METHOD FOR MAKING COFFIN SHELL SURFACES WITH STAGGERED SAWDAUST PULP PRE-COMPRESSION AND FORMING OF PRE-COMPACTED SURFACES AND A MECHANISMS

SYSTEM FOR ITS IMPLEMENTATION.

The invention reiates to a "method for making coffin shell surfaces with staggered sawdust pulp pre-compression and the forming of pre-compacted surfaces and to a "mechanisms system for the implementation of this method”. The entire shell of a coffin, consisting of two parts, i.e the body and the lid, is formed with the assembly of the body surfaces, i.e the bottom, its lateral surfaces, and of the lid surfaces, i.e the upper part (top) and its lateral surfaces.

The method consists in that each of the surfaces with which is made, a process in continuous steps where, the forming of flat pre-compacted surface of fixed width, small thickness and density, with sufficient consistency and resistance to minor stresses is initially achieved by staggered sawdust pulp- of special composition- compression. Then it is compacted with simultaneous heating to the final desired thickness until the final formed surface aquires the desired form and shape with the desired characteristics of firmness, strength, stiffness etc. Then, it will be ready for further processing and use.

The implementation of the method is carried out by a system of specially designed and adapted mechanisms consisting of a sawdust pulp stirring and homogenizing mechanism, an adjustable supply feed mechanism, a staggered compression mechanism and a final forming mechanism, operating with direct and continuous interaction for the making of shell surfaces with sawdust pulp staggered precompression of and forming of pre-compacted surfaces.

All the surfaces, which, are with little additional processing assembled and form the shell of a coffin are made with this method and the specially designed and adapted mechanisms system for its implementation.

Today, methods to make surface and coffin- in general- shell elements, have been developed with the use of wood pulp and mixing other materials in various compositions, such as composite thermoplastic materials, crushed materials of plant production mixed with sawdust or pulp of paper etc, where the pulp is propelled under pressure in closed type moulds and it is compressed with simultaneous heating until it obtains a stable form with the required characteristics of strength, firmness and appearance. Additionally, there is a development of methods, where the pulp is transferred in the form of dry pulp and it is "poured" into open-type moulds. There, it is compressed with simultaneous heating until it is stabilized and acquires the desired properties of strength and appearance.

Some of the most significant problems and disadvantages presented in the methods and ways used for making surfaces and coffin elements with the use of wood pulp so far, are:

-The methods using closed-type moulds require techniques of puip iiquefaction and installations with complex mechanisms. These are highly costly and make their application a deterrent for broadapplication in the production of surfaces and elements that manufacture a coffin.

- Special difficulties are encountered in the transportation and "moulding" of pulp in moulds, where complex mechanisms systems and installations are required burdening the production cost.

- The distribution of the pulp mass in the moulds during the compression process is uneven and not easily controlled, so the final surfaces present unevenness in the material density. Thus that creates problems in their further processing with the appearance of flimsy parts, different reaction in the dyeing, etc.

- It is almost impossible to evenly distribute the pulp mass across the entire area of large curved surfaces that require large moulds of big depth. This results in final surfaces with gaps and large flimsy parts (with significantly low material density and loose cohesion).

-Special difficulties arise that significantly increase the time and production cost, where the insertion of additional materials and coating elements on the external faces is required during the compression process within the moulds.

The invention aims to remedy the aforementioned problems and disadvantages. The invention refers to a "method for making coffin shell surfaces with sawdust pulp staggered pre-compression and forming of pre-compacted surfaces" and in "a mechanisms system for the implementation of this method. The "method for making coffin shell surfaces with staggered sawdust pulp pre compression and the forming pre-compacted surfaces" consists in that each of the surfaces, that assemble and form the shell, is made with a process during which sawdust pulp of a special composition is used and which includes the following consecutive steps:

In the first step, the following composotion materials of the pulp with the corresponding percentage proportions are mixed and homogenized with continuous stirring with the use of a special mechanism: a. 75% to 85% of fine-grained sawdust, with a grain size of 0,5 mm to 1 mm b. 7% to 15% of moisture (water) c. 5%-10% of industrial glue made of thermosetting polymers d. 0.5% to 2% of bio-degradation agent of the adhesive (glue)

Once the mixture is homogenized, the forming pulp is led to the second step of the process.

