EP2123826A2 - Method and device for producing a laminar product and the laminar product itself - Google Patents

Abstract

The method involves forming mold parts (36) using a forming tool (14), where the mold parts are an integral or separate part of a carrier (34). The tool is provided with mold cavities (16) in which the mold parts are separately formed by introducing a cellulosic suspension in the cavities such that each mold part is provided with a head part. The head part is widened in diameter compared with diameter of an arm, where the arm diameter tapers from a transitional zone to the carrier. The respective mold parts are removed by drying after partial solidification or hardening in the cavities. Independent claims are also included for the following: (1) a device for manufacturing a laminar product (2) a laminar product manufactured by a method.

Description

The invention relates to a method and a device for producing a surface product as well as the surface product itself.

In the prior art, a variety of pertinent solutions concerning surface products are known.

For example, by the WO 02/13647 A2 a method for producing a surface product known as a fastener part, comprising a plurality of integrally connected to a carrier and symmetrically constructed form elements in the form of hooking means in the manner of each one provided with a head stem, wherein a moldable material in a forming zone between a pressure tool and a mold is supplied.

In the known method, the opposing boundary walls are at least in a longitudinal section of the respective mold cavity continuously equipped with a convex trajectory, so that a smooth transition between the cross-sectional shapes of the stem and head part is achieved for a Verhakungsmittel the support member, so that it insofar comes to a non-inhibiting Entformungsprozeß for the surface product from the manufacturing device.

• Auswählen mindestens eines ersten Materials für eine erste Materialschicht,
• Auswählen mindestens eines zweiten Materials für eine zweite Materialschicht,
• Schmelzformen der ersten Schicht mit einer ersten Oberfläche und einer zweiten Oberfläche aus dem ersten Material,
• Schmelzformen der zweiten Schicht mit einer ersten Oberfläche und einer zweiten Oberfläche aus dem zweiten Material,
• Verbinden der ersten Oberflächen der ersten und zweiten Materialschicht, während sich die Schichten im geschmolzenen Zustand befinden, zur Ausbildung einer mehrlagigen Folie als Trägerteil und
• Ausbilden mehrere Stiele auf mindestens der zweiten Oberfläche der zweiten Materialschicht,
• wobei dieser Formschritt das Formen der mehreren Stiele aus mindestens dem ersten Material und/oder dem zweiten Material und das Verfahren weiterhin den Schritt des Steuerns der Verarbeitungsbedingungen und der Dicke, Viskosität und relativer Größen des ersten und zweiten Materials umfaßt, derart, dass das erste Material, das die erste Schicht bildet, in oder durch die auf der zweiten Oberfläche der zweiten Schicht ausgebildeten Stiele hindurch ragt und Teil der Stiele bildet.

By the EP 1 028 639 B1 A method is known for producing a carrier web of plastic material having a plurality of stems as surface product extending from at least one side of the web, said method comprising the steps of:

• Selecting at least one first material for a first material layer,
• Selecting at least one second material for a second material layer,
• Melting the first layer having a first surface and a second surface of the first material,
• Melting the second layer with a first surface and a second surface of the second material,
• Bonding the first surfaces of the first and second material layers while the layers are in the molten state to form a multilayer film as a support member and
• Forming a plurality of stems on at least the second surface of the second material layer,
• wherein said forming step comprises forming the plurality of stems from at least one of the first material and the second material, and the method further comprises the step of controlling the processing conditions and the thickness, viscosity, and relative sizes of the first and second materials such that the first material forming the first layer, protruding into or through the stems formed on the second surface of the second layer, and forming part of the stems.

Furthermore, this document discloses a web as a surface product solution, which is produced by this process. With this known solution, at least one of the two material layers is produced by coextrusion of the plastic material, wherein the stem ends are calendered with a further shaping roller in a further method step be so as to obtain a mushroom-shaped hook and loop closure material as the final product.

With the known methods can be a variety of different embodiments of a fastener part obtained as surface product with preferably mushroom-shaped fastener parts as mold elements on a band-shaped support member, which are characterized in that the respective form or closure element (stem and head) made of a solid plastic material , Although the plastic materials used here are recyclable and even at least partially biodegradable, the use of pertinent materials, especially with regard to packaging technology and with regard to increased environmental compatibility, still leaves something to be desired. There is also a growing shortage of raw materials on the markets, which is causing plastic prices to soar so that the end products produced from them are becoming expensive.

