STATION AND METHOD

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation under 35 U.S.C. § 120 of International Application No. PCT/GB2024/051662, filed Jun. 27, 2024, which claims priority to United Kingdom Application No. GB 2309859.3, filed Jun. 29, 2023, under 35 U.S.C. § 119(a). Each of the above-referenced patent applications is incorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates to a station and method for forming a hollow moulded fibre product to provide a formed hollow moulded fibre product.

BACKGROUND

It is desirable to reduce glass and plastics use in consumable items, particularly packaging. Non-necked receptacles, such as trays, bowls and other simple shapes, are commonly made from paper pulp. However, a more complex necked receptacle, like a bottle, jar or certain types of vase, is more difficult to engineer due to an internal narrowing of the receptacle between a main body portion of the receptacle and an opening of the receptacle. During manufacture of the necked receptacle, it may be desirable to employ a forming operation to improve properties of the necked receptacle.

SUMMARY

According to a first aspect of the present invention, there is provided a hollow moulded fibre product forming station, comprising: a mould for receiving a hollow moulded fibre product; an interface arrangement connectable to an expandable member, the expandable member changeable between a first configuration in which the expandable member is insertable into the hollow moulded fibre product, and a second configuration in which, in use, the expandable member urges the hollow moulded fibre product against an inner surface of the mould to form the hollow moulded fibre product and provide a formed hollow moulded fibre product; and a reservoir system configured so that, when the interface arrangement is connected to the expandable member, the reservoir system is able to supply a portion of fluid to, and receive the portion of fluid from, the expandable member via the interface arrangement to change the expandable member between the first configuration and the second configuration, wherein the reservoir system has a volume greater than a volume of the portion of fluid. As a result, the reservoir system may contain more fluid than is required to change the expandable member from the first to the second configuration (i.e., expand the expandable member). This may improve the functionality of the reservoir system when compared with a reservoir system having a lesser volume.

Optionally, the hollow moulded fibre product forming station is a necked hollow moulded fibre product forming station. Optionally, the hollow moulded fibre product is a necked hollow moulded fibre product. Optionally, the formed hollow moulded fibre product is a formed necked hollow moulded fibre product.

Optionally, the hollow moulded fibre product forming station comprises the expandable member.

Optionally, the reservoir system has a volume greater than a volume of the expandable member when the expandable member is in the second configuration.

Optionally, the hollow moulded fibre product forming station comprises a heater for heating the hollow moulded fibre product when the hollow moulded fibre product is in the mould.

As a result, a thermoforming operation may be applied to the hollow moulded fibre product. A thermoforming operation may improve the mechanical and aesthetic properties of the hollow moulded fibre product to a greater extent than a forming operation where the hollow moulded fibre product is not heated.

When the expandable member contacts the heated hollow moulded fibre product, the portion of fluid, which is inside the expandable member, may heat up. In example stations where the volume of the reservoir system is approximately the same or smaller than the volume of the portion of fluid, the portion of fluid may become heated over repeated forming operations leading to degradation of the expandable member which is susceptible to damage from heated fluid. As the volume of the reservoir system is greater than the volume of the portion of fluid, the temperature reached by the portion of fluid during operation may be lower than example stations where the volume of the reservoir system is approximately the same or smaller than the volume of the portion of fluid. This may improve the functionality of the station by reducing the likelihood of damaging the expandable member and thereby increasing the longevity of the expandable member. This may reduce downtime of the station required for maintenance or reduce the operating cost of the station due to the cost of replacing damaged expandable members.

Optionally, the reservoir system comprises a reservoir, and the reservoir has a volume greater than the volume of the portion of fluid.

Optionally, the reservoir has a volume greater than a volume of the expanded member when the expanded member is in the second configuration.

Optionally, the reservoir system comprises a further reservoir fluidically connected to the reservoir and configured to supply fluid to the interface arrangement; the reservoir is configured to receive fluid from the interface arrangement; the hollow moulded fibre product forming station comprises a valve located between the reservoir and the further reservoir; and the valve is configured to selectively allow or inhibit fluid flow between the reservoir and the further reservoir.

During changing the expandable member from the second to the first configuration (collapsing the expandable member), fluid received from the interface arrangement may be isolated in the further reservoir from fluid in the reservoir. The fluid in the reservoir may be cooler than the fluid in the further reservoir because it may have had time to cool from when it was previously used to expand the expandable member. The potentially cooler fluid in the reservoir may then be used to subsequently expand the expandable member. As a result, the fluid supplied to the expandable member may be cooler than if the two reservoirs and valve were not used, which may reduce the likelihood of the expandable member becoming damaged because the expandable member may be susceptible to damage from heated fluid.