In the second step, the homogeneous mixture of the pulp is propelled with the use of a special mechanism, with constant, adjustable and continuous supply, so that a homogeneous fixed cross-sectional pulp layer is formed (width x thickness), driven on a moving flat surface during in the third step of the process.

In the third step, the homogeneous fixed cross-sectional pulp layer, moving on a flat surface, is gradually compacted with the use of a special mechanism towards the direction of its movement, in such a way that its width remains fixed and its thickness is gradually and proportionally reduced. This way the density and the consistency of the pulp materials are increased evenly. So in the end of the third step a continuous coherent pre-compacted flat surface, with a fixed width and thickness less than 2 to 5 times the thickness of the original homogeneous layer is formed. Now, it has obtained sufficient resistance to minor stresses in order be transported without being crushed. The aforementioned surface is driven to the fourth step of the process.

In the fourth step, the leaf of the pre-compacted surface is compressed with strong pressure and simultaneous high heating with the use a special two- part mould mechanism, so that the thickness is reduced by 2 to 3 times and time it simultaneously takes the shape and the form of the two -part mould. By the compression, the sawdust grains come into a close contact and with the simultaneous heating as well as the catalytic action of the water, the thermosetting resins of the industrial glue, evenly enveloping the sawdust grains, are activated and react achieving a strong soldering. The surface remains at this state of compression and heating, until the complete activation and balancing of the industrial glue with the remaining components of the pulp and the finally formed surface obtains the required consistency and strength. Then it is decompressed and received ready for further processing and use.

For the cases where the pre-compacted surface is required to have increased resistance to stresses, the pulp mass is slightly heated with the use of a special heating device during the staggered compression in the third step of the process. This aims to achieve partial activation of the industrial glue and to increase the consistency of the pre-compacted surface.

For the optimization of the external face of the coffin surfaces a thin paper film is adapted with the use of a special mechanism. This film is impregnated with resin made of a thermoset polymer on the relevant face of the pre-compacted surface during its formation in the third step of the staggered pulp compression. The thin paper film loosely adheres to the external face of the pre-compressed surface, with a slight compression and heating in order to achieve the partial activation of the film's thermosetting resin and the loose soldering with the the pulp grains. The loose bonding allows the small movements of the film in relation to precompressed surface, so during the step of the forming it is shrunk without being torn. With the strong compression and the high heating during the fourth step of the forming, complete activation of the film's thermosetting resin is achieved, which, combined with the industrial glue of the pulp and the paper fibers compacted and arranged in the gaps of the sawdust grains, creating a thin smooth coating on the external face of the finally formed coffin surface.

For the cases that the finally formed surface has large curvatures, as it is the case that the single lid of the coffin is formed or increased stresses are caused to the pre-compressed surface during the forming, a reinforcing mesh, made of biodegradable thermoplastic polymer fibers approximately in the mid-thickness and the full width of the homogeneous pulp layer and the pre-compacted surface, is adjusted with the use of a special mechanism in the third step of the process. The slots of the mesh are larger than the sawdust grains, so that the pulp penetrates the mesh, which is incorporated by the staggered pulp compression into the interior of the pre-compressed flat surface. This way the consistency of the pulp grains is enhanced and the pre-compacted surface acquires plasticity and increased strength. Thus it is formed smoothly without being crushed during the step of forming.

"A mechanisms system for the implementation of this method" , as it is described above, consists of specially designed and adapted mechanisms operating with direct interaction as a single system for the making of coffin shell surfaces with staggered sawdust pulo pre-compression and pre-compacted surfaces. In particular, a system of mechanisms for the implementation of this method consists of the following mechanisms:

A stirring and homogenizing mechanism, where the first step of the method is applied and implemented. It consists of a stirring device specially designed and adapted to a shell of a similar special shape and dimensions. On the shell, there is a specially adapted spraying device of the liquid pulp components, i.e, water, glue and the material agent of biodegradation. On the shell, there is also a specially formed device with a hatch for evacuating the ready homogeneous pulp.