Furthermore, in the prior art as surface products a variety of paper or cardboard box products are known, which also used as so-called display packaging the modern consumer goods industry open the possibility to place a variety of products at the point of sale directly and aufzuständern. In general, the pertinent display packaging is formed in the manner of a display pallet and the like, as usual in other pallet systems transported, but then regularly at the place of installation and sale for the respective installation or sales team a variety of Handling steps is necessary to make the content of the display pallets salable.

To counter this disadvantage is in the WO 2007/059862 A1 Although already a stand part, in particular corrugated cardboard, solid board or the like Material consisting, shown, the individual faces along fold lines folded in a time-saving manner give a quick box or display structure; However, this development requires a high level of experience that not every manufacturer of cardboard or paper products has.

Furthermore, the consumer from everyday life also knows surface products made of paper, such as toilet paper, handkerchiefs, towels, wipes, etc., some of which are multi-layered, meet modern product requirements.

Based on this prior art, the present invention seeks to provide a method for producing a surface product available, with which can increase the application possibilities for pertinent surface products in an advantageous, process-reliable and cost-effective manner. The invention is also based on the object to provide a device with which the manufacturing process can be reliably realized process technology, as well as to offer a surface product to the market, which is cost-effective and takes into account increased environmental requirements. The pertinent objects solves a method according to the feature configuration of claim 1, a device with the feature configuration of claim 7 and a surface product according to the feature design of claim 9.

The inventive method is used to produce a surface product having at least partially cellulosic components, in particular made of paper or paperboard and having a support member, wherein by means of at least one forming tool individual mushroom-like form elements are formed, which are integral or separate part of the assignable support member and on this at least partially formed above.

Thus, for example, the support member may be constructed of cellulosic components, for example, entirely made of paper, which should be highly absorbent and by means of the shaping tool can be individual mushroom-like form elements as integral part of the support member on this above put on. In that regard, the individual form elements in the form of mushroom-like projections are likewise formed from cellulosic material, in particular from paper material. By the individual form elements, in particular with regard to the enlarged diameter head parts, now on the one hand, an increase in surface area for the support member and on the other allow the mold elements a kind of scratching effect, which improves the Abreinigungsergebnis, especially if the thus constructed surface product as a wipe in the home is used or as toilet paper its intended purpose.

In order to improve the absorbency even further, so far, the carrier part of the mentioned area product is constructed in several layers, with some of the layers may prove to be particularly absorbent and the other part serves mainly the stability of the overall product. Although it is also common in domestic household products to achieve the mentioned surface enlargement with scratching effect by impressing a relief-like structure in the paper material; but the molded, individually protruding mold elements, which otherwise leave the surface of the support member untouched, prove to be the better solution.

The scratching effect can be improved even further if the carrier part is again made of paper; However, the mold elements as a separate component, for example, consists of cellulose material with plastic parts, applied to the support member made of paper. The cellulose-plastic molded elements can be sprayed on the carrier part, for example, in the manner of enlarged drops with widened head diameters, wherein the Spraying device insofar then forms the forming tool. The sprayed or otherwise applied droplets retain their droplet shape due to the surface tension of the plastic material in spite of the cellulose base and can be appropriately cured and dried on the support member, for example using a heat source. The paper-like, possibly multi-layered support part then remains absorbent and the applied, on the support part solidified mushroom-like droplets, in turn, increase the scratching effect for improved cleaning of surfaces of any kind.

In a particularly preferred embodiment of the method according to the invention, however, the individual form elements are formed as mushroom-shaped closure elements, so that can be produced using the method according to the invention, a fastener closure part made of paper or cardboard. The adhesive fastener elements can be attached directly to paper or cardboard products such as boxes, optionally in one piece, so that the boxes can be reliably closed for receiving a packaged goods, without additional closure systems would be necessary, such as tapes, strapping, package cords and the like. In order to give the molded elements increased rigidity, it is preferably provided to offset the cellulosic suspension from which the mold elements can be produced with a plastics material, for example with a predeterminable percentage of conventional polymer material.

The surface fastener mainly built from paper material so far proves to be particularly easy to recycle and biodegradable. Moreover, it can be produced on an industrial scale, which has a cost effect on its production price. It is surprising to one of ordinary skill in the art that he uses surface-mount fasteners such as Velcro ^® fasteners using cellulosic material can build, that are reliable in use and long lasting usable.