Optionally, the hollow moulded fibre product forming station comprises a controller configured to cause the valve to switch between allowing and inhibiting fluid flow.

Optionally, the heater is configured to heat the hollow moulded fibre product to no less than 90° C. Heating the hollow moulded fibre product to no less than 90° C. may improve the mechanical and aesthetic properties of the formed hollow moulded fibre product compared with if the hollow moulded fibre product were heated to a temperature lower than 90° C.

Heating the hollow moulded fibre product to no less than 90° C. may also result in the temperature that the portion of fluid reaches during operation being greater than if the hollow moulded fibre product were heated to a temperature less than 90° C. As discussed previously, the volume of the reservoir system is greater than the volume of the portion of fluid, which may reduce the temperature reached by the portion of fluid during operation. This may be beneficial when the heater is configured to heat the hollow moulded fibre product to no less than 90° C. because of the greater temperatures reached by the portion of fluid during operation.

Optionally, the heater is configured to heat the hollow moulded fibre product to no less than 100° C. Heating the hollow moulded fibre product to no less than 100° C. may improve the mechanical and aesthetic properties of the formed hollow moulded fibre product compared with if the hollow moulded fibre product were heated to a temperature lower than 100° C. Optionally, the portion of fluid comprises water.

Heating the product to a temperature of no less than 100° C. may result in the portion of fluid being heated to temperatures of above 100° C. which may result in the portion of fluid evaporating and thereby rapidly expanding the expandable member, which may lead to bursting of the expandable member. This is a particular risk where the fluid is water. As discussed previously, the volume of the reservoir system is greater than the volume of the portion of fluid, which may reduce the temperature reached by the portion of fluid during operation. This may be beneficial when the heater is configured to heat the hollow moulded fibre product to no less than 100° C. because the temperature of the portion of fluid may be reduced to below 100° C. Thereby the likelihood of the expandable member bursting may be reduced compared with if the volume of the reservoir system were equal to the volume of the portion of fluid.

Optionally, the heater is configured to heat the hollow moulded fibre product to no less than 200° C.

Heating the hollow moulded fibre product to no less than 200° C. may improve the mechanical and aesthetic properties of the formed hollow moulded fibre product compared with if the hollow moulded fibre product were heated to a temperature lower than 200° C.

Heating the product to a temperature of no less than 200° C. may result in the expandable member being heated to over 200° C. which may result in the material of the expandable member degrading. As discussed previously, the volume of the reservoir system is greater than the volume of the portion of fluid, which may reduce the temperature reached by the portion of fluid during operation. This may be beneficial when the heater is configured to heat the hollow moulded fibre product no less than 200° C. because the portion of the fluid may be at a lower temperature than the expandable member and thereby may cool the expandable member. This may reduce the likelihood of the material of the expandable member degrading compared with if the volume of the reservoir system were less than the volume of the portion of fluid.

Optionally, the heater is configured to heat the hollow moulded fibre product directly.

Optionally, the heater is configured to heat the hollow moulded fibre product indirectly. For example, the mould may be heated to heat the hollow moulded fibre product.

Optionally, the volume of the reservoir system is no less than 1.1 times greater than the volume of the portion of fluid. As a result, the functionality of the reservoir system may be improved to a greater extent than if the reservoir system was less than 1.1 times greater than the volume of the portion of fluid.

For example, in stations comprising the heater, the temperature reached by the portion of fluid during operation may be lower when compared with having a volume of less than 1.1 times. Thereby the likelihood of the expandable member becoming damaged may be reduced.

Optionally, the volume of the reservoir is no less than 1.1 times greater than the volume of the portion of fluid.

Optionally, the volume of the reservoir system is no less than 1.1 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the volume of the reservoir is no less than 1.1 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the volume of the reservoir system is no less than 2 times greater than the volume of the portion of fluid.

In example stations comprising two expandable members, the reservoir system may be able to contain sufficient fluid to operate both expandable members simultaneously. Operating two expandable members using a single reservoir system may enable the throughput of the station to be increased without requiring an additional reservoir system, which might otherwise complicate the station and thereby increase the cost of the station.

Optionally, the volume of the reservoir is no less than 2 times greater than the volume of the portion of fluid.

