Method and device for manufacture of products from fibrous material from raw material, and product containing fibrous material

FIELD: textile, paper.

SUBSTANCE: invention relates to manufacture of products from fibrous material, namely egg cartons, glasses for drinks, food trays. There used is the first device which is permeable to air and water and the second device which is heated up to temperature at least 220C. Raw material is supplied to a forming bath. The first device is submerged into it and the initial product is shaped on it by means of application of negative pressure through it. After the first device is taken from initial raw material, it is supplied to the second device. Formed product from fibrous material is placed between the first and the second device. It is heated with the second device with evaporation of at least some water contained in the shaped product from fibrous material. Water is removed until dry matter content in it is at least 70%; after that the product is subject to drying with superhigh frequency radiation.

EFFECT: providing uniformity of strength properties of the product, effective dehydration and preventing its surface being burnt through.

29 cl, 33 dwg

 

The technical FIELD

This invention relates to the manufacture of feedstock products from fibrous material and, in particular, to three-dimensional objects, such as boxes for packing eggs and other packaging products, as well as to objects, such as cups for drinks or trays, such as trays for food.

BACKGROUND of the INVENTION

Articles of fibrous material, such as, for example, boxes for packing eggs, can be made from the feedstock in the process, in which the creation of a fibrous layer with modeling the desired shape, and then molded so the product is dehydrated and possibly putting some molding operations further processing.

In U.S. patent No. 6103179 described a method of manufacturing articles from fibrous material, which first covered the mold is immersed in forming a bath containing feedstock. Through vacuum formed into the fibrous layer of the specified thickness for the product of the fibrous material. Then the first covered the mold is removed from the molding of the tub. Then covered with the mold execute cyclic sequence in which the first stage of compaction covering the mold down under the power of it covered the mold, so that is the first Otzi the water, available in raw materials, followed by the transfer of articles from fibrous material to cover the mold, which is moved to the second position. Then the product of the fibrous material is subjected to a second extraction, after which it is subjected to final drying using microwave radiation frequency or infrared radiation.

In U.S. patent No. 66451235 described method of molding surround the farm from the fibrous pulp. In this way it is wet molding, which contains essentially rigid movable stamp for wet molding surround the first molding surface and essentially rigid fixed stamp for wet molding with the second molding surface. Dekel contains essentially rigid impermeable frame surrounding the inner space of the deckle containing prismatic vessel, the contour of the cross section of which covers the peripheral surface of the first stamp, so that the movable stamp for wet molding can traverse the axial length of the prismatic tanks in the inner space of the deckle. In the inner space of the deckle above a given section of the second molding surface is a cavity for fibrous pulp. In addition, there is a bootable tool designed to add fibrous slurries is in this cavity, and the pressing tool, providing the movement of the rolling stamp on the axial length of the prismatic container. This method involves adding a given quantity of fibrous pulp in the cavity for fibrous pulp and compressing the fibrous pulp that is located in this cavity, when the specified mode. Preformed farm then removed from the internal space of the deckle and move to the finishing device. In the finishing device preformed farm of wet fibrous material is further compacted and dried at high pressure between the heated shaped stamps to create the finished farm. After processing in the finishing device is ready, the farm is transferred membrane section further processing, which, as stated, includes operations such as attaching to the shell.

In U.S. patent No. 6582562 described method of making castings from the pulp through the use of the first and second pair of porous molds. In this method, first the mold is introduced into a pulp and apply vacuum to the first press mold to tformat pulp at the first press mold to the desired thickness. The second press mold are heated by hot air from a source of hot air, the first and second molds are combined and served vacuum to the first and second press-f is rmam during their connection. Then formed part away from the first mold, and it moves together with the second press-form. The second mold move and shoot with her depression for the separation from it of the formed part. This operation can be performed in conjunction with a conveyor belt. Stated that it is possible to use temperatures of drying at 300F (about 149C).

In U.S. patent No. 6136150 described the method and the device for receiving the flow of raw materials in molding the tub. Stated that tub molding is used for manufacturing products made of fibrous material, e.g. boxes for packing eggs or other packaging. This patent proposes the discharge of the flow of raw materials into the molding tub in its lower part with flowing up over the edge of this bath. Stated that this decision leads to the creation of the upward flow, and it is important for the formation of a fibrous layer of uniform thickness on a covered device that is used in this way.

