JP2008522045A - Method and machine for making textiles and new types of textiles from raw materials - Google Patents

Abstract

The present invention relates to a method and machine for making textile products. The invention also relates to a molded body produced by the inventive method. According to the invention, the textile product is formed on the first tool. The formed textile product is then sandwiched between a first tool and a second tool, and the surface of the second tool is heated to at least 220 ° C. to evaporate the water of the textile product. The tool is permeable to air and water. If the textile product is dehydrated to at least 70% dry solids, the textile product is subjected to microwave heating.
[Selection] Figure 1

Description

  The present invention relates to the manufacture of textile products from raw materials, in particular to three-dimensional objects such as egg cases and other packaging products, but for beverage cups for beverages or trays such as food trays, for example. Also related to objects such as

  Textile products such as egg boxes are made from raw materials in a process in which the fiber layer is created after the shaped fiber product is dehydrated and possibly undergoes some form of post-processing, and then shaped into the desired shape. Can do.

  U.S. Pat. 6103179 discloses a method for producing a textile product where a first male mold is immersed in a molding tank containing a raw material. The vacuum forms a fiber layer of a predetermined thickness for the textile product. The first male mold is then removed from the molding tank. The periodic arrangement of movements is performed on the female mold, where in the first pressing stage the female mold is pressed against the male mold with force so that the textile product moves to the second position. The first expression of raw water occurs after it has been transferred to the female mold. The textile product is then subjected to a second exposure after the textile product has undergone final drying using microwave or IR radiation.

  U.S. Pat. 6451235 discloses a method for forming a three-dimensional fiber truss from a fiber slurry. In this method, a wet consisting of an essentially rigid movable wet mold having a three-dimensional first mold surface and an essentially rigid fixed wet mold having a second mold surface. A molding station is used. The deckle consists of an essentially rigid impermeable frame surrounding a deckle interior space consisting of a prismatic volume that includes a cross-sectional profile that surrounds the peripheral surface of the first mold. The axial length of the prismatic volume of the internal space can be traversed. Within the deckle internal space, a slurry space exists above a predetermined region of the second molding surface. There are also filler means for adding the fiber slurry to the slurry space and pressing means for biasing the movable wet mold along the axial length of the prismatic volume. The method includes the addition of a predetermined amount of fiber slurry to the slurry space and compression of the fiber slurry contained in the slurry space at a preselected rate. The preform fiber truss is then removed from the deckle interior space and moved to the truss finishing station. At the truss finishing station, the wet preform fiber truss is further compressed and dried under pressurized pressure between heated forming dies to produce a finished fiber truss. After processing at the finishing station, the patch plate moves the finished fiber truss to the post-processing station. Post-processing is stated to include operations such as binding to the epidermis.

  U.S. Pat. US Pat. No. 6,582,562 discloses a method of producing a molded part from slurry by the use of first and second mating porous molds. In this method, the first mold is moved into the slurry and a vacuum is supplied to the first mold so that the slurry is on the first mold to the desired thickness. The second mold is heated by hot air from a hot air source, the first and second molds are fitted, and the vacuum is applied between the first and second molds during the fitting of the first and second molds. To be supplied. After this, the molded part is removed from the first mold, and the molded part moves with the second mold. The second mold is moved and the vacuum on the second mold is released so that the molded part can be separated from the second mold. This can be performed in connection with a conveyor belt. It is stated that a drying temperature of 3000 F (corresponding to about 1490 ° C.) can be used.

  U.S. Pat. 6136150 discloses a method and apparatus for achieving raw material flow in a molding tank. It is stated that molded tanks are used to produce textile products such as egg cases or other packaged products. In this patent it is proposed that the flow of the raw material of the molding tank is injected into the bottom of the molding tank and can flow over the edge of the tank. This is stated to lead to a flow that is guided upwards and is important for forming a fiber layer of uniform thickness on the male tool used in this method.

  During the production of textile products such as egg boxes and beverage cups, it is desirable that the final product shape can be controlled in a reliable manner. For many applications, it is also desirable that the final product does not bend more easily in one direction than the others because the final product has essentially uniform strength characteristics. If heat is used to dehydrate the textile, it is also desirable that the heat does not burn the surface of the textile. It is also desirable that the evaporated water can be discharged efficiently.