Optionally, the volume of the reservoir system is no less than 2 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the volume of the reservoir is no less than 2 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the volume of the reservoir system is no greater than 4 times greater than the volume of the portion of fluid. Beyond a volume of 4 times greater, any further improvements to the functionality of the reservoir system, such as further reducing the likelihood of damaging the expandable member, may be outweighed by the increased cost of increasing the volume of the reservoir system. Thereby, by having a volume of no greater than 4 times, the cost of the reservoir system may be reduced without significantly increasing the likelihood of damaging the expandable member.

Optionally, the volume of the reservoir is no greater than 4 times greater than the volume of the portion of fluid.

Optionally, the volume of the reservoir system is no greater than 4 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the volume of the reservoir is no greater than 4 times greater than the volume of the expanded member when the expanded member is in the second configuration.

Optionally, the hollow moulded fibre product forming station comprises a cooling system configured to cool the portion of fluid; and the hollow moulded fibre product forming station is configured to cause the cooling system to cool the portion of fluid before the fluid is supplied to the expandable member via the interface arrangement to change the expandable member from the first configuration to the second configuration. By cooling the portion of fluid before it is supplied to the expandable member to change the expandable member from the first configuration to the second configuration, the portion of fluid may be cooler than if no cooling system were used. Supplying cooler fluid to the expandable member may reduce the likelihood of the expandable member becoming damaged because the expandable member may be susceptible to damage from heated fluid.

Optionally, the cooling system is configured to cool the portion of fluid before the portion of fluid is supplied to the expandable member via the interface arrangement to change the expandable member from the first configuration to the second configuration. As a result, the temperature of the portion of fluid may be lower than if the portion of fluid were not cooled. This may further reduce the likelihood of the expandable member becoming damaged.

Optionally, the cooling system comprises a heat exchanger, a fluid movement device, and a cooling system fluidic flow path; the cooling system fluidic flow path has a first end connected to the reservoir system, and a second end connected to the reservoir system; the heat exchanger is located along the cooling system fluidic flow path; and the fluid movement device is configured to move fluid along the cooling system fluidic flow path and over the heat exchanger. During operation, the fluid movement device (e.g., a pump or a vacuum generator) moves fluid from the reservoir system (via the first end), over the heat exchanger, and back to the reservoir system (via the second end). Using a fluid movement device to actively move fluid over the heat exchanger rather than, for example, submerging the heat exchanger in the reservoir of the reservoir system and relying on convection to move fluid past the heat exchanger, may increase the flow rate of fluid over the heat exchanger. This increased flow rate may result in a greater heat transfer from the fluid moving over the heat exchanger to the heat exchanger and thereby increase the cooling provided to the fluid moving over the heat exchanger by the cooling system. Increase cooling may reduce the temperature of the portion of fluid and thereby reduce the likelihood of the expandable member being damaged.

Optionally, the hollow moulded fibre product forming station is configured to control the expandable member in a cycle in which the hollow moulded fibre product forming station causes: the expandable member to be inserted, in the first configuration, into the hollow moulded fibre product; the portion of fluid to be supplied to the expandable member from the reservoir system, via the interface arrangement, to change the expandable member from the first configuration to the second configuration, within the hollow moulded fibre product, to urge the hollow moulded fibre product against the inner surface of the mould; the expandable member to be maintained in the second configuration for a time period of no less than 10 s to form the hollow moulded fibre product and provide a formed hollow moulded fibre product; the portion of fluid to be received by the reservoir system from the expandable member, via the interface arrangement, to change the expandable member from the second configuration to the first configuration; and the expandable member to be withdrawn, in the first configuration, from the formed hollow moulded fibre product. Having a time period of no less than 10 s results in the hollow moulded fibre product being urged against the inside of the mould for a longer duration than if the time period were less than 10 s. Therefore, by having a time period of no less than 10 s, the mechanical and aesthetic properties of the formed hollow moulded fibre product may be improved compared with if the time period were less than 10 s. In stations comprising a heater, having a time period of no less than 10 seconds also results in the temperature reached by the portion of fluid being greater than if the time period were less than 10 s. As discussed previously, the volume of the reservoir system is greater than the volume of the portion of fluid which may reduce the temperature reached by the portion of fluid during operation. This may be beneficial when the time period is no less than 10 s because of the greater temperatures reached by the portion of fluid during operation. Optionally, the time period is no less than 90 s.

Optionally, the hollow moulded fibre product forming station is configured to cause: the cycle to be repeated in a subsequent cycle to provide an additional formed hollow moulded fibre product; and a further time period between the portion of fluid being received by the reservoir system from the expandable member in the cycle, and the portion of fluid being supplied to the expandable member in the subsequent cycle, to be no less than 2 s.

