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WO2015019061A1 - Procédé de fabrication d'un objet en pâte moulé - Google Patents

Procédé de fabrication d'un objet en pâte moulé Download PDF

Info

Publication number
WO2015019061A1
WO2015019061A1 PCT/GB2014/052360 GB2014052360W WO2015019061A1 WO 2015019061 A1 WO2015019061 A1 WO 2015019061A1 GB 2014052360 W GB2014052360 W GB 2014052360W WO 2015019061 A1 WO2015019061 A1 WO 2015019061A1
Authority
WO
WIPO (PCT)
Prior art keywords
pulp
moulded
tool
manufacturing
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/GB2014/052360
Other languages
English (en)
Inventor
Fuad KHAN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hpc Healthline UK Ltd
Original Assignee
Hpc Healthline UK Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hpc Healthline UK Ltd filed Critical Hpc Healthline UK Ltd
Publication of WO2015019061A1 publication Critical patent/WO2015019061A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/08—Impregnated or coated fibreboard
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds

Definitions

  • the present invention relates to method of manufacturing a moulded pulp object, and in particular a method of forming a surfactant proof moulded pulp receptacle.
  • a method of manufacturing a moulded pulp object comprising providing a pulp slurry comprising pulp fibres in an aqueous suspension; forming a layer of pulp on the surface of a mould tool to create a three dimensional moulded pulp object having a first surface facing inwardly in contact with the mould tool and a second surface facing outwardly from the mould tool; and then applying a barrier coating to the three dimensional moulded pulp object after it has been formed on the mould tool.
  • This may be while the pul p object is retained on the mould tool or while the pulp object is held on the transfer tool, or at any other suitable stage following the formation of the pulp layer on the mould tool, including when the pul p object is located on the drying conveyor.
  • the barrier coating is a surfactant proof coating.
  • the barrier coating may include any of the group comprising fluorocarbons, aqueous starch solutions, protein solutions, styrene based polymers, styrene acrylate based polymers, styrene butadiene polymers, non ionic acryl polymer, ammonia salt of modified acrylic copolymers, proteins, or cellulose derivatives, acrylic resins, styrene-acrylic resins, ethylene-vinyl acetate resins, styrene- butadiene rubber resins, polyvinyl alcohol resins, vinylidene chloride resins, waxes, fluorine resins, silicone resins, and copolymers and polyblends of these resins.
  • a barrier coating to the surface of the pulp object which is preferably a washbowl but which may be any pulp moulded product, following the moulding operation uses significantly less chemical than by applying the coating throughout the substrate through the addition of the chemical to the slurry prior to moulding.
  • the coating such as fluorochemical onto the surface of the object a greater concentration of the chemical is achieved at the surface for better performance at a significantly reduced cost, with no requirement for the presence of fluorochemical in the body of the washbowl.
  • a significantly greater amount would be required, thereby significantly increasing cost.
  • the surfactant proof material is sprayed onto the moulded pul p object. Spraying provides an effective means of the applying the fluorochemical solution to the surface of the object in an efficient, rapid and consistent manner.
  • the surfactant proof material comprises a fluorochemical, preferably containing multiple carbon-fluorine bonds, some of these are commonly known as fluorocarbons or fluoropolymers.
  • Fluoropolymers consist of a linear chain of strong carbon-fluorine bonds with other atoms, polymers or ionic groups attached at one end of the chain. Due to this structure one end of the polymer chain is lipophobic/oleophobic and the other end is hydrophilic. When the bowl's inner surface is coated with fluoropolymer the hydrophilic end of the chain is attracted to the pulp fibre and the lipophobic end becomes the solid interface to air or liquid.
  • the coating such as a surfactant proof material is preferably applied to the first surface of the moulded pulp object when it is on the transfer tool.
  • the transfer tool is a female tool
  • the inner first surface of a concave object such as a washbowl is outwardly facing when held on the transfer tool. Therefore spraying while the washbowl is retained on the transfer tool allows the inner first surface of the washbowl, that is initially in contact with the surface of the mould tool prior to transfer the transfer tool, to be coated.
  • the moulded pulp object may be removed from the mould tool using a corresponding transfer tool such that the second surface faces inwardly in contact with the surface of the transfer tool and the first surface faces outwa rdly.
