INSTALLATION AND METHOD FOR PRODUCING PRODUCTS MADE FROM PAPER PULP

Description

Field of the invention

[0001] The present invention relates to an installation and a method for producing products made from paper pulp. Particularly, but not exclusively, the invention relates to an installation with improved flexibility.

Background of the invention

[0002] Typical installations or plants for manufacturing products from paper pulp are often very large, stationary facilities assembled at least partly on site in production factories and hence not intended to be moved or easily modified once in operation. By their nature, such installations are not flexible in case of the need for a change in production and are in addition costly to manufacture, transport and maintain due to their sheer size and complexity.

[0003] With the currently available solutions on the market, paper pulp products may typically be made by attaching a number of custom made identical moulds to a large wheel and bringing one after the other in contact with paper pulp by rotating the wheel, while simultaneously applying an underpressure to the surface of each mould so as to suck paper pulp onto the surface of the mould when it is passed through the pulp mass. Once the turning of the wheel has moved the mould (having now a paper pulp blank sucked on to its surface) out of the paper pulp again, the blanks are typically transferred to intermediate transport means for going on to further processing steps such as a drying step.

[0004] With such known techniques, the appearance of the produced blanks is often disturbed by the formation of unwanted, uneven edges originating from a surplus of pulp material gathering at the lowermost parts of the mould. This is at least partly because gravity forces surplus pulp material to run to the lowest positioned edges of the mould thus resulting in the formation of uneven portions along the edge. In order for the finished product to have a straight and even edge it is often necessary to subsequently use e.g. a cutting tool in order to cut the edge straight which of course increases the price per unit.

[0005] Also, the blanks produced by the known techniques are limited in that the sides thereof cannot be produced with an angle in relation to vertical of less than around 8° because the resulting force component of the rotational movement of the large wheel and gravity causes the pulp material on the mould to lopside. This means that these existing products, when used as insides in packings, will require larger dimensions (i.e. more air space) of the outer packaging part in order for the insides to fit therein. This further has the effect that such larger dimensioned packings will take up more space e.g. during transportation which is of course less cost efficient and consequently also environmentally bad.

[0006] Another method for producing paper pulp blanks is disclosed in US patent 6,352,617. The document describes how a blank form can be provided on a turnaround table positioned over a vertically, movable tank containing pulp material. An underpressure is created and kept on the surface of the blank form and pulp material is sucked onto it as the tank is brought into engagement with the blank form by moving the tank upwards. The pulp material tank is subsequently lowered and the turnaround table is turned 180 degrees allowing the blanks to be picked up by an upper press form. The upper press form, now holding the blanks, is then moved into a position above a lower press form and is then descended to make the upper and lower press forms engage. When the blanks are sufficiently cured in the press form, they are subsequently moved by the mechanism of the upper press form to a conveyor belt for further manufacturing steps or packing. The method disclosed in this document involves the use of three different individual and complex tools for handling the blanks during manufacture and discloses only a single "production line".

[0007] In WO-A-2007/129972 a tank assembly for making fibre products from stock comprising a stock vat, a main tank, at least one inlet to said main tank from said stock vat and an outlet from said main tank is disclosed. The tank assembly further comprises at least one outlet tank having at least one inlet at its bottom connected to the inlet to said main tank and an outlet connected to said main tank so that stock from the mould tank is arranged to flow into said main tank and in that the horizontal cross-sectional area at the top of said mould tank is larger than the horizontal cross-sectional area at the bottom of said mould tank

[0008] Hence, an improved installation and production method for producing paper pulp products with an improved appearance and steeper side angle/slope would be advantageous, and in particular a more flexible and less costly installation and production method due to the use of a lesser number of tools and reduced size of the installation, would be advantageous. Furthermore, an installation facilitating an increased production rate and an improved efficiency and providing an economically feasible equipment for even small production batches is highly desirable.

Object of the invention

[0009] In the light of the above described shortcomings of the currently available techniques it is an object of the present invention to provide an installation having a high degree of flexibility which may be easily modified in case of a production change.

[0010] It is also an object of the present invention to provide an installation that is easily moved, maintained and repaired.

[0011] It is another object of the present invention to provide an installation with reduced manufacturing costs.

[0012] It is yet another object of the present invention to provide an installation wherein the number of required tools is reduced.

[0013] It is a further object of the present invention to provide a method for producing paper pulp products having an improved appearance.

[0014] It is yet a further object of the present invention to provide a method for producing paper pulp products with increased side inclination or slope.

[0015] It is yet another object of the present invention to provide a method for producing paper pulp products at an increased production rate and improved efficiency.

[0016] It is another object of the present invention to provide a paper pulp product having an improved appearance.

[0017] It is a still further object of the present invention to provide a paper pulp product having increased side inclination or slope.

[0018] It is a further object of the present invention to provide an alternative to the prior art.

