Patent Description:
From <CIT> there is known a method of producing products from a pulp slurry by applying the slurry layer to a porous mold and removing water from the slurry by simultaneously heating and pressing the slurry layer while drawing a vacuum through a mold wall, the other side of which being in contact with the slurry layer.

As is disclosed in <CIT>, the molding process may be performed in two or more successive pressing steps, which is advantageous as it shortens cycle time and thus increases the throughput of the production process, as compared to a process with a single pressing step.

In addition to increasing throughput, it is desirable to provide a process which is energy efficient as well.

<CIT> discloses a pulp molding process comprising a pulp-dredging step, a first pre-compression forming step, a second pre-compression forming step, a compression thermo-forming step and an edge-cutting step.

<CIT> relates to a method for producing a fibre product from stock.

An object of the present disclosure is to provide a more energy efficient method of producing products from pulp slurry.

The invention is defined by the appended independent claims, with embodiments being set forth in the appended dependent claims, in the following description and in the attached drawings.

According to a first aspect, there is provided a method of producing a 3D molded product from a pulp slurry, comprising applying a pulp slurry layer to a porous forming face of a first mold, in a first forming step, pressing the pulp slurry layer against the porous forming face of the first mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the first mold, transferring the pulp slurry layer to a porous forming face of a second mold, in a second, subsequent, forming step, pressing the pulp slurry layer against the porous forming face of the second mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the second mold. In the method, a first pressure at the rear side of the forming face of the first mold is lower than a second pressure at the rear side of the forming face of the second mold.

That is, the pressure provided at the rear sides of the forming faces during the pickup and pressing steps is lower than ambient pressure. Hence, the pressure can be seen as a vacuum.

Each mold may comprise at least two interacting mold parts, which are pressed towards each other and at least one of which presents the porous forming face. Some mold parts, or portions of a mold part, may have a nonporous surface, e.g. such portions where a specific surface structure is desired.

The invention is based on the understanding that a lower vacuum level is required in the second forming step than in the first forming step, which allows a saving of energy. This saving may be significant, as a substantial amount of energy is consumed by the vacuum equipment.

The first pressure may be <NUM>-<NUM> % of the second pressure, preferably <NUM>-<NUM> % or <NUM>-<NUM> %. Optionally, the first pressure may be <NUM>-<NUM> % of the second pressure, or even <NUM>-<NUM> % of the second pressure.

The first pressure may be <NUM>-<NUM> mbarA (millibar absolute), preferably <NUM>-<NUM> mbarA.

The first pressure may be <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, or <NUM>-<NUM> mbarA.

The drawing of vacuum through the porous forming face of the first mold may be initiated before the pressing of the pulp slurry layer against the porous forming face of the first mold is initiated.

Initiation of vacuum through the porous forming face of the mold is deemed to be initiated at the time when an underpressure, i.e. an air pressure lower than that present at the forming face is formed at the rear face of the porous forming face.

Initiation of the pressing of the pulp slurry layer against the porous forming face of the first mold part of the first mold is deemed to be initiated at first contact of the other mold part of the first mold with the pulp slurry layer.

The drawing of vacuum through the porous forming face may be initiated <NUM>-<NUM> second before the pressing of the pulp layer against the porous forming face of the first mold is initiated.

The vacuum may be drawn through the porous forming face of the first mold during a first vacuum suction time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second, more preferably <NUM>-<NUM> second.

In the first forming step, the forming face of the first mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or <NUM>-<NUM>.

In the first forming step, the pulp slurry layer may be pressed against the forming face of the first mold with a pressure of about <NUM>-<NUM> kPa, preferably <NUM>-<NUM> kPa.

In the first forming step, the pulp slurry layer may be pressed against the forming face of the first mold during a first pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second.

In the first forming step, an initial water content of the pulp slurry layer may be <NUM>-<NUM> % by weight and a final water content may be <NUM>-<NUM> % by weight, preferably about <NUM>-<NUM> % by weight.

The initial water content is taken when the pulp slurry layer is introduced into the first mold. The final water content is taken when the pulp slurry layer is removed from the first mold.

A second pressure may be <NUM>-<NUM> mbarA, preferably <NUM>-<NUM> mbarA.

The second pressure may be <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA or <NUM>-<NUM> mbarA. The drawing of vacuum through the porous forming face of the second mold may be initiated before the pressing of the pulp slurry layer against the porous forming face of the second mold is initiated.

