Forming method and forming machine for molded pulp bottle

Abstract

A forming method for a molded pulp bottle includes the steps of: (a) immersing a forming mold in a pulp tank that contains pulp to adsorb the pulp and form at least one bottle preform; (b) separating the forming mold from the pulp tank, followed by sucking the pulp into the chamber of the at least one bottle preform and adsorbing the pulp to an inner surface of the at least one bottle preform through the forming mold; (c) transferring the at least one bottle preform from the forming mold to a transfer platform with the at least one bottle preform being supported by at least one air bag; and (d) moving the at least one bottle preform supported by the transfer platform and the at least one air bag away from the forming mold. A forming machine for implementing the forming method is also disclosed.

What is claimed is: 
     
         1 . A forming method for molded pulp bottle comprising the steps of:
 (a) immersing a forming mold in a pulp tank that contains pulp to adsorb the pulp and form at least one bottle preform, the at least one bottle preform defining a chamber that has an opening extending in a horizontal direction;   (b) separating the forming mold from the pulp tank, followed by sucking the pulp into the chamber of the at least one bottle preform and adsorbing the pulp to an inner surface of the at least one bottle preform through the forming mold;   (c) transferring the at least one bottle preform from the forming mold to a transfer platform in an up-down direction with the at least one bottle preform being supported by at least one air bag; and   (d) moving the at least one bottle preform that is supported by the transfer platform and the at least one air bag away from the forming mold in the horizontal direction.   
     
     
         2 . The forming method as claimed in  claim 1 , wherein step (a) includes the following steps:
 (a1) driving the forming mold to immerse in the pulp tank, the forming mold including a forming upper mold and a forming lower mold engaged to each other and cooperatively defining at least one mold cavity for receiving the pulp and at least one mold opening communicating the at least one mold cavity with the outside and extending in the horizontal direction; and   (a2) adsorbing the pulp to the forming upper mold and the forming lower mold through suction airflow in the forming upper mold and the forming lower mold so as to form the at least one bottle preform.   
     
     
         3 . The forming method as claimed in  claim 2 , wherein step (b) includes the following steps:
 (b1) driving the forming mold to move away from the pulp tank and stopping the suction airflow in the forming mold;   (b2) sucking the pulp into the chamber of the at least one bottle preform through the at least one mold opening;   (b3) adsorbing the pulp to the inner surface of the at least one bottle preform through the suction airflow in the forming upper mold, the forming lower mold, and the at least one bottle preform;   (b4) stopping the suction airflow in the forming lower mold, and continuously sucking the at least one bottle preform through the suction airflow in the forming upper mold; and   (b5) driving the forming upper mold to move away from the forming lower mold in the up-down direction.   
     
     
         4 . The forming method as claimed in  claim 2 , wherein step (c) includes the following steps:
 (c1) driving the transfer platform to move in the horizontal direction to a position between the forming upper mold and the forming lower mold;   (c2) driving the forming upper mold to move down and engage the transfer platform;   (c3) inserting the at least one air bag in a deflated state into the chamber of the at least one bottle preform through the at least one mold opening;   (c4) inflating the at least one air bag to change from the deflated state to an inflated state for supporting the at least one bottle preform together with the transfer platform; and   (c5) driving the forming upper mold to move upwardly so as to separate from the transfer platform.   
     
     
         5 . The forming method as claimed in  claim 2 , wherein step (d) includes the following steps:
 (d1) driving the transfer platform to move in the horizontal direction for moving the at least one bottle preform to a hot pressing zone; and   (d2) driving the at least one air bag in a deflated state and the transfer platform to move away from the at least one bottle preform in the horizontal direction.   
     
     
         6 . A forming machine for implementing the forming method of  claim 1 , comprising:
 a pulp tank configured to contain pulp;   a forming mold including a forming upper mold, and a forming lower mold engageable with said forming upper mold and cooperating with said forming upper mold to define at least one mold cavity for receiving the pulp and at least one mold opening communicating said at least one mold cavity with the outside and extending in a horizontal direction, said forming mold being movable relative to said pulp tank in an up-down direction between a pulp suction position, in which said forming mold is immersed in said pulp tank for adsorbing the pulp to form at least one bottle preform, and a pulp replenishing position, in which said forming mold is remote from said pulp tank; and   at least one pulp replenishing unit including a pulp tube for guiding the flow of the pulp, and at least one plug that is hollow and that is configured to close said at least one mold opening, said at least one pulp replenishing unit being movable relative to said forming mold between a separated position, in which said at least one plug is spaced apart from said forming mold, and a closed position, in which said at least one plug is connected to said at least one mold opening for allowing the pulp to flow from said pulp tube to a chamber of said at least one bottle preform through said at least one plug.   
     