Summary of the invention

[0019] Thus, the above described objects and several other objects are intended to be obtained in a first aspect of the invention by providing

[0020] an installation for producing products from paper pulp comprising

• a vessel for paper pulp,
• at least one platform adapted to carry at least one blank mould, said platform is further adapted to engage and disengage the blank mould with the paper pulp in said vessel by a translatoric movement of the platform and the platform having means for pivoting,
• means for creating underpressure on at least a part of the surface of said blank mould for producing a blank, and
• at least two heatable press moulds adapted to receive said blank from the blank mould for drying and curing.

[0021] The invention according to the first aspect is particularly, but not exclusively, advantageous for obtaining an installation for producing paper pulp products adapted to bring at least one blank mould carried by at least one platform into engagement with paper pulp in a vessel by a translatoric movement. In the present application context, a translatoric movement is to be construed as solely a translatoric movement, such as in the sense of an explicit vertical or rectilinear movement (the "line" of which may be inclined), such as in the sense of a rectilinear downward and/or upward movement.

[0022] The installation according to the invention has suitable means that will create an underpressure on at least a part of the surface of the blank mould when the blank mould is brought into engagement with the paper pulp, so as to produce a blank by sucking paper pulp onto it. Depending on requirements of the product, however, the surface of the blank mould may be so adapted as to hinder the pulp from being sucked on to the surface in certain positions.

[0023] The means for creating the underpressure may preferably, but not exclusively, be an electrical pump connected to the blank mould by any kind of adequate conduit means for removing air and water sucked out of the paper pulp mass. The air stream may, however, be reversed so as to blow air in the direction of or through the blank mould. Other types of pumps or pumping systems may be used for generating the underpressure. The pump or pumping system may preferably, but not exclusively, be positioned on the platform carrying the blank mould. Alternatively, the connecting conduit means may be adapted to connect with an external pump or pumping system. The installation may comprise more than one pump or pumping system working either together or independently of each other.

[0024] The platform carrying the blank mould may preferably, but not exclusively, be attached to or made in one piece with frame elements positioned at opposing sides of the platform. The platform or the frame elements may preferably, but not exclusively, comprise one or more eyes or eyelets positioned at a periphery of the platform or the frame element for cooperation with one or more rail- or rod-like elements fixed between an upper and a lower cross-bar. This is intended to guide the platform in a translatoric movement when it is moved by suitable means. The means for moving may preferably, but not exclusively, be an actuator such as a cylinder or piston-like element connected to the platform. The actuator may preferably, but not exclusively, be driven by an electrical motor. The frame elements may preferably, but not exclusively, be hollow so as to contain wiring, fittings and conduits for being connected to the elements carried on the platform, such as the discharge conduit for removing air and water from the blank mould. More than one actuator means may be used. The actuation means may alternatively comprise a toothed gear transmission.

[0025] The vessel for paper pulp may be any shape and size of tank suitable to contain an appropriate volume of paper pulp. Preferably, but not exclusively, the tank comprises one open side in order for the blank mould to engage the paper pulp. The tank may be equipped with means for connection between the tank and an external source for facilitating possible continuous delivery of paper pulp to the tank. Preferably, the tank may further comprise means for generating a constant movement of the pulp mass for prevention of sedimentation and/or an unwanted increase of the viscosity of the pulp mass. The installation may comprise more than one vessel for containing paper pulp; i.e. containing differently coloured or otherwise differentiated paper pulp masses.

[0026] The platform for carrying the blank mould may be shaped and sized to carry more than one blank mould. If more than one blank mould is carried by the platform, these blank moulds may be identical and/or of different shapes and/or sizes. The number and positioning pattern of press moulds for receiving the blanks may preferably be adapted to correspond to the number and shapes of blank moulds. Thereby a number of blanks may be produced in each production cycle.

[0027] The pivoting means for pivoting the platform may preferably, but not exclusively, comprise turning and/or rotation means deposited in bearings positioned at opposite sides of the platform carrying the blank mould. The turning and/or rotation means may preferably be embedded in or fixed with the platform side. Alternatively, the means may be embedded in the frame elements. The turning and/or rotation means may preferably, but not exclusively, be a toothed gear connection e.g. comprising one or more releasable split or cotter pins for braking the platform in the correct positions. The turning and/or rotation means may preferably, but not exclusively, be actuated by an electric motor fitted in connection therewith. The one or more releasable split or cotter pins may also be actuated by any suitable electric and/or electromagnetic means. By arranging the pivoting means at opposing sides of the carrying platform, the uncured blanks may be rotated "on-the-spot", rendering the installation more flexible and less costly. Furthermore, by rotating the uncured, wet blank all excess water is forced by gravity to leave the blank and the mould thereby minimising the amount of water or moist that is to be removed from the wet blank.

[0028] As disclosed, the installation also comprises at least two heatable press moulds adapted to receive the blank after it has been shaped in the blank mould. The press moulds may preferably be made of a material having a high thermal conductivity, such as, but not limited to, aluminium. In order to improve the distribution of heat in the press moulds, as well as for providing an improved fixation of the press moulds to a receiving portion or similar of a supporting platform or another relevant part of the installation, the sides of the press moulds may preferably be wave-shaped such as, but not limited to, being approximately sinus-shaped. The temperature generated in the press moulds may preferably be controlled by suitable thermometer means connected to the controlling unit, so as to be sufficiently high to dry and cure the paper pulp product without any unintended overheating.