Initiation of the pressing of the pulp slurry layer against the porous forming face of the first mold part of the second mold is deemed to be initiated at first contact of the other mold part of the second mold with the pulp slurry layer.

The drawing of vacuum through the porous forming face may be initiated <NUM>-<NUM> second before the pressing of the pulp layer against the porous forming face of the second mold is initiated.

The vacuum may be drawn through the porous forming face of the second mold during a second vacuum suction time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second, more preferably <NUM>-<NUM> second.

In the second forming step, the forming face of the second mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or <NUM>-<NUM>.

In the second forming step, the pulp slurry layer may be pressed against the forming face of the second mold with a pressure of about <NUM>-<NUM> kPa, preferably <NUM>-<NUM> kPa.

In the second forming step, the pulp slurry layer may be pressed against the forming face of the second mold during a second pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second.

In the second forming step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight, by weight and a final water content may be about <NUM>-<NUM> % by weight, preferably about <NUM>-<NUM> % by weight.

The method may further comprise transferring the pulp slurry layer to a porous forming face of a third mold, and in a third, subsequent, forming step, pressing the pulp slurry layer against the porous forming face of the third mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the third mold thereby providing a third pressure at the rear side of the porous forming face of the third mold, wherein the second pressure is greater than the third pressure.

The third pressure may be <NUM>-<NUM> mbarA, preferably <NUM>-<NUM> mbarA.

The third pressure may be <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA or <NUM>-<NUM> mbarA.

The drawing of vacuum through the porous forming face of the third mold may be initiated before the pressing of the pulp slurry layer against the porous forming face of the third mold is initiated.

Initiation of the pressing of the pulp slurry layer against the porous forming face of the first mold part of the third mold is deemed to be initiated at first contact of the other mold part of the third mold with the pulp slurry layer.

The drawing of vacuum through the porous forming face may be initiated <NUM>-<NUM> second before the pressing of the pulp layer against the porous forming face of the third mold is initiated.

The vacuum may be drawn through the porous forming face of the third mold during a third vacuum suction time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second, more preferably <NUM>-<NUM> second.

The second pressure may be <NUM>-<NUM> % of the third pressure, preferably <NUM>-<NUM> % or <NUM>-<NUM> %. Optionally, the second pressure may be <NUM>-<NUM> % of the third pressure, or even <NUM>-<NUM> % of the third pressure.

The forming face of the third mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>.

In the third forming step, the pulp slurry layer may be pressed against the forming face of the third mold with a pressure of about <NUM>-<NUM> kPa, preferably <NUM>-<NUM> kPa.

In the third forming step, the pulp slurry layer may be pressed against the forming face of the third mold during a third pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second.

In the third forming step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> % or <NUM>-<NUM> % by weight, preferably about <NUM>-<NUM> % or <NUM>-<NUM> % by weight, and a final water content may be less than about <NUM> % by weight, preferably less than about <NUM> % by weight.

In one embodiment, in the first forming step, an initial water content of the pulp slurry layer may be <NUM>-<NUM> % by weight and a final water content may be <NUM>-<NUM>% by weight, preferably about <NUM>-<NUM> % by weight.

In the second forming step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight, and a final water content may be less than about <NUM> % by weight, preferably less than about <NUM> % by weight.

In one embodiment, said applying a pulp slurry layer to a porous forming face of a first mold may be preceded by a step of applying a pulp slurry comprising <NUM>-<NUM> % water to a porous forming face of a pickup mold, and drawing a vacuum through the porous forming face of the pickup mold to form the pulp slurry layer.

After drawing a vacuum through the porous forming face of the pickup mold, a final water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight.

A suction flow rate through the porous forming face of the pickup mold, during the drawing of a vacuum through the porous forming face of the pickup mold to form the pulp slurry layer from the pulp slurry, may be <NUM>-<NUM> /sec per square meter of the porous forming face, preferably <NUM>-<NUM> /sec per square meter of the porous forming face.

Consequently, the total amount of water drawn through the porous forming face of the pickup mold may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

It is understood that the suction flow rate may vary depending on type of product molded.

It is further understood that the suction flow rate may vary between different portions of the porous forming face presenting varying porosity.