By having a further time period of no less than 2 s, the temperature that the portion of fluid reaches during operation may be less than if the further time period were less than 2 s. Thereby the likelihood of the expandable member being damaged may be reduced compared with if the further time period were less than 2 s. Optionally, the further time period is no less than 5 s. Optionally, the further time period is no less than 30 s.

Optionally, the hollow moulded fibre product forming station comprises a vacuum generator configured to move the portion of fluid from the expandable member to the reservoir system, via the interface arrangement. Using a vacuum generator may reduce the cost of the station compared with, for example, using a pump because the vacuum generator required to draw the fluid at a required speed may be cheaper to purchase than the equivalent pump.

Additionally, in examples where the hollow moulded fibre product forming station is comprised by a receptacle manufacturing line, the receptacle manufacturing line may comprise other stations which employ a vacuum. In these examples, a common vacuum generator may be used for all the stations, which may reduce the cost and maintenance requirements of the system compared with, for example, if each station used a respective pump.

Optionally, the hollow moulded fibre product forming station comprises: an output fluidic flow path fluidically connecting the reservoir system to the interface arrangement; an output fluid movement device located along the output fluidic flow path, and configured to move the portion of fluid along the output fluidic flow path; and an output valve located along the output fluidic flow path, and configured to selectively allow or inhibit fluid flow along the output fluidic flow path. As a result, the output fluid movement device and output valve may be used to control when the portion of fluid is supplied to the expandable member via the interface arrangement and thereby when the expandable member is expanded.

Optionally, the hollow moulded fibre product forming station comprises: a return fluidic flow path, separate to the output fluidic flow path, fluidically connecting the interface arrangement to the reservoir system; a return fluid movement device configured to move the portion of fluid along the return fluidic flow path; and a return valve located along the return fluidic flow path, and configured to selectively allow or inhibit fluid flow along the return fluidic flow path; the output valve is configured to allow fluid flow along the output fluidic flow path when the return valve inhibits fluid flow along the return fluidic flow path; and the return valve is configured to allow fluid flow along the return fluidic flow path when the output valve inhibits fluid flow along the output fluidic flow path. Thereby, in use, the hollow moulded fibre product forming station is operable in two modes. In the first mode the output valve allows fluid flow, the return valve inhibits fluid flow, and the output fluid movement device moves the portion of fluid from the reservoir system to the expandable member along the output fluidic flow path to expand the expandable member. In the second mode, the output valve inhibits fluid flow, the return valve allows fluid flow, and the return fluid movement device moves the portion of fluid from the expandable member to the reservoir system along the return fluidic flow path. By having the separate fluidic flow paths, the portion of fluid may flow in a single direction to and from the expandable member. As a result, the fluid movement devices (which may be a pump or a vacuum generator), need only operate in a single direction which may simplify the fluid movement devices compared with, for example, a single fluidic flow path along which the portion of fluid flows in opposing directions to and from the expandable member, which may require a bi-directional fluid movement device to be used.

Optionally, the hollow moulded fibre product forming station comprises a controller configured to cause: the output valve to switch between allowing and inhibiting fluid flow; and the return valve to switch between allowing and inhibiting fluid flow.

Optionally, the hollow moulded fibre product forming station comprises a divert fluidic flow path connecting the output fluid movement device to the reservoir system, and connected to the output fluidic flow path between the output fluid movement device and the output valve; the output valve is located between the output fluid movement device and the interface arrangement; and when the output valve inhibits fluid flow along the output fluidic flow path, the output fluid movement device is configured to move fluid along the divert fluidic flow path. The output valve may be switched between inhibiting and allowing fluid flow to control when the portion of fluid is supplied to the expandable member and thereby when the expandable member is expanded. By providing the divert fluidic flow path, when the output valve inhibits fluid flow (for example, when the expandable member has been fully expanded), the output fluid movement device may continue to operate and recirculate fluid along the output fluidic flow path located between the reservoir system, the output fluid movement device, the divert fluidic flow path, and the reservoir system. Enabling the output fluid movement device to continue to operate even when the output fluid movement device is not required to move fluid to the expandable member may reduce the time required to expand the expandable member when the output valve is opened because the time required to increase the speed of the output fluid movement device to operational speed may be less if the output fluid movement device remains operational than if the output fluid movement device is turned off when the output valve is closed. In contrast, without the divert fluidic flow path, the output fluid movement device may need to be turned off to prevent damage to the output fluid movement device when the output valve inhibits fluid flow and then the speed of the output fluid movement device is increased from zero when the output valve allows fluid flow.