During the manufacture of articles from fibrous material, such as, for example, boxes for packing eggs and cups for drinks, it is desirable to control the shape of the finished product in a safe manner. In many application areas is also desirable n is the difference in the finished product of uniform strength characteristics, that it should not be bent more easily in one direction than in another. When using heating for dehydration products of fibrous material is also desirable no burning surface of this product. In addition, it is desirable that the evaporating water can be effectively removed.

The purpose of this invention is to provide an improved method and an improved device for the manufacture of feedstock products from fibrous material. In preferred versions of the present invention the method is performed in this manner, and this device is designed to achieve improved control over the shape of the finished product. In the preemptive versions of the present invention, the finished product also becomes essentially uniform strength characteristics. Additional objectives of this invention are effective dehydration and prevention of burning of the surface of the finished product.

The INVENTION

This invention relates to a method of manufacture of feedstock products from fibrous material. The proposed method involves the use of the first device, which is permeable to air and water, and the use of a second device. The second lighting shall obline heated to the surface temperature, component of at least 220C. in Addition, the use of molding the tub, which served raw materials. The first device is immersed in the raw material in the forming tub and on the first fixture molded original product of the fibrous material by the application of vacuum through the first device. Then the first device is removed from the source of raw materials and down to the second device to ensure that the molded articles of fibrous material between the first and second devices. Molded product made of a fibrous material is heated by the second device to ensure evaporation of at least part of the water from the specified item.

Molded product made of a fibrous material can then be subjected to dehydration in several stages, in which the product is placed between a pair of opposite devices. Removal of water from products made from fibrous material is carried out up until the dry matter content will not be at least 70%, at which this product may be subjected to a final drying by radiation of ultra-high frequency. Before the final drying by radiation of ultra-high frequency product of the fibrous material may be subjected to steam for achievements Bo is her uniform content of moisture.

The step of heating and evaporation, which is carried out between the first and second devices, preferably should last no more than 1 sec. During molding of articles from fibrous material clean water suitable way to the dry matter content in the 18-22% by weight, preferably 20% by mass.

Accordingly, the dry matter content of the used raw materials may be 0.4 to 0.7% by weight, preferably 0.5% by mass. The respective raw materials may be obtained from chemically treated thermomechanical pulp (TMDM).

In preferred versions of the present invention during the actual molding in the molding of the tub is not available feedstock. This can be achieved, for example, by conducting the initial raw material from the reservoir, bypassing the molding baths during the forming stage. After the stage of forming the source raw material from the reservoir can be re-submitted to the forming tub. The forming stage preferably takes 1-2 sec.

The first fixture and the second fixture are preferably pressed together with a force that creates excess pressure of not more than 1 MPa and preferably not more than 900 kPa. In fact in some cases it may be appropriate for very low pressure, the range of values which is can be 10-900 kPa. In addition, the application of mechanical pressure may not be applied.

Also preferably, the vacuum should be applied to the first device, when the product of the fibrous material is placed between the first device and the second heated device. In addition, in preferred versions of the second device is permeable to air and water. A vacuum is also applied to the second device, when the product of fibrous material placed between these devices, so that the steam and water are removed through the first and through the second device.

This invention also relates to a device for the manufacture of feedstock products from fibrous material. This device has a forming tub to accommodate raw material and the first device, permeable to air and water. This device further comprises a second, permeable to air and water. In addition, the device includes means attached to the first device and intended for lowering the device into the tub and lifting it out of the bath, and for transferring the first device to the second device. To the first device connected to the device, creating a negative pressure, i.e. vacuum source. For naked who evania second fixtures installed the heating device, able to heat the surface of the second fixture to a temperature of at least 220C for evaporation of the water present in the wet product from the fibrous material when the product is placed between the first and second devices. This device further comprises a microwave heater, designed for additional removal of water from products made from fibrous material which was previously removed water at his location between the first and second devices. In addition, there are means for moving articles from fibrous material from the second device to the microwave heater.

It is preferable to supply raw material to the forming tub through a pipeline to a reservoir. In addition, can be performed by a bypass pipe, which can be used selectively in order raw materials from the tank could be carried out or directly to the forming tub, or introduced back in closed loop.

In an advantageous variants perform in front of a microwave heater can be placed to the device, injection steam to the product of the fibrous material before putting it through the microwave heater could be steamed before it is processed from a microwave heater.

PR is doctitle the first device contains particles, which were subjected to sintering to create a porous body. Also in preferred embodiments, execution of the second device also contains particles that have been subjected to sintering to create a porous body. You should understand that you can review and other devices, other than devices made by the method of agglomeration.

In the preemptive versions of the first and second fixtures are installed in holders made with the possibility of rotation between different angular positions.