[0029] Also preferably, but not exclusively, the installation may comprise more than one section fitted with one or more press moulds, in the sense that the platform carrying one or more blank moulds may deliver the uncured blanks to e.g. a second section during the time the blanks of a first section are being dried and cured. In order to also continuously seeking to reduce the size of the overall installation, such a second section may preferably be positioned on opposite sides of the blank mould platform with respect to each other rather than in in-line steps. Any number of sections fitted with press moulds may of course be optimized quickly according to production needs, thus adding to the flexibility of the installation.

[0030] The at least two heatable press moulds are positioned on opposite sides of the blank mould platform. This is advantageous in at least that one blank mould may in a substantially continuous way deliver blanks to a "free" press mould while a blank is being cured in a "busy" press mould and so on. By distributing these receiving press moulds on each side of the blank mould platform, the production rate can be speeded up while the size of the overall installation is kept at a minimum.
Preferably, but not exclusively, the installation comprises a main frame of metallic beams and/or girders within which the space for the different elements and parts of the installation is defined.

[0031] In an embodiment of the invention, the blank mould is made from a sheet material having penetrations or made from a fine meshed material.

[0032] The invention is particularly, but not exclusively, advantageous for obtaining a blank mould with a surface where the penetrations are positioned adequately and sufficiently close to each other in order for the relatively long paper fibres of the pulp mass not to "slip" through the mould surface. In other words, if the blank mould surface is not sufficiently close penetrated or fine meshed, the paper fibres will be sucked through the surface together with the water and thus not generate a correctly shaped and/or surfaced blank. The actual size of each penetration may of course also be altered accordingly. However, if required, in some positions on the mould surface there may preferably be a different gap or distance between the penetrations or even no penetrations at all. Alternatively, the blank mould surface may be made from other easily formable and "drainable" materials, such as, but not limited to, clay, peat, ceramic or synthetic and plastic materials. The blank mould may preferably, but not exclusively, be implemented on a standardized module attached to the carrying platform so as to be very easily interchangeable in case of production change.

[0033] In an embodiment of the invention, the penetration size or the mesh size of the sheet material and the fine meshed material respectively, may preferably be less than 0.5 mm², preferably less than 0.1 mm², preferably less than 0.05 mm², preferably less than 0.02 mm², such as less than 0.017 mm². Also, the gap or distance between the penetrations may preferably be less than 0.2 mm, preferably less than 0.18 mm, preferably less than 0.15 mm, such as 0.13 mm.

[0034] In another embodiment of the invention according to the first aspect, the press mould of the installation may preferably comprise an inner and an outer form part. The outer form part is preferably a negative form part adapted to first receive the uncured, wet blank from the blank mould. The inner form part is preferably a positive form part adapted to engage with the uncured, wet blank positioned in the outer, negative form part. Alternatively, the uncured blank may also be received by the inner form part just as the inner form part may be made the negative part and the outer form part may be made the positive part. The parts of the press mould may preferably, but not exclusively, be implemented on standardized modules attached to, or being, supporting platforms so as to be very easily interchangeable in case of production change. The supporting platforms may comprise means for automatic horizontal movement. As previously mentioned, the sides of the press moulds may preferably comprise a wave-shape such as a sinus-curve; this may aid to improve the fixation with a corresponding wave-shape on the standardized module and/or the supporting platform carrying the press mould.

[0035] In yet another embodiment of the invention, the press mould comprises a heating element in either the inner or the outer form part or in both form parts. By adapting both the inner and the outer form with a heating element, the fastest and most even drying and curing of the blank is obtained. However, for specific purposes, the heating of the press mould may be so controlled as to obtain a different drying pattern of the blank e.g. by heating only the inner or the outer form part. The heating element for the press mould may preferably be an electrical heating element however, the necessary heat may be generated by use of another source such as gas burner etc. Also, one or more parts of the surface of the press mould form parts may alternatively be insulated if certain corresponding positions on the product require less drying or curing.

[0036] In a still further embodiment, the installation according to the first aspect of the invention comprises means for releasing the uncured blank from the blank mould. Such means may preferably, but not exclusively, comprise one or more ejector pins or the like e.g. adapted flush with the surface of the mould when not engaged. Alternatively, pressurized air, generated e.g. by the pump or pumping system of the installation and released through one or more suitably valved outlets may be applied to eject the uncured blank from the blank mould.

[0037] In yet another embodiment, the installation according to the first aspect of the invention comprises means for releasing the cured blank from the press mould. Such means may preferably, but not exclusively, comprise one or more ejector pins or the like e.g. adapted flush with the surface of the mould when not engaged. Alternatively, pressurized air coming from one or more suitably valved outlets may be applied to eject the cured blank from the press mould. The release means may be provided in either the inner or the outer form part of the press mould. Alternatively, the release means aided by pressurized air may also be so adapted as to first generate an underpressure on the surface of either of the form parts of the press mould and then subsequently reversing the air stream to eject the blank from the form part. Even further, in embodiments the surfaces of the press mould may comprise a coating or similar comprising a material that has the ability to assure easy removal of the cured blanks from the press mould. Such a material may be, but is not limited to, Teflon®, a registered trademark of DuPont.