  The object of the present invention is to provide an improved method and an improved machine for producing textiles from raw materials. In a preferred embodiment of the present invention, the method is performed in this manner and the machine is designed such that improved control of the final product shape is achieved. In a beneficial embodiment of the invention, the final product also obtains essentially uniform strength properties. Further objects of the invention include efficient dewatering and avoiding burning of the final product surface.

The present invention relates to a method for producing a textile product from raw materials. The inventive method consists of providing a first tool that is permeable to air and water, and providing a second tool. The second tool is heated to a surface temperature of at least 220 ° C. A molding tank is provided and the raw material is supplied to the molding tank. The first tool is immersed in the raw material of the tank and the initial textile product is formed on the first tool by applying inhalation through the first tool. The first tool is then removed from the raw material and the first tool is placed relative to the second tool so that the formed textile product is sandwiched between the first and second tools. The formed textile product is heated by the second tool so that at least a water portion of the formed textile product evaporates.
The formed textile product may subsequently undergo at least one additional dewatering step, where the textile product is sandwiched between a pair of opposing tools. Water is preferably removed from the textile product until a dry solid content of at least 70% is reached. When the textile product reaches a dry solids content of at least 70%, it can undergo final drying by microwaves. Prior to final drying by microwaves, the textile can be steamed to achieve a more even moisture content.

  The heating and evaporation steps performed between the first tool and the second tool should preferably last for more than 1 second. During the molding step, the textile is optimally dehydrated to 18-22 parts by weight, preferably 20 parts by weight of dry solids. The raw material used optimally has a dry solids content of 0.4 to 0.7% by weight. Preferably, it has a dry solid content of 0.5% by weight. A suitable raw material can be made from chemical thermomechanical pulp (CTMP).

    In the preferred embodiment of the present invention, the raw material is not fed into the molding tank during the actual molding step. This can be achieved during the molding step, for example by allowing the raw material from the mechanical bat to bypass the molding tank. After the molding step, the raw material from the mechanical bat can be fed again into the molding tank. The molding step preferably takes 1 to 2 seconds.

The first tool and the second tool should preferably be pressed against each other with a force producing an overpressure of 1 MPa or less, preferably 900 KPa or less. In practice, it may be appropriate to use a very low pressure, and the pressure can be in the range of 10 to 900 KPa. It is also conceivable that no mechanical pressure is applied.
Inhalation should also preferably be applied to the first tool when the textile product is sandwiched between the first tool and the heated second tool. Also in the preferred embodiment, the second tool is permeable to air and water. Inhalation is then applied to the second tool if the textile is sandwiched between the tools, so that steam and water are exhausted through the first tool and the second tool.

  The invention also relates to a machine for producing textiles from raw materials. The machine consists of a molding tank for holding the raw material and a first tool that is permeable to air and water. The machine further comprises a second tool that is permeable to air and water. The machine has means coupled to the first tool to lower the first tool to the tank, lift the first tool out of the tank, and guide the first tool to the second tool. An inhalation device, i.e. a source of negative pressure, is connected to the first tool. A source of heat, i.e. a heating device, is arranged to heat the second tool and evaporates the water of the wet textile product when the wet textile product is sandwiched between the first and second tools, The surface of the second tool can be heated to a temperature of at least 220 ° C. The machine further comprises a microwave heater for additional removal of the water of the textile product previously dehydrated between the first and second tools. There is also a means for moving the textile product from the second tool to the microwave heater.

  Preferably, the mechanical bat is arranged for supplying the raw material to the molding tank through a conduit. There may also be a bypass conduit that is used selectively so that the raw material from the mechanical bat can be passed directly to the molding tank or pumped around the annulus flow.

  In an advantageous embodiment, the steam shower can be placed in front of the microwave heater so that the textile product passed through the microwave heater is steamed before it is processed by the microwave heater. Can do.

  Preferably, the first tool consists of particles that have been sintered together to form a porous body. In a preferred embodiment, the second tool also consists of particles that are sintered together to form a porous body. Of course, it is understood that other tools of the sintered tool are also considered.

  In a useful embodiment, the first and second tools are mounted on a holder that can be rotated between different angular positions.

  In addition to the first and second tools, an additional tool is placed in the path from the first and second tool pair to the microwave heater, and the additional tool forms a cooperating pair of tools. However, here the textile product may undergo additional dewatering, and the additional tool is further arranged to transport the textile product towards the microwave heater.

