Abstract
A method for manufacturing a product, such a disposable cutlery, manufactured of a fibre material, includes feeding fibrous material as a material flow, binding the fibres into a coherent profile, and molding the cross-sectional profile of the profile into a blank with a desired cross-sectional profile using at least one roller pair or drum pair. The method further includes cutting products of the desired shape from the molded blank by aligning a cutting geometry of the products at the desired place on the blank.
Claims
1. A method for manufacturing a product, such a disposable cutlery, manufactured of a fibre material, the method comprising the steps of: feeding fibrous material as a material flow to a roll forming step; at which roll forming step the fibres are bound into a coherent profile, and the cross-sectional profile of the profile is moulded into a blank with a desired cross-sectional profile by means of at least one roller pair or drum pair; cutting products of the desired shape from the blank moulded at the roll forming step by aligning a cutting geometry of the products at the desired place on the blank.
2. A method as claimed in claim 1 for manufacturing a product, wherein the material fed as a material flow is fed as a powdery material, as a moist mass, as band-type material fed from a roll, or as a material flow fed in sheet form.
3. A method as claimed in claim 2 for manufacturing a product, wherein the material may be fed to the roll forming step as a combination of a plurality of material bands which are bound into each other at the roll forming step.
4. A method as claimed in claim 1 for manufacturing a product, wherein the roll forming step comprises pressing the material flow between one or more successive roller pairs or drum pairs, manufactured in the desired form, to the desired material density and the desired cross-sectional profile.
5. A method as claimed in claim 1 for manufacturing a product, further comprising a step of thermally or chemically pre-processing the material flow prior to roll forming.
6. A method as claimed in claim 1 for manufacturing a product, wherein the roll forming step is implemented as hot pressing whereby the rollers or drums used in roll forming are heated and kept at the desired temperature during moulding.
7. A method as claimed in claim 1 for manufacturing a product, wherein the roll forming step is followed by a cooling step.
8. A method as claimed in claim 1 for manufacturing a product, wherein the cutting step is carried out by mechanical cutting with a rotation punch or a flatbed punch, or with waterjet cutting, or with laser cutting.
9. A method as claimed in claim 1 for manufacturing a product, wherein the cutting step is performed together with the roll forming step.
10. A method as claimed in claim 2 for manufacturing a product, wherein the material flow fed to the roll forming step includes no more than 10 percent by weight of a binding agent improving the binding of the fibres.
11. A method as claimed in claim 10 for manufacturing a product, wherein the binding agent is a natural substance such as starch or lignin.
12. A disposable product manufactured by the method according any one of claims 1 to 11.
13. A disposable product as claimed in claim 12, characterised in that the product is a disposable cutlery.
Description
[0022] In the following, the disclosure is disclosed in closer detail with reference to the accompanying drawings, in which:
[0023] FIG. 1 shows a principled diagram of a manufacturing line used for the implementation of the method as a cross section.
[0024] FIG. 2 shows a cross section of a blank used for manufacturing disposable forks, profiled at the roll forming step of the method between roll forming drums.
[0025] FIG. 3 shows the blank of FIG. 2 as a plane figure, and principled positioning and alignment of forks in the blank, to be cut off the blank.
[0026] FIG. 4 shows a plane figure of a blank roll-formed for the manufacture of disposable knives by the method of the disclosure and positioning the cutting geometry of the products on the blank.
[0027] FIG. 5 shows a partial cross-section A-A of the blank according to FIG. 4.
[0028] FIG. 6 shows a principled drawing of a feeding solution of the method according to the disclosure for a material flow, in which three separate material layers are fed to a roll forming step, which are bound into a coherent profile at the roll forming step.
[0029] FIG. 7 shows a principled drawing of the structure and cross section of a material flow fed into a roll forming step of the method, in which cross-section of the material flow fed to the roll forming step differs from a material flow of equal thickness.
