• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A large lightweight 3-D shaped molded pulp material, for example a container, comprising a large pulp molded outer shell lined with a reinforcing core spacer material, conforming to and adhering to said shell, and an inner shell made of molded pulp or a flexible paper based material. A method for manufacturing such a lightweight material involves pressing slurried pulp between a first male mold half [5] covered with elastomeric material [6] and a second female mold half [3], to form the molded pulp outer shell [17], and gluing the reinforcing core spacer material [18] to the interior of said molded pulp shell [17] and gluing the inner shell to said spacer material.
    公开号:SE1550866A1
    申请号:SE1550866
    申请日:2015-06-23
    公开日:2016-12-24
    发明作者:Sundblad Per；HANSSON Torbjörn；Ollevik Tommy；Hellberg Mårten
    申请人:Organoclick Ab；
    IPC主号:
    专利说明:

    TITLELarge Lightweight Molded Material and Method for its Manufacture TECHNICAL FIELDGenerally, embodiments of the invention relate to large lightweight molded materials, and to the method of making such molded materials.
    More specifically, different embodiments of the application relate interalia to different 3-D shaped lightweight material made by using spacer lined materials.
    BACKGROUNDPulp molding is known in the art for producing small packages such asegg cartons, disposable food dishes, box inserts and other protective packing materials etc.
    RELATED ART US 6 245 199 describes a method of pulp molding trays where thestarting material is a suspension containing cellulose fibers. The malemold half is dipped in a bath of the suspension, and the mold halves are then pressed together under heat and pressure.
    SE 529 897 C2 describes the pulp molding of a tray where a dewateringreceptacle is used to shape a tray of pulp which is then transferred to acompression tool where the tray is subjected to pressure and heat. It involves a transfer step and is not readily usable for large containers.
    EP 0466653 describes a coffin made of molded pulp Without any reinforcing spacer lining.
    WO06016072 describes a large container, in this case a coffin made up of panels consisting of honeycomb layers With paper sheet faces.
    However, none of the related art discloses or hints at how to achieve the solutions provided by the present invention.
    OBIECT OF THE INVENTIONThe present invention intends to solve a complex of difficult-to-reconcile interrelated problems still present in the designs of the prior art: It has been very difficult to use existing pulp molding methods toproduce very large three dimensional objects. This is due partially to theproblem of thermal expansion and contraction of the two metal moldhalves used in the compression of the pulp in the press. If the dimensionsof the mold halves change, due to unavoidably becoming cooler andhotter during the compression process, the strength of the container Willbe compromised and the surface Will not be smooth and even. This is nota problem if the surface quality and the strength of the finished object isof no great importance, such as for packaging materials or disposabledishes, but where the strength and surface finish of the finished moldedproduct is of great importance then this is a problem. In general it isdifficult to achieve uniformity of strength and surface in pulp molded products, particularly in such products which are thin.
    It is now possible to make a large volume lightweight shell of moldedpulp with improved strength and smoothness using the mold halves andapparatus described and claimed in our co-pending patent applicationNo. 1550864-1, entitled Pulp Molding Apparatus and Molds for Use Therein.
    Providing a large pulp molded 3-D shaped material, which is lightweight,very strong, With smooth and even outer surface and above all is easy and inexpensive to manufacture has hitherto proved very difficult.
    SUMMARYThis entire complex of problems listed above finds its solution in the invention as defined in the appended main patent claims.
    BRIEF DESCRIPTION OF DRAWINGSEmbodiments of the invention Will now be described in more detail With reference to the appended drawings, wherein: Fig. 1 shows a cross sectional view of a container made of a light-weight material according to the invention.
    Fig. 2 shows a perspective view of the light-weight container shown in Fig. 1.
    Fig. 3 shows schematically the pair of mold halves used in a methodwhich can be used to manufacture the shell for a material according to the invention.
    Figs. 4a-f show a frame which can be used with such mold halves to manufacture a shell for a material according to the invention.
    DETAILED DESCRIPTIONThe large lightweight 3-D shaped pulp molded material according to theinvention is shown in the form of a container in cross section in Fig. 1 and in perspective in Fig. 2. The lightweight exemplary container in the material according to the invention is built up as a Sandwich construction by three different parts comprising: An outer shell 17 made of 3-D shaped molded pulp. This is the surface ofthe material and Will by, for example, using the novel method for producing large molded pulp objects described in our co-pending PatentApplication No. 1550864-1, entitled Pulp Molding Apparatus and Molds for Use Therein i) , have a smooth and even surface and make possible complex 3-D shaped designs. ii) A core 18 composed of a flexible spacer structure that may but isnot limited to a core of ReBoardW, a paper honeycomb structure,a molded core structure (as described in e.g. InternationalPatent Application No. WO2o1o138o66 A1), or the corrugatedcore structure made by fluting used in corrugated boards. iii) An inner shell 19 made of molded pulp or a flexible paper based material such as a linerboard or paperboard.
