Apparatus and method for making molded pulp products from nanocellulose fibers

A method for making a three-dimensional molded pulp product of nanocellulose fibers using an apparatus including a mold base, a guide ring, and a filtration screen, the method comprising the steps of:

• securing the guide ring to the mold base to create a molding chamber spaced from the filtration screen;
• depositing a fluid suspension of the nanocellulose fibers on the filtration screen in the mold base;
• inserting a mold into the guide ring to contact the suspension on the filtration screen, wherein the mold includes an interior groove with a surface arranged to retain the nanocellulose fibers thereto;
• applying a substantially uniform pressure to the mold so that compressed nanocellulose fibers on the filtration screen extend into the interior groove to form the molded pulp product;
• releasing the pressure applied to the mold for a selectable period of time;
• and
• removing the mold and the guide ring to extract the molded pulp product from the mold base.

An apparatus for making a two-dimensional molded pulp product using nanocellulose fibers in a fluid, the apparatus comprising:

• a mold base having a perimeter;
• a guide ring affixed to the perimeter of the mold base;
• a filtration screen retained between the mold base and the guide ring;
• and
• a mold of selectable configuration removably connected to the guide ring, wherein the mold,
• wherein the guide ring is configured to stand off from the mold base to establish a molding chamber between the mold base and the mold for receiving therein the fluid with the nanocellulose fibers, and
• wherein the filtration screen is arranged to enable the fluid to pass from the chamber while holding in the chamber at least a portion of the nanocellulose fibers when pressure is applied to the mold to press those nanocellulose fibers to form the molded pulp product in the chamber,
• wherein the molding chamber is of substantially uniform dimension, and
• wherein at least a portion of the molding chamber has a surface arranged to keep the nanocellulose fibers retained thereto while forming the molded pulp product to minimize shrinkage thereof while forming.

A method for making a two-dimensional molded pulp product of nanocellulose fibers using an apparatus including a mold base, a guide ring, and a filtration screen, the method comprising the steps of:

• securing the guide ring to the mold base to create a molding chamber spaced from the filtration screen;
• depositing a fluid suspension of the nanocellulose fibers on the filtration screen in the mold base;
• inserting a mold into the guide ring to contact the suspension on the filtration screen, wherein the mold includes a surface arranged to retain the nanocellulose fibers thereto;
• applying a substantially uniform pressure to the mold so that compressed nanocellulose fibers on the filtration screen to form the molded pulp product;
• releasing the pressure applied to the mold for a selectable period of time;
• and
• removing the mold and the guide ring to extract the molded pulp product from the mold base.