Pulp-molded lid and molding device thereof
The present invention relates to a pulp-molded lid and its molding device. The molding device comprises a first lid molding die and a second lid molding die. The first lid molding die comprises a snap-fit molding part and a rim molding part, so that a snap-fit section of the pulp-molded lid and a circular rim section at the edge of the pulp-molded lid are formed when the first lid molding die and the second lid molding die are coupled with each other. The rim section and the snap-fit section are used to strengthen the combination of the pulp-molded lid and an external container, so that the combination is more stable.
The present application is based on, and claims priority from, Taiwanese application number 105130752, filed on Sep. 23, 2016 to TIPO, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION 1. Field of the InventionThe present disclosure relates to a pulp-molded lid, particularly a pulp-molded lid and a molding device thereof wherein the pulp-molded lid comprises a snap-fit section which is formed with the pulp-molded lid integrally and coupled with a cup.
2. Description of the Prior ArtPaper cups and bowls are disposable consumables ubiquitous in our daily lives. Currently, the manufacturers considering costs of manufacturing materials and requests for distinct products have created various methods to manufacture these disposable consumables.
To manufacture a paper product with firm texture or styling or a thicker layer, a manufacturer should deposit paper pulp to a certain thickness for molding. However, if paper products are extruded from a thicker layer of deposited paper pulp in a conventional manufacturing process which aims at manufacturing thinner paper cups or bowls, it is quite often to see the appearance of convex edges or irregular surface wrinkles of the paper products. These disfigures the aesthetic exteriors or structural strength of those paper products.
Furthermore, an appropriate manufacturing process based on pulp molding (also known as the pulp die molding method) developed recently is applicable to paper products with a certain thickness. However, the inside embossed or barb-like patterns which contribute to securing the combination of a cup lid and a paper cup are mostly disposed on the rim and/or the snap-fit section of an ordinary pulp-molded cup lid and shaped on a formed lid in a secondary local roll-extrusion process.
In this regard, there is an increased time cost in a secondary roll-extrusion process for rework which also often causes defects or disfigurements to the lids which are the finished products.
SUMMARY OF THE INVENTIONTo solve the problems in the prior arts, an integrated pulp-molded lid provided in the present disclosure reduces manufacturing time and costs.
The pulp-molded lid comprises a central section and a rim section which encircles the central section, accommodates an upper wall edge of an external container coupled with the pulp-molded lid, and clamps the wall edge of the external container.
Furthermore, the rim section comprises a snap-fit section, which is downwardly connected with the upper wall edge of the external container, manufactured with the central section as well as the rim section integrally, and further coupled with a protrusion encircling the external container for a firm combination of the pulp-molded lid and the external container when the rim section clamps the upper wall edge of the external container.
To manufacture the pulp-molded lid, the present disclosure provides a molding device of a pulp-molded lid which comprises a first lid molding die and a second lid molding die: the first lid molding die comprises a first molding unit with a center molding part for shaping of the corresponding central section of the pulp-molded lid and a rim molding part for shaping of the corresponding rim section of the pulp-molded lid; the rim molding part comprises a snap-fit molding part recessed from an outer edge of the rim molding part and situated at one side far away from the center molding part for shaping of the snap-fit section of the pulp-molded lid; the second lid molding die comprises a second molding unit for shaping of a corresponding exterior profile of the pulp-molded lid.
As mentioned previously, a manufacturing process of a pulp-molded lid in the present disclosure is similar to that of a conventional pulp-molded lid in general. In pulp-based hot press molding steps, the elastic pulp-molded lid features the snap-fit section which is slightly deformed for separation from the snap-fit molding part in a de-molding process and characteristic of a profile similar to that of the snap-fit molding part. As such, the snap-fit section is coupled with a protrusion extended outward from a cup rim of an external container which is to be connected to the snap-fit section at the pulp-molded lid as required in standards of product manufacturing.
The features, content, advantages and effects of a pulp-mold lid and a molding device thereof in the present disclosure are explained in embodiments and accompanying drawings which are schematic views to illustrate the patent specification but not intended to limit the scope of patent claims.
