Method for producing molded parts from fiber material, which fiber material is degradable in an environmentally friendly way

Abstract

The invention relates to a method ( 100 ) for manufacturing molded parts ( 10 ) from biodegradable fiber material ( 11 ) by means of a fiber molding process in a fiber molding system ( 20 ), comprising the following steps of providing ( 110 ) a pulp ( 1 ) as a liquid solution containing a biodegradable fiber material; contacting ( 120 ) a suction tool ( 2 ) with the pulp by placing it on or at least partially dipping it into the pulp, wherein the suction tool comprises a suction head ( 21 ) with a three-dimensionally shaped suction head suction side ( 21 i ), whose shape is adapted to a contour of the subsequent molded part; molding ( 130 ) the molded part by sucking the fiber material onto the suction head suction side ( 21 i ) by means of negative pressure in the suction tool; pre-pressing ( 140 ) the molded part in a pre-pressing station ( 3 ) with a pre-pressing pressure (VD) to reduce a proportion of the liquid solution in the molded part; hot-pressing ( 150 ) the pre-pressed molding at a hot-pressing pressure (HD) for finishing the molded part and for further reducing the proportion of the liquid solution in the molded part in a hot-pressing station ( 4 ); and outputting ( 160 ) the finished molded part ( 10 ). The invention also relates to such a fiber molding system for carrying out the above-mentioned method and to a molded part manufactured by means of such a fiber molding system or by means of such a method.

1 - 47 . (canceled) 
     
     
         48 . A method for manufacturing molded parts from biodegradable fiber material, the method comprising:
 providing a pulp as a liquid solution containing the biodegradable fiber material;   contacting the pulp with a suction head of a suction tool;   creating a formed part by generating negative pressure in the suction tool to draw the biodegradable fiber material into contact with the suction head;   pre-pressing the formed part in a pre-pressing station with a pre-pressing pressure to create a pre-pressed molded part; and   hot-pressing the pre-pressed molded part with a hot-pressing pressure to create a finished molded part.   
     
     
         49 . The method of  claim 48 , further comprising:
 subsequent to the pre-pressing the formed part, transferring the pre-pressed molded part to a hot-pressing station using the suction tool, wherein the pre-pressed molded part is removed from the suction tool prior to the hot-pressing.   
     
     
         50 . The method of  claim 48 , wherein the contacting the suction tool with the pulp includes completely submerging the suction head in the pulp. 
     
     
         51 . The method of  claim 48 , wherein the hot-pressing includes:
 inserting the pre-pressed molded part into a hot-pressing lower tool using the suction tool; and   pressing a hot-pressing upper tool onto the hot-pressing lower tool such that the pre-pressed molded part is positioned between the hot-pressing upper tool and the hot-pressing lower tool.   
     
     
         52 . The method of  claim 51 , wherein the hot-pressing is performed at a temperature of at least 150° C., and wherein, during the hot-pressing, the hot-pressing pressure is applied for a pressing time of 20 seconds or less. 
     
     
         53 . The method of  claim 51 , wherein, during the hot-pressing, the hot-pressing upper tool is heated to a higher temperature than the hot-pressing lower tool. 
     
     
         54 . The method of  claim 53 , wherein, during the hot-pressing, a difference in temperature between the hot-pressing upper tool and the hot-pressing lower tool is between 25° C. and 60° C. 
     
     
         55 . The method of  claim 48 , further comprising:
 subsequent to the hot-pressing, applying one or functional layers to the finished molded part.   
     
     
         56 . A method for manufacturing molded parts from biodegradable fiber material, the method comprising:
 providing a pulp as a liquid solution containing the biodegradable fiber material;   contacting a suction tool with the pulp by at least partially dipping the suction tool into the pulp, wherein the suction tool includes a suction head with a three-dimensionally shaped suction side;   creating a formed part by establishing negative pressure in the suction tool to draw the biodegradable fiber material onto the three-dimensionally shaped suction side of the suction head;   pre-pressing the formed part in a pre-pressing station with a pre-pressing pressure to create a pre-pressed molded part; and   hot-pressing the pre-pressed molded part with a hot-pressing pressure to create a finished molded part.   
     
     
         57 . The method of  claim 56 , wherein the formed part is retained on the suction tool during the pre-pressing. 
     
     
         58 . The method of  claim 56 , wherein the pre-pressing includes performing membrane pressing wherein a pre-pressing lower tool includes a membrane, and wherein the pre-pressing pressure is applied to the membrane as gas pressure. 
     
     
         59 . The method of  claim 56 , wherein the pre-pressing is performed at a temperature of 80° C. or less. 
     
     
         60 . The method of  claim 56 , wherein the hot-pressing pressure applied during the hot-pressing is greater than the pre-pressing pressure applied during the pre-pressing. 
     
     
         61 . The method of  claim 60 , wherein the hot-pressing pressure is between 0.5 N/mm 2  and 1.5 N/mm 2 , and wherein the pre-pressing pressure is between 0.2 N/mm 2  and 0.3 N/mm 2 . 
     
     
         62 . A fiber-molding system for producing a molded part from biodegradable fiber material, the fiber-molding system comprising:
 a reservoir configured to hold a pulp as a liquid solution containing the biodegradable fiber material;   a movement unit;   a suction tool mounted on the movement unit, wherein the suction tool includes a suction head, wherein the movement unit is configured to contact the pulp with at least a portion of the suction head, and wherein the suction tool is configured to create a formed part by drawing the biodegradable fiber material into contact with the suction head;   a pre-pressing station for pre-pressing the formed part with a pre-pressing pressure to create a pre-pressed molded part; and   a hot-pressing station configured to hot-press the pre-pressed molded part with a hot-pressing pressure to create a finished molded part.   
     
     
         63 . The fiber-molding system of  claim 62 , wherein a suction side of the suction head is formed from a porous screen, and wherein the suction tool includes a plurality of suction channels distributed around one or more sides of the porous screen. 
     
     
         64 . The fiber-molding system of  claim 63 , wherein the suction channels are arranged in an uneven distribution such that fewer suction channels per surface unit are arranged in a region of one or more edges in the formed part. 
     
     
         65 . The fiber-molding system of  claim 63 , wherein the pre-pressing station includes a pre-pressing lower tool that is configured to receive at least a portion of the suction tool such that, during the pre-pressing, the formed part is positioned between the suction tool and the pre-pressing lower tool and the suction tool is pressed toward the pre-pressing lower tool with the pre-pressing pressure. 
     
     
         66 . The fiber-molding system of  claim 62 , wherein the hot-pressing station includes a hot-pressing lower tool with a hot-pressing side adapted to a contour of the molded part, wherein the hot-pressing lower tool includes one or more channels on the hot-pressing side. 
     
     
         67 . The fiber-molding system of  claim 66 , wherein the hot-pressing station further includes a hot-pressing upper tool that is configured to interface with the hot-pressing lower tool such that, during hot-pressing, the pre-pressed molded part is positioned between the hot-pressing lower tool and the hot-pressing upper tool and the hot-pressing upper tool is pressed towards the hot-pressing lower tool with the hot-pressing pressure.