  • the surfactant proof material is applied to the first surface of the moulded pulp object when it is on the transfer tool. It is preferable to form a receptacle such as a washbowl using a male mould which enables the inner surface of the washbowl to be compressed under the action of the vacuum against the surface of the mould tool forming a smooth and non-porous inner surface to the bowl. This is advantageous as the inner surface defines the operable surface in use.
  • the transfer tool is preferably arranged to transfer the moulded pulp object to a further processing operation.
  • the transfer tool is preferably arranged to transfer the moulded pulp object to a drying operation and the surfactant proof coating is applied to the moulded pul p object on the transfer tool prior to being transferred to the drying operation.
  • Liquid is removed from the layer of pulp material on the mould tool during the formation of the moulded pulp object, and the surfactant coating is preferably applied to the moulded pul p object after the liquid removal stage.
  • the object is coated after de-watering and prior to drying.
  • an apparatus for manufacturing a moulded pulp object comprises a pulp slurry container for containing a pulp slurry comprising pulp fibres in an aqueous suspension; a mould tool arranged to be submerged into the pul p slurry container; means for drawing a layer of pulp fibres onto the surface of the mould tool to create a three dimensional pulp object; and means for applying a surfactant proof coating to the three dimensional pulp object after it has been formed on the mould tool.
  • the means for applying a surfactant proof coating to the three dimensional pulp object preferably comprises a spray for spraying a coating solution comprising fluorocarbon. This advantageously enables the application of a surfactant proof material in an efficient and economical manner.
  • the mould tool is preferably configured such that when the layer of pulp fibres is formed on the surface of the mould tool a first surface faces inwardly in contact with the mould tool and a second surface facing outwardly from the mould tool.
  • the apparatus preferably further comprises a transfer tool arranged to remove the moulded pulp object from the mould tool and transfer it to a further processing operation.
  • the spray is preferably arranged to apply the surfactant proof coating to the second surface of the moulded pulp object while it is retained on the mould tool.
  • the spray may be arranged to apply the surfactant proof coating to the first surface of the moulded pulp object while it is retained on the transfer tool.
  • the mould tool is preferably a male tool configured to form a moulded pulp receptacle having an inner volume with an inner surface corresponding to the outer surface of the mould tool, and the transfer tool is a female tool inversely corresponding to the shape of the mould tool. It will be appreciate that this arrangement could be inverted.
  • a vacuum source is preferably arranged to remove liquid from the moulded pulp object while it is retained on the mould tool, and control means configured to control the spray to apply the surfactant proof coating to the after the operation of the vacuum source to remove liquid from the moulded pulp object.
  • a moulded pulp liquid receptacle comprises a three dimensional moulded pulp body comprising a base and at least one wall having an inner surface defining a liquid receiving volume; and a surfactant proof layer formed on the inner surface.
  • Figure 1 shows a mould tool and transfer tool arrangement according to the present invention with the pulp object retained on the mould tool
  • Figure 2 shows the arrangement of claim 1 with the transfer tool in engagement with the mould tool
  • Figure 3 shows the arrangement of Figure 1 with the pulp object removed from the mould tool by the transfer tool
  • Figure 4 shows a moulding process according to an embodiment of the present invention
  • Figure 5 shows a spraying operation according to an embodiment of the present invention.
  • pulp paper slurry is formed by loading bales of recycled waste paper or virgin pulp into a hydrapulper comprising a water filled tank having a powerful agitator for breaking up the bales into small pieces.
  • the hydrapulper's action defibrillates the paper/pulp into its requisite fibres in an aqueous suspension that is commonly known as slurry.
  • the slurry is held in a holding tank with agitators, thus keeping the consistency of the fibre suspension even and preventing settling at the bottom of the tank.
  • a sizing agent may be added to the slurry during the hydrapulping process or just after this process as the slurry is being transferred to a holding tank to water proof the pulp material.
  • the pulp slurry is pumped to the moulding tank.