    By using a sandWich construction as described above, complex 3D-shaped designs may be utilized in the material While at the same time obtain a high strength material.
    In one of the embodiments of the invention, a shell 17 is made of moldedpulp and is lined in the embodiment shown With ReBoardÜM) With only asingle linerboard, on its exposed interior surface. The ReBoardTM thencomposes both the core structure (ii) above) and the inner shell (iii)above). As one of the linerboards has been removed from a normalreboard material, the ReBoardTM 18 can be bent, Without breaking, to conform to the inside of the molded pulp shell 17 before being glued to the shell, which will then replace the missing linerboard of the reinforcing ReBoardTM spacer structure.
    It is of course also possible to use other core materials used as spacermaterials to line the molded pulp shell 17 that are able to conform to theinterior curvature of the molded pulp shell. A honeycomb structure,having walls extending perpendicular to the surface of the shell 17 is alsoone possible spacer material, as well as the corrugated core used incorrugated board, or pulp molded spacer material as described above,thereafter covered With another inner shell made of molded pulp of a paper-based material in order to create a strong lightweight material.
    In order to improve the properties further of the material, variousfunctional additives may be used when producing the molded parts of thematerial. Additives that may be used in order to increase thefunctionality of the material may be fire retardants, hydrophobizationadditives, dry strength additives and wet strength additives. This may beadded in the pulp slurry used to make the molded material or may be added as a surface treatment by e.g. spraying or coating.
    The molded 3-D shaped material is characterized by having an even andsmooth surface and good mechanical properties. The density of themolded materials needs to be at least 1oo kg / m8 in order to obtainproper stiffness but may be even higher depending on the pressure used during the molding process.
    The molded material may be made of pulp from various fibers such asvirgin wood fibers (e.g chemothermo-mechanical pulp, chemical pulp ormechanical pulp), recycled wood fibers, textile fibers made of viscose,cotton or other cellulosic fibers, but may also be made of pulp comprising fibers mixed with thermoplastic fibers such as polylactic acid (as described in e.g. patent no EP2171154 A1) in order to create composite materials.
    An apparatus is shown in Fig. 4 which can be used to make the moldedpulp shell to form the container of the present invention and is describedin our co-pending patent application No. 1550864-1, entitled PulpMolding Apparatus and Molds for Use Therein.
    It comprises a frame 1, holding a stationary platform holding a female mold half 3 and below it a movable platform 12 holding a male mold half Six synchronously motor driven nuts on six long screw rods 4 move themale mold half 5 from the slurry bath 16 (99.5 % water and o.5% pulpfibers at 25-30 degrees C) to engagement in the female mold half 3,which is heated.
    Fig. 3 shows in longitudinal cutaway view a pair of mold halves 3, 5 usedfor manufacturing shells 17 for the reinforced containers of the presentinvention. The male mold half 5 is made of hollow aluminum and iscoated with an elastomer 6 which is ca 30 mm thick. This elastomer ispreferably sprayed onto the aluminum mold half. It is also possible tocast the elastomer onto the aluminum mold half. A typical elastomershould be hydrophobic but not be subject to hydrolysis. An advantageoushardness, particularly for a sprayed on elastomer is 70 A-Shore, toprovide optimal elastic properties. 5 mm diameter through-holes spaced15 mm from each other cover the elastomer layer and connect tothrough-holes 8 in the aluminum body of the male mold half 5. Withinthe male mold half there is generated a vacuum of 0.5-0.9 bar. On top ofthe elastomer layer there is a wire mesh. In this case it is a 1oo mesh (i.e. 1oo threads per inch) and is approximately 1 mm thick. The wire mesh can also be laid in multiple layers which Will further contribute todistributing the vacuum forces more evenly. The female mold-half 3 ismade of aluminum and has in this example a weight of 7oo kg. It isheated to ca. 200 degrees C., for example by means of heating rodsembedded in the material of the female mold-half 3. This is the mostenergy effective method of heating the female mold-half. Its inner surfaceWill create the outer surface of the product. The two mold halves, or partsof the mold halves such as an insert, can be made of porous aluminum toincrease strength over sintered material and to increase heatconductivity. The male mold-half 5 after being dipped in the slurry bath 6(see Fig. 4a) dewaters the slurry through vacuum to approximately 20%dryness (8o% water) and the male mold-half 5 is then pressed into thefemale mold-half 3 down to a gap of ca. 1 mm between the two moldhalves. It can vary for this particular product between ca. 0.8 and ca. 1.2mm without detrimental effects. The material is then dried underpressure at an elevated temperature (>1oo degrees, preferably 150degrees). Due to absorbing coolness from the male mold-half 3 (temp ofca. 250 C), the hot aluminum female mold-half 5 (initially ca. 2oo° C) willin turn drop ca. 13 degrees C during the compression process. Thistemperature change causes the female mold-half to shrink over its lengthapproximately 7-8 mm with corresponding contractions in its width (2.5mm) and height (1.5 mm). This is compensated for by the elastomer layer6. The temperatures in both the female and male mold-halves will varyup and down during the compression process thus repeatedly changingslightly the dimensions on the molds. In conventional pulp moldingprocesses, these dimensional variations would cause stresses andunevenness in the finished product, possibly even ruptures. In thisparticular exemplary product, without an elastomer layer, the temperature of the female mold-half must be rather precise, i.e. in this example between ca. 1950 and 2040 C. This precision is difficult to achieveand maintain in an industrial process of this type. These problems havebeen experienced even in the manufacture of relatively small pulpmolded products, and require precise adjustment of the temperature toavoid them. Most pulp molded products, such as egg cartons, are severalmillimeters thick and are thus more porous and it makes no differenceWhether such products have a rough surface. A product With a roughsurface cannot be used in many applications. For a large product, theproblems of dimensional heat expansion/contraction Will be greatlyincreased. These problems have hitherto made it impossible tomanufacture large pulp molded products With reasonable reject rates and with a smooth surface.