In addition to the first and second devices on the path from the pair of the first and second devices to microwave heater can be placed accessories, forming a cooperating pair of devices in which the product of the fibrous material may be subject to additional dehydration, in addition, these accessories can be adapted for transporting articles from fibrous material to a microwave heater.

This invention also relates to a shaped product mainly containing fibers, which form the fabric of continuous and sustainable form, preferably forming a bulk product, in which the mass of the blade is 150-600 g/m2and fiber on Antonovna randomly so in the plane of the paintings regardless of the direction received essentially the same strength characteristics.

BRIEF DESCRIPTION of DRAWINGS

Figure 1 schematically depicts the layout of the devices used in the proposed method.

Figa-2h illustrate a sequence of dip molding device in raw material placed in the tub.

Figure 3 depicts in more detail the molding device is immersed in the bath.

Figure 4 depicts the molding device shown in figure 3, to host molded product made of a fibrous material.

Figure 5 illustrates the connection of the first device with the second device and placing between them the articles of fibrous material.

6 depicts a view of a perspective view of a group of holders forming devices arranged in series.

Fig.7 depicts this same group of holders of molding devices depicted in Fig.6, but in the top view.

Fig depicts a side view of a group of holders forming devices shown in Fig.6 and 7.

Figa-9h illustrates the transfer of the dried until ready products from fibrous material to the conveyor belt.

Figure 10 depicts a portion of the device shown in figure 1.

11 depicts an exploded view of a pair Formosa the different devices, used in this invention.

Fig depicts a cross-section of the pair of molding devices, shown at 11.

Fig depicts in more detail the microstructure forming devices shown in Fig.

Fig depicts a view of a perspective view of the holder of the molding device, in which there are multiple devices.

Figa-15c illustrate the characteristics of the molded product according to this invention in comparison with prior art.

Fig depicts part of a preferential option for the execution of the molding equipment used in the proposed method.

DETAILED description of the INVENTION

Refer to figure 1, which shows a device for the manufacture of products from fibrous material. On the left of figure 1 shows a section of raw material preparation, in which the briquettes 20 fibrous mass can be separated and converted into raw materials in pulpera 22 and then conducted to the reservoir 7 devices. In the tank 7 feedstock can be supported in the movable state of the mixer 21 to prevent the formation of flakes. From the reservoir 7 feedstock may be fed through line 8 to the tub 6, which is used in the proposed method. In preferred embodiments perform during the actual molding in the form of owocow tub 6 feedstock is not available. This can be achieved, for example, by conducting the initial raw material from the reservoir 7 to bypass the molding 6 baths during the forming stage. After the stage of forming the feedstock from the reservoir 7 can again be submitted to the forming tub 6. The forming stage may take, respectively, 1-2 sec. When the fibrous mass is not held to the forming tub 6, a fibrous mass in the tub 6 can be at rest. This solution leads to the advantage that the formed product from the pulp becomes more uniform properties in all directions, due to more random orientation of the fibers. To prevent the formation of flakes in the pipeline(s), host(s) to the tub 6, the feedstock during molding can be directed through the bypass pipe 9, so that the feedstock is maintained in the movable state. After molding articles from a fibrous material on the device 1, is immersed in the raw material placed in the tub 6, of the articles of fibrous material to remove water between the opposite pairs of devices, and then it is posted to a microwave heater 17 for final drying. For transporting the products 10 of fibrous material to a microwave heater 17 can be used conveyor belt 15. At the end of the production line can be collecting installation 23 for stacking of finished products 10 foot 24. Collecting installation 23 may include a suction device (not shown) for lifting the dried until ready products 10.

Next, with reference to figa-2h and figure 3-5 shows an explanation of the implementation of this method. On Figa shown that the first device is located on the holder 14 that is installed to rotate on an axis or pivot 14. On Fig.2b it is shown that the holder 13 by turning or rotation are shown in the position in which the first device 1 is turned to the initial raw material 19 is placed in the tub 6. The first device 1 is installed on the holder 13 with the possibility of lowering raw materials 19. This solution can be achieved by a special means for lowering and lifting of the first device 1 relative to the holder 13. Such means may include a telescopic arm 18 with hydraulic control, which is shown schematically, for example, on figs. Next, the first device 1 is dipped in raw materials 19, until it reaches the position shown figa that more detail is shown in figure 3. As can be seen from figure 3, the first device 1 has a profiled surface 25 corresponding to the shape of the product of the fibrous material to be molded. The first device 1 is permeable to air and water, in addition, it is connected to the source of the IR vacuum i.e. the suction device 2, which can apply a vacuum through the first device 1, so that the water together with the fibers by vacuum drawn to the first device 1. Water will pass through the first device 1 and can be returned to the raw material 19 through the return pipe (not shown). However, the fibers remain on the shaped surface 25 of the first device 1 and form the initial product 10 of fibrous material, as shown in figure 4. Thus, the first device 1 serves as a molding device for a source of molding articles from a fibrous material. Raw materials are preferably obtained from chemically treated thermomechanical pulp (TMDM), but may also be other fibrous mass of non TMDM. In this context TMDM is the preferred fibrous mass as raw material, obtained from TMDM, relatively easier dehydrated. As a percentage of the density of the raw material can be 0.5% by weight or about 0.5% by weight. However, it can also be provided by other density values.

