METHOD FOR PRODUCING MOULDED PARTS FROM FIBROUS MATERIAL

Abstract

The present disclosure relates to a first molding station (1) for the partial-moulding (210) and pre-molding (220) of molded parts (10) made of fibrous material, a fiber molding system (100) with such a first molding station (1) and a method (200) for operating this first molding station (1) or the fiber moulding system (100), and a molded part (10) produced using such a method.

Claims

1. A molding station for a fiber molding system for the partial-molding and pre-molding of a molded part out of fibrous material, comprising: a reservoir having a pulp as a liquid solution comprising the fibrous material for the molded part to be partial-molded; a first and second suction tool as partial-molding station with, in each case, a plurality of suction heads for drawing the fibrous material for the partial-molding of the molded part out of the reservoir having the pulp; a pre-pressing station with a pre-pressing tool having a contour that is or can be adapted to the first and second suction tool for pre-molding the partial-molded molded parts located in the first or second suction tools, wherein the molded parts are pressed onto the pre-pressing tool with a pre-pressing pressure in order to reduce a moisture content in the molded part and to bring about a shape stabilization of the molded part; and a transport device comprising a carrier with the first suction tool arranged on a first side of the carrier and the second suction tool arranged on the opposite, second side of the carrier, wherein the respective suction heads are arranged on a side of the suction tools facing away from the carrier in each case, wherein by means of the transport device, possibly independently of each other, the carrier can be rotated and moved along a route at least from a first position for receiving fibrous material from the reservoir of pulp by means of one of the suction tools to a second position for exerting the pre-pressing pressure on the molded parts located in the suction tool.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0062] In addition, further features, effects and advantages of the present disclosure are explained with reference to the attached drawing and the following description. Components which at least essentially correspond in terms of their function in the individual figures are identified by the same reference symbols, with the components not having to be numbered and explained in all figures.

[0063] In the figures:

[0064] FIG. 1: schematic representation of an embodiment of the first molding station according to the present disclosure in a method sequence for the fiber molding process of (a)-(h);

[0065] FIG. 2: schematic representation of a further embodiment of the first molding station according to the present disclosure in a method sequence for the automatic tool change of (a)-(m);

[0066] FIG. 3: schematic representation of a further embodiment of the first molding station according to the present disclosure with a pulp-changing system;

[0067] FIG. 4: an embodiment of the fiber molding system according to the present disclosure; and

[0068] FIG. 5: an embodiment of the method according to the present disclosure for producing molded parts from fibrous material;

DETAILED DESCRIPTION

[0069] FIG. 1 shows a schematic representation of an embodiment of the first molding station 1 according to the present disclosure in a method sequence for the fiber molding process of (a)-(h). FIGS. 1a-h show the molding station 1 for the partial-molding 210 (see FIGS. 1b, 1g) and pre-molding 220 (see FIG. 10 of a molded part 10 (see FIG. 1f) out of fibrous material comprising a reservoir 6 having a pulp as liquid solution comprising the fibrous material for the molded part 10 to be partial-molded, a first and second suction tool 2, 2a, 2b as partial-molding station 20 (between the correspondingly marked lines) with in each case a plurality of suction heads 21 for drawing the fibrous material for the partial-molding 210 of the molded part 10 out of the reservoir 6 having the pulp; a pre-pressing station 30 (between the correspondingly marked lines) with a pre-pressing tool 31 with a contour that is or can be adapted to the first and second suction tool 2, 2a, 2b for the pre-molding 220 of the partial-molded molded parts 10 located in the first or second suction tools 2, 2a, 2b, wherein the molded parts 10 are pressed onto the pre-pressing tool 31 with a pre-pressing pressure VD (see FIG. 1f, in order to reduce a moisture content in the molded part 10 and to bring about a dimensional stabilization of the molded part 10, and a transport device 4 comprising a carrier 40 (here a cuboid with a certain thickness) with the first suction tool 2, 2a arranged on a first side 40a of the carrier 40 and the second suction tool 2, 2b arranged on the opposite second side 40b of the carrier 40, wherein the respective suction heads 21 are arranged on a side of the suction tools 2, 2a, 2b facing away from carrier 40 in each case, wherein by means of the transport device 4, possibly independently of each other, the carrier 40 can be rotated (see white arrow D) and moved B (white arrow F, B) along a route F at least from a first position P1 for receiving fibrous material from the reservoir 6 of pulp by means of one of the suction tools 2, 2a, 2b to a second position P2 for exerting the pre-pressing pressure VD on the molded parts 10 located in the suction tool 2, 2a, 2b. Here, the first and the second suction tool 2, 2a, 2b is connected to a gas-line system 42 via the carrier 40 such that a negative pressure generated in the gas-line system 40 by means of one or more vacuum pumps 43 is made available as suction pressure at the respective suction heads 21 for drawing in the fibrous material. The location of the vacuum pump 43 can also be chosen differently. The gas-line system 42 is here arranged in the vertical travel rails of the transport device 4. The carrier 40 is moved B vertically along the rails and can independently thereof be rotated D between the first and the second position P1, P2.