An adjustable supply feed mechanism, where the second step of the method is implemented. It consists of a shell with a shape of funnel specially adapted to the evacuation device of the stirring and homogenization mechanism. At the base of the funnel there is a special customized adjustable rotary feeder for propelling a fixed amount of pulp at the output of the funnel. At the output of the funnel, there is a specially designed and adapted device with a slot for the insertion and adaptation of the reinforcement mesh. At the external part of the slot there are specially adapted guide cylinders and at the internal part there is a special adapted grid for holding the reinforcement mesh.

A staggered compression mechanism, where the the third step is implemented. It consists of a conveyor belt with a flat strap specially adapted to the output of the adjustable supply feed mechanism ,in which specially designed and adjusted pairs of identical cylinders rotating in the direction of the conveyor belt movement, where the one cylinder is firmly attached and tangent to the bottom of the flat strap and the second cylinder is adjusted above the flat strap, in specially shaped vertical slide devices within which the bearing ends of the cylinder can be moved and and mounted in such a way that its position is adjusted at the desired distance from the first cylinder. The pairs of the cylinders are adapted to normal distances apart. The first pair of the cylinders is adapted at a distance from the output of the adjustable supply feed mechanism capable of forming the homogeneous fixed cross-sectional pulp layer. The distance between the cylinders of each pair is adjustable and is scaled down to each subsequent pair towards the direction of movement of the conveyor belt up to the last pair of cylinders, in which the distance between them is equal to the desired thickness of the pre-compacted surface. For the adaptation of the thin paper film on the lower face of the precompacted surface adjacent to the conveyor belt ,a second similar and of identical dimensions short length conveyor belt with at least two pairs of identical dimension pairs of cylinders moving with the same speed and towards the same direction, is adjusted immediately after the last pair of cylinders.

For the continuous feeding of the thin film on the lower or upper face of the precompacted surface, a special mechanism is respectively adapted to the lower or the upper part of the seconconveyor belt, consisting of a rotating drum inwhich the film is wrapped in. For the continuous feeding of the reinforcement mesh in the pulp mass, at the beginning of the conveyor belt of the staggered compression mechanism, a mechanism is specially adapted consisting of a rotating drum, in which the reinforcement mesh is wrapped.

A final forming mechanism, where the the fourth step of the method is implemented. It consists of a two- part mould specially designed and adapted to a press machine (presser) at the output of the staggered compressing mechanism and the pre-compacted surface. The one the "negative relief of the one part of the mould has the same form and shape as the external face, and the "negative relief of the other part has the same form and shape as the internal face of the desired forming surface of the coffin. In the body of the two parts of the two part mould, there is a specially designed and adapted heating device with electrical resistors and / or diathermic oil, with the ability to raise the temperature up to 250 degrees Celsius on the relief surfaces.The edges on the ends of the two- part "relief surfaces" across the entire perimeter of the mould are specially shaped with inclinations and cutting capacity so that the protruding parts of the pre-compacted surface are cut off and driven to crushing and reuse for the formation of pulp with the compression of the closed position.

The invention with the remedy of the above mentioned disadvantages also presents the following advantages.

- The sawdust pulp is driven into the shaping moulds with simple mechanisms systems, which are low cost in regards to the installation, operation and maintenance. Thus a significant reduction of the production cost is achieved.

- An ideal distribution of the material is achieved in the phase of the staggered compression, with complete homogeneity and uniformity of the density in the pre compacted surface, which is fully controlled during the phase of forming, achieving this way the optimal final external face of the formed surface, without discontinuities and with uniformed material density. These result in the elimination of the problems of the further final processing (of the texture finish), colouring, e.t.c.

- By forming the pre-compacted surfaces that are shaped by the specific composition of the pulp and the insertion of a stiffened malleable mesh, the form and the manufacture of shell surfaces with large curvatures and depth are both feasible. The same can happen with the entire coffin lid of fixed and controlled thickness, the controlled reinforcement configuration, the controlled thickening in the folds, created on the pre-compacted surface during the forming phase, and respectively with the optimal external appearance.

