US-20260124784-A1 - A METHOD FOR MANUFACTURING A CELLULOSE PRODUCT AND A CELLULOSE PRODUCT

US20260124784A1US 20260124784 A1US20260124784 A1US 20260124784A1US-20260124784-A1

Abstract

A cellulose product comprising a non-flat cellulose product structure, a protective inner layer, and a protective outer layer. The cellulose product structure comprises an interior surface, an exterior surface, and an edge structure arranged between the interior surface and the exterior surface. The protective inner layer is applied to the interior surface, and the protective outer layer is arranged in connection to the exterior surface of the cellulose product structure. The protective inner layer and the protective outer layer are forming an integrated structure that is fully enclosing the cellulose product structure, and a sealed outer volume is formed by the protective inner layer and the protective outer layer.

Inventors

Ove Larsson
Philip Fawcus
Mark Jones
Mark Farrell
Stuart Dunlop

Assignees

Pulpac AB

Dates

Publication Date: 20260507
Application Date: 20221031
Priority Date: 20211105

Claims (20)

1 . A method for manufacturing a cellulose product, wherein the method comprises the steps: providing a non-flat cellulose product structure, wherein the cellulose product structure comprises an interior surface, an exterior surface, and an edge structure arranged between the interior surface and the exterior surface; applying a protective inner layer to the interior surface; and arranging a protective outer layer in connection to the exterior surface of the cellulose product structure; wherein the protective inner layer and the protective outer layer are forming an integrated structure that is fully enclosing the cellulose product structure, wherein a sealed outer volume is formed by the protective inner layer and the protective outer layer.
2 . The method according to claim 1 , wherein the method further comprises the steps: providing an air-formed cellulose blank structure and feeding the cellulose blank structure to a forming mould; forming the non-flat cellulose product structure from the cellulose blank structure in the forming mould by heating the cellulose blank structure to a forming temperature (T F ), and pressing the cellulose blank structure with a forming pressure (P F ), wherein the cellulose product structure during forming is shaped with the interior surface, the exterior surface, and the edge structure arranged between the interior surface and the exterior surface.
3 . The method according to claim 2 , wherein the method further comprises the steps: applying the protective inner layer to the interior surface and/or the protective outer layer to the exterior surface during forming of the non-flat cellulose product structure from the cellulose blank structure in the forming mould.
4 . The method according to claim 2 , wherein the method further comprises the steps: applying one or more substances through liquid application and/or sputter deposition to the cellulose blank structure before forming of the non-flat cellulose product structure from the cellulose blank structure in the forming mould; forming the protective inner layer onto the interior surface and/or the protective outer layer onto the exterior surface from the applied one or more substances during forming of the non-flat cellulose product structure from the cellulose blank structure in the forming mould.
5 . The method according to claim 1 , wherein the protective inner layer and the protective outer layer are formed by a single material sheet, wherein the method further comprises the steps: applying the single material sheet to the interior surface for forming the protective inner layer and applying the single material sheet around the exterior surface and the edge structure for forming the protective outer layer.
6 . The method according to claim 1 , wherein the protective inner layer is formed by a first material sheet and the protective outer layer is formed by a second material sheet, wherein the method further comprises the steps: applying the first material sheet to the interior surface for forming the protective inner layer; applying the second material sheet around the exterior surface for forming the protective outer layer; and attaching the protective outer layer to the protective inner layer.
7 . The method according to claim 1 , wherein the method further comprises the steps: forming the protective inner layer through liquid application or sputter deposition of a material sheet onto the interior surface, and/or forming the protective outer layer through liquid application or sputter deposition of a material sheet onto the exterior surface.
8 . The method according to claim 3 , wherein the method further comprises the steps: attaching and sealing a protective cover layer to a part of the protective inner layer and/or a part of the protective outer layer, wherein an enclosed and sealed inner storage volume is formed between the protective cover layer and the protective inner layer.
9 . (canceled)
10 . The method according to claim 6 , wherein the method further comprises the steps: attaching and sealing a protective cover layer to a part of the protective inner layer, wherein the protective cover layer is formed by the second material sheet, wherein an enclosed and sealed inner storage volume is formed between the protective cover layer and the protective inner layer.
11 . (canceled)
12 . The method according to claim 1 , wherein the method further comprises the step: at least partly adhering the protective inner layer to the interior surface when applying the protective inner layer to the interior surface.
13 . A cellulose product comprising a non-flat cellulose product structure, a protective inner layer, and a protective outer layer; wherein the cellulose product structure comprises an interior surface, an exterior surface, and an edge structure arranged between the interior surface and the exterior surface, wherein the protective inner layer is applied to the interior surface, wherein the protective outer layer is arranged in connection to the exterior surface of the cellulose product structure, wherein the protective inner layer and the protective outer layer are forming an integrated structure that is fully enclosing the cellulose product structure, wherein a sealed outer volume is formed by the protective inner layer and the protective outer layer.
14 . The cellulose product according to claim 13 , wherein the non-flat cellulose product structure is dry-formed from an air-formed cellulose blank structure.
15 . (canceled)
16 . (canceled)
17 . The cellulose product according to claim 13 , wherein the protective inner layer is liquid impermeable or fluid impermeable and/or the protective outer layer is liquid impermeable or fluid impermeable.
18 . The cellulose product according to claim 13 , wherein the protective inner layer and/or the protective outer layer are arranged as a polymer film layer, a cellulose material layer, a layer formed through liquid application, or a sputter deposition layer.
19 . The cellulose product according to claim 13 , wherein the cellulose product further comprises an enclosed and sealed inner storage volume; wherein the sealed inner storage volume is formed between a protective cover layer ( 6 ) and the protective inner layer.
20 . The cellulose product according to claim 13 , wherein the cellulose product comprises a filling cavity formed by the protective inner layer and the interior surface, wherein the filling cavity is configured for receiving a filling substance.

