A method of making a three-dimensional product, and a blank useful for making a three-dimensional product
AssigneeCampen Machinery A/S
InventorsFlemming KRISTENSEN, Jens Erik Thordahl PETERSEN
Life of this patent
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Abstract
A method of making a three-dimensional product having a bottom and an upright peripheral wall extending from the bottom, by the hot pressing in a pressing cavity of a blank cut out of a web including at least a first layer of a non-woven airlaid fluff material.
Claims26
A method of making a three-dimensional product comprising a bottom and an upright peripheral wall extending from said bottom, by hot pressing in a pressing cavity of a blank cut out of a web comprising a layer of a non-woven airlaid fluff material;
- wherein said non-woven airlaid fluff material comprises:
- natural fibers;
- less than 10 percent by dry weight thermoplastic fibers;
- less than 10 percent by dry weight adhesive;
- and
- less than 2 percent by dry weight of thermosetting resin;
- wherein said blank comprises:
- a first segment configured to define said bottom;
- and
- a plurality of further segments extending from said first segment and configured to define together said upright peripheral wall after said hot pressing, said plurality of further segments each comprising respective opposite edge portions;
- said method comprising:
- reorienting said further segments such that edge portions of neighboring further segments contact each other;
- and
- wherein said hot pressing is selected such that a hydrogen bonding between said natural fibers of said edge portions of neighboring further segments that contact each other results from said hot pressing, to provide said three-dimensional product.
A three-dimensional product comprising a bottom and an upright peripheral wall extending from said bottom, by hot pressing in a pressing cavity of a blank cut out of a web comprising a layer of a non-woven airlaid fluff material;
- wherein said non-woven airlaid fluff material comprises:
- natural fibers;
- less than 10 percent by dry weight thermoplastic fibers;
- less than 10 percent by dry weight adhesive;
- and
- less than 2 percent by dry weight of thermosetting resin;
- wherein said blank comprises:
- a first segment configured to define said bottom;
- and
- a plurality of further segments extending from said first segment and configured to define together said upright peripheral wall after said hot pressing, said plurality of further segments each comprising respective opposite edge portions;
- wherein said three-dimensional product is manufactured by the method comprising:
- reorienting said further segments such that edge portions of neighboring further segments contact each other;
- and
- wherein said hot pressing is selected such that a hydrogen bonding between said natural fibers of said edge portions of neighboring further segments that contact each other results from said hot pressing, to provide said three-dimensional product.
(canceled)
A flat or substantially flat blank comprising:
- a layer of a non-woven airlaid fluff material comprising:
- a first segment with a polygonal or round contour;
- and
- a plurality of further segments projecting outwards from said first segment;
- wherein said blank has a density selected in a range of 30 kg/cm3-350 kg/m3 and a thickness selected in a range of 1.5 mm-20 mm;
- wherein said layer comprises:
- natural fibers;
- less than 10 percent by dry weight thermoplastic fibers;
- less than 10 percent by dry weight adhesive;
- and
- less than 2 percent by dry weight of thermosetting resin.
Dependencies are inferred from the claim text.