- The insertion of reinforcing elements and the addition of elements for the optimization of the texture of the surfaces' external face is easily made, almost automatically and more effectively, in parallel with the formation of the precompacted surfaces by reducing the time of treatment with corresponding reduction of the production cost.

The invention referred to a " method for making coffin shell surfaces with staggered sawdust pulp pre-compression and pre-compacted surfaces and a mechanisms system for the implementation of this method", as it is described above, is illustrated in the drawings. The the brief description of these is an exemplary and not limitative embodiment of the invention, where:

- Drawing 1 shows a schematic flowchart of the method. - Drawing 2 shows a schematic arrangement of the mechanisms' system for the implementation of the method.

- Drawing 3 shows a schematic detail of the feed mechanism.

- Drawing 4 shows a schematic detail of the staggered compression mechanism

- Drawing 5 shows a schematic detail of the two-part mould of the forming mechanism in the open position.

- Drawing 6 shows a schematic detail of the two-part mould of the forming mechanism in the closed position

- Drawing 7 shows a face with the body surfaces of the coffin shell.

- Drawing 8 shows a face with the surfaces of a coffin shell lid.

The "method for the making of coffin shell surfaces with staggered sawdust pulp pre-compression and the forming of pre-compacted surfaces and a mechanisms system for its implementation" as it is described and shown in the drawings 1 to 7, it refers to the surfaces from which the coffin shell is assembled and manufactured. These are of two parts, the body (1) and the lid (2). The surfaces of the body (1) are the bottom (1.1) and its lateral surfaces (1.2), the lid surfaces (2) are the upper part (top) (2.1) and its lateral surfaces (2.2).

The "method for the making of coffin shell surfaces with staggered sawdust pulp pre-compression and the forming of pre-compacted surfaces and a mechanism system for its implementation" as it is described in each of the surfaces (1.1, 1.2, 2, 2.1 and 2.2), with which the shell of the coffin is assembled and formed, is made with a process of continuous steps and it is implemented with a system of mechanisms that are specifically designed and adapted for its implementation.

At the first step (100) of the process there is the mixing and the homogenization of the materials that are used specially and in specific quantities for the composition of the pulp. In particular there is a mixture of: 75%-85% fine- grain sawdust (a) with grain size 0,5 mm to1 mm, 7% to 15% water (b) for the adjustment of the pulp moisture, 5% to 10% industrial glue (c) from thermosetting polymers and 0,5% to 2% bio-degradation factor (d) of the. The mixing and the homogenization of the materials (a,b,c,d) is made in a specially designed and adapted stirring and homogenizing mechanism (10) inwhich a specific amount of fine-grained sawdust (a) is added, depending on the capacity of the shell (12). This (a) is constantly stirred with a specially adapted rotating stirring device(11). In this specific amount of sawdust (a) and under the constant stirring, the proportional quantity of water (b) is added through a specially adapted spray device (13). Then, the corresponding quantity of the industrial glue (c) and of the bio-degration factor (d) of the glue in the predictive percentage proportions are added too. When the mixture of the materials is homogenized, the specially adapted evacuation device (14) which is on the shell (12) is activated in an open position (16) and the homogenized sawdust pulp (15) is driven to the mechanism of the second step (200) of the process.

In the second step (200) of the process, the homogenized sawdust pulp (15) is propelled with constant, adjustable and continuous supply, so a homogenized fixed cross-sectional pulp (201) (width x thickness), which is driven to the third step (300) of the process with a specially designed and adapted adjustable supply feed mechanism, (20), whose funnel-shaped shell (21) is specially adapted in the evacuation device (14) of the stirring and homogenizing mechanism (10) is formed(10). At the base of the shell (21) there is a specially adapted adjustable rotary feeder (22), with which the homogeneous pulp (15) is propelled to the output (23) of the shell (21) with constant and continuous supply, adjustable in a way that a homogenized fixed cross-sectional layer (24) pulp with the desired dimensions (width x thickness) to be formed. This is driven into the moving flat belt surface (32) of the staggered compression mechanism (30)