A suction flow rate through the porous forming face of the pickup mold, during the drawing of a vacuum through the porous forming face of the pickup mold to form the pulp slurry layer from the pulp slurry, may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM> /sec per square meter of the porous forming face.

In the first forming step, a suction flow rate through the porous forming face of the first mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the pickup mold during the drawing of a vacuum through the porous forming face of the pickup mold to form the pulp slurry layer from the pulp slurry, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the pickup mold during the drawing of a vacuum through the porous forming face of the pickup mold to form the pulp slurry layer from the pulp slurry.

In another embodiment, said applying a pulp slurry layer to a porous forming face of a first mold comprises applying a pulp slurry comprising <NUM>-<NUM> % water to the porous forming face of the first mold, and drawing a vacuum through the porous forming face of the first mold to form the pulp slurry layer.

A final water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight.

A suction flow rate through the porous forming face of the first mold, during the drawing of a vacuum through the porous forming face of the first mold to form the pulp slurry layer from the pulp slurry, may be <NUM>-<NUM> /sec per square meter of the porous forming face, preferably <NUM>-<NUM> /sec per square meter of the porous forming face.

Consequently, the total amount of water drawn through the porous forming face of the first mold may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

A suction flow rate through the porous forming face of the first mold, during the drawing of a vacuum through the porous forming face of the first mold to form the pulp slurry layer from the pulp slurry, may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM> /sec per square meter of the porous forming face.

In the first forming step, a suction flow rate through the porous forming face of the first mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold during the drawing of a vacuum through the porous forming face of the first mold to form the pulp slurry layer from the pulp slurry, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold during the drawing of a vacuum through the porous forming face of the first mold to form the pulp slurry layer from the pulp slurry.

According to any one of the embodiments, in the first forming step, a suction flow rate through the porous forming face of the first mold may be <NUM>-<NUM> /sec per square meter of the porous forming face, preferably <NUM>-<NUM> /sec per square meter of the porous forming face.

Consequently, in the first forming step, the total amount of water drawn through the porous forming face of the first mold may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

In the first forming step, a suction flow rate through the porous forming face of the first mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM> /sec per square meter of the porous forming face.

In the second forming step, a suction flow rate through the porous forming face of the second mold may be <NUM>-<NUM>/sec per square meter of the porous forming face, preferably <NUM>-<NUM>/sec per square meter of the porous forming face.

Consequently, in the second forming step, the total amount of water drawn through the porous forming face of the second mold may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

In the second forming step, a suction flow rate through the porous forming face of the second mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

In the second forming step, a suction flow rate through the porous forming face of the second mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold in the first forming step, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold in the first forming step.

In the third forming step, a suction flow rate through the porous forming face of the third mold may be <NUM>-<NUM>/sec per square meter of the porous forming face, preferably <NUM>-<NUM>/sec per square meter of the porous forming face.

Consequently, in the third forming step, the total amount of water drawn through the porous forming face of the third mold may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

In the third forming step, a suction flow rate through the porous forming face of the third mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

In the third forming step, a suction flow rate through the porous forming face of the third mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the second mold in the second forming step, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the second mold in the second forming step.

<FIG> schematically illustrates a pickup tool <NUM> which is partially immersed in container <NUM> holding a pulp slurry <NUM>. The pickup tool is mounted to a tool holder <NUM>, which together with the pickup tool defines a vacuum chamber <NUM> that is connected to a pressure regulator P1. The pressure regulator may have the capability of selectively generating an at least partial vacuum (i.e. air pressure lower than ambient air pressure) and/or an air pressure greater than ambient air pressure.

While the pickup tool is immersed in the pulp slurry <NUM>, the pressure regulator P1 may generate a vacuum, causing pulp fibers <NUM> to stick to a product face of the pickup tool <NUM>.

<FIG> schematically illustrates the pickup tool <NUM> transferring the pulp fibers <NUM> to a transfer tool <NUM>. The transfer tool may be connected to a second pressure regulator P2, which is capable of generating a vacuum or an air pressure. The transfer tool may also be mounted on a transfer tool holder <NUM> so as to define a vacuum chamber <NUM>, which is connected to the second pressure regulator.

During the transfer of the pulp fibers <NUM> from the pickup tool to the transfer tool, an air pressure greater than ambient pressure may be generated by the first pressure regulator P1 to cause the pulp fibers to release from the pickup tool.