[0070] In FIG. 1a the second suction tool 2b comprises pre-pressed blanks 10. In FIG. 1b, after pre-pressing 220 has been carried out, the carrier 40 is driven into the first position P1 without rotation D of the carrier 40, that now molded parts 10 are partial-molded out of the reservoir 6 having pulp in the first suction tool 2a facing away from the pre-pressing tool 31. In FIG. 1c, after partial-molding 210 has been carried out, the carrier 40 is driven to a suitable position between the first and the second position P1, P2 and rotated D, in order to transfer the pre-pressed blanks 10 of the second suction tool 2b in FIG. 1d to the transfer unit 41 of the transport device 4, in order to remove them from the route F of the carrier 40 for forwarding to subsequent processes (see FIGS. 1e, 1f). Here, the pre-pressed blanks 10 can be ejected from the suction tool 2b by means of a pressure surge and thus transferred to the transfer unit 41. In the meantime a spraying unit 7 sprays the first suction tool 2a having the partial-molded blanks 10 with a liquid before the pre-pressing 220 during the route F of the carrier 40 to the second position P2. Here, the spraying unit 7 is controlled in a lateral movement over the surface of the first suction tool 2a. Only the respective end positions of this movement for the spraying unit 7 are shown in FIGS. 1d and 1e. Thereafter the renewed movement B of the carrier 40 to the first position, where the blanks are now partial-molded 210 in the second suction tool 2b, is effected, see FIG. 1g. After the rotation D shown in FIG. 1h the steps as already described previously are effected for the same purpose.

[0071] FIG. 2 shows a schematic representation of a further embodiment of the first molding station 1 according to the present disclosure in a method sequence for the automatic tool change of (a)-(m). The first molding station 1 comprises here a changing system 5 for the automatic replacement of the suction tools 2a, 2b and the pre-pressing tool 31, wherein a tool carrier 51 movable out of the first molding station 1 is provided in the changing system 5 for transporting the replaced tools 2a, 2b, 31 away from the first molding station 1 and the tool carrier 51 can pass through a reversed sequence for the insertion of new tools 2a, 2b, 31. Here, the carrier 40 is designed as part of the changing system 5 in order to remove the suction tools 2a, 2b and the pre-pressing tool 31 from the positions in the partial-molding and pre-pressing station 20, 30 during the replacement and to transfer them to the tool carrier 51, or to pass through a reversed sequence during the insertion of new tools 2a, 2b, 31. For this purpose, the carrier 40 comprises, between the first and the second side 40a, 40b, an end face 40c which is equipped with a receiving and release means 52a, 52b for removing the pre-pressing tool 31 from the pre-pressing station 30 and for holding it during the transport of the pre-pressing tool 31 to the tool carrier 51.