    The present invention Was developed in order to produce shells for largecontainers With very feW rejects and no necessity of precisely monitoringand continually adjusting the temperatures of the tWo mold-halves. Sincethe elastomer is used to absorb much of the dimensional variation of themale and female mold-halves, they can be made much lighter andthinner than otherWise since they Will not require a large mass to preventtemperature variations. For instance in this example the female mold-half Weighs ca. 750 kg. If it had to maintain a more constant temperatureit might have to have a mass of several tons, requiring more energy to heat such a large mass and maintain the heat.
    For example, a casket has in general curved sides, something Which isexpensive to produce in plyWood or With Wood planks. According to thepresent invention it is possible to produce shells of ca. 1-2 mm inthickness, Which provides the maximum stiffness. Thicknesses greater or less than this thickness (1-2 mm) provide less stiffness.
    These problems are solved by coating the surface of the male mold-halfWith an elastomeric material, onto which the Wire mesh or meshes is/ arethen applied. This elastomeric material continually compensates for thevarying dimensions of the two mold-halves during the compression/ heating process.
    It is also advantageous for molding the shell to mount the stationarymold half (in this case the female mold half) to be slightly horizontallymoveable (+- 25 mm) to make sure that any heating expansion will notprevent a correct horizontal alignment between the male and female mold halves during the pressing operation.
    It is also advantageous to equip the pulp molding apparatus withmechanical jacks, combined with a more incremental final stage for thecompression step. This final stage can also be accomplished with the aid of hydraulic pistons.
    As can be seen in Fig. 3, the male mold half 5 is provided with channels14 and large holes 8 beneath the elastomer layer 6 in order to prevent anyreduction of the vacuum which holds the pulp slurry and dewaters it on the surface of the wire mesh.
    The invention further describes a method to produce the 3-D shapedmolded lightweight material described above. The steps to produce the material comprises: i) Provide a 3-D shaped molded material 17 with the apparatusdescribed above with or without addition of functional additivesused as outer shell in the sandwich material ii) Provide a spacer material 18 used as core in the sandwichmaterial, and glue said core spacer material to the 3-D shaped molded material iii) Provide an inner shell 19 made of a 3-D shaped molded materialor a flexible paper based material which Will adhere to the spacer material.
    The manner of providing the three dimensional molded material will nowbe described with reference to the figures and in particular to Figs. 4a-4f.One apparatus for achieving this for comprises a frame 1, holding astationary platform 2 on which is mounted a female mold half 3 andbelow it a movable platform 12 holding a male mold half 5. Figs. 4a, 4band 4f show the apparatus in its mold-separated position and Figs. 4c, 4dand 4e show the apparatus its mold-compressed positon for forming themolded pulp shell. The same reference numerals for the samecomponents are used throughout all of the drawings. The apparatus isshown in Fig. 4a in perspective view in the mold-separated position withthe male mold half 5 submerged in a slurry bath 16. The liquid slurryitself is not shown in the figure. This same mold-separated position is shown in vertical section in Fig. 4b.
    The male mold half 5 is submerged in a pulp slurry bath 16 (99.5 % waterand o.5% pulp fibers at 25-30 degrees C) and a suction system 17 isconnected to the hollow interior cavity 15 of the male mold, whereby a coating of pulp slurry is sucked onto the surface of the male mold half 5.