[0038] In another embodiment of the invention, the installation comprises means for delivering paper pulp to the vessel containing the pulp. The pulp mass may be delivered in portions or, preferably, the means may be adapted as to deliver a continuous flow of pulp mass to the vessel when the installation is in operation. The means for delivering paper pulp may preferably, but not exclusively, comprise an external (i.e. an individual unit) paper shredding machine or mill having a mixing chamber adapted with means for cutting up any paper material added to the chamber through a paper inlet and one or more valved fluid inlets for addition of water and/or other additives. The paper material, water and/or additives are mixed in the mixing chamber and together produce the suspension constituting the paper pulp. The paper pulp is then delivered to the vessel of the installation by suitably valved conduit means connected to a feeding pump. Alternatively, the paper shredding machine may be an integrated part of the installation.

[0039] In yet another embodiment, the installation comprises means for transporting the cured blanks to a packaging area. Relevant transportation means, such as, but not limited to, endless conveyor belts or sloping chutes with cylinder rollers can be used for transporting the cured blanks released from the press mould to a packaging area. Programmable robots may be applied in the packaging area for collecting and stacking the products and/or for further processing. The packaging area may be an integrated part of the installation or it may be an external area.

[0040] In a still further embodiment of the invention, the installation comprises means for engagement with a transportation device. Such means may preferably, but not exclusively, be two hollow crossing bars attached to or fixed integrally with a bottom girder of the installation main frame adapted to receive the forks of a fork-lift. The crossing bars may be suitably reinforced, e.g. by increasing the wall thickness thereof. Alternatively, the means for engaging with a transportation device may be a hook or a hook-like means attached to or fixed integrally with a top girder of the installation main frame adapted to cooperate with lifting means such as any type of crane.

[0041] In another embodiment of the invention, the external dimensions of the main frame of the installation are adapted to fit within the cross section of a 20 (6 m) or a 40 foot (12 m) normal shipping container. This facilitates easy transportation thus increasing flexibility and reducing initial transportation costs of the installation.

[0042] All the functions and necessary steps for actuating the different elements and means comprised by the installation may preferably be controlled by a controlling unit comprising processor, memory and remote communication means. The controlling unit may be attached to and thus controlled directly from a position on the installation or it may be connected to a remote controlling centre by any suitable network means.

[0043] The above described objects and several other objects are intended to be obtained in a second aspect of the invention by providing

[0044] a method for producing products from paper pulp comprising the steps of

• bringing a blank mould into engagement with paper pulp in a vessel by a translatoric movement of the blank mould,
• providing underpressure on at least a part of the surface of said blank mould for producing a blank,
• disengaging the blank mould from the paper pulp by a translatoric movement thereof and subsequently pivoting the blank mould,
• releasing the blank from the blank mould into a heatable press mould for drying and curing and subsequently releasing it from said press mould.

[0045] The invention according to the second aspect is particularly, but not exclusively, advantageous for producing paper pulp products with an improved appearance and steeper side angle/slope by a more flexible and less costly production method, at least partly due to the use of a lesser number of tools and to a reduced size of the production installation.

[0046] The method preferably comprises bringing at least one blank mould carried by at least one platform into engagement with paper pulp in a vessel by a translatoric movement. Once the at least one blank mould is engaged with the paper pulp mass, underpressure is provided on at least a part of the blank mould surface. Thereby paper pulp is sucked on to the blank mould resulting in the formation of a blank on the surface of the blank mould intended to correspond to the shape thereof, unless other means are provided for the creation of special features of the blank.

[0047] Once paper pulp has been sucked on to the blank mould and an uncured blank is formed, the blank mould is disengaged from the paper pulp and excess water and/or moist leaves the blank. Subsequently the blank mould is pivoted. By pivoting the blank mould containing the uncured blank after disengaging it from the paper pulp, gravity forces any remaining water or moist to run off to the inside of the blank mould. Thereby the amount of water or moist that has to be removed from the wet blank is minimised before further processing steps, which is a major advantage.

[0048] Once the surplus of water has dripped off from the uncured blank, the blank is released from the blank mould by release means into a heatable press mould where it is dried and cured before being released from the press mould preferably by release means therein. Compared to the known techniques the need for a transferring tool for moving the wet blank to the press mould is avoided because the pivoted wet blank can be transferred directly from the blank mould to the heatable press mould, which is of course a further major advantage over the known techniques since it further increases the simplicity of the method by reducing the number of necessary tools. This furthermore has the advantage that the dimensions of the press mould or its individual form parts can be immediately adapted to the desired size(s) of the blanks, i.e. avoiding any need for a progressive adaptation to the correct size involving additional press moulds such as it is otherwise known in the art.

