurry spreads evenly as the forming operation proceeds, thereby avoiding the forming die being trimmed along its entire perimeter by the forming and trimming stations described herein. Fig. 7 shows an enlarged cross-sectional view of the upper forming die 700 of the forming and trimming station. As described elsewhere herein, the upper molding die 700 includes an underlying structural support 702 covered by a grid portion 704. The structural support 702 and the mesh portion 704 define the desired form of the formed fibrous product. The structural support 702 defines a number of vacuum conduits 706, 708 distributed therein. During the forming process, the upper forming die 700 is lowered into a slurry tank (not shown) and a vacuum is applied to the various pipes to draw the slurry onto the mesh portion 704. By providing enlarged apertures or channels 710 below the mesh portion 704, more slurry may be drawn into specific portions of the mesh portion 704. In the example shown, the voids or channels may have a height H of about 5 millimeters, about 10 millimeters, about 15 millimeters, or about 20 millimeters. The plurality of vacuum conduits 708 may be distributed along the top of the channel 710, for example, about 5 millimeters, about 10 millimeters, about 15 millimeters, or about 20 millimeters from the center.

By more precisely shaping the edges of the fibrous product during the initial shaping stage (e.g., using the liquid finishing features described above), there may be less excess edge material when the partially shaped fibrous component is pressed on the pressing station. The pressing station can thus ensure a precise edge of the finished profiled fibre portion with simplified technology. Fig. 8 shows a partial schematic view of two molds in mating engagement of a pressing station 800 and utilizing this edge forming technique. The pressing station 800 includes a lower mold 802, in this case a core mold structure. An upper mold 804 in the form of a part transfer mold having a cavity structure. The terms "core mold" and "cavity mold" are described above. A fiber portion 806 is provided between the lower die 802 and the upper die 804. The lower mold 802 and the upper mold 804 each define at least one (but typically a plurality) of vacuum channels 808. The vacuum channels 808 are each connected to a dedicated vacuum source 810, which functions as described above. The lower die 802 and the upper die 804 each include heating elements 812. In the case of the dedicated pressing station 800, the elements 802 to 812 are used.

Improved temperature control during operation of the 800 press station is expected to improve the quality of the formed fibrous part and to improve the throughput of the production line. In one example, each mold 802, 804 has an internal heating element 812. Element 812 may be a simple internal channel through which a heating fluid may flow. In an alternative example, a resistive heater may be installed in each die 802, 804. Heating elements 812 are known in the art, and any suitable heating technique now known or later developed may be used. Examples of heated molds 802, 804 may further have one or more temperature sensors T. The temperature sensors may monitor the temperature in the dies 802, 804, the temperature of the surfaces of the dies 802, 804, the temperature of the fiber component 806, or any other location within, on, or near the dies 802, 804. Further, to provide finer control of the temperature, the dies 802, 804 may be divided into multiple sections or portions, and the temperature of each section may be independently monitored and controlled. Each section may have one or more temperature sensors and one or more internal heating elements. By monitoring and controlling the temperature of various portions of the mold, it is believed that the performance of the mold can be further improved.

Fig. 9A and 9B show a perspective view and a partially enlarged perspective view of the upper molding die 900, respectively. Fig. 9A and 9B are described simultaneously, and the mesh cover is not clearly described. The upper molding die 900 (shown inverted in fig. 9A and 9B) is formed from a machined unitary part 902. In the relevant part, the integral part 902 forms therein a mould region 904 which, in the example shown, is delimited at its outer extent by walls 906. The wall 906 also defines an extent of an uppermost portion of a molded fiber product (not shown) formed in the mold region 904. The member 902 further defines a groove or channel 908 for fluid conditioning operations as described elsewhere herein. The channel 908 is in fluid communication with one or more supply inlets 910 into which fluid is injected for the dressing operation. In the illustrated mold 900, four supply inlets 910 are used, but other configurations are contemplated. Multiple supply inlets 910 can be desired in order to evenly distribute the fluid within the channel 908. The width of the channel 908 may define the size of the fluid spray ejected from the channel during the trimming operation. In an example, the channel 908 can have a maximum width (e.g., a dimension extending from the wall 906) of about 1 millimeter, about 2 millimeters, about 3 millimeters, about 4 millimeters, about 5 millimeters, about 6 millimeters, about 7 millimeters, about 8 millimeters, about 9 millimeters, about 10 millimeters.

