MOLDED FIBER PART PRODUCTION LINES USING TRIMLESS FORMING AND PRESSING MOLDS
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.
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.