[0030] In FIG. 1, a material flow 2 is fed, supported by a feed belt 13 shown with dotted lines, in the direction of the arrow 1 through nips of rollers 4 at the first step of roll forming. The material may be heated before the first roll forming step to a temperature required by the action of a binding agent, by means of a radiant heater 3, for example. Alternatively (or additionally), the roll forming drums may be used for heating the material (by making use of the hot oil technique, known per se, for example). The profiled material flow formed at the first roll forming step is led to a second roll forming step to the nip of rollers 6, in which the profile is moulded to its final shape. The feed belt 13 is guided to a return route through deflector rolls 5. The roll-formed profile 7 is led through cooling elements 8 to a cutting step, at which products of a desired shape are cut off the profile by laser cutting, for example. In the exemplary solution of FIG. 1, a laser cutting unit 10 is integrated to operate in connection with continuous profile manufacture, and the laser cutting unit is programmed to operate in the area between positions A and B in the figure. Advantageously, the laser cutting unit 10 has a plurality of parallel cutting nozzles 12 to guarantee a required production capacity. During the cooling and cutting step, the profile is supported by means of support rollers 9 shown in the figure, for example.
[0031] FIG. 2 shows a cross-section of a blank 14 profiled at the roll forming step for the manufacture of disposable forks, in the nip between roll forming drums 15 and 16. The roll forming drums are so shaped that the desired form for the tine part 17 of the forks, to be cut off the blank 14, is obtained. The line A-A in the figure describes the alignment on the blank 14 of cutting off products at the subsequent manufacturing step.
[0032] FIG. 3 shows a part of the blank 14 according to FIG. 2 as a plane figure, and the principled positioning and alignment of the cutting geometry 18 of disposable forks 19 to be cut off the blank 14. The line A-A in the figure refers to the corresponding line in the previous FIG. 2, and illustrates the performed alignment on the blank 14 for cutting off products.
[0033] FIGS. 4 and 5 show, as an example, part of a roll-formed blank 20 relating to the manufacture of disposable knives, and positioning products 23 to be cut off the blank as well as aligning the cutting geometry 24 on the blank. FIG. 5 shows part of the cross-section A-A of the blank 20 in FIG. 4, as well as the location of the alignment line B-B shown in FIG. 4 in the cross section. The saw-toothed geometry of the blade part 25 cutting off the products for improving the cutting efficiency of the knives is accomplished at cutting off the products. The blank profile shown in FIG. 5 is advantageously so implemented that the bottom surface 21 of the blank is moulded with a cylindrical flatbed drum, and the top surface of the profile is moulded by a drum machined in the form required by the profile.
[0034] FIG. 6 shows a principled solution for feeding in material to the roll forming step, in which the material to be roll-formed consists of a plurality of separate material layers having different characteristics. Into the nip between the roll forming drums 26 and 27, a band 28 of the profile being formed is fed as a centre layer, and bands 29 and 30 as the surface layers from the rolls 31 and 32. Powerful mechanical pressing, binding agent characteristics of the material layers, and thermal processing, if needed, at the roll forming step cause the different material layers to bind into each other as a coherent profile 33 with the desired characteristics and cross-sectional form.
[0035] FIG. 7 shows a solution of feeding in material, by means of which it is possible to implement at the roll forming step greater differences in material thickness desired in the cross section of the profile at different places thereof. The figures show the cross section of the material flow fed in as well as an axonometric view of the material flow fed in. In the solution according to FIG. 7, in connection with a wide material band 34, narrower material bands 35 and 36 having different thicknesses are fed to the roll forming step at the desired places of the profile cross-section.
[0036] The use and technical applicability of the disclosure are not restricted to the aforedescribed exemplary solution of the products or shapes of different profiles. It is additionally possible to combine and vary different feeding solutions of the material flow fed to the roll forming step within the scope of the options disclosed in the above and of prior art.
[0037] In the method, the material requirements, moulding of the roll forming rollers, and the number of the drum pairs needed in roll forming are defined product-specifically.