The initial molding may take about 1-2 seconds. Upon completion of the initial stage of forming the first device 1 (forming device) is lifted from the raw material 19, as is provided on file. At this point in the molded product 10 dry matter content is about 20%, but this value may be somewhat lower or higher, in fact its range is, for example, 18-22%. As shown in fig.2f-2h, the holder 13 may then be rotated, and the first device 1 is again moved by the bracket 18 to the side from the case holder 13. On fig.2f-2h shows that the first device 1 is moved horizontally to the right side in the drawing. However, it should be understood that there may be other trends and patterns of movement. The first device 1 is moved to connect with the second device 3, as conventionally shown in fig.2h and in more detail on figure 5. During this movement of the suction device 2 continues to be operable, so that the original article 10 of fibrous material is firmly held by the first device 1. The second device 3 has a profiled surface 26, which coincides with the profiled surface 25 of the first device 1. When combining the first device 1 to the second device 3 molded product 10 is held between the devices 1, 3. In these drawings, the first device 1 is shown as a covered device, while the second device 3 is shown as covering the device. is what solution is most suitable, because it facilitates the molding process, however, the first device 1 can also be covering the device. For the second heating device 3 has a heater 5, so that the profiled surface 26 of the second device reaches a temperature preferably at least 220C. in Addition, can be used in temperatures exceeding 220C. the Actual temperature of the surface of the second device 3 may be 220C-400C. Despite the fact that to achieve effective dehydration preferably the surface temperature of the second device 3 must be at least 220C, it is necessary to understand what can be provided by temperatures below 220C. for Example, the temperature may be up to 200C, therefore the data range of temperature may be 200C.-400C. In preferred embodiments, execution of the second device 3 is also permeable device, therefore, the suction device 4 can also be attached to the second device 3 to Annex depression, when the second device 3 costacabana with the first device 1. Due to the high temperature of the second device 3 is the evaporation of water in the product 10. Due to the permeability of the at least first device 1 pairs can in order to stand out through the first device 1. If the suction device 2 of the first device is operable, it helps to remove the pair. When the permeability of the second device 3 pairs can also be removed through the second device 3, the removal efficiency can be increased if the suction device 4 of the second device is in action. During evaporation, the product 10 is held between the devices 1, 3. When the evaporation of water occurs at such high temperatures, the evaporation process is developing intensively and rapidly. In accordance with a widespread theory is the product of a fibrous material will be subjected to the process of the so-called "impulse drying". It is assumed that the evaporated water that comes out of the articles of fibrous material, will also displace the water remaining between the fibers, which has not been evaporated, resulting in a very effective dehydration. This invention is not limited to any specific theory, clarifying the phenomena that occur in such conditions. However, practical experience has shown that the surface temperature of 220C condition very effective dehydration. Experimentally it was found that the degree of dryness in 50% or more can be obtained at the first stage udaleniya between the devices 1, 3. The timing between the devices 1, 3 should preferably be very small, suitable can be no more than 1 sec. In some cases it may be appropriate time less than 1 sec. The pressure in the capture zone between the devices 1, 3 should be no higher than 1 MPa. Preferably the mechanical pressure should not be higher than 900 kPa. For example, the range of values of the mechanical pressure may be 10-900 MPa. In some cases, pressure may actually be zero.

