Porous mold for a roll support and spacing structure

摘要

An improved porous mold for fabricating a formed mold pulp structure to protectively support at least one roll of web material. The mold has a forming surface that contains a first molding cavity surrounded by a periphery. The molding container has sidewalls extending from at least a portion of the periphery into the molding cavity. Within the molding cavity is at least one generally semi-cylindrical hump and land formation areas positioned adjacent the hump and one land formation areas at an end of the hump. A first mold forming surface on the hump is smooth and dished longitudinally such that a transverse cross-section of the first mold forming surface across the hump in the molding cavity is generally concave between the respective sidewalls. The first molding cavity also has a chamfered portion between the hump and an adjacent sidewall and the first molding cavity can have a plurality of humps separated by land formation areas. The porous mold can also have a second molding cavity parallel to the first molding cavity and separated by a longitudinal hinge portion that is coplanar with the periphery of the forming surface.