The mushroom-shaped closure elements of an adhesive closure part can be combined with mushroom-shaped closure elements of another adhesive closure part to form a repeatedly openable and closable adhesive closure with each other; but it is also conceivable to connect a conventional loop or loop material of a closure part with the closure part with the hook or mushroom-shaped form elements made of paper. In order to achieve a special security in the closure geometry, it is preferably provided that a thermosetting curable molding compound is applied to the free head side of the respective mold element, which stiffen the paper head in order to ensure a safe Unterhakungsmöglichkeit. The thus produced closure of paper forming elements together with paper carrier part builds particularly easy and the cellulose material used can be obtained inexpensively in very large quantities on the world market, which is already no longer the case with some types of plastic.

If it depends on a further reduction in weight, the individual mold elements can also be obtained as a hollow element, d. H. the interior of the stem of the mold element forms a cavity, which in turn can be filled if necessary, for example with flame-retardant or flame-resistant materials, so as to be able to ensure increased fire safety in safety-relevant areas. In that regard, the extinguishing agent can be introduced directly into the surface fastener.

Since in the application of the method according to the invention cellulose-containing suspensions are used which are very hydrous; Thus, for example, 1% solids can come to 99% water content, this fact takes into account the manufacturing device insofar as the forming tool consists of a forming wire. In this case, the sieve structure used in each case can also be multi-layered, so that a part of the sieve structure mainly serves the shaping of the form elements and the respective other sieve element primarily complies with the drainage task. If preferred stainless steel screens are used, the corrosion has been effectively countered, even if, if appropriate, by further additives of the suspension this should have a certain acid content.

The surface product produced by the method and the device, as stated above, can be used for a variety of applications, the list is not complete. Other applications are conceivable in the field of clothing; but there are also technical applications conceivable, for example in the field of aerospace engineering, rail technology, mechanical engineering, motor vehicle construction etc ..

Fig.1

eine schematische Darstellung einer Herstellvorrichtung zum Durchführen des erfindungsgemäßen Verfahrens;

Fig.2

eine gegenüber der Fig. 1 geänderte Ausführungsform der Herstellvorrichtung;

Fig. 3

in stark vergrößertem Maßstab einzelne Formelemente eines Flächenproduktes, hergestellt mit einer Herstellvorrichtung nach den Fig. 1 und 2;

Fig. 4 bis 6

einen Teilausschnitt betreffend verschiedene Flächenprodukte auf der Grundlage des Flächenproduktes nach der Fig. 3.

In the following, the solution according to the invention will be explained in more detail with reference to various embodiments according to the drawing. This show in principle and not to scale representation of the

Fig.1

a schematic representation of a manufacturing apparatus for performing the method according to the invention;

Fig.2

one opposite the Fig. 1 modified embodiment of the manufacturing device;

Fig. 3

on a greatly enlarged scale individual form elements of a surface product, manufactured with a manufacturing device according to the Fig. 1 and 2 ;

4 to 6

a partial section concerning different surface products on the basis of the surface product after the Fig. 3 ,

The manufacturing device according to the Fig. 1 shows their basic structure in horizontal manufacturing orientation. Between two roller-shaped guide bodies 10, of which at least one is drivable, extends a band-shaped forming wire 12, which is part of a designated as a whole by 14 forming tool. The forming wire 12 has a plurality of individual mold cavities 16, which pass completely through the forming wire 12 and the respective cavity 16 has seen from the side according to the sectional view of the Fig. 1 the shape of a hyperboloid of revolution. However, other cavity forms are also possible here. The manufacturing device according to the Fig. 1 also has an additional circulating dewatering belt 18 which is arranged in a flat surface with the forming wire 12 between this and the two guide bodies 10. The dewatering belt 18 is provided with a continuous perforation 20, wherein the openings formed in the manner of a fine perforation form far more passages with a smaller cross-sectional area than those formed by the mold cavities 16 of the forming wire 12.

The subdivided in the manner of upper run and lower run bands 12 and 18 have in the plane of a certain width and in the Fig. 1 Cavities 16, which are shown in only one plane, extend as well as the perforation 20 into the plane of the drawing over a predeterminable distance. The thus formed screen belts 12 and 18 may each have several 100 or 1000 through holes on 1cm ² strip material surface. The better understanding because but are in the presentation after the Fig. 1 the proportions so far not correctly reproduced. In any case, the perforation 20 is such stated that the pulp material remains substantially in the mold cavities 16 and can not escape unintentionally.