Let us turn now to Fig.6, which shows several rows of holders 13 of the molding devices. As shown, for example, on Fig, each holder 13 is made to rotate and this contains the axis 14, which can rotate together with the holder 13 or the holder 13 can perform the rotation on the axis 14. Each of the holders 13 are additional devices 11, 12, such as covered devices 11 and covering the fixture 12. Each of the devices 11, 12 can create a capture together with at least one other device on the adjacent holder 13. Each of the devices 11, 12 can be permeable, and can be connected to the suction device, as well as the first device 1 and the second device 3. Devices 11, 12 can be installed on one or a few is such telescopic brackets 18 or on the actuator, ensure that the movement of the devices 11, 12 from their respective holders 13 or to them. In this way, the device 11 on the same holder 13 can be moved horizontally to the device 12 adjacent the holder 13 for the removal of water from products of fibrous material held between the devices 11, 12. Devices 11, 12 and the holders 13 also acts as a conveyor for delivering articles 10 to microwave heater 17. This function is performed as follows. The product 10 is held on the covered device 1, 11 or covering device 3, 12 due to the vacuum applied through the permeable device 1, 3, 11, 12. For example, consider the case in which the product 10 is initially retained on the covered device 1, 11. The bracket 18 (or brackets 18) moves the covered device 1, 11 to the covering device 3, 12, where the removal of water from products 10. Then reset the vacuum created through the covered device 1, 11, and then the product 10 is held by vacuum generated through the covering device 3, 12. Covered device 1, 11 is returned to its original position. Then the holder 13 of the covering device 3, 12 is rotated 180, so the product of fibrous material is drawn to a new covered device 12. It should be understood that this process can be repeated to ensure the transfer of the product 10 to the next covered the device and next to the microwave dryer. Thus, the devices 11, 12 and their holders 13 are located with the possibility of shipment of the product 10 to a microwave heater. For a clearer understanding of the layout of additional devices 11, 12 reference is also made 7.

As can be seen most clearly on Fig, each holder 13 can contain multiple adjacent devices 12, so that the possible production and final processing of many products 10 simultaneously. It should be understood that each of the additional pairs of devices 11, 12 may be similar to the first device 1 (forming device and the second device 3, in addition, in the capture of created pairs of additional devices 11, 12 may be an additional dehydration. In this case, the additional devices 11, 12 are used for dewatering and transport of the product(s) 10. In the preemptive versions of the present invention between the first device 1 and the second device 3 can be maintained relatively low pressure, while between successive pairs of devices 11, 12 IP is resultsa higher pressure and lower temperature. For example, a higher pressure up to 1 MPa, can be used in the nip pressure between the last pair of devices 11, 12. It should be understood that typically additional dehydration is carried out in the gripping pressure between the additional devices 11, 12. When using more than two grippers pressure may increase from capture to capture, so that the lowest pressure used in the first engagement, a higher pressure is used in subsequent seizures, and a very high pressure will be in the final capture. Accordingly, the pressure may be increased stepwise from capture to capture.

In accordance with figa-9h conveyor belt can be located at the end of the route molding devices. Fig.9 illustrates the horizontal location of the last holder 13. It should be understood that the product 10 is held by vacuum applied to the covered device 11. The holder 13 is located above a conveyor belt 15. On fig.9b holder 13 is rotated so that the device 11 is turned to the conveyor belt 15. The device 11 is moved down, as shown in figs, while the vacuum is reset, causing the fall of the articles of fibrous material to the conveyor belt 15. It is also possible to blow air through the device 11 to which deystviya the exit of the product 10. The product of fibrous material is then transported to a microwave heater, while the device 11 returns to its initial position as shown in figa-9h.

Figure 10 can see that in front of a microwave heater 17 can be mounted sprayer 16 steam blows steam product 10. This process is intended to achieve a more uniform distribution of moisture in the product 10. It should be understood that the use of steam is an optional feature of this invention, and it is possible to provide embodiments of the present invention, in which the steam is not used. Preferably the articles of fibrous material to remove water to a dry matter content of at least 70%, before it come to the heater 17. However, it should be understood that the dry matter content at the approach of a microwave heater may be below 70%.