    Six synchronously motor driven nuts on six long screw rods 4 move themale mold half 5 from the slurry bath 16 into pressure engagement withthe female mold half 3, which is heated, in the compression position of the molds shown in Figs. 4c, 4d and 4e.
    The large molded material of the invention may be of any size. Themethod of the invention is in particular of use when the material has a size larger than what can be made with conventional molding technology. 11 The 3-D molded material of the invention may for example have a length of 1 m or longer or in another example a diameter of 1 m or bigger.
    权利要求:
    Claims (1)
    [1] 1. A large lightweight three dimensional molded material comprising: An outer shell (17) of molded pulp and a reinforcing spacer (18)conforming to and adhering to the interior of said shell and aninner shell made of molded pulp or a flexible paper based material adhering to said spacer liner. . |/lolded material according to Claim 1, characterized in that the said spacer is a honeycomb sheet of hexagonal cells. . |/lolded material according to Claim 1, characterized in that said reinforcing spacer (18) and said inner shell is made of a Re-board© with a single cover paper sheet. . |/lolded material according to Claim 3, characterized in that said Re- board© spacer has only a single interior cover sheet (19). . |/lolded material according to Claim 1, characterized in that said reinforcing spacer liner comprises hollow cells separated by walls substantially perpendicular to said shell. . |/lolded material according to Claim 1, characterized in that said reinforcing spacer comprises a honeycomb structure made of paper. . |/lolded material according to Claim 1, characterized in that said reinforcing spacer is made of a spacer structure made of molded pulp. 13 8. |/lolded material according to Claim 1, characterized in that said partsmade of molded pulp have been made with functional additives such asfire-retardants, hydrophobization additives, dry strength additives and/or a wet strength additives. 9. |/lolded material according to Claim 1 characterized by a material coveralso comprising an outer shell of molded pulp and a reinforcing spacer liner. 10.Molded material according to any of the preceding claims in which the material has a length of at least 1 m. 11.Method of producing a molded 3-D shaped material according to one ofClaims 1-10, characterized by:a. Pressing a water based pulp slurry between a first male mold half (5)covered with elastomeric material (6) and a second female mold half (3),and drying the material at elevated temperature under pressure, to formthe molded pulp shell (17),b. providing a core spacer structure and gluing said reinforcing spacerstructure (18) to the interior of said molded pulp shell (17).c. provide an inner shell made of molded pulp or another flexible paper based material and gluing it to the core spacer structure. 12. |/|ethod according Claim 11, characterized in that said pressing iseffected in a frame (1) in which one of said mold halves (5) ismounted in means for translational movement towards the other mold half, means for compressing and holding said pair (3,5) ofmold 14 halves fitted against each other and a bath (10) of pulp slurry, and inthat said means for translational movement is adapted for immersinga first mold half in said bath ofpulp slurry and moving said first mold half into fitting compression against said second mold half.
    类似技术:
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    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    WO2016209158A1|2015-06-23|2016-12-29|Organoclick Ab|Large lightweight coffin and method for its manufacture|US2518164A|1946-07-02|1950-08-08|Leonard S Meyer|Apparatus for producing composite sheet material|
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    US5272852A|1991-03-01|1993-12-28|Cascades Inc.|Fluff-type organic insulating pulp and method of fabrication and application|
    JPH09117480A|1995-10-25|1997-05-06|Zentaro Kojima|Coffin cover, die unit for forming coffin cover, and production of coffin cover|
    US5771549A|1996-06-24|1998-06-30|Batesville Casket Company, Inc.|Casket shell structures|
    CN1164832C|1999-03-26|2004-09-01|花王株式会社|Paper making mold for pulp mold molding production and method and device for producing pulp mold molding|
    DE19922785A1|1999-05-18|2000-11-23|Hsieh Chuan Ren|Coffin for use in crematoria is of recycled waste paper materials shaped by vacuum drawing and stabilized in a press to be dried and painted|
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    CN103330630B|2013-06-26|2015-08-12|浙江国立包装有限公司|A kind of method utilizing useless corrugated paper to manufacture coffin without environment pollution|SE539866C2|2015-06-23|2017-12-27|Organoclick Ab|Pulp Molding Apparatus and Molds for Use Therein|
    US10569495B2|2017-05-08|2020-02-25|The Boeing Company|Composite structure assembly having a conformable core|
    CN108729308B|2018-06-11|2020-02-11|杭州西红柿环保科技有限公司|Paper pulp molding product and preparation method thereof|
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    SE1550866A|SE539902C2|2015-06-23|2015-06-23|Large Lightweight Three Dimensional Object and Method for Producing the Object|SE1550866A| SE539902C2|2015-06-23|2015-06-23|Large Lightweight Three Dimensional Object and Method for Producing the Object|
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    AU2016281463A| AU2016281463B2|2015-06-23|2016-06-23|Large lightweight molded material and method for its manufacture|
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