Alternatively, or as a supplement, a vacuum may be generated by the second pressure regulator P2, causing the pulp fibers to be received by the transfer tool <NUM>.

<FIG> schematically illustrates a pressing arrangement comprising a male pressing tool <NUM> and a female pressing tool <NUM>. One, or both, of the pressing tools may be mounted on a respective tool holder <NUM>, <NUM> and be connected to a respective vacuum chamber <NUM>, <NUM>. The vacuum chambers may be connected to a respective pressure regulator P3, P4.

One, or both, of the pressing tools may be provided with a heating element <NUM>, <NUM>, energized by an energy supply E1, E2 and optionally controlled by a controller C. The heating may be achieved by electric heating elements, hot air or liquid or induction.

The pressing tools and their associated tool holders may be movable relative one another between an open position, wherein a partially molded pulp product may be inserted, and a pressing position, wherein the pressing tools are forced towards each other thus pressing the product <NUM>" between product faces of the respective tool <NUM>, <NUM>.

When in the pressing position, heat may be supplied by one, or both, of the heaters <NUM>, <NUM>.

During the pressing step, one or both pressure regulators P3, P4 may provide a vacuum to assist in the evacuation of water vapor from the product <NUM>".

As an alternative, one of the pressure regulators may provide a vacuum while the other one provides a pressure greater than the ambient air pressure.

Optionally, hot air or steam may be introduced through the molds during the pressing process (<FIG>).

It is noted that two or more successive pressing steps may be used, e.g. to gradually form all or parts of the product <NUM>" and/or to apply additional features to the product, such as coatings, décors and the like.

In one embodiment, steps are performed in accordance with what has been described with respect to <FIG>.

Referring to <FIG>, a production process will now be described.

In a first step <NUM>, a pulp slurry layer is provided, e.g. as described with reference to <FIG>, wherein a porous pickup tool may be submerged in a pulp slurry with vacuum being applied to a rear side of the pickup tool.

Alternatively, the pulp slurry may be applied to the pickup tool by a coating operation, such as spray coating.

The porous wall portion of the pickup tool may have a surface porosity of <NUM>-<NUM> % with hole sizes <NUM>-<NUM> in diameter, preferably <NUM>-<NUM>.

In a second step <NUM>, the pulp slurry layer is transferred from the pickup tool to a first press tool. The transfer may be performed by the pickup tool, or by means of a separate transfer tool, which may have a transfer tool wall portion that is porous. During the transfer step, a vacuum may be applied to the rear side of the transferring tool wall, such that the pulp slurry layer is held to the transferring tool wall. In order to release the pulp slurry layer from the transferring tool wall, it is possible to instead apply pressurized air to the rear side of the transferring tool wall.

Alternatively, the pulp slurry layer may be applied directly to the first press tool. That is, the pulp slurry layer may be formed directly on the first press tool by application of the pulp slurry to the porous forming face of the first press tool. The pulp slurry layer may be applied directly to the first press tool by submerging a tool part of the first press tool, presenting a porous wall portion, in a pulp slurry with vacuum being applied to a rear side of the porous wall portion. Alternatively, the pulp slurry may be applied to the porous forming face of the first press tool by a coating operation, such as spray coating.

Applying the pulp slurry layer to the first press tool may be preceded by forming of the pulp slurry layer from the pulp slurry. For example, a pulp slurry comprising <NUM>-<NUM> % water may be applied to a porous forming face of the pickup tool as described above. Further, a vacuum may be drawn through the porous forming face of the pickup tool to form the pulp slurry layer. After the drawing of vacuum through the pickup tool, a final water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight.

A suction flow rate through the porous forming face of the pickup tool during the forming of the pulp slurry layer from the pulp slurry may be <NUM>-<NUM>/sec per square meter of the porous forming face, preferably <NUM>-<NUM>/sec per square meter of the porous forming face.

A suction flow rate through the porous forming face of the porous pickup tool during the forming of the pulp slurry layer from the pulp slurry may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

Consequently, a total amount of water drawn through the porous forming face of the porous pickup tool during the forming may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

It is understood that the suction flow rate may vary depending on type of product molded. It is further understood that the suction flow rate may vary between different portions of the porous forming face presenting varying porosity.