The drive direction of the guide body 10 is in the Fig. 1 reproduced with arrows, so that in the selected drive direction, the two bands 12 and 18, in the direction of the Fig. 1 seen, move relative to the upper run position from left to right, both bands with the same axial travel speed. Furthermore, the device according to the Fig. 1 an applicator 22, which provided on its underside with individual nozzles, the spray application, allows an even closer presented suspension. Likewise on the upper side of the upper run, a drying device 24 is arranged in the direction of travel of the two belts 12 and 14 behind the application device 22, which by means of hot air or other heat radiation (UV, IR, ultrasound) over a certain drying zone, the drying of the suspension material. On the underlying upper side of the upper run a collecting device 26 is arranged, which captures excess water of the suspension and removes it from the manufacturing device.

Furthermore, cooling devices (not shown) may be present which cool the finished surface product, which may also facilitate demolding to that extent. In addition, a blower 28 may be provided on the top of the lower run, which helps in demolding the product to be produced, the pertinent demolding process can be supported by a removal roller 30, the finished fabric produced the manufacturing device of the same for removal and further processing or shipping takes. Furthermore, the production device can still have a calendering roller 32 for a post-forming operation, which will be explained in more detail below.

To obtain the desired surface product, a cellulose-containing suspension is applied via the applicator 22 to the top of the upper run of the forming wire 12 and the aqueous suspension or Zelluslosebrei penetrates into the mold cavities 16 of the forming wire 12 a. In the pertinent shaping process remains on the top of the upper strand of the forming wire 12, a belt-like support member 34 with which the individual mold elements 36 are integrally connected. In order to facilitate the entry of the suspension, preferably in the form of cellulose pulp in the mold cavities 16, an entry auxiliary device 38, for example, consisting of two oppositely disposed spinning rollers, which support the described entry with a corresponding contact force and the density of the support member 34 with pretending.

It can be provided here several pressure rollers, which are omitted for simplicity in the illustration. As an alternative or in addition to the mentioned spinning rollers, the auxiliary recording device 38 may also have an air knife arrangement (not shown in more detail) with which the entry is supported to the extent described in the manner of an air curtain and under overpressure. The molding process is driven at such a speed that in any case excess water escape from the suspension and can penetrate the perforation 20 of the dewatering belt 18 in order to be able to be discharged from the trough-like collecting device 26 from the production device can. The already indicated drying device 24 also serves from the other side to the drying of the pulp to be solidified, which forms the paper structure for the surface product.

If the pulp, in particular in the region of the lower run of the production device dried to the extent that the band-shaped support member 34 can be deducted from the top of the forming wire 12, preferably using the removal roller 30 and the finished mold elements 36 are made pulled out the assignable mold cavities 16, which can be supported by the indicated blowing device 28 with by this compressed air blows through the perforation 20 of the dewatering belt 18, and through the mold cavities 16 of the forming wire 12 from the rear region forth. The thus shaped mold elements 36 together with the carrier part 34 have a basically geometric structure, as in Fig. 3 as well as in the Fig. 4 shown. In order to plan accordingly head tops, as in the Fig. 5 shown presses the calendering roller 32 from above on the head-side projections of the front end of each mold element 36, with the result that a flattened head geometry according to the idealized representation of the Fig. 5 established.

As already indicated, the formation of the surface product is a cellulosic suspension in which about 1% solids to 99% water content falls. To form the cellulosic suspension, fibers are preferably used having a diameter between 1 .mu.m and 100 .mu.m, preferably of the order of 10 .mu.m, and the length of the respective pulp fiber should be in the range of 10 .mu.m to 2 mm, preferably about 100 .mu.m. It has proven to be particularly favorable to obtain pulp fibers from vegetable raw materials, wherein preferably pine and spruce as the feedstock result in a long-fiber pulp which can be used particularly well within the framework of the described production device.

However, it has been shown in practice that a pure pulp suspension depending on the application for the finished surface product as a paper product may prove to be too stable, so that the use of plastic materials, such as polymer blends, makes sense, and it has proved to be particularly favorable 10 to 15.5% polymer material in the suspension to use. Further, additives may be added to the cellulosic suspension, such as wet strength agent in the form of melamine resin or in the form of epichlorohydrin resin. To an increased attachment To prevent the cellulose pulp on the forming wire 12, an anti-sticking agent, for example in the form of talcum powder, may be applied to the forming wire 12 with its cavities 16 by suitable means (not shown). Other additives may be provided to cleave formaldehyde from the pulp suspension or to remove impurities that could hinder the process.

