Molded fiber part production lines using trimless forming and pressing molds

Abstract

A method of manufacturing a molded fiber part includes drawing a fiber slurry onto a forming mold to form a partially-formed molded fiber part. The forming mold includes a forming mold reference dimension along a first axis of the partially-formed molded fiber part. The partially-formed molded fiber part is inserted into a press mold. The press mold includes a press mold reference dimension along the first axis of the partially-formed molded fiber part, wherein the press mold reference dimension is greater than the form mold reference dimension. A compressive pressure is applied to the partially-formed molded fiber part with the press mold, so as to expand the partially-formed molded fiber part towards the press mold reference dimension.

What is claimed is: 
     
         1 . A method of manufacturing a molded fiber part, the method comprising:
 drawing a fiber slurry onto a forming mold to form a partially-formed molded fiber part, wherein the forming mold comprises a forming mold reference dimension along a first axis of the partially-formed molded fiber part;   inserting the partially-formed molded fiber part into a press mold, wherein the press mold comprises a heating element, and wherein the press mold comprises a press mold target dimension along the first axis of the partially-formed molded fiber part, wherein the press mold target dimension is greater than the form mold reference dimension;   applying a compressive pressure to the partially-formed molded fiber part with the press mold;   applying an elevated temperature to the partially-formed molded fiber part with the heating element, wherein application of the compressive pressure and the elevated temperature expands the partially-formed molded fiber part towards the press mold target dimension and substantially solidifies the partially-formed molded fiber part into the molded fiber part; and   removing the molded fiber part from the press mold.   
     
     
         2 . The method of  claim 1 , wherein drawing the fiber slurry onto the forming mold comprises:
 drawing the fiber slurry to a first depth proximate substantially the entire forming mold; and   drawing the fiber slurry to a second depth proximate a predetermined area of the forming mold, wherein the second depth is greater than the first depth.   
     
     
         3 . The method of  claim 2 , wherein the predetermined area is adjacent an outer edge of the partially-molded fiber part. 
     
     
         4 . The method of  claim 2 , wherein the predetermined area is adjacent an interior feature of the partially-molded fiber part. 
     
     
         5 . The method of  claim 2 , wherein the forming mold comprises a porous surface adjacent the forming mold reference direction, and wherein the porous surface extends away from a lowermost surface of the forming mold, and wherein drawing a fiber slurry onto a forming mold draws the fiber slurry to a depth greater than a depth of the fiber slurry adjacent the lowermost surface. 
     
     
         6 . The method of  claim 1 , wherein a portion of the forming mold adjacent the fiber slurry comprises a porosity greater than a portion of the forming mold distal the fiber slurry. 
     
     
         7 . The method of  claim 1 , wherein drawing the fiber slurry onto the forming mold comprises drawing the fiber slurry onto a screen disposed adjacent the forming mold. 
     
     
         8 . The method of  claim 1 , wherein the press mold target dimension is defined by an outermost extent of the press mold and wherein applying the compressive pressure and the elevated temperature expands the partially-formed molded fiber part to contact the outermost extent of the press mold. 
     
     
         9 . The method of  claim 8 , wherein the contact between the partially-molded fiber part and the outermost extent of the press mold is about substantially the entire perimeter of the press mold. 
     
     
         10 . The method of  claim 1 , wherein the contact is characterized by an absence of fiber feathering.