Method and apparatus for manufacturing fiber-reinforced, foamed paperlike products
First Claim
1. A method of manufacturing a molded product having a blown, foamy structure via an injection mold designed to form said molded product, said method comprising:
- forming a fluid mass substantially free of gelatinized matter and having a low viscosity, said fluid mass comprising a natural polymer and natural fibers;
maintaining said fluid mass at temperatures below a gelatinization temperature such that substantially no gelatinization of said natural polymers occurs in said fluid mass outside said injection mold;
injecting said fluid mass under high pressure into said injection mold such that said fluid mass substantially fills said injection mold under said high pressure;
heating said injection mold to raise the temperature of said fluid mass, while under said high pressure, to a baking temperature at least equal to or above said gelatinization temperature, to cause baking of said injected fluid mass with gelatinization and cross linking of said natural polymers, and with bonding of said natural polymers to said natural fibers to form said molded product with said natural fibers extending throughout said molded product; and
removing said molded product from said injection mold.
1 Assignment
0 Petitions
Accused Products
Abstract
A method for manufacturing products with a blown foamy structure, starting from a mass comprising at least natural polymers such as starch and fibers, in particular natural fibers, wherein the mass (M, S) is passed under pressure into or through a mould (23, 63) and the mass (M, S) is heated in the mould (23, 63) in a manner such as to give rise to gelatinization and cross-linking of the natural polymers, with the fibers extending through the product, while the mass prior to the introduction into the mould has temperature which is below the gelatinization temperature and in the mould is brought at least to the baking temperature.
-
Citations
24 Claims
-
1. A method of manufacturing a molded product having a blown, foamy structure via an injection mold designed to form said molded product, said method comprising:
-
forming a fluid mass substantially free of gelatinized matter and having a low viscosity, said fluid mass comprising a natural polymer and natural fibers;
maintaining said fluid mass at temperatures below a gelatinization temperature such that substantially no gelatinization of said natural polymers occurs in said fluid mass outside said injection mold;
injecting said fluid mass under high pressure into said injection mold such that said fluid mass substantially fills said injection mold under said high pressure;
heating said injection mold to raise the temperature of said fluid mass, while under said high pressure, to a baking temperature at least equal to or above said gelatinization temperature, to cause baking of said injected fluid mass with gelatinization and cross linking of said natural polymers, and with bonding of said natural polymers to said natural fibers to form said molded product with said natural fibers extending throughout said molded product; and
removing said molded product from said injection mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
-
-
19. A method of manufacturing a molded product via extrusion molding with an extrusion die designed to form said molded product, said molded product having a blown, foamy structure, said method comprising:
-
forming a fluid mass outside said extrusion die, said fluid mass comprising a natural polymer and natural fibers;
maintaining said fluid mass when outside said extrusion die at temperatures below a gelatinization temperature such that substantially no gelatinization of said natural polymers occurs in said fluid mass;
continuously feeding said fluid mass under pressure through an orifice in said extrusion die;
heating said fluid mass while said fluid mass moves through said extrusion die to a baking temperature at least equal to or above said gelatinization temperature, to cause gelatinization and cross linking of said natural polymers to form said molded product with said natural fibers extending throughout; and
removing said molded product from said extrusion die. - View Dependent Claims (20, 21, 22, 23, 24)
-
Specification