  Reference is first made to FIG. In FIG. 1, a machine for producing a textile product is shown. On the left of FIG. 1, the resource preparation portion is shown, where the pulp sachet 20 disintegrates and dissolves in the raw material of the pulp making machine 22 and then passes to the mechanical vat 7. In the mechanical bat 7, the raw material can be kept moving by the rocking device 21 to avoid agglomeration. From the mechanical bat 7, the raw material can be fed through a conduit 8 to a tank 6 used in the process of the present invention. In the preferred embodiment of the invention, no raw material is supplied to the molding tank 6 during the actual molding step. This can be achieved during the molding step, for example by bypassing the raw molding tank 6 from the mechanical bat 7. After the molding step, the raw material from the mechanical bat 7 can be fed again into the molding tank 6. The molding step optimally takes 1-2 seconds. If the pulp is not passed through the molding tank 6, the pulp 19 in the molding tank 6 can be stationary. This is accompanied by the advantage that the formed fiber product obtains uniform properties in all directions since the fiber orientation is more stochastic. In order to avoid agglomeration of the conduit leading to the molding tank 6, the raw material can be sent in the bypass conduit 9 during molding, so that the raw material is kept moving. After the textile product has been formed on the tool 1 immersed in the raw material held in the tank 6, the textile product is dehydrated between opposing pairs of tools and a microwave heating device 17 for final drying. Followed by. The conveyor belt 15 can be used to carry the textile product 10 to the microwave heater 17. There may be a pick-up unit 23 used to place the final product 10 on the stack 24 after the production line is finished. The pick-up unit 23 may have an inhalation device (not shown) for picking up the already dried product 10.

  The operation of the process will now be described with respect to FIGS. 2a to 2h and FIGS. 3 to 5. In FIG. 2 a, the first tool 1 is placed in a holder 14 that can pivot on a drive shaft or pin 14. In FIG. 2 b, the holder 13 is pivoted or rotated to a position where the first tool 1 faces the raw material 19 held in the tank 6. The first tool 1 is placed on the holder 13 so as to be lowered to the raw material 19. This can be performed by special means for raising and lowering the first tool 1 with respect to the holder 13. Such means may include, for example, a telescopic hydraulically actuated arm 18 shown schematically in FIG. 2c. The first tool 1 is then lowered to the raw material 19 until it reaches the position shown in FIG. This position is shown in more detail in FIG. As can be seen in FIG. 3, the first tool 1 has a contoured surface 25 corresponding to the shape of the textile product to be formed. The first tool 1 is permeable to air and water. It is also connected to a negative pressure source that can apply inhalation through the first tool 1, i.e. the inhalation device 2, so that water and fibers are sucked towards the first tool 1. The water passes through the first tool 1 and is returned to the raw material 19 through a return conduit (not shown). However, the fibers remain on the contoured surface 25 of the first tool 1 and form the initial fiber product 10 as shown in FIG. Thus, the first tool 1 serves as a forming tool for the initial forming of the textile product. The raw material used is preferably based on chemical thermomechanical pulp (CTMP), but may be other pulps where CTMP can be considered. CTMP is the preferred pulp in this context because it is relatively easy to dehydrate the feed based on CTMP. The concentration of the raw material can be 0.5% by weight or about 0.5% by weight. However, other concentration values may also be considered.

