Patent ID: 6083447
Filing Date: 2000-07-04
Classification: D21J

Abstract:
A method for molding articles from a fibrous slurry comprising fibers and water, the method comprising the steps of:constructing a first forming die for producing a molded article for testing, said forming die having molding surfaces contoured to the same shape as the article to be molded;inserting said first forming die into the fibrous slurry;applying vacuum pressure to provide suction through said first forming die to draw the fibrous slurry against said molding surfaces of said first forming die and to draw water through said first forming die to form a molded article;removing said first forming die from the fibrous slurry;removing said molded article from said first forming die;testing said molded article to determine the shock-absorbing characteristics of said molded article; andusing said first forming die to create a second forming die and repeatedly using said second forming die for producing a plurality of finished products;wherein said first forming die for producing a molded article for testing is made from a water insoluble material comprising a plurality of interconnecting walls which define an open pattern of interconnected cells which join together to form irregular passages extending through said material and sufficiently sized for drawing water from the fibrous slurry through said first forming die, and wherein said porous material can be shaped using hand-powered cutting tools.