Optionally, the hollow moulded fibre product forming station comprises a divert valve located along the divert fluidic flow path, and configured to allow fluid to flow along the divert fluidic flow path when the output valve inhibits fluid flow, and inhibit fluid flow along the divert fluidic flow path when the output valve allows fluid to flow. As a result, when fluid flow along the divert fluidic flow path is undesirable, i.e., when fluid flow to the expandable member is desired, the divert valve inhibits fluid flow. As a result, increased flow rates to the expandable member, for a given rating of output fluid movement device, may be achieved which may reduce the time required to expand the expandable member and thereby increase the throughput of the hollow moulded fibre product forming station when compared with not having the divert valve.

Optionally, the hollow moulded fibre product forming station comprises a controller configured to cause the divert valve to switch between inhibiting or allowing fluid flow.

Optionally, the interface arrangement provides a common inlet and outlet to the expandable member. By providing a common inlet and outlet rather than a separate fluidic flow path to operate as an inlet and a further separate fluidic flow path to operate as an outlet, the interface arrangement may be simplified which may result in a more robust and reliable interface arrangement. This may reduce downtime of the hollow moulded fibre product forming station when compared with, for example, if the interface arrangement comprised the separate fluidic flow path to operate as an inlet and the further separate fluidic flow path to operate as an outlet.

Optionally, the interface arrangement comprises an interface arrangement valve; the interface arrangement valve is configured to selectively inhibit or allow fluid flow through the interface arrangement. As a result, the interface arrangement valve may inhibit fluid flow to facilitate the detachment and replacement of the expandable member, and then allow fluid flow to facilitate the flow of fluid into and out of the expandable member. Detaching the expandable member may occur when performing maintenance on the station, for example replacing the expandable member if the expandable member has become damaged. Having the interface arrangement valve inhibit fluid flow prior to detaching the expandable member may enable the expandable member to be detached without losing fluid from the hollow moulded fibre product forming station. A replacement expandable member can then be attached to the interface arrangement. This may be desirable to reduce the downtime required when performing maintenance compared with not having an interface arrangement valve, in which case the fluid in the station may need to be replenished before recommencing operation.

Optionally, the hollow moulded fibre product forming station comprises a controller configured to cause the interface arrangement valve to switch between inhibiting and allowing fluid flow.

Optionally, the hollow moulded fibre product forming station comprises: a further mould for receiving a further hollow moulded fibre product; and a further interface arrangement connectable to a further expandable member, the further expandable member changeable between a further expandable member first configuration in which the further expandable member is insertable into the further hollow moulded fibre product, and a further expandable member second configuration in which, in use, the further expandable member urges the further hollow moulded fibre product against an inner surface of the mould to form the further hollow moulded fibre product and provide a further formed hollow moulded fibre product; the reservoir system is configured so that, when the further interface arrangement is connected to the further expandable member, the reservoir system is able to supply a further portion of fluid to, and receive the further portion of fluid from, the further expandable member via the further interface arrangement to change the further expandable member between the further expandable member first configuration and the further expandable member second configuration, wherein the reservoir system has a volume greater than a combined volume of the portion of fluid and the further portion of fluid. As a result, the reservoir system can operate both expandable members, which may reduce the complexity of the hollow moulded fibre forming station and thereby may increase the reliability of the station and/or reduce the cost of the station when compared to, for example, having a separate reservoir system for each expandable member. Having multiple expandable members may increase the throughput of the station compared with having a single expandable member.

Optionally, the reservoir system has a volume greater than a combined volume of the expanded member when the expanded member is in the second configuration and the further expandable member when the further expandable member is in the further expandable member second configuration.

According to a second aspect of the present invention, there is provided a method of forming a hollow moulded fibre product to provide a formed hollow moulded fibre product, the method comprising: containing fluid within a reservoir system; inserting an expandable member in a first configuration into a hollow moulded fibre product located within a mould; and retaining a portion of the fluid within the reservoir system whilst moving a further portion of the fluid from the reservoir system into the expandable member to change the expandable member from the first configuration to a second configuration in which the expandable member urges the hollow moulded fibre product against an inner surface of the mould.

According to a third aspect of the present invention, there is provided a hollow moulded fibre product forming station controller configured to cause a hollow moulded fibre product forming station to perform the method of the second aspect of the present invention.

According to a fourth aspect of the present invention, there is provided a non-transitory storage medium storing machine-readable instructions that, when executed by a hollow moulded fibre product forming station controller, cause the hollow moulded fibre product forming station controller to cause a hollow moulded fibre product forming station to perform the method of the second aspect of the present invention.