  The initial molding step can take about 1-2 seconds. When the initial molding step is completed, the first tool 1 (molding tool) is lifted from the raw material 19 as shown in FIG. The formed fiber product 10 then has about 20% dry solids, but the dry solids can also be somewhat lower or somewhat higher, realistically, for example, in the range of 18-22%. There is. As shown in FIGS. 2 f to 2 h, the holder 13 may then rotate, and the first tool 1 is moved once again by the arm 18 away from the body of the holder 13. In FIGS. 2f to 2h, the first tool 1 is moved horizontally and at right angles in the figure. However, it should be understood that other directions and patterns of motion are also possible. The first tool is shown symbolically in FIG. 2h and moved to mate with the second tool 3, as shown in more detail in FIG. During this movement, the inhaler 2 continues to operate so that the initial textile product 10 is securely held by the first tool 1. The second tool 3 has a contoured surface 26 that matches the contoured surface 25 of the first tool 1. When the first tool 1 faces the second tool 3, the formed textile product 10 is held between the tools 1 and 3. In the figure, the first tool 1 is shown as a male tool, while the second tool 3 is shown as a female tool. Although it is considered the most appropriate solution since it makes the forming process easier, the first tool 1 may also be a female tool. The heating device 5 is arranged to heat the second tool 3 so that the contoured surface 26 of the second tool 3 preferably reaches a temperature of at least 220 ° C. Temperatures much higher than 220 ° C can also be used. The realistic interval of the surface temperature of the second tool 3 is 220 ° C. to 400 ° C. The surface temperature for the second tool 3 to achieve effective dewatering is preferably at least 220 ° C, but it should also be understood that temperatures below 220 ° C are contemplated. For example, the temperature may be as low as 200 ° C. Thus, the interval for temperature can be from 200 ° C to 400 ° C. In a preferred embodiment, the second tool 3 is also a permeable tool and the inhalation device 4 also applies inhalation through the second tool 3 when the second tool 3 mates with the first tool 1. Therefore, there is a possibility that the second tool 3 is connected. Due to the high temperature of the second tool 3, the water of the textile 10 evaporates. Since at least the first tool 1 is permeable, the vapor can escape through the first tool 1. When the first tool inhaler 2 is in operation, this facilitates the discharge of steam. If the second tool 3 is also permeable, the vapor can also be exhausted through the second tool 3, which is more efficient than when the second tool inhaler 4 is in operation. become. The textile product 10 is held between the tools 1, 3 during evaporation. When water evaporates at such high temperatures, the evaporation process is abrupt and sudden. According to the prevailing theory, textile products undergo a so-called “impact drying” process. This indicates that the evaporated water exiting the textile product also forces residual water between the fibers that did not evaporate. This leads to very effective dehydration. The present invention is not bound to any particular theory that occurs exactly under such circumstances. However, practical experience has demonstrated that a surface temperature of 220 ° C. leads to very effective dehydration. It has been observed that dry levels of 50% and higher can already be obtained in the first dewatering step between tools 1,3. The nip time between tools 1 and 3 is preferably very short, and only 1 second may be appropriate. In some cases, a time of 1 second or less is appropriate. The pressure in the nip between the tools 1, 3 should preferably not be higher than 1 MPa. Preferably, the mechanical pressure should not be higher than 900 KPa. For example, the mechanical pressure can be in the range of 10 to 900 MPa. In some cases, the pressure may actually be zero.

  Reference is now made to FIG. In FIG. 6, it can be seen how several tool holders 13 are arranged in a row. For example, as shown in FIG. 8, each tool holder 13 is pivotable and has a drive shaft 14 for it. The drive shaft 14 can rotate with the tool holder, or the tool holder 13 can pivot on the drive shaft 14. On each tool holder 13, there are additional tools 11, 12, such as a male tool 11 and a female tool 12. Each tool 11, 12 can have at least one other tool on an adjacent tool holder 13 to form a nip together. Each tool 11, 12 is permeable and may be coupled to an inhalation device such as the first tool 1 and the second tool 3. The tools 11, 12 are mounted on one or several telescoping arms 18 or some other actuator for moving the tools 11, 12 away from or toward the respective holder 13. Can be placed. In this way, the tool 11 on one holder 13 may be moved horizontally towards the tool 12 on the adjacent holder 13 to dehydrate the textile product held between the tools 11, 12. There is. The tools 11, 12 and the tool holder 13 there also serve as a conveyor for carrying the textile product 10 towards the microwave heater 17. This works as follows. The textile product 10 is held on the male tool 1, 11 or the female tool 3, 12 by inhalation through the permeable tool 1, 3, 11, 12. As an example, a reference is then made when the textile product 10 is first held on the male tools 1, 11. The arm 18 (or arms 18) moves the male tool 1, 11 toward the female tool 3, 12. The textile product 10 is dehydrated. Inhalation by the male tools 1, 11 is released and then the textile product 10 is held by inhalation through the female tools 3, 12. The male tools 1, 11 return to their original positions. The tool holder 13 of the female tool 3, 12 is then rotated 180 ° so that the textile product faces the new male tool 12. It can be appreciated that this process can be repeated so that the textile product 10 is moved to the next male tool and further to the microwave dryer. Tools 11, 12 and their holders 13 are thus arranged to carry the textile product 10 towards the microwave heater. For additional explanation of the placement of additional tools 11, 12, reference is also made to FIG.