Description

TECHNICAL FIELD The present disclosure relates to a method for manufacturing a cellulose product. The disclosure further relates to a cellulose product comprising a non-flat cellulose product structure. BACKGROUND Cellulose fibres are often used as raw material for producing or manufacturing cellulose products. Products formed of cellulose fibres can be used in many different situations where there is a need for having sustainable products. A wide range of cellulose products can be produced from cellulose fibres and a few examples are disposable bowls and cups used for holding and storing for example food, beverages, or other types of liquid substances and goods. One common drawback with products made of cellulose fibres is the ability to absorb moisture from the surrounding environment. When absorbing moisture, the structural rigidity of the cellulose products is decreased, and the products may become unstable and not suitable for holding goods anymore. This may happen if the products are used in environments with high humidity or if being exposed to water. If the cellulose products, such as cups, are used for holding liquids for short-time use, the cellulose fibres may be mixed with plastic materials or a plastic film layer is applied to the inner side of the products to withstand the impact from the liquids. However, today for products demanding longer times for storage, such as liquids or food where there is a need for longer shelf-times, other materials than cellulose fibres are used. Instead, most packaging solutions are using plastic materials or metals to avoid the drawbacks with non-rigid and unstable cellulose products. There is thus a need for an improved and more environmentally friendly solution, where recyclable products containing cellulose fibres can be used for holding food, beverages, or other types of liquid substances and goods for longer periods, allowing long shelf-times during transportation, storage, and sales. SUMMARY An object of the present disclosure is to provide a method for manufacturing a cellulose product and a cellulose product where the previously mentioned problems are avoided. This object is at least partly achieved by the features of the independent claims. The dependent claims contain further developments of the method for manufacturing a cellulose product and the cellulose product. The disclosure concerns a method for manufacturing a cellulose product. The method comprises the steps: providing a non-flat cellulose product structure, where the cellulose product structure comprises an interior surface, an exterior surface, and an edge structure arranged between the interior surface and the exterior surface; applying a protective inner layer to the interior surface; and arranging a protective outer layer in connection to the exterior surface of the cellulose product structure, where the protective inner layer and the protective outer layer are forming an integrated structure that is fully enclosing the cellulose product structure, and where a sealed outer volume is formed by the protective inner layer and the protective outer layer. Advantages with these features are that the method is providing an efficient solution for producing environmentally friendly and recyclable cellulose products, where the products can be used for holding food, beverages, or other types of liquid substances and goods for longer periods, allowing long shelf-times during transportation, storage, and sales. The sealed outer volume formed by the protective inner layer and the protective outer layer is efficiently preventing the cellulose product structure from moisture, and the construction of the cellulose product is thus preventing the cellulose fibres of the cellulose product structure from absorbing moisture from the surrounding environment. The solution is maintaining the structural rigidity of the cellulose products even if being exposed to moisture or liquids, for example in environments with high humidity or if being exposed to water. The protective inner layer and the protective outer layer may be removed from the cellulose product structure for an efficient recycling of materials used. The protective layers may be separated from the cellulose product structure for example by peeling off the protective layers from the cellulose product structure. After the removal of the protective layers from the cellulose product structure, the cellulose product structure can be recycled as a paper product (PAP) and the protective layers for example as plastic materials. As an alternative, the protective inner layer and the protective outer layer are made of materials that can be recycled with the cellulose product structure. In certain embodiments, the method further comprises the steps: providing an air-formed cellulose blank structure and feeding the cellulose blank structure to a forming mould; forming the non-flat cellulose product structure from the cellulose blank structure in the forming mould by