[0049] According to the invention the step of releasing the blank from the blank mould is performed by alternating the release of the blank between two heatable press moulds positioned on opposite sides of the blank mould. This is advantageous in at least that one blank mould may in a substantially continuous way deliver blanks to a "free" press mould while a blank is being cured in a "busy" press mould and so on. By distributing these receiving press moulds on each side of the blank mould platform, the production rate can be speeded up while the size of the overall installation is kept at a minimum.

[0050] The means for implementing the method for producing products from paper pulp may preferably, but not exclusively, comprise any or all of the means of the installation according to the first aspect of the invention.

[0051] Particularly, but not exclusively, in the method according to the second aspect of the invention the blank mould may be engaging and disengaging the paper pulp by translatoric movements to and from a position above the vessel with paper pulp. By engaging the blank mould into the paper pulp vessel by a translatoric movement from above and disengaging it by "reversing" said translatoric movement, the formation of any uneven portions at positions along the sides of the blank is avoided, thus assuring that the finished product has nice and even, straight edges. This is a further advantage because the subsequent use of a cutting or punching tool is avoided.

[0052] In an embodiment according to the method of the second aspect of the invention, the pivoting angle of the blank mould is between 0° and 270°, preferably such as between 45° and 225° and preferably such as 180°. By pivoting the blank mould in an angle between 0° and 270° the formed blank may be so angled in the blank mould as to provide the best position for gravity to force any surplus of water away from the blank in order to avoid the formation of uneven edges as previously described. In an embodiment wherein the blank mould is pivoted substantially 180°, or even precisely 180°, a method for producing paper pulp products, in which one or more parts of the surface of the product has a particularly steep inclination, is achieved.

[0053] The pivoting of the blank mould may preferably, but not exclusively, be performed around its longitudinal or its latitudinal axis, or the pivoting may be composed by both a longitudinal and a latitudinal motion depending on production requirements.

[0054] In an embodiment of the method according to the second aspect, the blank is received by a negative form part of the press mould whereupon a positive form part of the press mould is brought into engagement with the blank so as to dry and cure said blank between the parts of the press mould. Alternatively, the blank may be received a positive form part of the mould followed by the engagement of a negative form part.

[0055] In yet a further embodiment, the method comprises a step of transporting the finished product to a packaging area.

[0056] Due to the flexibility of the installation according to the invention it may further be possible to make a rapid change in producing paper pulp products of different colors as this may only necessitate a quick exchange of the blank and press moulds.

[0057] The first and second aspect of the present invention may each be combined with any of the other aspect. These and other aspects of the invention will be apparent from and elucidated with reference to the above-described embodiments.

Brief description of the figures

[0058] 

Figure 1 is a schematic side view of an installation according to the invention in an initial position.

Figure 2 is a schematic side view of an installation according to the invention in a position where a blank mould engages the paper pulp.

Figure 3 is a schematic side view of an installation according to the invention wherein the blank mould has been raised and pivoted 180°.

Figure 4 is a schematic side view of an installation according to the invention wherein a blank is being dried and cured in a press mould and wherein the production of the next blank is underway.

Figure 5 is a schematic, perspective view of a platform for carrying a blank mould in an initial position.

Figure 6 is a schematic, perspective view of a platform for carrying a blank mould in a pivoted position.

[0059] The installation and method according to the invention will now be described in more detail in regard to the accompanying figures. The figures show one way of implementing the present invention and is not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.

Detailed description of an embodiment

[0060] Figure 1 shows an installation generally indicated by reference numeral 1. The installation 1 comprises a main frame 2 of metallic beams and/or girders within which the space for the different elements and parts of the installation is defined. Also shown is a vessel for paper pulp 3. In the depicted embodiment the vessel 3 is placed in a centre section B of the installation. The figure further shows a blank mould 5 carried on a platform 4 provided with a toothed gear assembly 6 for pivoting the platform carrying the blank mould. An electric motor for powering the pivoting action of the platform 4 is not shown. The platform may be given a translatoric movement by piston 8 actuated by an electric motor on the platform (also not shown). Opposite, but otherwise identical sections A and C each comprise a press mould 7 having an outer, negative form part 11 and an inner, positive form part 12. The form parts 11 and 12 are placed on platforms 13 and 14. The platform 13 carrying the outer form part 12 is shown with means 10 for providing a sliding movement of the platform such as cylinder rolls. Platform 13 is connected to an electrical actuator for providing the sliding movement (not shown). Figure 1 also show means 9 for engagement with a transportation device, such as a fork lift.

[0061] Figure 2 shows the installation now in a situation wherein the blank mould 5 is brought into engagement with paper pulp in the vessel 3. As can be seen the piston 8 is now fully extended. When the piston is actuated the platform 4 is given a translatoric movement, in this embodiment in the sense of a rectilinear, vertical movement in a downward direction. Once the blank mould 5 is engaged ("submerged") in the paper pulp, a pump or pumping system (not shown) for providing an underpressure on the surface of the blank mould 5 is engaged thereby causing paper pulp to be sucked onto the blank mould 5 for the formation of a blank.