  As can be seen most clearly in FIG. 14, each tool holder 13 can have a plurality of tools 12 arranged next to each other, so that a plurality of textile products 10 are produced simultaneously, Can be finished. Each additional pair of tools 11, 12 can act in the same way as the first tool 1 (molding tool) and the second tool 3, and further dewatering of the additional tools 11, 12 It should be understood that this can occur at the nip formed between the pair. The additional tools 11, 12 serve both for the purpose of dewatering and for conveying the textile product 10. In an advantageous embodiment of the invention, the pressure between the first tool 1 and the second tool 3 may be kept relatively low, while higher pressures and lower temperatures are used for the next pair of tools. 11 and 12 are used. For example, high pressures up to 1 MPa can be used in the pressing nip between the last pair of tools 11, 12. It should be understood that typically additional dewatering occurs at the press nip between the additional tools 11, 12. If more than one pressing nip is used, the nip pressure is the lowest pressure used in the first nip, the higher pressure used in the next nip, and the highest pressure used in the last nip. The nip can be increased from nip to nip. The pressure can therefore increase in steps from nip to nip.

  With respect to FIGS. 9a to 9h, the conveyor belt 15 may be located at the end of the tool path. FIG. 9a shows how the last tool holder 13 is in a horizontal position. It should be understood that the textile product 10 is retained by inhalation into the male tool 11. The tool holder 13 is located above the conveyor belt 15. In FIG. 9 b, the tool holder 13 is rotated so that the tool 11 then faces the conveyor belt 15. The tool 11 shown in FIG. 9c moves downward, stops the suction and drops the textile product onto the conveyor belt 15. Alternatively, air can also be blown with the tool 11 to help the textile 10 leave the tool 11. The textile product is then conveyed towards the microwave heater, while the tool 11 returns to its original position as shown in FIGS. 9e to 9h.

  In FIG. 10, it can be seen how the microwave heater 17 can be preceded by a steam shower 16 that blows steam onto the textile 10. The purpose of this is to achieve a more even moisture distribution of the textile product 10. It should be understood that the use of steam is an optional feature of the present invention and it is possible to recognize embodiments of the invention in which steam is not used. Preferably, the textile is dehydrated to at least 70% dry solids before reaching the microwave heater 17. However, it should be understood that microwave heaters can be reached with 70% or less dry solids.

  The design of the tool 1, 3, 11, 12 according to a possible embodiment of the invention will now be described in more detail with reference to FIGS. FIG. 11 is an exploded view of the first tool 1 and the second tool 3. As shown in FIG. 11, the heater 5 is arranged as close as possible to the second tool 3 so as to be connected directly to the tool 3 or at a certain distance from the second tool 3. There is a possibility that. As can be seen in FIG. 12, both tools 1, 3 comprise a channel 27 through which water and air can pass. As shown in FIG. 12, the tools 1, 3 can consist of different layers 28, 29, 30. These layers are part of the tool structure with different transmittance. Inner layer 28 forms the base structure with a relatively high degree of transmittance. The intermediate layer 29 may have a relatively low transmittance, and the thin surface layer 30 may have a much lower transmittance. The tool may conveniently be made of small metal spheres that are sintered together to form different layers.

  As shown in FIG. 13, the surface layer 30 may be formed by small spheres 31, while the intermediate layer 29 may be formed by somewhat larger metal spheres 32. The base structure 28 is formed by the largest sphere 33. The smallest particles 31 may have a diameter in the range of 0.01 mm to 0.18 mm, and the particles 32 in the intermediate layer 29 may have a diameter in the range of 0.18 mm to 0.25 mm. Larger particles or spheres 33 of the base layer can have a diameter of 0.71 mm to 1 mm. Particles 31, 32, 33 are particles sold in the form of metal powder and can be obtained from Poppelgatan 15,571,39, Naassjo, CALLO, Sweden. CALLO sells metal powder under the name Callo 25, a spherical metal powder with particles having a diameter of 0.09 to 0.18 mm. The chemical composition is 89% Cu and 11% Sn. Suitable particles are also available from Buckley Road, Rochdale, Lanciashire OL12 9DT, Mackin Metal Powders, UK.

  The porosity of tool 1 is about 40%. A porosity value of 40% can be applied to all layers. Embodiments of the invention in which different layers of the tool have different porosity can also be recognized.

  The smaller spheres 31 form a fine surface layer that gives the textile a smooth surface, while the inner layers 29, 28 improve the transmission. The channel 27 that passes through the sintered structure may have a tapered tip that reaches the surface of the tool that improves the transmission.