The following is a more detailed explanation of the design of the devices 1, 3, 11, 12 in accordance with a possible alternative implementation of the present invention with reference to 11-13. 11 is an exploded view of the first device 1 and the second device 3. As shown in figure 11, the heater 5 can be located close to the second device 3 may attached directly to the fixture is 3 or located some distance from him. As you can see in Fig, both devices 1, 3 made with channels 27 through which can pass through water and air. As shown in Fig, devices 1, 3 can contain different layers 28, 29, 30, which are parts of the structure devices having different permeability. The inner layer 28 forms a basic structure with a relatively high degree of permeability. The intermediate layer 29 has a relatively low permeability, and a thin surface layer 30 may even have a low permeability. These fixtures can be mostly made of small metal balls, which are subjected to sintering for the formation of different layers. As shown in Fig, the surface layer 30 may be formed of small balls 31, while the intermediate layer 29 can be formed from several larger metal balls 32. The basic structure formed by the biggest balls 33. The smallest particles 31 can have a diameter in the range from 0.01 to 0.18 mm, whereas particles 32 in the intermediate layer 29 may have a diameter in the range of 0.18 to 0.25 mm, the Largest particles or balls 33 in the base layer can have a diameter of 0.71-1 mm Particles 31, 32, 33 can be the type of particles that are commercially available in the form of a metallic powder and can be purchased in the firm CALLO AB, Poppelgatan 1557139 N is ssj, Sweden. The firm CALLO AB sells metal powder called Callo 25, which represents a metal powder with spherical particles having a diameter of 0.09-0.18 mm, with the chemical composition of 89% Cu and 11% Sn. In addition, suitable particles can be purchased in the firm Makin Metal Powders Limited, Bucley Road, Rochdale, Lancashire OL12 9DT, England.

The porous structure of the device 1 may be about 40%. The value of porosity of 40% may apply to all layers. In addition, can be provided by embodiments of the present invention, in which the various layers of the device have different porosity.

More small balls 31 form a thin surface layer, which gives the product of the fibrous material smooth surface, while the inner layers 29, 28 improve permeability. The channels 27, which pass through the sintered structure may have pointed ends of the surface-reaching adaptations that improve permeability.

Let us now turn to Fig. In an embodiment shown in Fig, section 34 of the surface 25 of the first device 1 is covered or coated to provide impermeable or substantially impermeable. On impervious area 34 forming a layer of fibers is not running, hence the availability on the product of the fibrous mater is Ala holes, the shape of which corresponds to the impervious area 34. Impervious area 34 can be obtained, for example, by painting or coating with impervious sheet material surface area 25. It should be understood that this property (the presence of impervious area) is completely optional, and the invention could be made without this additional property. As for the method, it should be understood that this invention may be regarded as including (optional) stage use fixtures with impervious area 34. The proposal to use the device with impenetrable plot can be used independently of the other constructive solutions or complete fixture, device, or method.

The advantage of the porous structure provided agglomerated particles 31, 32, 33 of the metal, is that water and steam can easily pass through devices 1, 3, 11, 12, which reduces the risk of delamination during the evaporation process. In addition, the advantage of the structure obtained by the method of agglomeration is the possibility of a very uniform output pair on the entire surface of the device.

The advantage of using a high temperature is to achieve effective dehydration. Compression otnositel the high pressure, before passing to a microwave heater (in wet condition articles of fibrous material), leads to the advantage of the optimal qualities of the surface prior to drying by radiation of ultra-high frequency. Thus, there is no need for pressing articles of fibrous material after drying, radiation, ultra high frequency, which can be harmful to the product. Stage heat radiation of ultra-high frequency causes the advantage of improved hygiene. The use of high temperature also provides the advantage that the surface of the fibrous material becomes more compacted, which is useful from the point of view of rigidity in bending.

It should be understood that in some embodiments, performing the heat radiation of ultra-high frequency may be eliminated or replaced any other way, for example by heating in the infrared spectrum.

It should be understood that the concept of delay in supply of raw materials to the form 6 during the forming stage can be applied regardless of the execution of this method otherwise.

This invention also relates to the product of a fibrous material, which can be obtained by the above method. On figa-15C illustrates the properties of the molded product, made in accordance with this invention. Figa shows that qualitative aspects (which are important in many fields of application products, molded of fibrous pulp, for example in packaging production) this product can greatly exceed the product of the prior art, for example, created a hot molding or by forming a fibrous mass. It is assumed that the quality of our products due to the possibility of achieving a high density, in the range of 600-900 kg/m3without any weakening of the fibrous structure. In accordance with the methods of the prior art density exceeding 500 kg/m3that is rarely achieved without also at least to get a quality aspect below the desirable level. As you can see in figs, products obtained by hot forming fibrous mass may have a density level higher than 500 kg/m3. However, when using thermoforming, which includes heating after pressing, the fibrous structure is partially destroyed, which greatly impairs the qualitative aspects, for example, in terms of tensile strength. In particular, at the corners and other areas of the product that are sharp curves/arcs will provide what about the negative effects of such heating after pressing, whereas in accordance with this invention corners and areas of sharp curves also represent essentially the same type of continuous homogeneous structure of the canvas, which essentially flat areas of the product, which, in turn, provide equally high-quality aspects essentially all areas of the product. In the preemptive versions of the fibrous fabric of the product is uniform in thickness or substantially uniform thickness. However, it should be understood that articles of fibrous material obtained as described above may at least in some cases to have a density less than 600 kg/m3or higher than 900 kg/m3.

