Method of producing a cushion from waste paper or pulp

Abstract

This invention provides a paper molded cushion having a sufficient shock absorbing ability without substantial deformation during the drying process even if the shape of the cushion is very complex. The process comprises the steps of mechanically fluffing waste paper or pulp, adding a proper amount of adhesive to the fluffed paper of pulp, mixing uniformly, casting the mixture in a mold having water drainage small apertures thereof, heating said mold with the mixture therein by dielectric heating or microwave heating, thereby drying the molded paper cushion to a predetermined water content level and taking out the molded paper cushion from the mold. It is also possible to heat and dry the molded paper product under reduced pressure conditions for accelerating the water evaporation or to add a small amount of foamable synthetic plastic particles with the adhesive for making voids inside the molded paper cushion; consequently, the weight of the paper cushion is effectively reduced and the shock absorbing ability is increased. Further if the shape of the product is complex, the mold is divided into plurality of cross-sectional layer parts corresponding to the cross-section of the desired shape and the molded paper parts are assembled with adhesives to form the final shape of the paper cushion.