  Reference is now made to FIG. In the embodiment of FIG. 16, the portion 34 of the surface 25 of the first tool 1 is covered or coated so as to be impermeable or essentially impermeable. On the impervious point 34, no fiber layer is formed. Therefore, the textile product has a hole having a shape corresponding to the impermeable portion 34. The impervious point 34 can be achieved, for example, by applying a part of the surface 25 or covering a part of the surface 25 with a sheet of impervious material. It should be understood that this feature (impervious point) is completely optional and the present invention can be practiced without this optional feature. With respect to the method, it should be understood that the invention can be construed to include the (optional) step of using the tool at the impermeable location 34. The idea of using a tool in an impermeable location can be used regardless of how the tool, machine or method is separately designed or implemented.

  The porous structure provided by the sintered metal particles 31, 32, 33 has the advantage that water and steam can easily escape through the tools 1, 3, 11, 12. This reduces the risk of delamination during the evaporation process. The sintered structure also has the advantage that steam can escape in a very even way over the entire surface of the tool.

  High temperatures are accompanied by the advantage that efficient dehydration is achieved. Pressing at a relatively high pressure before the microwave heater (if the textile is wet) is accompanied by the advantage that good surface properties can be achieved before drying in the microwave. Thus, there is no need to press the textile product, which can be harmful to the textile product after drying in the microwave. The microwave heating step is associated with improved hygiene benefits. The use of high temperatures also has the advantage that the surface of the textile is small so that it is beneficial in terms of bending hardness.

It should be understood that in certain embodiments, microwave heating can be eliminated or replaced by several other heating methods such as IR heating.
It should be understood that the idea of stopping the supply of raw material to the tank 6 during molding can be used regardless of how the process is performed separately.

The invention also relates to a textile product obtainable by the method described above. In FIGS. 15A to 15C, the properties of the moldings produced according to the invention are shown. FIG. 15A demonstrates its quality aspects (e.g., important in many areas where shaped fiber pulp products are used as in the packaging industry), for example, produced by thermoforming or conventional pulping This is a significant improvement in the invention related to the prior art products that are made. One reason for the high quality of the inventive product could be that high densities in the range of 600 to 900 kg / m ³ are achieved without causing any weakness in fiber netting. According to prior art methods, densities of 500 and above are rarely achieved without obtaining quality aspects at least below the desired level. As can be seen in FIG. 15C, thermoformed pulp products can obtain levels of 500 kg / m ³ or higher. However, when using thermoforming, including heating after pressing, fiber net processing partially collapses to sharply reduce some quality aspects such as, for example, tension indicators. In particular, the corners and other areas of the body that exhibit sharp bends / curves are negatively affected by such post-pressing heating, while according to the invention, corners and areas with sharp radii are also present. It also shows a continuous and homogeneous fabric structure of essentially the same type as the essentially planar region of the body, which in turn provides an equally good quality aspect in each part of the product. In an advantageous embodiment, the textile fabric of the product is of equal thickness or essentially equal thickness. However, it should be understood that the textile product obtained by the described method may have a density lower than 600 kg / m ³ or a density higher than 900 kg / m ³ at least in certain cases.

  A further major advantage of the present invention is that very smooth surfaces can occur on both sides of the body. Products produced by the present invention can easily obtain roughness in the range of about 750 to 1,000 ml / min (ISO 8791-2, Bendtsen), while traditional molded pulp products , Usually having a roughness above 1,500 ml / min on at least one side. One of the reasons that conventional products exhibit higher roughness than usual may be mentioned that the conventional technique is to use a wire mesh to form the surface.

A further advantage of the present invention is that the product achieves a high tension index, usually in the range of 65 to 100 kNm / kg, which is certainly a significant advantage compared to conventional molded pulp products (Fig. See 15B). Furthermore, good specific tear strength is also achieved. Another advantage is that the method of the present invention achieves a large amount of bonding between the fibers of the surface layer so that the bonding strength of the surface layer is an intermediate layer near the central portion of the woven fabric forming the body. Somehow higher than the bond strength. As a result, a function similar to the I-beam, i.e. hardness, is achieved and the bending resistance is improved.
Finally, it may be achieved without subsequent pressing to separately increase manufacturing costs and negatively affect at least some or one quality aspect as described above, Of course, this is a beneficial embodiment of the product of the present invention. In FIG. 15B, because of all the advantages described above, the product tension index produced by the present invention may have a high value regardless of the shape of the body, while according to conventional methods, the product It is shown that it exhibits an indicator of decreased tension with increasing body shape complexity. In Table 15C, several average values have been empirically revealed compared to the invention due to two prior art methods: conventional pulp molding and thermoforming. As is apparent from this table, the products of the present invention may have a number of advantages with respect to quality aspects as compared to prior art products.