  • the slurry is diluted to a consistency amenable to moulding. Dilution can be achieved through several methods, the two most common being through a ⁇ ' connection where the pipe from the water tank and the slurry storage tank converge into one pipe causing dilution of the slurry.
  • An alternative method uses a dilution tank where fixed amounts of white water and slurry are mixed.
  • the pulp fibres in aqueous suspension are drawn onto a tool 2 having a porous surface capable of having a vacuum drawn therethrough.
  • the tool may include vacuum holes and preferably covered by a porous surface layer such as a stainless steel gauze 4, as shown in Figure 1.
  • the surface of the tool itself may be formed from a porous material obviating the requirement for a separate gauze. This is done by dipping or submerging the tool 2 into the moulding tank and applying vacuum to the tool 2.
  • the tool 2 is a male tool for forming a hollow receptacle such as a washbowl.
  • the male tool defines the internal volume of the washbowl.
  • the application of vacuum causes pulp fibres to be drawn to the gauze 4 as the white water of the slurry is sucked through the gauze 4 forming a layer 6 of pulp on the outer surface of the tool 2. With a layer of pulp fibres 6 formed on the tool 2, the tool 2 is retracted from the moulding tank.
  • the layer 6 of pulp forms a 'felt' of pulp covering the gauze in the shape of the outer surface of the mould tool 2, defining a three dimensional pulp washbowl 8. It will be appreciated that while the following description describes the object as a washbowl this is not limiting and the process may apply to any suitable three dimensional object and in particular to a pulp receptacle.
  • the mould tool 2 has been removed from the moulding tank a further vacuum is then applied to dewater the layer 6 of pulp retained on the mould to remove as much of the water held within the pulp material as much as possible.
  • the porous surface of the mould tool 2 creates a corresponding relatively 'smooth' inner surface of the bowl which is typically lightly textured though smoother than the outer surface.
  • the surface of the mould tool may be stainless steel or any other suitable material.
  • the outer surface 12 of the washbowl 8 retains a relatively rougher texture due to the pulp material not having been compressed against a mould surface.
  • the moulded pulp washbowl is removed from the moulding tool 2 using a transfer tool 14.
  • the pul p has a water content of between 40-80% and more preferably between 50-70% by weight. I n the embodiment described the water content upon application is approximately 68% by weight.
  • the transfer tool 14 is a corresponding female tool that is the inverse shape of the moulding tool 2 with a smooth inner surface 16 comprising vacuum holes. The two tools meet and the inner surface 16 of the transfer tool 14 is brought into engagement with the outer surface 12 of the moulded pulp object 8 or 'felt'. The moulded pulp object 8 is then transferred to the transfer tool 14 by application of a vacuum to the transfer tool 14 which hold the pulp object 8 in engagement with the transfer tool 14.
  • the vacuum force applied by the transfer tool is sufficient to hold the pulp object in engagement with the transfer tool, but is significantly less than the vacuum force applied by the tool to draw the pulp onto the tool and/or dewater the pulp.
  • the transfer tool 14 then either deposits the mould onto a conveyor for drying through a hot air tunnel or to a set of drying tools if the mould is being dried between heated tools, commonly known as 'thermoformed', 'dry in place', or 'press to dry' processes.
  • the transfer tool 14 may be heated to assist in the drying process.
  • the transfer tool 14 removes the washbowl 8 from the moulding tool 2 following dewatering and transfers the washbowl 8 to a conveyor 18.
  • the conveyor 18 carries the washbowls 8 through a drying tunnel 20 in which a heater 22 directs heated air onto the washbowls 8 to dry the pulp and remove the remaining water content.
  • the sizing agent in the pulp material which was added during the slurry stage makes the dried pulp washbowl 8 waterproof. As such, clean water may be poured into the washbowl 8 and held without leakage.
  • surfactants such as soaps, oils or gels pulp in the water, which are typically present during most hospital applications where a washbowl is required, act to break down the pulp material upon contact, leading to ruptures and leaks.
  • a spray 22 is provided that is configured to spray a barrier coating onto the washbowl.
  • the surface barrier coating may comprise any barrier coating for a pulp product, and preferably from the group of surface barriers including a fluorocarbons, aqueous starch solutions, protein solutions, styrene based polymers, styrene acrylate based polymers, styrene butadiene polymers, non-ionic acryl polymer, ammonia salt of modified acrylic copolymers, proteins, or cellulose derivatives, acrylic resins, styrene- acrylic resins, ethylene-vinyl acetate resins, styrene-butadiene rubber resins, polyvinyl alcohol resins, vinylidene chloride resins, waxes, fluorine resins, silicone resins, and copolymers and polyblends of these resins.