An additional major advantage in accordance with this invention is the ability to create very smooth surfaces on both sides of the product. Products manufactured in accordance with this invention, can easily obtain a roughness in the range of about 750-3000 ml/min (ISO 8791-2, Bendtsen), whereas the product obtained in the usual molding fibrous pulp, at least on one side typically have a roughness greater than 1500 ml/min. Can be noted that one of the reasons that conventional products have a higher roughness, is that for the most part in traditional techniques is to form the surface of the used wire mesh.

An additional advantage in accordance with this invention is the acquisition of a product of the high limit of the tensile strength, typically in the range 50-100 kNm/kg, which does provide a significant advantage compared to products obtained from a conventional molding fibrous pulp (see fig.15b). In addition, it also achieves the optimal rate of resistance to strain in the range of 5-15 Nm2/kg, more preferably 8 to 15 Nm2/kg, and provides resistance to the air paintings, including corners and sharp bends of the products in the range 60-200 seconds on gerli (Gurley), preferably at least 70 and more preferably at least 80. Another advantage is that the adhesive force of the surface layer on 5-50%, more preferably 7-30% greater than the adhesive force of the intermediate layer, located near the Central part of the canvas forming the product, because the proposed method provides a higher number of connections between the fibers in the surface layer. When this is achieved the objective of creating I-beams, namely improving the rigidity of the product and resistance to bending.

In conclusion, certain preferred aspects of the proposed product is that it can be manufactured without the such subsequent pressing, which would otherwise increase the cost of production and, as noted above, also have a negative impact on at least some or one qualitative aspect. The offered product can also be performed without any subsequent pressing more than 1.5 MPa after reaching the dry matter content, of at least 70%, preferably 80% and more preferably 90%. On fig.15b shown that thanks to all the above benefits, the rate limit of the tensile strength of the proposed product may have a high value regardless of the form of paintings, while the rate limit of the tensile strength of products made according to traditional methods, will decrease with increasing complexity of the shape of the canvas. In the table on figs presents some average values for the two methods of the prior art, obtained experimentally, that is, for traditional molding fibrous mass and for forming, in comparison with the proposed method. As should be pretty obvious from this table that the proposed product can have many advantages in terms of qualitative aspects in comparison with products of the prior art.

1. The method of manufacture of feedstock products in onestage material, including
a) using the first device (1), which is permeable to air and water,
b) a second device (3) and temperatures up to at least 220C,
(c) forming a bath (6) and feed it raw material
d) immersing the first device (1) in the feedstock in the bath (6),
e) forming on the first device (1) primary products (10) of the fibrous material by the application of vacuum through the first device (1),
f) removing the first device (1) of the feedstock,
g) summing the first device (1) to the second device (3) with the provision of the premises of the molded product (10) of the fibrous material between the first and second devices (1, 3) and the second heating device (3) to ensure evaporation of at least part of the water is present in the molded article (10) of the fibrous material, and
h) removing water from the molded product (10) of the fibrous material as long as the dry matter content it will not be, at least 70%, after which the specified product (10) is subjected to drying by radiation of ultra-high frequency.

2. The method according to claim 1, characterized in that the heating and evaporation, which are performed between the first device (1) and the second device 3), continue to not more than 1 C.

3. The method according to claim 1, characterized in that during the forming stage to the forming tub (6) does not serve raw materials.

4. The method according to claim 3, characterized in that during the step of molding the feedstock is conducted from the reservoir (7) to bypass the molding of the bath (6), and after the step of molding the feedstock is supplied from the specified tank (7) forming a bath (6).

5. The method according to claim 1, characterized in that the forming stage continue 1-2 C.

6. The method according to claim 1, wherein removing water from the product (10) of fibrous material is produced in several stages between the other devices, and then exposed to steam to the drying of this product radiation of ultra-high frequency.

7. The method according to claim 1, characterized in that the dry matter content of the feedstock is 0.4 to 0.7% by weight, preferably 0.5% by mass.

8. The method according to claim 1, characterized in that during the forming stage of the product (10) of the fibrous material to remove the water content of dry matter in the 18-22% by weight, preferably 20% by mass.

9. The method according to claim 1, characterized in that the first device (1) and second device (3) are pressed to each other with a force that creates excess pressure of not more than 1 MPa, preferably not more than 900 KPa.