In the third step (300) of the process, the homogeneous fixed cross-sectional pulp layer (301) is gradually compacted towards the direction of its movement, so its width remains fixed, and its thickness gradually decreases (302) resulting in the forming of a conitnuous coherent pre-compacted flat surface, with a cross- section of the same width and less than 2 to 5 times of the thickness of the initial layer (301) at the end of the third step leading to the fourth step (400) of the process. The homogeneous layer of fixed cross-sectional pulp layer (24) is driven from the output (23) of the adjustable supply feed mechanism (20) to the input of the staggered compression mechanism (30) consisting of a conveyor belt (31) with a flat strap (32) specially adapted to the output (23) of the adjustable supply feed mechanism (20). The homogeneous fixed cross-sectional layer of pulp (24) is transferred to the strap (32) between the first pair of identical cylinders (33,34) rotating towards the direction of the belt movement (32), where a cylinder (33) is steadily adjusted and tangent to the bottom of the flat strap (32) and the second cylinder (34) is adjusted above the flat strap (32), in specially designed vertical slide devices (35) in which the bearing ends of the cylinder are moved and fixed (34) so that its position is adjusted at a distance from the first cylinder (33) a little less than the thickness of the fixed cross-sectional pulp layer (24). The homogeneous pulp layer (24), passing through cylinders (33,34), is slightly compressed and decreases its thickness accordingly, while at the same time it is carried with the belt (32) and the propelling of the rotating cylinder(34) between the cylinders of the subsequent pairs which are specially adapted to the conveyor belt (31) at normal distances up to the last pair of cylinders. The distance between the cylinders gradually decreases in each subsequent pair in the direction strap movement (32) from the first pair of cylinders (33,34) to the last pair of cylinders(36,37), so that the mass of the pulp is respectively compressed and the density and consistency of the pulp are respectively and evenly increased. At the last pair of cylinders (36,37), the distance between them is adjusted so that by increasing the density of the homogeneous pulp layer (24), the desired consistency and strength is achieved, and its thickness is equal to the desired thickness of the pre-compressed surface (38), as it is formed at the output of the staggered compression mechanism (30) and it is propelled to the final forming mechanism (40) of the fourth step (400) of the process.

In the fourth step (400) of the process, the pre-compressed flat surface from the output (303) of the third step (300) of the process is driven between the two parts (411,412) of the two-part mould that is specially designed and adapted to a press machine (presser) which are in an open position (410). The pre-compacted surface formed in the third step (300) of the staggered compression, is compacted with simultaneous heating, when the two parts (411,412) of two-part mould come to the closed position (420) so that its thickness decreases by 2 to 3 times and at the same time it takes the shape and the form (421) of the two-part mould. At the same time the protruding parts (422) from the two-part mould are cut off during the compression and are removed for the crushing and the reuse in the forming of the pulp. At this state of the compression and heating, the surface (421) remains until it acquires the required characteristics of consistency, hardness and stress resistance. Then it is decompressed when the two parts (411,412) of the two-part mould return to an open position (430) and the finally formed surface (431) is received ready for further processing and use. For the application and the implementation of the fourth step (400) of the process, the pre-compressed surface (38) is propelled from the output of the staggered compression mechanism (30) to a specially designed and adapted mechanism of final form (40) and more specifically between the two parts (41,42) of the two-part mould, whose relief surfaces (43,44) are shaped in such a way that the one part (41) has the same "negative relief', form and shape (43) as the external face and the other part has the same (42) "negative relief”, form and shape (44) as the internal side of the desired shape of the coffin shell surface (1.1, 1.2, 2, 2.1, 2.2).The dimensions (length x width) of the part (45) of the pre-compressed surface (38), which is propelled between the two parts (41,42) of the two part mould, are larger than the dimensions of the" relief " formulation (43,44) of the two parts (41,42) of the two-part mould, so that by shrinking during the compression, the section (45) of the pre-compressed surface protrudes across the entire perimeter of the two part- mould (41,42). Section (45) of the pre-compacted surface is compacted with strong pressure between the two parts (41,42) of the two- part mould until its final thickness is reduced by 2 to 3 times and it takes the relief faces’ (43,44) shape and form (46) of the two parts (41 ,43) of the two-part mould. With the compression at the final position of the two parts (41,42) of the two- part mould, the protruding parts (48) of the section (45) of the pre-compressing surface are cut off with edges (47) and they are driven for crushing and reuse in the pulp formation. In this position the compressed surface (46) which has acquired the final shape and form between the two parts (41 ,42) of the two-part mould, is heated to high temperature with an adjustable heating device (49) specially adapted to the body of the two parts (41,42) of the two-part mould. It remains there, until the industrial glue with the remaining components of the pulp are fully activated and balanced, and until it obtains the required consistency and strength. Then it is decompressed with the removal of the two parts (41 ,42) of the two- part mould in the open position and it is received ready for further processing and use.