  • a surface coating solution is provided containing a fluorocarbon as an active ingredient.
  • the spray 22 is used to apply a coating of surfactant proofing fluorocarbon solution to the inner surface 10 of the washbowl 8 while it is held on the transfer tool 14.
  • the inner surface 10 of the washbowl 8 defines the liquid containing volume of the washbowl 8 and is the surface in immediate contact with the liquid contained by the washbowl. Therefore, providing the inner surface 10 is surfactant proofed, the remaining body of the washbowl 8 is protected from degradation.
  • the 'rough' outer surface 12 of the washbowl may be coating with the surfactant proofing solution by spraying the outer surface 12 of the washbowl 8 while it is still retained on the mould tool 2.
  • this spraying stage is conducted after the pulp layer 8 has been dewatered.
  • a common spray 22 may be used to spray both the inner surface 10 and outer surface 12.
  • a separate spray bar (not shown) may be positioned above the moulding tool for spraying the pul p layer 8 following dewatering and prior to transfer.
  • a sizing agent to the pulp slurry ensures that when the surfactant proofing solution is sprayed onto the surface of the washbowl 8 a film is created by preventing penetration and ensuring that it is not drawn into the pulp. I nstead the surfactant proofing solution remains on the surface and forms a surfactant proof film during the drying stage. This maximises the concentration of the surfactant proofing material at the surface of the washbowl providing a dense surface film.
  • the fluorochemical is both hydrophobic and lipo/oliophobic and as such both waterproofs and provides surfactant resistance.
  • a sizing agent may not be required, although the addition of the sizing agent would still assist in floating the sprayed fluorochemical layer on the surface creating the surface film.
  • the above barrier coatings are described as being applied to a pulp product including a sizing agent, the invention is not limited to this combination a nd it is contemplated that the above described coatings may alternatively be applied to a pul p that does not include a sizing agent.
  • the mould tool 2 is described as being a male tool, with the transfer tool 14 being a corresponding female tool, in an alternative arrangement the mould tool may be a female 2, with the transfer tool 14 being a corresponding male tool.
  • the inner surface of the washbowl which means the inner surface of the washbowl in use rather than relative to the mould tool
  • the spraying is conducted while the washbowl is retained on the mould tool during which time the inner surface of the washbowl is outwardly facing away from the surface of the mould tool.
  • the outer surface of the washbowl is to be sprayed then this is done while the washbowl is retained on the transfer tool.
  • the spray is applied to the pulp object 8 when it is held on the transfer tool.
  • the relatively high vacuum force applied by the mould tool 2 may act to draw the surfactant proof solution into the pulp material, thereby reducing the surface concentration and hence the efficacy of the surface film and/or requiring the spraying of additional chemical solution to counter absorption.
  • the vacuum force of the transfer tool is of a low enough level to avoid such action.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Paper (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un objet en pâte moulé, qui comprend la fourniture d'une suspension de pâte, contenant des fibres de pâte dans une suspension aqueuse ; la formation d'une couche de pâte (6) sur la surface d'un outil (2) de moule, afin de créer un objet en pâte moulé en trois dimensions ayant une première surface (10) faisant face vers l'intérieur, en contact avec l'outil de moule, et une seconde surface (12) faisant face vers l'extérieur depuis l'outil (2) de moule ; puis l'application d'un revêtement résistant aux tensioactifs sur l'objet en pâte moulé en trois dimensions, une fois qu'il a été formé sur l'outil (2) de moule. Le revêtement résistant aux tensioactifs peut être appliqué tandis que l'objet en pâte est retenu sur l'outil (2) de moule, pendant que l'objet en pâte est maintenu sur l'outil (14) de transfert ou lorsque l'objet en pâte est situé sur le transporteur (18) de séchage.
PCT/GB2014/052360 2013-08-07 2014-07-31 Procédé de fabrication d'un objet en pâte moulé Ceased WO2015019061A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1314115.5 2013-08-07
GB1314115.5A GB2519059B (en) 2013-08-07 2013-08-07 A method of manufacturing a moulded pulp object