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A pulp-molded lid of an ordinary paper cup in which a beverage would normally be carried, the pulp-molded lid 1 in
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Furthermore, when the first lid molding die 22 is bored for placement of a heating rod and a thermocouple or the first lid molding die 22 casted with thermal conductive materials is securely installed on a heating plate in the embodiment, a first lid heating and molding die, which is heated directly or via thermal conduction to increase temperature of the first molding unit 220 inside and dry paper pulp, is created; on the other hand, when the second lid molding die 20 is bored for placement of a heating rod and a thermocouple or the second lid molding die 20 casted with thermal conductive materials is securely installed on another heating plate, a second lid heating and molding die, which is heated directly or via thermal conduction to increase temperature of the second molding unit 200 inside and dry paper pulp, is created and comprises a plurality of pore channels 2021 through which the dried pulp-molded lid 1 is drawn. It should be reiterated that neither the first molding unit 220 in the first lid molding die 22 nor the second molding unit 200 in the second lid molding die 20 are provided with a strainer 226 inside.
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Step S801: the first molding unit is covered with pulp slurry when the first lid pulp-sucking and molding die is immersed in pulp slurry.
Step S802: the first lid pulp-sucking and molding die is removed from pulp slurry and excessive water, which is included in pulp slurry deposited on the first molding unit and unused in a manufacturing process, is drained from the pore channels and the strainer.
Step S803: the second lid pulp-sucking and molding die is driven to fit into the first lid pulp-sucking and molding die so that a raw lid featuring a profile similar to that of a desired pulp-molded lid is shaped with dehydrated paper pulp adhered to and matching the strainer on the first molding unit.
Step S804: the raw lid is sucked by the second lid pulp-sucking and molding die through the pore channels for separation from the first lid pulp-sucking and molding die in a de-molding process.
Step S805: the raw lid is held in the first lid heating and molding die with which the second lid pulp-sucking and molding die is coupled.
Step S806: the second lid heating and molding die is driven to fit into the first lid heating and molding die completely for sealing the raw lid between the first and second lid heating and molding dies.
Step S807: the raw lid is heated and dried by the first lid heating and molding die as well as the second lid heating and molding die and totally dehydrated for shaping of the pulp-molded lid.
Step S808: the pulp-molded lid is sucked by the second lid heating and molding die for separation.
According to a manufacturing process from step S801 to step S808, a pulp-molded lid is shaped.
An alternative manufacturing process different from that of the above embodiment is introduced in the present disclosure. In the alternative embodiment, the profile of a first molding unit (a second molding unit) in a lid pulp-sucking and molding die (as well as a lid heating and molding die) is exchanged to the profile of a second molding unit (a first molding unit). When a molding unit to shape an exterior profile of a pulp-molded lid is first immersed in pulp slurry and driven to fit into another molding unit which is used to shape an interior profile of a snap-fit section on the pulp-molded lid, a pulp-molded lid featuring an identical profile can be created with two dies at reversed positions.
In summary, a pulp-molded lid and a molding device thereof for once-and-for-all die molding of a snap-fit section in the patent application, which are innovative work in technical ideas and features several effects in contrast to conventional molded lids, meets novelty and non-obviousness for patentability.
Claims
1. A pulp-molded lid, which is made of paper pulp and comprises a central section at the center and an annular rim section encircling the central section and having two side walls and further a snap-fit section extended from the outside one of the two side walls, protruding inward;
- wherein the snap-fit section is integrally formed with the pulp-molded lid; and
- wherein when an external container is coupled to the pulp-molded lid, the snap-fit section expands and then contracts based on physical elasticity of paper pulp so that the pulp-molded lid can couple to a protrusion extended from a cup rim of the external container.
2. A molding device of a pulp-molded lid for manufacturing of the pulp-molded lid as claimed in claim 1, comprising:
- a first lid molding die, which comprises a first molding unit for shaping of a complete interior profile of the pulp-molded lid wherein the first molding unit has a center molding part for shaping of the central section of the pulp-molded lid and a rim molding part for shaping of the rim section of the pulp-molded lid and the rim molding part has an annular snap-fit molding part situated at an outer edge and at one side far away from the center molding part for shaping of the snap-fit section of the pulp-molded lid; and
- a second lid molding die, which comprises a second molding unit for shaping of a complete exterior profile of the pulp-molded lid and is driven to fit into the first lid molding die for shaping of the pulp-molded lid between the second lid molding die and the first lid molding die.