[0062] Figure 3 shows the installation in the situation wherein the blank mould 5 having a blank sucked on to its surface (blank not shown) has been disengaged from the paper pulp in the vessel by a translatoric movement, in this embodiment in the sense of a rectilinear, vertical movement in an upward direction. Furthermore, the depicted embodiment shows that the platform 4 carrying the blank mould 5 with the blank has been pivoted/rotated 180° by means of toothed gear assembly 6. Further to this, the figure also shows that in this embodiment platform 13 supporting the outer form part 11 of the press mould, has been moved horizontally so as to be in a position below the pivoted platform 4, but above vessel 3. By placing the blank mould 5 and the blank in this position, excess water is forced out of the pulp mass by the force of gravity and thereby minimising the amount of water/moist that is to be removed from the wet blank. The platform 4 carrying blank mould 5 and the wet blank is then pivoted back ("reversed") into the initial position and released into the outer part 11 of the press mould below the platform 4. The release means is/are not shown. After having received the wet blank, the platform 13 is moved back to its initial position by a horizontal movement and engaged by the inner form part 12 of the press mould 7 carried by platform 14, by extending piston 8 of section C. Simultaneous with this step, the platform 4 carrying the blank mould 5 is brought into engagement with paper pulp in vessel 3 for initiating the next production cycle.

[0063] In figure 4 the blank is being dried and cured in press mould 7 in section C of the installation while carrying platform 4 with the blank mould 5 has again been moved in a downward, vertical direction so as to form the next blank on the surface of the blank mould 5. When blank mould 5 is disengaged from the vessel 3, platform 15 carrying an outer part 16 of another press mould in section A of the installation is given a horizontal movement so as to be positioned below carrying platform 4. Thereupon the wet blank is released into form part 16 and platform 15 is moved back into section A. Simultaneously the form parts 11 and 12 of press mould 7 in section C are separated by retracting piston 8 and subsequently the now cured blank is released from press mould 7 (release means not shown) and transported to a packaging area (not shown). The production cycle of the depicted embodiment continues in the described manner by alternating the drying and curing of the wet blank between the press moulds of sections A and C.

[0064] Figure 5 shows an example of the carrying platform 4 for carrying the blank mould 5 (not shown) in the "non-engaged" position. The platform is provided with a pump or pumping system 17 and appropriate conduit means 18 for disposal or recycling of excess paper pulp and/or water being sucked through the surface of the blank mould 5. The conduit means in the depicted embodiment are guided through a hollow part of frame means 20 and provided with an outlet 19 in a position above the platform 4. Preferably, the conduit means 19 can be connected to a flexible hose for remote disposal. Also shown is means 21 for connecting the platform frame to an end of piston 8 (not shown) e.g. by an eye and pin connection.

[0065] Figure 6 shows the platform 4 of figure 5, now in a position pivoted 180°. The blank mould 5 is not shown, but is intended to be attached on surface 22 of platform 4 by relevant means. Also shown is the conduit 19 and eyes or eye-lets 23 for connection with a rod or rod-like element for guiding the translatoric movement of platform 4.

[0066] Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is set out by the accompanying claim set. In the context of the claims, the terms "comprising" or "comprises" do not exclude other possible elements or steps. Also, the mentioning of references such as "a" or "an" etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.

Claims

1. An installation for producing products from paper pulp comprising

- a vessel (3) for paper pulp,

- at least one platform (4) adapted to carry at least one blank mould (5), said platform (4) is further adapted to engage and disengage the blank mould (5) with the paper pulp in said vessel (3) by a translatoric movement of the platform (4) and having means for pivoting (6),

- means for creating underpressure on at least a part of the surface of said blank mould (5) for producing a blank, and

- at least two heatable press moulds (7) adapted to receive said blank from the blank mould (5) for drying and curing,

wherein said at least two heatable press moulds (7) are positioned on opposite sides of said platform (4).

2. An installation according to claim 1, wherein said blank mould (5) is made from a sheet material having penetrations or from a fine meshed material.

3. An installation according claim 2, wherein said sheet material or fine meshed material has a penetration size or a mesh size respectively of less than 0.5 mm², such as less than 0.1 mm², such as less than 0.05 mm², such as less than 0.02 mm², such as less than 0.017 mm².

4. An installation according to any one of the preceding claims, wherein said press mould (7) comprises an inner and an outer form part.

5. An installation according to claim 4, further comprising a heating element in said inner and/or outer form part.

6. An installation according to claim 5, wherein said heating element uses electricity for generating the heat.

7. An installation according to any one of the preceding claims, further comprising means for releasing the blank from the blank mould (5).

8. An installation according to any one of the preceding claims, further comprising means for releasing the blank from the press mould (7).

9. An installation according to any one of claims 1-8, further comprising means for delivering paper pulp to said vessel (3) from an external source.

10. An installation according to any one of claims 1-9, further comprising means for transporting the cured blank to a packaging area.

11. An installation according to any one of claims 1-10, further comprising means for engagement with a transportation device.

12. An installation according to any one of claims 1-11 having external dimensions adapted to fit within the cross section of a 6,096 or 12,192 meter (20 or 40 foot) container.