As an alternative to forming the pulp slurry layer before applying the pulp slurry layer to the first press tool, forming the pulp slurry layer may be performed during and/or after applying the pulp slurry layer to the first press tool. For example, a pulp slurry comprising <NUM>-<NUM> % water may be applied directly to a porous forming face of the first press tool as described above. That is, the pulp slurry layer may be formed directly on the first press tool by application of the pulp slurry to the porous forming face of the first press tool.

Further, a vacuum may be drawn through the porous forming face of the first press tool to form the pulp slurry layer. After the drawing of vacuum through the first press tool, a final water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight.

A suction flow rate through the porous forming face of the first press tool during the forming of the pulp slurry layer from the pulp slurry may be <NUM>-<NUM>/sec per square meter of the porous forming face, preferably <NUM>-<NUM>/sec per square meter of the porous forming face.

A suction flow rate through the porous forming face of the first press tool during the forming of the pulp slurry layer from the pulp slurry may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

Consequently, a total amount of water drawn through the porous forming face of the first press tool during the forming may be <NUM>-<NUM> liters/second per square meter of the porous forming face.

In a third step <NUM>, the pulp slurry layer may be pressed in the first press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn.

In this first pressing step <NUM>, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thus resulting in a vacuum at the rear side of the porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool. The porous wall portion of the first forming tool may have a surface porosity of <NUM>-<NUM> % with hole sizes <NUM>-<NUM>, preferably <NUM>-<NUM>.

The pressure applied to the rear side of the porous wall portion may be on the order of low or medium level vacuum. That is, a first pressure may be <NUM>-<NUM> mbarA (millibar absolute), preferably <NUM>-<NUM> mbarA. The first pressure may be <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA or <NUM>-<NUM> mbarA.

In the first pressing step, a suction flow rate through the porous wall portion of the first mold may be <NUM>-<NUM>/sec per square meter of the porous forming face of the first mold, preferably <NUM>-<NUM>/sec per square meter of the porous forming face of the first mold.

In the first pressing step, a suction flow rate through the porous forming face of the first mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

In one embodiment, wherein the pulp slurry layer is picked up by a porous pickup tool and then transferred to the first press tool, a suction flow rate through the porous forming face of the first mold in the first pressing step, may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the porous pickup tool during the drawing of a vacuum through the porous forming face of the pickup tool to form the pulp slurry layer from the pulp slurry, as described above. Preferably, a suction flow rate through the porous forming face of the first mold in the first pressing step may be <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the porous pickup tool during the drawing of a vacuum through the porous forming face of the first mold to form the pulp slurry layer from the pulp slurry.

In another embodiment, wherein the pulp slurry layer is picked up by the first press tool or applied directly to a porous forming face of the first press tool, a suction flow rate through the porous forming face of the first press tool in the first pressing step, may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first press tool during the drawing of a vacuum through the porous forming face of the first press tool to form the pulp slurry layer from the pulp slurry, as described above. Preferably, a suction flow rate through the porous forming face of the first press tool in the first pressing step may be <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first press tool during the drawing of a vacuum through the porous forming face of the first press tool to form the pulp slurry layer from the pulp slurry.

The forming face of the first mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or <NUM>-<NUM>, and in most cases <NUM>-<NUM>. Typically, all mold faces contacting the pulp slurry layer are heated.

A pressing pressure between mold faces may be on the order of about <NUM>-<NUM> kPa, and in most cases <NUM>-<NUM> kPa.

The pressing pressure may be applied during a first pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second. In most settings, a pressing time on the order of <NUM>-<NUM> second is sufficient, and often also <NUM>-<NUM> second.

Typically, in this first step, an initial water content of the pulp slurry layer is <NUM>-<NUM> % by weight and after the pressing step has been performed, a final water content may be <NUM>-<NUM> % by weight, typically about <NUM>-<NUM> % by weight.

After the first pressing step <NUM>, the pulp slurry layer, now with a substantial amount of its solvent removed, may be transferred <NUM> to a second press tool. The transfer <NUM> may be performed in the same manner as the first transfer step <NUM>, and with similar equipment. The second press tool may be designed essentially as the first press tool.

In a second pressing step <NUM>, the pulp slurry layer may be pressed in the second press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn. In this second pressing step <NUM>, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thus resulting in a vacuum at the rear side of the porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool.

The porous wall portion of the second forming tool may have a surface porosity of <NUM>-<NUM> % with hole sizes <NUM>-<NUM>, preferably <NUM>-<NUM>.