Figure 2 is a schematic view of the layout of a machine used in the inventive method. Fig. 4 shows the order in which the forming tool is immersed in the raw material held in the tank. Fig. 2 shows in more detail the molding tool immersed in the raw material. Fig. 4 shows the molding tool of Fig. 3 with a textile product formed on the tool. It shows how the first tool mates with the second tool and the textile is sandwiched between the two tools. A group of tool holders arranged in an array is shown in perspective. The same group of tool holders of FIG. 6 is shown, but here viewed from above. FIG. 8 shows a side view of the tool holder shown in FIGS. 6 and 7. It shows how the already dried textile product is transferred to the conveyor belt. Fig. 2 shows a part of the machine shown in Fig. 1; Figure 2 shows an exploded view of a tool pair used in the present invention. 12 shows a cross section of the tool pair shown in FIG. FIG. 13 shows the microstructure of the tool shown in FIG. 12 in more detail. A tool holder with multiple tools is shown in perspective. Figure 3 shows the properties of the molded product produced by the invention compared to the prior art. Figure 3 shows the properties of the molded product produced by the invention compared to the prior art. Figure 3 shows the properties of the molded product produced by the invention compared to the prior art. Details of useful examples of tools used in the inventive method are shown.

Claims (29)

A method for producing a textile product from raw materials,
The following steps: a) providing a first tool (1) that is permeable to air and water;
b) providing a second tool (3) and heating the second tool (3) to at least 220 ° C .;
c) provision of the molding tank (6) and supply of raw materials to the molding tank (6);
d) immersion of the first tool (1) in the raw material supplied to the tank (6);
e) forming an initial textile product (10) on the first tool (1) by applying inhalation through the first tool (1);
f) removal of the first tool (1) from the raw material;
g) of the first tool (1) relative to the second tool (3) such that the formed textile product (10) is sandwiched between the first and second tools (1, 3); Induction and heating by the second tool (3) such that at least a portion of the water of the formed textile product (10) evaporates;
And h) a process comprising dehydrating the formed fiber product (10) such that a dry solid content of at least 70% is reached, and then the fiber product (10) is subjected to microwave drying. 2. The method according to claim 1, wherein the heating and evaporating steps last between as little as 1 second and are performed between the first tool (1) and the second tool (3). Characterized in what is being done. 2. A method according to claim 1, characterized in that no raw material is supplied to the molding tank (6) during the molding step. 4. The method according to claim 3, wherein during the molding step, raw material from the mechanical bat (7) is diverted from the molding tank (6), and after the molding step, from the mechanical bat (7). Characterized in that the raw material is fed to the molding tank (6). 2. A method according to claim 1, characterized in that the shaping step lasts 1 to 2 seconds. The method according to claim 1, wherein the textile (10) is dewatered in several dewatering steps between opposing tools, followed by steam before it is dried by microwaves. A method characterized in receiving. 2. A method according to claim 1, characterized in that the raw material has a dry solids content of 0.4 to 0.7% by weight, preferably 0.5% by weight. 2. A method according to claim 1, characterized in that the textile product (10) is dehydrated to a dry solid content of 18 to 22% by weight, preferably 20% by weight. 2. The method according to claim 1, wherein the first tool (1) and the second tool (3) are pressed against each other with a force generating an overpressure of about 1 MPa, preferably not exceeding 900 KPa. Characterized in what is being done. 2. A method according to claim 1, characterized in that the pressure is in the range of 10 to 900 KPa. 2. A method according to claim 1, characterized in that the raw material is made from chemical thermomechanical pulp (CTMP). 2. The method according to claim 1, wherein inhalation also occurs when the textile product (10) is sandwiched between the first tool (1) and the heated second tool (3). A method characterized in that it is applied to the tool (1). 13. A method according to claim 12, wherein the second tool (3) is also permeable to air and water, and when the textile product (10) is sandwiched between the tools (1, 3), inhalation is also possible. Also applied to the second tool (3), characterized in that steam and water can be discharged by both the first tool (1) and the second tool (3) . A machine for producing a textile product (10) from raw materials,
a) Molding tank (6) for holding raw materials,
b) a first tool (1) that is permeable to air and water;
c) a second tool (3) that is permeable to air and water;