13. A method for producing products from paper pulp comprising the steps of

- bringing a blank mould (5) into engagement with paper pulp in a vessel (3) by a translatoric movement of the blank mould (5),

- providing underpressure on at least a part of the surface of said blank mould (5) for producing a blank,

- disengaging the blank mould (5) from the paper pulp by a translatoric movement thereof and subsequently pivoting the blank mould (5),

- releasing the blank from the blank mould (5) into a heatable press mould (7) for drying and curing and subsequently releasing it from said press mould (7),

wherein the step of releasing the blank from the blank mould (5) is performed by alternating the release between two heatable press moulds (7) positioned on opposite sides of said blank mould (5).

14. A method according to claim 13, wherein the pivoting angle of the blank mould (5) is between 0° and 270°, such as between 45° and 225°, such as 180°.

15. A method according to claim 13 or 14, wherein the blank is received by a negative form part of the press mould whereupon a positive form part of the press mould is brought into engagement with said blank so as to dry and cure said blank between said parts of the press mould.

16. A method according to any one of claims 13-15, further comprising a step of transporting the finished product to a packaging area.

Ansprüche

1. Anlage zur Herstellung von Produkten aus Zellstoff, umfassend

- einen Behälter (3) für Zellstoff,

- mindestens eine Bühne (4), die dazu beschaffen ist, mindestens eine Rohlingform (5) zu tragen, wobei die Bühne (4) weiterhin dazu beschaffen ist, die Rohlingform (5) mittels einer translatorischen Bewegung der Bühne (4) mit dem Zellstoff in dem Behälter (3) in Berührung zu bringen und daraus zu entfernen, und Mittel zum Schwenken (6) aufweist,

- Mittel zum Generieren eines Unterdrucks an mindestens einem Teil der Fläche der Rohlingform (5) zur Herstellung eines Rohlings und

- mindestens zwei heizbare Pressformen (7), die dazu beschaffen sind, den Rohling aus der Rohlingform (5) zum Trocknen und Härten aufzunehmen,

wobei die mindestens zwei heizbaren Pressformen (7) an gegenüberliegenden Seiten der Bühne (4) angeordnet sind.

2. Anlage nach Anspruch 1, wobei die Rohlingform (5) aus einem Blechmaterial mit Löchern oder aus einem feinmaschigen Material hergestellt ist.

3. Anlage nach Anspruch 2, wobei das Blechmaterial oder das feinmaschige Material eine Lochgröße bzw. Maschenweite von weniger als 0,5 mm², wie weniger als 0,1 mm², wie weniger als 0,05 mm², wie weniger als 0,02 mm², wie weniger als 0,017 mm² aufweist.

4. Anlage nach einem der vorhergehenden Ansprüche, wobei die Pressform (7) ein inneres und ein äußeres Formteil umfasst.

5. Anlage nach Anspruch 4, weiterhin umfassend ein Heizelement in dem inneren und/oder äußeren Formteil.

6. Anlage nach Anspruch 5, wobei das Heizelement Strom für die Wärmeerzeugung verwendet.

7. Anlage nach einem der vorhergehenden Ansprüche, weiterhin umfassend Mittel zum Freigeben des Rohlings aus der Rohlingform (5).

8. Anlage nach einem der vorhergehenden Ansprüche, weiterhin umfassend Mittel zum Freigeben des Rohlings aus der Pressform (7).

9. Anlage nach einem der Ansprüche 1-8, weiterhin umfassend Mittel zum Fördern von Zellstoff von einer externen Quelle zu dem Behälter (3).

10. Anlage nach einem der Ansprüche 1-9, weiterhin umfassend Mittel zum Transport des gehärteten Rohlings zu einem Verpackungsbereich.

11. Anlage nach einem der Ansprüche 1-10, weiterhin umfassend Mittel zum Eingreifen in eine Transportvorrichtung.

12. Anlage nach einem der Ansprüche 1-11 mit Abmessungen, die so beschaffen sind, dass sie in den Querschnitt eines 6,096- oder 12,192-Meter- (20- oder 40-Fuß-) Containers passen.

13. Verfahren zum Herstellen von Produkten aus Zellstoff, umfassend die Schritte

- Inberührungbringen einer Rohlingform (5) mit Zellstoff in einem Behälter (3) durch eine translatorische Bewegung der Rohlingform (5),

- Bereitstellen eines Unterdrucks an mindestens einem Teil der Fläche der Rohlingform (5) zur Herstellung eines Rohlings,

- Trennen der Rohlingform (5) von dem Zellstoff durch eine translatorische Bewegung derselben und anschließendes Schwenken der Rohlingform (5),

- Freigeben des Rohlings aus der Rohlingform (5) in eine heizbare Pressform (7) zum Trocknen und Härten und anschließendes Freigegeben aus der Pressform (7),

wobei der Schritt des Freigebens des Rohlings aus der Rohlingform (5) durch Alternieren der Freigabe zwischen zwei an gegenüberliegenden Seiten der Rohlingform (5) angeordneten heizbaren Pressformen (7) durchgeführt wird.