Publications (1)

Publication Number Publication Date
WO2015019061A1 true WO2015019061A1 (fr) 2015-02-12

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WO (1) WO2015019061A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017168152A1 (fr) * 2016-03-29 2017-10-05 Hpc Healthline Uk Limited Récipient jetable pour instruments chirurgicaux
WO2018117816A1 (fr) * 2016-12-22 2018-06-28 Land Life Company B.V. Procédé de préparation d'un produit de pâte biodégradable
CN112779821A (zh) * 2019-11-11 2021-05-11 祖美股份有限公司 利用流体修整操作的模制纤维产品生产线
CN112878104A (zh) * 2021-01-11 2021-06-01 王道玲 一种纸浆模塑产品辅助用剂的喷施方法
CN112941972A (zh) * 2021-02-18 2021-06-11 古翊君 一种纸托加工方法及其应用
EP3985170A1 (fr) * 2020-10-19 2022-04-20 Valmet Technologies Oy Moule pour la fabrication d'un produit fibreux moulé
WO2022218772A1 (fr) 2021-04-12 2022-10-20 Stora Enso Oyj Structure de fibre de cellulose comprenant une couche barrière
CN117265917A (zh) * 2023-11-08 2023-12-22 山东智沃机械设备有限公司 一种植物纤维纸浆模塑与改性淀粉混合模压餐具生产工艺

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2532409A (en) * 2014-09-29 2016-05-25 Hpc Healthline Uk Ltd A disposable commode pan
US11654600B2 (en) * 2016-07-26 2023-05-23 Footprint International, Inc. Methods, apparatus, and chemical compositions for selectively coating fiber-based food containers
CN106012693A (zh) * 2016-07-26 2016-10-12 永发（上海）模塑科技发展有限公司江苏分公司 尺寸稳定的镀层模具及其镀层工艺
US11939129B2 (en) 2016-07-26 2024-03-26 Footprint International, LLC Methods and apparatus for manufacturing high-strength fiber-based beverage holders

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EP0731214A2 (fr) * 1995-03-07 1996-09-11 Rexam Corrugated South West Limited Objets moulés en pâte à papier
US20060048909A1 (en) * 2004-09-08 2006-03-09 Chi-Yee Yeh Paper pulp mold packing structure of frozen foods for oven and method of producing the same
WO2006057610A2 (fr) * 2004-11-26 2006-06-01 Pakit International Trading Company Inc Procede et machine de fabrication de produits fibreux a partir d'une composition de fabrication et nouveau type de produit fibreux
US7370788B1 (en) * 1998-12-28 2008-05-13 Kao Corporation Formed body
WO2011065911A1 (fr) * 2009-11-27 2011-06-03 Pakit International Trading Company Inc. Procédé d'application d'une barrière sur un produit fibreux moulé et produit obtenu par ledit procédé