Fig. 10A and 10B show a perspective view and a partially enlarged sectional view, respectively, of an upper or first molding die 1000. Fig. 10A and 10B are described simultaneously, and the mesh cover generally used for the molding die is not clearly described. An upper or first forming die 1000 (shown inverted in fig. 10A and 10B) is formed from a machined unitary member 1002. In a related part, the unitary member 1002 forms a mold area 1004 therein, which in the illustrated example is surrounded by a wall 1006 that also defines an extent of an uppermost portion of the formed fibrous product 1005 formed in the mold area 1004. Member 1002 further defines a groove or channel 1008 (hidden in fig. 10A) for use in fluid conditioning operations described elsewhere herein. The channel 1008 is in fluid communication with one or more supply connections 1010a into which fluid is injected for the trimming operations described elsewhere herein. In the illustrated mold 1000, four supply connections 1010a connected to the same number of supply inlets are used, but other configurations are contemplated. To evenly distribute the fluid within the channel 1008, multiple supply connections 1010a and inlets are desired. The width of the channel 1008 may define the size of the fluid spray emitted from the channel during the trimming operation. In an example, the channel 1008 can have a maximum width (e.g., a dimension extending from the wall 1006) of about 1 millimeter, about 2 millimeters, about 3 millimeters, about 4 millimeters, about 5 millimeters, about 6 millimeters, about 7 millimeters, about 8 millimeters, about 9 millimeters, about 10 millimeters. Thus, if the channels 1008 or fluid outlet slots 1014 substantially surround the mold area, the fluid ejected therefrom may be in a substantially annular flow. The illustrated example differs from that shown in fig. 9A and 9B in that it includes a seal ring 1012 that at least partially seals the seal channel 1008. In this example, the seal 1012 is a separate, replaceable component that covers the channel 1008 and defines a fluid outlet channel 1014 between the seal 1012 and the wall 1006. The maximum width of the fluid outlet slot 1014 may be about 0.5mm, about 0.75mm, about 1mm, about 1.25mm, about 1.5mm, or greater. Thus, wider channels 1008 are more easily formed, molded, or machined, and sealing rings 1012 can be used to fine tune the size and performance of the fluid spray. The seal ring 1012 is replaceable so that wear caused by fluid flow and pressure can be quickly remedied. The seal ring 1012 may be made of aluminum, steel, or other material. Additionally, baffles may be disposed proximate to the junction 1010a to direct the injected fluid therein in a more desirable direction to reduce undesirable pressure drops, turbulence, and the like. In general, the fluid may be oriented in a direction substantially parallel to wall 1006, or in a direction substantially orthogonal to the uppermost extent of wall 1006.

Fig. 10B shows several vacuum channels 1016 connected to a vacuum source (not shown). The vacuum channels 1016 terminate at openings within the mold area 1004 (as defined by the outer extent of the walls 1006). Channels 1008 and outlet slots 1014 are disposed outside of mold region 1004 to ensure that fluid ejected therefrom is directed on portions of product 1005 extending beyond wall 1006.

Fig. 11 illustrates a method 1100 of making a shaped fiber component. The method begins in operation 1102 by placing a first forming die into a slurry tank containing a plurality of fibers and a liquid. The first forming die may be any one of the forming dies shown herein or variations thereof as will be apparent to those skilled in the art upon reading the present disclosure. In general, the first forming die may comprise a first die region, at least one fluid inlet and a plurality of vacuum channels. Typically, a plurality of first forming dies is provided (e.g. placed as follows) in the pulp tank at the same time, which enables a plurality of fibre products to be formed at the same time. In operation 1104, a vacuum vessel communicatively coupled to the plurality of vacuum channels is actuated to draw at least a portion of the plurality of fibers onto a forming mold to form a partially formed molded fiber component. Once a predetermined amount of fiber (based on vacuum application time, fiber thickness detected at the mold region, etc.) is drawn onto the first mold region, the first forming mold is removed from the pulp tank (operation 1106). A component transfer system including features such as including a second forming die is then aligned with the first forming die and pressure is applied to the partially formed molded fibrous component (operation 1108).

The method 1100 continues with operation 1110 in which the trim is separated from the partially formed molded fiber component, for example, by spraying a fluid onto the edges of the partially formed molded fiber component. Trims that may be removed from a partially molded fibrous component may also be referred to as scrap trims, as the trims separated from the component are undesirable in the finished product. In an example, the trim separation can be performed substantially simultaneously with the pressure application. As described elsewhere herein, such trim separation may be performed by a fluid-based system. Fluid may be received from at least one fluid inlet and ejected from a fluid outlet at least partially defined by the first forming die (operation 1112). In another example, the trim piece is separated from the partially formed molded fibrous product by ejecting fluid from a fluid outlet at least partially defined by the second forming die (operation 1114). Regardless of which molding die the fluid is ejected from, the fluid may be directed away from the first die region (operation 1116). In an example, this may occur when the ejected fluid contacts a contoured or angled surface of the opposing portion of the mold. In an example, operations 1108 and 1110 may be performed substantially simultaneously due to the location and configuration of the various vacuum ports and fluid outlets relative to the mold region of the first molding die. More specifically, a plurality of vacuum channels are fluidly connected to the first mold region, wherein at least one fluid inlet is fluidly connected to a fluid outlet disposed on the first forming mold at a location remote from the first mold region. The fluids used in the conditioning process, as well as the conditioning materials separated during these processes, may be obtained (operation 1118) and, if desired, reprocessed (operation 1120). Reconditioning of the trim and fluid is illustrated, for example, in fig. 3 and 4. Once the trim is separated from the partially molded fibrous part, the part may be transferred to a downstream station (operation 1122).