[0072] In FIGS. 2a, 2b the tool carrier 51 travels into its position underneath the carrier in order to receive the tools 2a, 2b and 31. For this purpose, the carrier 40 is rotated between the first and the second position P1, P2 such that its end face 40c faces the pre-pressing tool 31 (FIG. 2c). Thereafter, the carrier 40 travels in the direction of the second position P2 and brings its receiving and release means 52a, 52b into contact with corresponding counterparts 53a, 53b of the pre-pressing tool 31, with the result that the pre-pressing tool 31 is released from its holder in the pre-pressing station 30 (FIGS. 2d, 2e). Thereafter, the carrier 40 rotates by half a rotation in the direction of the tool carrier 51 (FIG. 2f), in order to deposit the removed pre-pressing tool 31 in the tool carrier 51 (FIG. 2g). Here, the carrier 40 comprises a pre-pressing tool releasing mechanism 54 for the held pre-pressing tool 31, in order that the pre-pressing tool 31 is freed for receipt by the tool carrier 51. With a further rotation, the second suction tools 2b is positioned over the tool carrier 51 and to free by means of a suction tool releasing mechanism 55 for receipt by the tool carrier 51 (FIGS. 2h, 2i). Through a further rotation D of the carrier 40, the first suction tools 2a will now position above the already received suction tool 2b and likewise to free this by the suction tool releasing mechanism 55 for receipt by the tool carrier 51 (FIGS. 2j-2l). The tool carrier 51 with the tools 2a, 2b and 31 is then moved out of the first molding station 1 for the replacement of the tools 2a, 2b, 31, see arrow (FIG. 2m).

[0073] FIG. 3 shows a schematic representation of a further embodiment of the first molding station 1 according to the present disclosure with a pulp-changing system 8, wherein the first molding station 1 comprises at least one further reservoir 6, 6b having pulp, wherein the pulp-changing system 8 is designed to provide, in a process dependent manner, one or other of the reservoirs 6, 6a, 6b having other pulp for the partial-molding of the molded parts 10 before the first position P1 is reached by the carrier 40. In this embodiment, the pulp-changing system 8 comprises rails 81 for this purpose, on which the reservoirs 6, 6a, 6b having pulp can be displaced, and a drive means 82 for displacing the reservoirs 6, 6a, 6b having pulp, which is actuated by the transport device 4 or the first molding station 1 or the fiber molding system 100 in a process dependent manner. The transport device 4 or the controller of the first molding station or of the fiber molding system are provided to drive the carrier 40 on the route F between the first and the second position P1, P2 such that, at a first point in time, in the first position P1, the molded part 10 is partial-molded in one of the suction tools 2a out of a first of the reservoirs 6, 6a having pulp and the same suction tool 2a, at least at a second point in time later than the first point in time before the pre-pressing 220, the molded part 10 is further partial-molded at least out of a second of the reservoirs 6, 6b having other pulp. The same is also possible with the suction tool 2b.

[0074] FIG. 4 shows an embodiment of the fiber molding system 100 according to the present disclosure for producing a molded part 10 from fibrous material by means of a fiber molding process performed in the fiber molding system 100 comprising a first molding station 1 according to the disclosed embodiments for the partial-molding and pre-molding of the molded part 10 and a second molding station 60 comprising a hot-pressing station 65 for the finish-molding of the molded parts 10 by means of hot pressing of the pre-molded molded parts 10. The fiber molding system 100 furthermore comprises a pulp preparation and resupply unit 50 for the resupply of pulp for the reservoir 6, which is visible here on the base of the first molding station 1. Here, the hot-pressing station 65 can be thermally decoupled from other components of the second molding station 60, possibly an actively cooled separation is arranged between the hot-pressing station 65 and the other components of the second molding station 60. The second molding station 60 can moreover comprise at least two hot-pressing stations 65 (not shown in detail here), which optionally hot press the pre-molded blanks 10 of the first molding station 1 in a process dependent manner, possibly with different hot-pressing parameters. The fiber molding system 100 here additionally comprises a punching station 70 for severing excess fibrous material from the finish-molded molded part 10, which is arranged following (behind) the second molding station 60 in the machine direction M in the process. Furthermore, the fiber molding system 100 comprises a controller 90.