d) lowering the first tool (1) into the tank (6), lifting the first tool (1) from the tank (6), and against the second tool (3) Means coupled to the first tool (1) for guiding the first tool (1);
e) a source of negative pressure (2) coupled to the first tool (1);
f) when the wet textile product (10) is sandwiched between the first and second tools (1, 3) to evaporate the water of the wet textile product (10); A source of heat (5) arranged to heat the tool (3) and capable of heating the surface of the second tool (3) to a temperature of at least 220 ° C;
g) a microwave heater (17) for additional removal of water of the textile (10) previously dehydrated between the first tool (1) and the second tool (3);
And h) a machine comprising means for moving the textile product (10) from the second tool (3) to the microwave heater (17). 15. A machine as claimed in claim 14, wherein a mechanical bat (7) is arranged for supplying raw material to the forming tank (6) through a conduit (8), and a bypass conduit (9) is also provided for the mechanical bat. A machine characterized in that the raw material from (7) is used selectively so that it can be pumped around the flow that is either passed directly into the molding tank (6) or is made into an annulus. 15. A machine according to claim 14, wherein a steam shower (16) is placed in front of the microwave heater (17), so that it is processed before it is processed by the microwave heater (17). Machine characterized in that the textile (10) passed through the wave heater (17) can be steamed. 15. A machine according to claim 14, characterized in that the first tool (1) is composed of particles sintered together to form a porous body. 18. A machine according to claim 17, characterized in that the second tool (3) is also composed of particles sintered together to form a porous body. 19. A machine according to any of claims 14 to 18, wherein the first and second tools (1, 3) are mounted on a holder that can rotate between different angular positions. Machine characterized. 20. Machine according to any of claims 14 to 19, wherein in addition to the first and second tools (1, 3), additional tools are from the pair of the first and second tools. , Arranged in a path to the microwave heater (17), wherein the additional tool forms a cooperating pair of tools, wherein the textile product undergoes additional dewatering and the additional tool Is characterized in that it is further arranged for transporting the textile product (10) towards the microwave heater (17). The fiber is a continuous and stable shape, preferably a molded body composed mainly of fibers to form a woven fabric that forms a three-dimensional body, wherein said basis weight The amount is in the range of 150 to 600 g / m ² , where the orientation of the fibers is essentially such that the same strength characteristics are obtained regardless of the direction within the plane of the woven fabric. A shaped body that is probabilistic, characterized in that said density is in the range of 600 to 900 kg / m ³ , preferably at least 700. 22. A shaped body according to claim 21, wherein the corners and / or areas having sharp radii are also essentially the same type of continuous homogeneous woven fabric as the essentially flat surface of the body. A molded body characterized in showing. 23. A molded body according to any of claims 21 to 22, wherein the roughness of the essential part of the surface on both sides of the body is from 750 according to bendsen ISO 8791-2. Molded body characterized in the range of 3,000 ml / min, and preferably 750 to 2,000 ml / min, more preferably 750 to 1,500 ml / min on at least one side. 24. A molded body according to any one of claims 21 to 23, wherein the tension indicator is in the range of 50 to 100 kNm / kg, more preferably 65 to 100 kNm / kg, even more preferably 80 to 100 kNm / kg. A molded body characterized in that it is most preferably 90 to 100 kNm / kg. A molded body according to any of claims 21 24, characterized in that the ratio tear strength, range of 5 to 15 Nm ² / kg, more preferably 15 Nm ² / kg to 8 Molded body. 26. A molded body according to any of claims 21 to 25, wherein the bond strength of the surface layer of the body is such that the bond of the intermediate layer near the central portion of the woven fabric forming the body. Molded body characterized in a range of 5 to 50% higher than strength, preferably 7 to 30% higher. 27. A molded body according to any of claims 21 to 26, wherein the air resistance for the woven fabric comprising corners / sharp curves of the body is in the range of 60 to 200 sek, preferably by gurley. A molded body characterized in that it is at least 70, more preferably at least 80. 28. A molded body according to any of claims 21 to 27, wherein the body is characterized in that it can be obtained without subsequent pressing. 28. A molded body according to any of claims 21 to 27, wherein the body obtains at least 70% dry solids, preferably after obtaining 80% dry solids, A molded body characterized in that it is obtainable even without a subsequent pressing action after more than 1.5 MPa after obtaining 90% dry solids.

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