     
         7 . The forming machine as claimed in  claim 6 , wherein said at least one plug includes a plurality of plugs, said pulp tube including a pulp inlet tube section extending in a front-rear direction, a vertical tube section extending downwardly from one end of said pulp inlet tube section into said pulp tank, a pulp outlet tube section parallel to said pulp inlet tube section, and two tube connection sections connected between said pulp inlet tube section and said pulp outlet tube section and communicating with said pulp inlet tube section and said pulp outlet tube section, said pulp inlet tube section being distal to said forming mold, said vertical tube section having a pulp inlet port distal to said one end of said pulp inlet tube section for introducing the pulp, said pulp outlet tube section being adjacent to said forming mold, said plurality of said plugs being connected to and spacedly arranged along a length of said pulp outlet tube section, each of said plugs having a pulp outlet passage hole extending therethrough for outputting the pulp. 
     
     
         8 . The forming machine as claimed in  claim 6 , further comprising a transfer unit which includes a transfer platform, and at least one air bag that is changeable between a deflated state and an inflated state, said transfer platform being movable relative to said forming mold in a front-rear direction between a waiting zone, in which said transfer platform is remote from said forming mold, and a forming zone, in which said transfer platform is located between said forming upper mold and said forming lower mold, and is connectable with said forming upper mold, wherein, when said at least one air bag is in the deflated state, said at least one air bag is insertable into and removable from said chamber of said at least one bottle preform, and when said at least one air bag is in the inflated state, said at least one air bag together with said transfer platform is capable of supporting said at least one bottle preform, and said transfer platform is capable of carrying said at least one bottle preform to move in a direction away from said forming zone. 
     
     
         9 . The forming machine as claimed in  claim 8 , further comprising a machine frame unit that defines said forming zone, a hot pressing zone spaced apart from said forming zone, and said waiting zone located between said forming zone and said hot pressing zone, wherein said pulp tank, said forming mold and said at least one pulp replenishing unit are arranged in said forming zone, said forming mold being movably mounted on said machine frame unit in the up-down direction, said transfer unit being movable relative to said forming mold among said forming zone, said waiting zone, and said hot pressing zone in the front-rear direction. 
     
     
         10 . The forming machine as claimed in  claim 9 , wherein said machine frame unit includes a machine frame, four spaced-apart guide posts extending in the up-down direction and connected to said machine frame, and two rails that are mounted on said machine frame, that are spaced apart from each other in the horizontal direction, and that extend from said forming zone through said waiting zone to said hot pressing zone in the front-rear direction, said guide posts extending through said pulp tank, said forming mold being slidable along said guide posts, said transfer unit being slidable along said rails. 
     
     
         11 . The forming machine as claimed in  claim 10 , wherein each of said rails has a middle rail portion mounted on said machine frame and located in said waiting zone, and a front rail portion located in said forming zone and connected to said forming lower mold, and wherein, when said forming lower mold and said front rail portions of said rails are moved in the up-down direction until said front rail portions are respectively connected to said middle rail portions of said rails, said forming upper mold is driven to move down and engage said transfer platform. 
     
     
         12 . The forming machine as claimed in  claim 10 , further comprising a driving unit which includes two forming cylinders, each of said forming cylinders being mounted on said machine frame, and having a telescopic rod, said telescopic rods of said two forming cylinders being respectively connected to said forming upper mold and said forming lower mold. 
     
     
         13 . The forming machine as claimed in  claim 12 , wherein said driving unit further includes at least one pulp replenishing cylinder mounted on said machine frame and having a telescopic rod connected to said pulp tube. 
     
     
         14 . The forming machine as claimed in  claim 12 , wherein said transfer unit further includes an air bag assembly, said air bag assembly including at least one air tube, and said at least one air bag sleeved on said at least one air tube, said driving unit further including at least one support cylinder that has a telescopic rod connected to said at least one air tube. 
     
     
         15 . The forming machine as claimed in  claim 6 , wherein said forming upper mold defines an upper air chamber located above said at least one mold cavity, and is formed with a plurality of upper passage holes communicating with said at least one mold cavity and said upper air chamber, and an upper connecting port opening through a peripheral wall of said upper air chamber in the horizontal direction and communicating said upper air chamber with the outside, said upper connecting port being located at one end of said upper air chamber that is adjacent to said at least one mold cavity in the up-down direction, and being configured for suction airflow to pass therethrough and suck air and pulp inside said at least one mold cavity such that the air and liquid in the pulp are sucked into said upper air chamber through said upper passage holes and are then discharged out of said upper air chamber through said upper connecting port.