14. Verfahren nach Anspruch 13, wobei der Schwenkwinkel der Rohlingform (5) zwischen 0° und 270°, wie zwischen 45° und 225°, wie 180° liegt.

15. Verfahren nach Anspruch 13 oder 14, wobei der Rohling von einem negativen Formteil der Pressform aufgenommen wird, wonach ein positives Formteil der Pressform mit dem Rohling in Berührung gebracht wird, um den Rohling zwischen den Teilen der Pressform zu trocknen und zu härten.

16. Verfahren nach einem der Ansprüche 13-15, weiterhin umfassend einen Schritt des Transportierens des fertigen Produkts zu einem Verpackungsbereich.

Revendications

1. Installation de fabrication de produits à base de pâte à papier comprenant :

- une cuve (3) pour pâte à papier,

- au moins une plate-forme (4) adaptée pour supporter au moins un moule ébaucheur (5), ladite plate-forme (4) étant également adaptée pour engager et dégager le moule ébaucheur (5) dans de la pâte à papier dans ladite cuve (3) par un mouvement de translation de la plate-forme (4) et possédant des moyens de pivotement (6),

- des moyens pour créer une dépression sur au moins une partie de la surface dudit moule ébaucheur (5) pour produire une ébauche, et

- au moins deux moules de pressage (7) chauffants adaptés pour recevoir ladite ébauche provenant du moule ébaucheur (5) afin de la sécher et de la durcir,

dans laquelle au moins deux moules de pressage (7) chauffants sont positionnés de part et d'autre de ladite plate-forme (4).

2. Installation selon la revendication 1, dans laquelle ledit moule ébaucheur (5) est constitué d'un matériau en feuille doté de pénétrations ou d'un matériau à mailles fines.

3. Installation selon la revendication 2, dans laquelle ledit matériau en feuille ou matériau à mailles fines possède respectivement une taille de pénétrations ou une ouverture de maille inférieure à 0,5 mm², telle qu'inférieure à 0,1 mm², telle qu'inférieure à 0,05 mm², telle qu'inférieure à 0,02 mm², telle qu'inférieure à 0,017 mm².

4. Installation selon l'une quelconque des revendications précédentes, dans laquelle ledit moule de pressage (7) comprend une partie forme interne et externe.

5. Installation selon la revendication 4, comprenant également un élément chauffant dans ladite partie forme interne et/ou externe.

6. Installation selon la revendication 5, dans laquelle ledit élément chauffant utilise de l'électricité pour générer la chaleur.

7. Installation selon l'une quelconque des revendications précédentes, comprenant également des moyens pour libérer l'ébauche du moule ébaucheur (5).

8. Installation selon l'une quelconque des revendications précédentes, comprenant également des moyens pour libérer l'ébauche du moule de pressage (7).

9. Installation selon l'une quelconque des revendications 1 à 8, comprenant également des moyens pour fournir de la pâte à papier à ladite cuve (3) depuis une source externe.

10. Installation selon l'une quelconque des revendications 1 à 9, comprenant également des moyens pour transporter l'ébauche durcie vers une zone de conditionnement.

11. Installation selon l'une quelconque des revendications 1 à 10, comprenant également des moyens d'enclenchement avec un dispositif de transport.

12. Installation selon l'une quelconque des revendications 1 à 11, dont les dimensions externes sont adaptées pour entrer dans la section transversale d'un conteneur de 6,096 ou 12,192 mètres (20 ou 40 pieds).

13. Procédé de fabrication de produits à base de pâte à papier comprenant les étapes consistant à :

- engager un moule ébaucheur (5) dans de la pâte à papier dans une cuve (3) par un mouvement de translation du moule ébaucheur (5),

- créer une dépression sur au moins une partie de la surface dudit moule ébaucheur (5) pour produire une ébauche,

- dégager le moule ébaucheur (5) de la pâte à papier par un mouvement de translation de celui-ci puis faire pivoter le moule ébaucheur (5),

- libérer l'ébauche du moule ébaucheur (5) et la transférer dans un moule de pressage (7) chauffant afin de la sécher et de la durcir puis la libérer dudit moule de pressage (7),

dans lequel l'étape de libération de l'ébauche du moule ébaucheur (5) est réalisée en alternant la libération entre deux moules de pressage (7) chauffants positionnés de part et d'autre dudit moule ébaucheur (5).

14. Procédé selon la revendication 13, dans lequel l'angle de pivotement du moule ébaucheur (5) est compris entre 0° et 270°, tel qu'entre 45° et 225°, tel que 180°.

15. Procédé selon la revendication 13 ou 14, dans lequel l'ébauche est reçue par une partie forme négative du moule de pressage après quoi une partie forme positive du moule de pressage vient s'engager sur ladite ébauche de manière à sécher et durcir ladite ébauche entre lesdites parties du moule de pressage.

16. Procédé selon l'une quelconque des revendications 13 à 15, comprenant également une étape de transport du produit fini vers une zone de conditionnement.

Drawing