However, in the second pressing step <NUM>, the pressure applied at to the rear side of the porous wall portion may be higher than that provided in the first pressing step <NUM>.

In particular, the pressure provided in the first pressing step <NUM> may be <NUM>-<NUM> % of that provided in the second pressing step <NUM>, preferably <NUM>-<NUM> %, <NUM>-<NUM> %, <NUM>-<NUM> % or <NUM>-<NUM> %.

In the second pressing step, the absolute pressure applied to the rear side of the porous forming face of the second mold may be <NUM>-<NUM> mbarA, preferably <NUM>-<NUM> mbarA, but always greater than in the first pressing step.

The second pressure may be <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA, <NUM>-<NUM> mbarA or <NUM>-<NUM> mbarA.

The drawing of vacuum through the porous forming face of the second mold may be initiated before the pressing of the pulp slurry layer against the porous forming face of the second mold is initiated.

In the second pressing step, a suction flow rate through the porous wall portion of the second mold may be <NUM>-<NUM>/sec per square meter of the porous forming face of the second mold, preferably <NUM>-<NUM>/sec per square meter of the porous forming face of the second mold.

A suction flow rate through the porous forming face of the second mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

In the second pressing step, a suction flow rate through the porous forming face of the second mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold in the first pressing step, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the first mold in the first pressing step.

The forming face of the second mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or <NUM>-<NUM>, and in most cases <NUM>-<NUM>. Typically, all mold faces making up the second mold and contacting the pulp slurry layer may be heated.

The pressing pressure may be applied during a second pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second. In most settings, a pressing time on the order of <NUM>-<NUM> second is sufficient, and often also <NUM>-<NUM> second.

Typically, in this second pressing step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> %, typically about <NUM>-<NUM> % by weight.

A final water content may be about <NUM>-<NUM> % by weight, preferably about <NUM>-<NUM> % by weight.

After the second pressing step <NUM>, the pulp slurry layer, now with a substantial amount of its solvent removed, may be transferred <NUM> to a third press tool. The transfer <NUM> may be performed in the same manner as the first transfer step <NUM> and/or the second transfer step <NUM>, and with similar equipment. The third press tool may be designed essentially as the first press tool.

In a third pressing step <NUM>, the pulp slurry layer may be pressed in the third press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn. In this third pressing step <NUM>, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thus resulting in a vacuum at the rear side of the porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool.

The porous wall portion of the third forming tool may have a surface porosity of <NUM>-<NUM> % with hole sizes <NUM>-<NUM>, preferably <NUM>-<NUM>.

However, in the third pressing step <NUM>, the pressure applied at to the rear side of the porous wall portion may be higher than that provided in the second pressing step <NUM>.

In particular, the pressure provided in the second pressing step <NUM> may be <NUM>-<NUM> % of that provided in the third pressing step <NUM>, preferably <NUM>-<NUM> %, <NUM>-<NUM> %, <NUM>-<NUM> % or <NUM>-<NUM> %.

In the third pressing step, an absolute pressure provided at the rear of the porous wall portion of the third mold may be <NUM>-<NUM> mbarA, preferably <NUM>-<NUM> mbarA, but always greater than in the second pressing step.

In the third pressing step, a suction flow rate through the porous wall portion of the third mold may be <NUM>-<NUM>/sec per square meter of the porous forming face of the third mold, preferably <NUM>-<NUM>/sec per square meter of the porous forming face of the third mold.

A suction flow rate through the porous forming face of the third mold may be <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, <NUM>-<NUM>/sec, or <NUM>-<NUM>/sec per square meter of the porous forming face.

In the third pressing step, a suction flow rate through the porous forming face of the third mold may be <NUM>-<NUM> % of a suction flow rate through the porous forming face of the second mold in the second pressing step, preferably <NUM>-<NUM> % or <NUM>-<NUM> % of a suction flow rate through the porous forming face of the second mold in the second pressing step.

The forming face of the third mold may be heated to about <NUM>-<NUM>, preferably <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or <NUM>-<NUM>, and in most cases <NUM>-<NUM>. Typically, all mold faces making up the third mold and contacting the pulp slurry layer may be heated.

The pressing pressure may be applied during a third pressing time of <NUM>-<NUM> second, preferably <NUM>-<NUM> second. In most settings, a pressing time on the order of <NUM>-<NUM> second is sufficient, and often also <NUM>-<NUM> second.