In cases when a slight heating of the pulp mass is required during its staggered compression, it is specially adapted to cylinders from the the first pair (33,34) to the last pair (36,37) of the staggered compression mechanism (30), adjustable heating device with electric resistors and / or diathermic liquid, with surface lifting capacity of a temperature up to 100 degrees Celsius.

For optimizing the external face of surfaces (1.1, 1.2, 2,2.1, 02.2) of the shell coffin, a thin paper film (72) impregnated with thermosetting polymer resin is adapted to the corresponding face of the pre-compacted surface (28). For the adjustment of the thin paper film (72) on the lower face of the pre-compacted surface (28) adjacent to the strap (32) of the conveyor belt (31), immediately after the last pair of cylinders (36,37,) a second identical conveyor belt (60) of the same length and the same dimensions, with at least two identical and of the same dimensions pairs of cylinders (61,62) and (63,64), moving at the same speed and towards the same directions of cylinders' the movement is adapted. For the continuous feed of the thin paper film (72) on the lower face of the pre-compacted surface (28)adjacent to the strap (32) of the conveynor belt (31) a specially designed device (70) shall be respectively adjusted to the lower part of the second conveyor belt (60) consisting of a rotating drum (71) in which the paper film (72) is wrapped. The paper film (72) is propelled by the cylinders (61,63) and the strap (65) of the conveyor belt (60) and it is adapted with loose compression to its corresponding lower face of the pre-compacted surface (28).

For the adjustment of the thin film of paper (82) on the top of the pre-compressed surface (28) a specially designed corresponding device (80) is adapted respectively at the top part of the second conveyor belt (60). This device consists of an identical rotating drum (81) in which the film of the paper (82) is wrapped and propelled by the cylinders (62,64) and is adapted with loose compression in the corresponing top side of the precompressed surface (28). For the cases that the finally formed surface has large curvatures or it receives significant stresses during the forming, such as in the case that the lid(2) of the coffin shell is adapted to the pre-compacted surface (38), a reinforcement mesh (52) is adapted to the precompressed surface (38) with the use of a specially adjusted mechanism (50) at the beginning of the conveyor belt (31) of the staggered compression (30) mechanism which consists of a rotating drum (51) wrapped in the reinforcemnet mesh (52). The reinforcement mesh (52) is initially adapted in the mid-thickness of the homogeneous fixed cross-sectional pulp layer (24) with a specially adapted device at the output (23) of the adjustable feed mechanism (20) where there is a specially formed slot (25) through which the mesh (52) is inserted driven by two specially adapted driving cylinders (26) in the outer part of the slot (25) and it moves up to a specially adapted retaining grid (27) in the middle of the slot (25) and in the midthickness of the homogeneous fixed cross -sectional pulp (24) layer.

By The "Method for making coffin shell surfaces with staggered sawdust pulp precompression and forming of pre-compacted surfaces and a system of mechanisms for its implementation" as it is described and revealed in the above paragraph and in the drawings, the surfaces (1.1, 1.2, 2, 2.1, 2.2) of the body (1) and lid (2) of a coffin, in any size with the proportional dimensions, inany shape or form and with any relief configuration and colour representations of the outer face.

By assembling the above surfaces (1.1, 1.2, 2, 2.1, 2.2) made by the method and a mechanisms system, as it is described and revealed in the above paragraph and drawings, a coffin shell is made in any size with the proportional surface dimensions, in any shape or form and with any formation of relief and color representations at the outer face.