• Ammonium Phosphat (AP)
• Ammonium Polyphosphat (APP)
• Resorcinol bis-Diphenylphosphat (PDP)
• Roter Phosphor (RP)
• Tri-n-butyl Phosphat (TBP)
• Tricresyl Phosphat (TCP)
• Triphenyl Phosphat (TPP).

It has proved particularly advantageous to use cellulose feedstock on staple fibers of the same length, wherein so-called bicomponent fibers can also be used, each of which has a cellulose core which is surrounded by a polymer shell. The pertinent cellulose input material is freely available on the market, so that will not be discussed in more detail here. As experience has shown that the paper surface product is easily flammable, additional materials can be used in order to have a flame-retardant or active extinguishing medium. Particularly suitable for this purpose are the following groups of substances:

• Ammonium phosphate (AP)
• Ammonium polyphosphate (APP)
• Resorcinol bis-diphenyl phosphate (PDP)
• Red phosphorus (RP)
• Tri-n-butyl phosphate (TBP)
• Tricresyl phosphate (TCP)
• Triphenyl phosphate (TPP).

As an active extinguishing medium may preferably be provided an extinguishing gas such as nitrogen, wherein as a nitrogen carrier, in particular melamine comes into question but also magnesium hydroxide (MDH). Preferably, it may further be provided that at least in the support member 34 nanoparticles such as silicates or graphite are introduced or applied, which also very have good erase properties and beyond the paper support member 34 can stiffen if necessary.

It is particularly advantageous, however, to put on the underside of the upper strand of the belts 12 and 18 a vacuum device, not shown, which, for example, arranged in the catcher 26, the dewatering of the fiber suspension favors, and pulp material as long as from the individual mold cavities 16 sucks with until a hollow stem cross-section (not shown) is created for the single mold element 36, which rests in the other with its edge-side material on the respectively assignable mold cavity 16. The hollow stem part produced so far can then be provided with a flame-retardant agent or else serve to introduce another stiffening agent, for example in the form of a polymer-plastic material to be injected. Preferably, however, it is held to essentially obtain a whole as a whole of paper or cardboard material surface product as a finished product, which is considered from the weight side is very easy and so far can always find use where it depends on a weight reduction, for example in the technical Area of aircraft construction, where the use of such flexible surface products would be possible as a cable tie or the like. Also, upholstery fabrics, wall coverings or the like could be safely determined with the indicated paper closure material in lightweight construction.

As processing temperatures for the applied aqueous pulp suspension temperatures around 60 ° C have proven to be favorable, and a residence time of 10 to 15 minutes at a temperature of 70 ° C for the drying zone by means of the drying device 24. To damage the finished surface product as little as possible , a Teflon coating for the calendering roll 32 is preferably provided. Furthermore, unspecified, Binder and crosslinking materials are used to promote solidification of the pulp material.

If a calender roll 32 as shown in the Fig. 1 is used, can be flat head sides for the mold elements 36 reach as in the Fig. 5 demonstrated. These can then be provided as a starting material from the free head side with a thermosetting molding compound as the respective head part 40, which forms a kind of protection or Verhakungskappe in hemispherical shape. The thermosetting molding composition to this effect can be applied to the free end faces of the mold elements 36 via a conventional applicator, such as spray or doctor device and in the cured state, the head part 40 configured in this way is configured together with the underlying mold element 36 as a mushroom-shaped hooking element, so that in this respect a hookable Adhesive closure part is created, which forms with corresponding elements of another adhesive closure part (not shown) a repeatedly openable and closable adhesive closure.

If, however, a structure is maintained, as in the Fig. 3 and 4 is shown as an example, the pertinent solution of a surface product is particularly suitable for use in the fields of tissue paper, toilet paper and wipes. Since the pulp material for the support member 34 may be very thin, is in a preferred embodiment of the surface product according to the representations of the 4 to 6 below the support member 34 to form a multi-layer system, a support layer 42 is present, for example, formed from a thin-walled polymer material or the like. The pertinent support layer 42 may also be elastic, so that when stretched the contrast rigid paper support member 34 can tear between the mold elements 36, with the result that depending on the applied strain the mold elements 36 move away from each other and in a starting position according to the representations after the 4 to 6 via the support member 34 in turn reach their initial position shown.