Typically, in this third pressing step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> % or <NUM>-<NUM> % by weight, preferably about <NUM>-<NUM> % or <NUM>-<NUM> % by weight, and a final water content may be less than about <NUM> % by weight, preferably less than about <NUM> % by weight.

After the third pressing step <NUM>, the pulp slurry layer, now with most of its solvent removed, may be transferred <NUM> out of the machine.

Optionally, additional steps, such as surface treatment, cutting or printing may be performed on the thus essentially dry product. The product may then be packaged, stored and shipped.

It is noted that the third pressing step <NUM>, and thus also its related transfer step <NUM>, is optional. Hence, the process may be finished after the second pressing step <NUM> with the output step <NUM> following immediately.

Thus, in the first pressing step, an initial water content of the pulp slurry layer may be <NUM>-<NUM> % by weight and a final water content may be <NUM>-<NUM>% by weight, preferably about <NUM>-<NUM> % by weight.

In the second pressing step, an initial water content of the pulp slurry layer may be about <NUM>-<NUM> %, preferably about <NUM>-<NUM> % by weight, and a final water content may be less than about <NUM> % by weight, preferably less than about <NUM> % by weight.

In a specific example, a <NUM> pulp tray, of the kind used to package meat, was produced. A pickup tool comprising a porous pickup mold was submerged into an <NUM>-<NUM> % by weight European white birch pulp slurry for <NUM>-<NUM> seconds. An absolute pressure of <NUM>-<NUM> mbarA was applied to the rear side of the pickup tool.

The pulp slurry layer thus picked up was lifted off the pickup tool using a first transfer tool having a porous mold to the rear side of which a vacuum of <NUM> mbarA was applied. The pulp slurry layer was transferred to a first press mold.

In the first press mold, the pulp slurry layer was subjected to a pressing pressure of <NUM> kPa during <NUM> second, while the porous forming faces were heated to <NUM> and a vacuum level of <NUM> mbarA was applied to the rear side of the porous forming faces.

A second transfer tool, similar to the first transfer tool, was used to pick the pulp slurry layer off the first pressing tool and place it onto the second pressing tool. The second transfer tool applied a vacuum of <NUM> mbarA to the rear side of the transfer tool's porous surface, for <NUM> second.

The initial weight of the pulp slurry layer applied onto the first mold forming face was <NUM>. After the first pressing operation, the total weight of the pulp slurry layer was <NUM>.

In the second press mold, the pulp slurry layer was subjected to a pressing pressure of <NUM> kPa during <NUM> second, while the porous forming faces were heated to <NUM> and a vacuum level of <NUM> mbarA was applied to the porous forming faces.

A third transfer tool, similar to the first and second transfer tools, was used to pick the pulp slurry layer off the second pressing tool and place it onto the third pressing tool. The third transfer tool applied a vacuum of <NUM> mbarA to the rear side of the transfer tool's porous surface, for <NUM> second.

The initial weight of the pulp slurry layer applied onto the second mold forming face was <NUM>. After the second pressing operation, the total weight of the pulp slurry layer was <NUM>.

In the third press mold, the pulp slurry layer was subjected to a pressing pressure of <NUM> kPa during <NUM> seconds, while the porous forming faces were heated to <NUM> and a vacuum level of <NUM> mbarA was applied to the porous forming faces.

A fourth transfer tool, similar to the first, second and third transfer tools, was used to pick the pulp slurry layer, which now was essentially finished, off the third pressing tool and place it onto a conveyor belt. The fourth transfer tool applied a vacuum of <NUM> mbarA to the rear side of the transfer tool's porous surface, for <NUM> second.

Claim 1:
A method of producing a 3D molded product from a pulp slurry, comprising:
applying a pulp slurry layer to a porous forming face of a first mold,
in a first forming step (<NUM>), pressing the pulp slurry layer against the porous forming face of the first mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the first mold,
transferring (<NUM>) the pulp slurry layer to a porous forming face of a second mold,
in a second, subsequent, forming step (<NUM>), pressing the pulp slurry layer against the porous forming face of the second mold, while heating the pulp slurry layer and drawing a vacuum through the porous forming face of the second mold,
characterized in that
a first pressure at the rear side of the porous forming face of the first mold is lower than a second pressure at the rear side of the porous forming face of the second mold.