In some examples of any of the above aspects, the hollow moulded fibre product is a bottle, a jar or a type of vase. In some examples of any of the above aspects, the hollow moulded fibre product is a bottle.

According to a fifth aspect of the present invention, there is provided a receptacle manufacturing line comprising the hollow moulded fibre product forming station of the first aspect of the present invention for providing a formed hollow moulded fibre product and apparatus for performing at least one additional process on the formed hollow moulded fibre product to provide the receptacle.

The apparatus may comprise an interior coater and the at least one additional process may comprise the interior coater coating at least a portion of an interior of the hollow moulded fibre product to produce an internally coated hollow moulded fibre product. The apparatus may comprise a closure-part applicator and the at least one additional process may comprise the closure-part applicator applying a closure part to the hollow moulded fibre product or the internally coated hollow moulded fibre product to produce a closable or closed hollow moulded fibre product. The apparatus may comprise an exterior coater and the at least one additional process may comprise the exterior coater coating at least a portion of an exterior of the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product to produce an externally coated hollow moulded fibre product. The apparatus may comprise a decorator and the at least one additional process may comprise the decorator decorating the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product or the externally coated hollow moulded fibre product to produce a decorated hollow moulded fibre product. The apparatus may comprise a dryer and the at least one additional process may comprise the dryer drying the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product or the externally coated hollow moulded fibre product or the decorated hollow moulded fibre product to produce a dried hollow moulded fibre product. The apparatus may comprise an evaluator and the at least one additional process may comprise the evaluator evaluating the hollow moulded fibre product, the internally coated hollow moulded fibre product, the closable or closed hollow moulded fibre product, the externally coated hollow moulded fibre product, the decorated hollow moulded fibre product, or the dried hollow moulded fibre product to produce an evaluated hollow moulded fibre product. In some examples, the receptacle is the hollow moulded fibre product, the internally coated hollow moulded fibre product, the closable or closed hollow moulded fibre product, the externally coated hollow moulded fibre product, the decorated hollow moulded fibre product, the dried hollow moulded fibre product, or the evaluated hollow moulded fibre product.

In some examples, the formed hollow moulded fibre product is a thermoformed hollow moulded fibre product.

In some examples, the receptacle is a bottle, jar or a type of vase. In some examples, the receptacle is a bottle.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a receptacle, the method comprising performing the method of the second aspect of the present invention to provide a formed hollow moulded fibre product, and then performing at least one additional process on the formed hollow moulded fibre product to provide the receptacle.

The at least one additional process may comprise coating at least a portion of an interior of the hollow moulded fibre product to produce an internally coated hollow moulded fibre product. The at least one additional process may comprise applying a closure part to the hollow moulded fibre product or the internally coated hollow moulded fibre product to produce a closable or closed hollow moulded fibre product. The at least one additional process may comprise coating at least a portion of an exterior of the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product to produce an externally coated hollow moulded fibre product. The at least one additional process may comprise decorating the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product or the externally coated hollow moulded fibre product to produce a decorated hollow moulded fibre product. The at least one additional process may comprise drying the hollow moulded fibre product or the internally coated hollow moulded fibre product or the closable or closed hollow moulded fibre product or the externally coated hollow moulded fibre product or the decorated hollow moulded fibre product to produce a dried hollow moulded fibre product. The at least one additional process may comprise evaluating the hollow moulded fibre product, the internally coated hollow moulded fibre product, the closable or closed hollow moulded fibre product, the externally coated hollow moulded fibre product, the decorated hollow moulded fibre product, or the dried hollow moulded fibre product to produce an evaluated hollow moulded fibre product. In some examples, the receptacle is the hollow moulded fibre product, the internally coated hollow moulded fibre product, the closable or closed hollow moulded fibre product, the externally coated hollow moulded fibre product, the decorated hollow moulded fibre product, the dried hollow moulded fibre product, or the evaluated hollow moulded fibre product.

In some examples, the receptacle is a bottle, jar or a type of vase. In some examples, the receptacle is a bottle.

According to a seventh aspect of the present invention, there is provided a method of providing a content-containing receptacle, the method comprising providing a receptacle obtained by the method of the sixth aspect of the present invention and providing the contents in the receptacle to provide the content-containing receptacle.

In some examples, the providing the contents in the receptacle comprises putting the contents into the receptacle. In contrast, in some examples, the providing the receptacle comprises providing the receptacle with the contents already present in the receptacle, thereby providing the contents in the receptacle.