[0075] FIG. 5 shows an embodiment of the method 200 according to the present disclosure for producing molded parts 10 from fibrous material by means of a fiber molding process in a fiber molding system 100 according to the present disclosure with a first molding station 1 according to the present disclosure and a second molding station comprising the following steps of the partial-molding 210 of the molded part 10 out of a reservoir 6 having a pulp as liquid solution with the fibrous material by means of a first and/or second suction tool 2, 2a, 2b as partial-molding station 20 of the first molding station 1; of the pre-molding 220 of the partial-molded molded part 10 in a pre-pressing station 30 in the first molding station 1; of the finish-molding 230 of the pre-molded molded part 10 in the second molding station 60 by means of hot pressing; and finally of the outputting 240 of the finish-molded molded part 10 from the fiber molding system 100. Here, within the fiber molding system, a severing 250 of excess fibrous material from the finish-molded molded part 10 by a punching station 70 arranged behind the second molding station 60 in the machine direction can be effected.

[0076] At this point it should be explicitly mentioned that features of the solutions described above or in the claims and/or figures may also be combined where appropriate, in order also to be able to implement or achieve explained features, effects and advantages in a correspondingly cumulative manner.

[0077] It is to be understood that the embodiment example explained above is merely a first design of the disclosed embodiments. In this respect, the design of the disclosed embodiments is not limited to this embodiment example.

[0078] The following numbered clauses set out various non-limiting embodiments disclosed herein:

Set A

[0079] A1. A first molding station (1) for a fiber molding system (100) for the partial-molding (210) and pre-molding (220) of a molded part (10) out of fibrous material, possibly environmentally degradable fibrous material, in a fiber molding process comprising: [0080] a reservoir (6) having a pulp as liquid solution comprising the fibrous material for the molded part (10) to be partial-molded; [0081] a first and second suction tool (2, 2a, 2b) as partial-molding station (20) with, in each case, a plurality of suction heads (21) for drawing the fibrous material for the partial-molding (210) of the molded part (10) out of the reservoir (6) having the pulp; [0082] a pre-pressing station (30) with a pre-pressing tool (31) having a contour that is or can be adapted to the first and second suction tool (2, 2a, 2b) for pre-molding (220) the partial-molded molded parts (10) located in the first or second suction tools (2, 2a, 2b), wherein the molded parts (10) are pressed onto the pre-pressing tool (31) with a pre-pressing pressure (VD) in order to reduce a moisture content in the molded part (10) and to bring about a shape stabilization of the molded part (10); and [0083] a transport device (4) comprising a carrier (40) with the first suction tool (2, 2a) arranged on a first side (40a) of the carrier (40) and the second suction tool (2, 2b) arranged on the opposite, second side (40b) of the carrier (40), wherein the respective suction heads (21) are arranged on a side of the suction tools (2, 2a, 2b) facing away from the carrier (40) in each case, wherein by means of the transport device (4), possibly independently of each other, the carrier (40) can be rotated (D) and moved (B) along a route (F) at least from a first position (P1) for receiving fibrous material from the reservoir (6) of pulp by means of one of the suction tools (2, 2a, 2b) to a second position (P2) for exerting the pre-pressing pressure (VD) on the molded parts (10) located in the suction tool (2, 2a, 2b).
A2. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is provided to drive the carrier (40) into the first position (P1) after pre-pressing (220) with one of the suction tools (2, 2a, 2b) has been carried out in the second position (P2), without rotation (D) of the carrier (40), that now molded parts (10) can be partial-molded out of the reservoir (6) having pulp in the suction tool (2, 2a, 2b) facing away from the pre-pressing tool (31) during the pre-pressing (220) that has been carried out.
A3. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is provided to rotate (D) the carrier (40), after pre-pressing (220) of the molded parts (10) with one of the suction tools (2, 2a, 2b) has been carried out and after partial-molding (210) of the molded parts (10) in the other of the suction tools (2, 2a, 2b) has been carried out, to a suitable position between the first and the second position (P1, P2) and to transfer the pre-pressed molded parts (10) to a transfer unit (41) of the transfer device (4), in order to remove them from the route (F) of the carrier (40) for forwarding to subsequent processes.
A4. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is provided to eject the pre-pressed blanks (10) from the suction tool (2, 2a, 2b) by means of a pressure surge and thus to transfer them to the transfer unit (41).
A5. The first molding station (1) according to any previous clause within set A, wherein the transfer unit (41) comprises a plurality contour adapted to the shape and number of blanks (10) on the side (41a) facing the suction tool (2, 2a, 2b) for the transfer of the blanks (10) to this contour.
A6. The first molding station (1) according to any previous clause within set A, wherein the first molding station (1) furthermore comprises a spraying unit (7), which is provided at least to spray the suction tool (2, 2a, 2b) having the partial-molded blanks (10) with a liquid before the pre-pressing (220) during the route (F) of the carrier (40) to the second position (P2).
A7. The first molding station (1) according to any previous clause within set A, wherein the spraying unit (7) is furthermore designed and provided to provide the blanks (10) with a functional coating after the pre-pressing (220) on the route (F) of the carrier (40) in the direction of the first position (P1), possibly likewise by means of spraying.
A8. The first molding station (1) according to any previous clause within set A, wherein the first and the second suction tool (2, 2a, 2b) is connected to a gas-line system (42) via the carrier (40) such that a negative pressure generated in the gas-line system (40) by means of one or more vacuum pumps (43) is made available as suction pressure at the respective suction heads (21) for drawing in the fibrous material.
A9. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is provided by a robot arm, freely movable in space, with installed carrier (40).
A10. The first molding station (1) according to any previous clause within set A, wherein the contour of the pre-pressing tool (31) adapted to the first and second suction tool (2, 2a, 2b) is manufactured at least in part from an elastomer, possibly silicone, or in that the pre-pressing tool (31) comprises a flexible membrane for covering the blanks (10) and the pre-pressing pressure (VD) is applied as a gas pressure to the membrane, which is then pressed onto the outer contour of the blanks (10).
A11. The first molding station (1) according to any previous clause within set A, wherein the first molding station (1) comprises a changing system (5) for the automatic replacement of the suction tools (2, 2a, 2b) and the pre-pressing tool (31), wherein a tool carrier (51) movable out of the first molding station (1) is provided in the changing system (5) for transporting the replaced tools (2, 2a, 2b, 31) away from the first molding station (1) and the tool carrier (51) can pass through a reversed sequence for the insertion of new tools (2, 2a, 2b, 31).
A12. The first molding station (1) according to any previous clause within set A, wherein the carrier (40) is designed as part of the changing system (5) to remove the suction tools (2, 2a, 2b) and the pre-pressing tool (31) during the replacement from the positions in the partial-molding and pre-pressing station (20, 30) and to transfer them to the tool carrier (51), or to pass through a reversed sequence during the insertion of new tools (2, 2a, 2b, 31).
A13. The first molding station (1) according to any previous clause within set A, wherein the carrier (40) comprises, between the first and the second side (40a, 40b), at least one end face (40c) which is equipped with a receiving and release means (52a, 52b) for removing the pre-pressing tool (31) from the pre-pressing station (30) and for holding it during the transport of the pre-pressing tool (31) to the tool carrier (51).
A14. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is designed to rotate the carrier (40) between the first and the second position (P1, P2) for a removal of the pre-pressing tool (31) from the pre-molding station (30) such that its end face (40c) faces the pre-pressing tool (31), and then bring the receiving and release means (52a, 52b) of the carrier (40) into contact with corresponding counterparts (53a, 53b) of the pre-pressing tool (31), with the result that the pre-pressing tool (31) is released from its holder in the pre-pressing station (30).
A15. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is furthermore designed to deposit the removed pre-pressing tool (31) in the tool carrier (51) by continuing the rotation (D) of the carrier (40), possibly the carrier (40) comprises a pre-pressing tool releasing mechanism (54) for the held pre-pressing tool (31), in order that the pre-pressing tool (31) is freed for receipt by the tool carrier (51).
A16. The first molding station (1) according to any previous clause within set A, wherein the carrier (40) is furthermore designed, after positioning of one of the suction tools (2, 2a, 2b) via the tool carrier (51), to free this by means of a suction tool releasing mechanism (55) for the held suction tool (2, 2a, 2b) for receipt by the tool carrier (51), and to position the other of the suction tools (2, 2a, 2b) above the already received suction tool (2, 2a, 2b) by rotating (D) the carrier (40), and likewise to free this by the suction tool releasing mechanism (55) for the held suction tool (2, 2a, 2b) for receipt by the tool carrier (51).