Fig. 12 illustrates an example of a suitable operating environment 1200 in which one or more of the present examples can be implemented. This is merely an example of a suitable operating environment and is not intended to suggest any limitation as to the scope of use or functionality thereof. Other well known computing systems, environments, and/or configurations that may be suitable for use include, but are not limited to, personal computers, server computers, hand-held or notebook computer devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smart phones, network computers, minicomputers, mainframe computers, smart phones, tablet computers, distributed computing environments that include any of the above systems or devices, and the like. In an example, a computing system may include one or more product manufacturing management systems, which may be a single unit, for all of the workstations, systems, and subsystems of the production line examples described herein. In other examples, the computing system may be a network of single computing systems (e.g., one or more independent computing systems for each workstation, system, and subsystem).

In its most basic configuration, operating environment 1200 typically includes at least one processing unit 1202 and memory 1204. Depending on the exact configuration and type of computing device, memory 1204 (which stores instructions for making molded fiber components as described herein) may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. This most basic configuration is illustrated in fig. 12 by dashed line 1206. Additionally, environment 1200 may also include storage devices (removable 1208 and/or non-removable 1210) including, but not limited to, magnetic or optical disks or tape. Similarly, the environment 1200 may also have input devices 1214 such as a touch screen, keyboard, mouse, pen, voice input, etc., and/or output devices 1216 such as a display, speakers, printer, etc. One or more communication connections 1212, such as LANs, WANs, point-to-point, bluetooth, RF, etc., may also be included in the environment.

Operating environment 1200 typically includes at least some form of computer readable media. Computer readable media can be any available media that can be accessed by processing unit 1202 or other devices utilizing the operating environment. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disks (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, solid state memory, or any other medium which can be used to store the desired information. Communication media embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.

The operating environment 1200 may be a single computer operating in a networked environment using logical connections to one or more remote computers. The remote computer may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above, as well as other elements not mentioned. Logical connections may include any method supported by the available communication media. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.

In some examples, the components described herein include modules or instructions executable by computer system 1200 that may be stored on computer storage media and other tangible media and transmitted in communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data information. Combinations of any of the above should also be included within the scope of readable media. In some examples, computer system 1200 is part of a network that stores data in remote storage media for use by computer system 1200.

Fig. 13 is an example of a network 1300 in which the various systems and methods disclosed herein may operate. In an example, a portable device, such as client device 1302, can communicate with one or more servers, such as servers 1304 and 1306, over network 1308. In an example, the client device may be a laptop, tablet, personal computer, smartphone, PDA, netbook, or any other type of computing device, including a single controller for packaging the various components of the system and the computing device in fig. 12. In an example, servers 1304 and 1306 can be any type of computing device, such as the computing device illustrated in FIG. 12. The network 1308 may be any type of network capable of facilitating communication between a client device and one or more servers 1304 and 1306. Examples of such networks include, but are not limited to, LANs, WANs, cellular networks, and/or the Internet.

In an example, the various systems and methods disclosed herein may be performed by one or more server devices. For example, in an example, the systems and methods disclosed herein may be performed using a single server, such as server 1304. The portable device 1302 may interact with the server 1304 via the network 1308 to send test results from the device under test for analysis or storage. In further examples, portable device 1302 may also perform the functions disclosed herein, such as by collecting and analyzing test data.

In alternative examples, the methods and systems disclosed herein may be performed using a distributed computing network or a cloud network. In these examples, the methods and systems disclosed herein may be performed by two or more servers, such as servers 1304 and 1306. Although specific network examples are disclosed herein, one of ordinary skill in the art will appreciate that other types of networks and/or network configurations may be used to perform the systems and methods disclosed herein.

The systems and methods disclosed herein are implemented and performed using the examples described herein, using software, hardware, or a combination of software and hardware. Although specific means are recited as performing specific functions throughout the disclosure, one of ordinary skill in the art will appreciate that these means are provided for illustrative purposes and that other means may be used for performing the functions disclosed herein without departing from the scope of the disclosure.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties (e.g., molecular weight, reaction conditions, and so forth) used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated otherwise, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the technology are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

It will be apparent that the system and method described herein are well adapted to carry out the objects and advantages mentioned as well as those inherent therein. Those skilled in the art will recognize that the methods and systems of the present description may be implemented in many ways and are therefore not limited by the exemplary examples and illustrations described above. In this regard, any number of the features of the different examples described herein may be combined into one single example, and alternate examples having fewer than or greater than all of the features described herein are possible.

Various examples have been described for the purpose of this disclosure, but various changes and modifications may be made within the intended scope of the disclosure. Many other changes may be made which will suggest themselves to those skilled in the art without departing from the spirit and scope of the invention.