The contents may be in the form of, for example, a liquid, a powder, other flowable materials, one or more solid objects, or a combination thereof. For example, the contents may be a foodstuff such as a condiment, a beverage such as an alcoholic beverage, a household care product such as a detergent or other cleaning product, a personal care product such as a hair care product or a personal cleansing product or a healthcare product or a pharmaceutical product or a cosmetics product, a fragrance product such as a perfume, a vehicle product such as motor oil, or an industrial product. Other suitable contents will be apparent to the skilled reader in view of the content of this application and their common general knowledge.

In some examples, the receptacle is a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

Optionally, the method of the seventh aspect comprises: closing an opening of the receptacle after the providing contents in the receptacle, and/or applying a label or indicia to the receptacle.

In some examples, the closing comprises applying a closure (such as a lid or a cap or a heat seal) to the receptacle to close the opening. In some examples, the closing comprises applying a heat seal to the receptacle and (e.g., thereafter) applying a lid or a cap to the receptacle.

In some examples, the applying the label or indicia to the receptacle occurs after the providing the contents in the receptacle (that is, the label or indicia is applied to the content-containing receptacle). In other examples, the applying the label or indicia to the receptacle occurs before or during the providing the contents in the receptacle.

In some examples, the applying occurs before the closing. In some examples, the applying occurs after the closing. In some examples, the applying occurs during the closing.

According to an eighth aspect of the present invention, there is provided use of a receptacle obtained by the method of the seventh aspect of the present invention to contain contents. The use could be, for example, by a person (such as a natural person or a company) who puts the contents into the receptacle, or by a person who transports the contents, or by a person who wishes to dispose of (e.g. to a consumer or end user), offer to dispose of (e.g. to a consumer or end user), import, or keep the contents whether for disposal or otherwise. The contents may, for example, be in the form of any of those discussed above.

In some examples, the receptacle is a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

Optional features of aspects of the present invention may be equally applied to other aspects of the present invention, where appropriate.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic view of an example receptacle manufacturing line for performing a method of manufacturing receptacles from paper pulp;

FIG. 2 is a schematic view of an example necked hollow moulded fibre product forming station;

FIG. 3 is a schematic view of a first interface arrangement, first expandable member, and first mould of the example necked hollow moulded fibre product forming station of FIG. 2;

FIG. 4 is a schematic view of a reservoir system of the example necked hollow moulded fibre product forming station of FIG. 2;

FIG. 5 is a schematic view of a first fluidic loop of the example necked hollow moulded fibre product forming station of FIG. 2;

FIG. 6 is a schematic view of a second fluidic loop of the example necked hollow moulded fibre product forming station of FIG. 2;

FIG. 7 is a schematic view of a cooling system of the example necked hollow moulded fibre product forming station of FIG. 2;

FIG. 8 is a schematic view of the example necked hollow moulded fibre product forming station of FIG. 2 at a first time increment during operation;

FIG. 9a is an enlarged schematic view of the first mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the first time increment;

FIG. 9b is an enlarged schematic view of the second mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the first time increment;

FIG. 10 is a schematic view of the example necked hollow moulded fibre product forming station of FIG. 2 at a second time increment during operation;

FIG. 11a is an enlarged schematic view of the first mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the second time increment;

FIG. 11b is an enlarged schematic view of the second mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the second time increment;

FIG. 12 is a schematic view of the example necked hollow moulded fibre product forming station of FIG. 2 at a third time increment during operation;

FIG. 13a is an enlarged schematic view of the first mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the third time increment;

FIG. 13b is an enlarged schematic view of the second mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the third time increment;

FIG. 14 is a schematic view of the example necked hollow moulded fibre product forming station of FIG. 2 at a fourth time increment during operation;

FIG. 15a is an enlarged schematic view of the first mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the fourth time increment;

FIG. 15b is an enlarged schematic view of the second mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the fourth time increment;

FIG. 16 is a schematic view of the example necked hollow moulded fibre product forming station of FIG. 2 at a fifth time increment during operation;

FIG. 17a is an enlarged schematic view of the first mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the fifth time increment;

FIG. 17b is an enlarged schematic view of the second mould of the example necked hollow moulded fibre product forming station of FIG. 2 at the fifth time increment;

FIG. 18 is a schematic view of an alternative example necked hollow moulded fibre product forming station;

FIG. 19 shows a non-transitory computer-readable storage medium according to an example;

FIG. 20 shows an example method of forming a necked hollow moulded fibre product to provide a formed necked hollow moulded fibre product and an example method of manufacturing a necked receptacle;

FIG. 21 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and

FIG. 22 shows a method of providing a content-containing receptacle.