Hereinafter, a modified manufacturing apparatus according to the Fig. 2 explained in more detail. In the solution after the Fig. 2 In turn, a roller-shaped drive body 10 is used, which is to rotate in the direction of the arrow shown. On the guide body 10, a forming wire 12 is arranged, which corresponds to the forming wire 12 according to the solution of the manufacturing device according to the Fig. 1 equivalent. Again, the forming wire 12 can be easily worn in case of wear against a new exchange, without having to change the guide body 12. Also, preferably made of stainless steel forming wires 12 are cleaned off from time to time, so it is advantageous if you can remove them from the guide body 12 without problems. In principle, however, it would also be conceivable to introduce the mold cavities 16 directly into the guide body 10 as part of the same. In the present case, however, the guide body 10 shown is provided along its upper side with a perforation, not shown, over which the dehydration can take place, so that parallels exist in this respect to the perforation 20 of the dewatering belt 18 according to the solution Fig. 1 ,

Also the solution after the Fig. 2 has a collecting device 26 for water, which is preferably formed in the present case as a vacuum device. In the direction of the arrow below, the drying device 24 is arranged, to which in turn the blowing device 28 is connected. The devices 24, 26 and 28 are arranged stationary and the guide body roller 10 rotates together with the forming wire 12 about the pivot axis 44 of the overall device. The solution after the Fig. 2 again has the peel-off or removal roller 30 and the insertion aid 38 is this time of a circumferential, one-piece band formed around Deflection rollers 56 is guided around and otherwise has a drive direction according to the arrow, which corresponds to the drive direction of the forming screen roller 10, 12.

The band of the insertion aid 38 may preferably be made of a flexible, resilient material; but here is also the use of metal foil materials, such as an aluminum foil or the like possible. The band of the recording auxiliary device 38 can be driven independently or preferably be taken by the friction during the rotational movement of the guide body 10. Furthermore, the solution according to the Fig. 2 a doctor device 48, with which the pulp-containing suspension can be applied to the forming wire 12. The band-shaped insertion auxiliary device 38 then in turn helps to introduce the pulp suspension into the mold cavities 16 of the forming wire 12 while forming the band-shaped carrier part 34. The finished surface product, the representation of the Fig. 3 corresponds, is then discharged on the bottom of the manufacturing device. Again, it has proved to be favorable to apply by means of an unspecified applicator talcum on the forming wire 12 with its mold cavities 16. If the removal roller 30 has a cooling section, this can lead to the molded elements 36 shrinking somewhat in the mold cavities 16, which helps to make the removal process considerably easier.

Claims (9)

A method for producing a surface product, which comprises at least partially cellulosic constituents, in particular of paper or cardboard, and a carrier part (34), wherein by means of at least one forming tool (14) individual mold elements (36) are formed, the one piece or separately part of attributable support member (34) and are at least partially formed above this, characterized in that the forming tool (14) is provided with a plurality of mold cavities (16), in which the mold elements (36) by introducing a cellulosic suspension in the respective Cavity (16) are individually formed so that the respective mold element (36) is mushroom-like with a widened in diameter head part against a, at least in the foot transition area to the support part (34) tapered diameter of the associated stem part is provided, and that the respective mold elements (36) temporally after at least partially solidifying or hardening in the mold cavity (36) are removed by drying out of this. A method according to claim 1, characterized in that the carrier part (34) and / or the mold elements (36) are formed from a cellulosic suspension, in particular from a cellulose pulp. A method according to claim 2, characterized in that the suspension additives are added, such as - plastic materials, Wet strength agent, Binder and crosslinker materials, - flame retardants. Method according to one of claims 1 to 3, characterized in that the respective carrier part (34) of the surface product is formed in multiple layers. Method according to one of claims 1 to 4, characterized in that on the free head side of at least part of the mold elements (36) a thermosetting molding compound as a head part (40) is applied. Method according to one of claims 1 to 5, characterized in that at least part of the mold elements (36) are formed as a hollow body. Device for carrying out the method according to one of claims 1 to 6, characterized in that the forming tool (14) in the manner of a forming wire (12) is formed, the cavities (16) form the mold elements (36). Apparatus according to claim 7, characterized in that in addition to the respective forming wire (12) still perforated drainage means (18, 20) are present, which are in contact with the forming wire (12). Surface product produced by a process according to claims 1 to 6 and with a device according to claims 7 and 8, characterized in that at least partially individual mold elements (36) protrude over a support member (34), each consisting of cellulosic material, and that the respective form element (36) is provided in a mushroom-like manner with a head part widened in diameter in relation to a diameter of the associated stem part which is tapered, at least in the foot transition area to the carrier part (34).

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