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EP0642726B1 (fr) * 1992-05-27 1998-11-25 CONAGRA, Inc. Bac a aliments et analogue, comprenant des revetements appliques par pression
FR2812643B1 (fr) * 2000-08-07 2002-09-13 Atofina Nouveaux copolymeres fluores, leur utilisation pour le revetement et l'impregnation de substrats, et les substrats ainsi traites
GB2439947B8 (en) * 2006-07-31 2021-08-18 Vernacare Ltd Washbowl formed from paper pulp composition

Patent Citations (5)

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Publication number Priority date Publication date Assignee Title
EP0731214A2 (fr) * 1995-03-07 1996-09-11 Rexam Corrugated South West Limited Objets moulés en pâte à papier
US7370788B1 (en) * 1998-12-28 2008-05-13 Kao Corporation Formed body
US20060048909A1 (en) * 2004-09-08 2006-03-09 Chi-Yee Yeh Paper pulp mold packing structure of frozen foods for oven and method of producing the same
WO2006057610A2 (fr) * 2004-11-26 2006-06-01 Pakit International Trading Company Inc Procede et machine de fabrication de produits fibreux a partir d'une composition de fabrication et nouveau type de produit fibreux
WO2011065911A1 (fr) * 2009-11-27 2011-06-03 Pakit International Trading Company Inc. Procédé d'application d'une barrière sur un produit fibreux moulé et produit obtenu par ledit procédé

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11109935B2 (en) 2016-03-29 2021-09-07 Hpc Healthline Uk Limited Disposable container for surgical instruments
WO2017168152A1 (fr) * 2016-03-29 2017-10-05 Hpc Healthline Uk Limited Récipient jetable pour instruments chirurgicaux
WO2018117816A1 (fr) * 2016-12-22 2018-06-28 Land Life Company B.V. Procédé de préparation d'un produit de pâte biodégradable
NL2018041B1 (en) * 2016-12-22 2018-06-28 Land Life Company B V Process to prepare a biodegradable pulp product
CN112779821A (zh) * 2019-11-11 2021-05-11 祖美股份有限公司 利用流体修整操作的模制纤维产品生产线
US12325158B2 (en) 2019-11-11 2025-06-10 Congruens Group, Llc Molded fiber product production line utilizing fluid trim operation
US12330350B2 (en) 2019-11-11 2025-06-17 Congruens Group, Llc Molded fiber product production line utilizing fluid trim operation
EP3985170A1 (fr) * 2020-10-19 2022-04-20 Valmet Technologies Oy Moule pour la fabrication d'un produit fibreux moulé
CN114438830A (zh) * 2020-10-19 2022-05-06 维美德技术有限公司 用于制造模制纤维产品的模具
CN114438830B (zh) * 2020-10-19 2024-05-10 维美德技术有限公司 用于制造模制纤维产品的模具
CN112878104A (zh) * 2021-01-11 2021-06-01 王道玲 一种纸浆模塑产品辅助用剂的喷施方法
CN112941972A (zh) * 2021-02-18 2021-06-11 古翊君 一种纸托加工方法及其应用
WO2022218772A1 (fr) 2021-04-12 2022-10-20 Stora Enso Oyj Structure de fibre de cellulose comprenant une couche barrière
CN117265917A (zh) * 2023-11-08 2023-12-22 山东智沃机械设备有限公司 一种植物纤维纸浆模塑与改性淀粉混合模压餐具生产工艺

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GB2519059B (en) 2017-07-05
GB201314115D0 (en) 2013-09-18
GB2519059A (en) 2015-04-15

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