3. A molding device of a pulp-molded lid as claimed in claim 2 wherein the first molding unit optionally comprises a plurality of pore channels penetrating the first molding unit inside and each of the pore channels creates suction by which excessive water in pulp slurry during shaping of the pulp-molded lid is drained or pressure in a pulp molding process is regulated.
4. A molding device of a pulp-molded lid as claimed in claim 2 wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels is used to regulate pressure during shaping of the pulp-molded lid or create suction by which the pulp-molded lid is sucked and separated from the first lid molding die.
5. A molding device of a pulp-molded lid as claimed in claim 3 wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels is used to regulate pressure during shaping of the pulp-molded lid or create suction by which the pulp-molded lid is sucked and separated from the first lid molding die.
6. A molding device of a pulp-molded lid as claimed in claim 2 wherein the first lid molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first lid pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first lid pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second lid molding die for shaping of the pulp-molded lid by the second molding unit in a second lid pulp-sucking and molding die.
7. A molding device of a pulp-molded lid as claimed in claim 3 wherein the first lid molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first lid pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first lid pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second lid molding die for shaping of the pulp-molded lid by the second molding unit in a second lid pulp-sucking and molding die.
8. A molding device of a pulp-molded lid as claimed in claim 2 wherein the second lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a second lid heating and molding die; and
- the first lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a first lid heating and molding die.
9. A molding device of a pulp-molded lid as claimed in claim 3 wherein the second lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a second lid heating and molding die; and
- the first lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a first lid heating and molding die.
10. A molding device of a pulp-molded lid for manufacturing of the pulp-molded lid as claimed in claim 1, comprising:
- a first lid molding die, which comprises a first molding unit for shaping of a complete exterior profile of the pulp-molded lid;
- a second lid molding die, which comprises a second molding unit for shaping of a complete interior profile of the pulp-molded lid wherein the second molding unit has a center molding part for shaping of the central section of the pulp-molded lid and a rim molding part for shaping of the rim section of the pulp-molded lid and the rim molding part has an annular snap-fit molding part situated at an outer edge and at one side far away from the center molding part for shaping of the snap-fit section of the pulp-molded lid;
- wherein the second lid molding die and the first lid molding die are coupled with each other for shaping of the pulp-molded lid with paper pulp held between the second lid molding die and the first lid molding die.
11. A molding device of a pulp-molded lid as claimed in claim 10 wherein the first molding unit optionally comprises a plurality of pore channels penetrating the first molding unit inside and each of the pore channels creates suction by which excessive water in pulp slurry during shaping of the pulp-molded lid is drained or pressure in a pulp molding process is regulated.
12. A molding device of a pulp-molded lid as claimed in claim 10 wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels is used to regulate pressure during shaping of the pulp-molded lid or create suction by which the pulp-molded lid is sucked and separated from the first lid molding die.
13. A molding device of a pulp-molded lid as claimed in claim 11 wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels is used to regulate pressure during shaping of the pulp-molded lid or create suction by which the pulp-molded lid is sucked and separated from the first lid molding die.
14. A molding device of a pulp-molded lid as claimed in claim 10 wherein the first lid molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first lid pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first lid pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second lid molding die for shaping the pulp-molded lid by the second molding unit in a second lid pulp-sucking and molding die.
15. A molding device of a pulp-molded lid as claimed in claim 11 wherein the first lid molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first lid pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first lid pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second lid molding die for shaping the pulp-molded lid by the second molding unit in a second lid pulp-sucking and molding die.
16. A molding device of a pulp-molded lid as claimed in claim 10 wherein the second lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a second lid heating and molding die; and
- the first lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a first lid heating and molding die.
17. A molding device of a pulp-molded lid as claimed in claim 11 wherein the second lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a second lid heating and molding die; and
- the first lid molding die which is casted with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded lid is a first lid heating and molding die.
Type: Application
Filed: May 15, 2017
Publication Date: Mar 29, 2018
Inventor: Ming-Chih LIN (Yi-Lan County)
Application Number: 15/595,893