10. The method according to claim 1, characterized in that the range of testing the response to pressure is 10-900 KPa.

11. The method according to claim 1, characterized in that the feedstock is obtained from chemically treated thermomechanical wood pulp.

12. The method according to claim 1, characterized in that the vacuum is applied also to the first device (1)when the product (10) of fibrous material is placed between the first device (1) and the second heated device (3).

13. The method according to item 12, wherein the second device (3) is also permeable to air and water, and a vacuum is also applied to the second device (3)when the product (10) of fibrous material is placed between the devices (1, 3) to enable the removal of steam and water through the first device (1) and through the second device (3).

14. Device for the manufacture of feedstock products (10) made of a fibrous material containing:
a) forming a bath (6), designed to accommodate raw material
b) the first device (1), permeable to air and water,
c) a second device (3), permeable to air and water,
(d) means attached to the first device (1) intended for lowering this device (1) in the bath (6) and lifting it out of the bath (6), as well as to transfer the first device (1) to the second device (3),
e) a vacuum source (2)connected to the first lighting is Oleniy (1),
f) a heat source (5), used for heating the second device (3) and is arranged to heat the surface of the second device (3) to a temperature of at least 220C for evaporation of the water present in the wet product (10) of the fibrous material when the product (10) is placed between the first and second devices (1, 3),
g) a microwave heater (17), designed to further remove water from the product (10) is made of a fibrous material that was previously removed water between the first device (1) and second device (3), and
h) a means of moving the article (10) of the fibrous material from the second device (3) to a microwave heater (17).

15. The device according to 14, characterized in that it comprises a reservoir (7), intended for the supply of raw material in the forming tub (6) through line (8), and the bypass conduit (9), which can be used selectively to ensuring the supply of raw materials from the specified tank (7) directly to the forming tub (6) or discharge it back in the closed loop.

16. The device according to 14, characterized in that in front of a microwave heater (17) is mounted sprayer (16) couple with the possibility of steam treatment of the product (10) is made of a fibrous material, which must be p is avedano through the microwave heater (17), before it can be processed from a microwave heater (17).

17. The device according to 14, characterized in that the first device (1) contains particles that have been subjected to agglomeration with the creation of the porous body.

18. The device according to 17, characterized in that the second device (3) contains particles that were tucked in the Metropolitan area with the creation of the porous body.

19. The device according to 14, characterized in that the first and second fixtures (1, 3) are mounted on the holders, made with the possibility of rotation between different angular positions.

20. Device according to any one of PP-19, characterized in that in addition to the first and second devices (1, 3) on the route from the pair of the first and second devices to a microwave heater (17) are accessories that form the interacting pairs of devices in which the product of the fibrous material may be subject to additional dehydration, and additionally made with the possibility of moving the article (10) of the fibrous material to a microwave heater (17).

21. The shaped product mainly containing fibers, which form the fabric of continuous and sustainable form, preferably forming a bulk product, in which the mass of the blade is 150-600 g/m2and fiber is oriented with ocinum way what in the plane of the paintings regardless of the direction received essentially the same strength characteristics, in which the range of density values is 600-900 kg/m3preferably at least 700.

22. The shaped product according to item 21, wherein the angles and/or areas of sharp curves also represent, essentially, the same type of continuous uniform cloth as essentially flat surface of the product.

23. The shaped product according to item 21, wherein the range of values of roughness significant part of the surfaces on both sides of the product is 750-3000, ml/min, preferably at least on one side 750-2000 ml/min, more preferably 750-1500 ml/min, Bendtsen ISO 8791-2.

24. The shaped product according to item 21, wherein the range indicator of the ultimate tensile strength is 50 to 100 kNm/kg, more preferably 65-100 kNm/kg, more preferably 80-100 kNm/kg, most preferably 90-100 kNm/kg

25. The shaped product according to item 21, wherein the range indicator of the resistance to strain is 5-15 Nm2/kg, more preferably 8 to 15 Nm2/kg.

26. The shaped product according to item 21, wherein the adhesive force of its surface layer on 5-50%, more preferably 7-30% more than the bond strength of the tick layer, located near the Central part of the canvas forming the product.

27. The shaped product according to item 21, wherein the resistance of the air paintings, including corners and sharp bends product is 60-200 with gerli, preferably at least 70 and more preferably at least 80.

28. The shaped product according to any one of p-27, characterized in that it can be done without any subsequent pressing.

29. The shaped product according to any one of p-27, characterized in that it can be done without any subsequent pressing more than 1.5 MPa after reaching the dry matter content constituting at least 70%, preferably 80% and more preferably 90%.



 

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2 tbl

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