[0084] A17. The first molding station (1) according to any previous clause within set A, wherein the first molding station (1) comprises at least one further reservoir (6, 6b) having pulp and a pulp-changing system (8), which is designed to provide, in a process dependent manner, one or other of the reservoirs (6, 6a, 6b) having other pulp for the partial-molding of the molded parts (10) before the first position (P1) is reached by the carrier (40).

A18. The first molding station (1) according to any previous clause within set A, wherein the pulp-changing system (8) comprises rails (81) for this purpose, on which the reservoirs (6, 6a, 6b) having pulp can be displaced, and a drive means (82) for displacing the reservoirs (6, 6a, 6b) having pulp, which is actuated in a process dependent manner by the transport device (4).
A19. The first molding station (1) according to any previous clause within set A, wherein the transport device (4) is provided to drive the carrier (40) on the route (F) between the first and the second position (P1, P2) such that, at a first point in time, in the first position (P1), the molded part (10) is partial-molded in one of the suction tools (2, 2a, 2b) out of a first of the reservoirs (6, 6a) having pulp and the same suction tool (2, 2a, 2b), at least at a second point in time later than the first point in time before the pre-pressing (220), the molded part (10) is further partial-molded at least out of a second of the reservoirs (6, 6b) having other pulp.

Set B

[0085] B1. A fiber molding system (100) for producing a molded part (10) from fibrous material by means of a fiber molding process performed in the fiber molding system (100) comprising at least one first molding station (1) according to any previous clause within set A for the partial-molding and pre-molding of the molded part (10) and a second molding station (60) comprising a hot-pressing station (65) for the finish-molding of the molded part (10) by means of hot pressing of the pre-molded molded part (10).
B2. The fiber molding system (100) according to any previous clause within set B, wherein the fiber molding system (100) furthermore comprises a pulp preparation and resupply unit (50) for the resupply of pulp for the reservoir (6).
B3. The fiber molding system (100) according to any previous clause within set B, wherein the hot-pressing station (65) is thermally decoupled from other components of the second molding station (60), possibly an actively cooled separation is arranged between the hot-pressing station (65) and the other components of the second molding station (60).
B4. The fiber molding system (100) according to any previous clause within set B, wherein the second molding station (60) comprises at least two hot-pressing stations (65), which optionally hot press the pre-molded blanks (10) of the first molding station (1) in a process dependent manner, possibly with different hot-pressing parameters.
B5. The fiber molding system (100) according to any previous clause within set B, wherein the fiber molding system (100) additionally comprises a punching station (70) for severing excess fibrous material from the finish-molded molded part (10).

Set C

[0086] C1. A method (200) for producing molded parts (10) from fibrous material, possibly environmentally degradable fibrous material, by means of a fiber molding process in a fiber molding system (100) according to any previous clause within set B with a first molding station (1) according to any previous clause within set A and a second molding station (60) comprising the following steps. [0087] partial-molding (210) of the molded part (10) out of a reservoir (6, 6a, 6b) having a pulp as liquid solution with the fibrous material by means of a first and/or second suction tool (2, 2a, 2b) as partial-molding station (20) of the first molding station (1); [0088] pre-molding (220) of the partial-molded molded part (10) in a pre-pressing station (30) in the first molding station (1); [0089] finish-molding (230) of the pre-molded molded part (10) in the second molding station (60) by means of hot pressing; and [0090] outputting (240) of the finish-molded molded part (10) from the fiber molding system (100).
C2. The method according to any previous clause within set C, additionally comprising the step of severing (250) excess fibrous material from the finish-molded molded part (10) by a punching station (70) arranged behind the second molding station (60) in the machine direction.

[0091] At this point it should be explicitly pointed out that features of the solutions described above or in the claims and/or figures can also be combined if appropriate in order to be able to implement or achieve the features, effects and advantages explained in a cumulative manner.

[0092] It goes without saying that the exemplary embodiment explained above is merely a first embodiment of the present disclosure. In this respect, the design of the disclosed embodiments is not limited to this exemplary embodiment.