DETAILED DESCRIPTION

The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of embodiments of the invention.

FIG. 1 shows a receptacle manufacturing line for performing a method of manufacturing receptacles, in this case necked receptacles, and more specifically in this case in the form of bottles, from paper pulp (i.e., which can form the basis of an example fibre suspension). By “necked receptacle” it is meant that the receptacle has an internal narrowing, or “neck”, between a main body portion, in which most of or all the contents of the receptacle are stored in use, and an opening through which the contents can enter or leave the receptacle in use. The internal width of the receptacle at the neck may be the same as or different to the internal width of the opening. However, the internal width of the neck is smaller than that of the main body portion, so that a shoulder is defined by and between the neck and the main body portion. This shoulder complicates manufacture of the receptacle, since it interferes with subsequent removal (and, in some cases, insertion) of whatever mould tool is inserted into the receptacle to form the internal shape of the receptacle. Examples of necked receptacles are bottles, jars, and certain types of vases. The process is merely exemplary and is provided to give context to examples of the present invention.

Broadly speaking, the exemplary process comprises providing a fibre suspension, introducing the fibre suspension into a mould cavity of a porous first mould and expelling a liquid (such as water) from the fibre suspension to produce a hollow moulded fibre product (which may be called a wet precursor or embryo) in the mould cavity, further moulding the hollow moulded fibre product to produce a hollow further-moulded fibre product, drying and then internally-coating the hollow further-moulded fibre product to produce an internally coated product, drying the internally coated product to produce a dried product, applying a closure part to the dried product to produce a closable or closed product, externally-coating and/or decorating the closable or closed product to produce an externally coated and/or decorated product, and then drying the externally coated or decorated product to produce another dried product. As will be apparent at least from the following description, modifications may be made to the exemplary process to provide variants thereof in which other examples of the present invention may be embodied. For example, in some cases, either the internal coating or the external coating and/or decorating may be omitted. Moreover, in the present case and as indicated by the stars labelled Ins. 1 to Ins. 5 in FIG. 1, the process comprises inspecting or evaluating the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, and the dried product to produce respective evaluated products. In some examples, the receptacle is the hollow moulded fibre product, the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, one of the dried products, or one of the respective evaluated products.

In this example, providing the fibre suspension comprises preparing the fibre suspension from ingredients thereof. More specifically, the preparing comprises providing pulp fibres, such as paper pulp fibres, and mixing the pulp fibres with a liquid to provide hydrated pulp fibres. In this example, the pulp fibres are provided in sheet form from a supplier and the liquid comprises water and one or more additives. In this example, the liquid is mixed with the pulp fibres to provide hydrated pulp fibres having a solid fibres content of 1wt % to 5wt % (by dry mass of fibres). In examples, the one or more additives includes a sizing agent, such as alkylketene dimer (AKD). The hydrated pulp fibres typically comprise AKD in an amount of 0.4wt % with respect to the total dry mass of the solid fibres in the hydrated pulp fibres. In some examples, one or more additives are present in the liquid at the point of mixing the pulp fibres with the liquid. In some examples, one or more additives are included in the hydrated pulp fibres after mixing the pulp fibres with the liquid (for example, the pulp fibres are hydrated for a period of time, such as from 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fibres). The hydrated pulp fibres are passed between plates of a valley beater 11 or refiner that are in motion relative to each other. This fibrillates some, or all, of the fibres, meaning that cell walls of those fibres are caused to become partially delaminated so that wetted surfaces of those fibres comprise protruding hairs or fibrillations. These fibrillations will help to increase a strength of bonds between the fibres in the dried end product. In other examples, the valley beater 11 or refiner may be omitted.

The resultant processed pulp is stored in a vat 12 in a relatively concentrated form (for example, a solid fibres content of 1wt % to 5wt %) to reduce a required storage space. At an appropriate time, the processed pulp is transferred to a mixing station 13 at which the processed pulp is diluted in further water and, optionally, mixed with one or more additives (as well as, or in place of, the one or more additives provided with the hydrated pulp fibres) to provide the fibre suspension ready for moulding. In this example, the solid fibres account for 0.7wt % of the resultant fibre suspension (by dry weight of fibres), but in other examples the proportion of solid fibres in the fibre suspension may be different, such as another value in the range of 0.5wt % to 5wt %, or 0.1wt % to 1wt %, of the fibre suspension (by dry weight of fibres). In some examples, the one or more additives mixed with the processed pulp and water includes a dewatering agent, such as modified and/or unmodified polyethylene imine (PEI), for example modified PEI sold under the trade name Polymin® SK. In some examples, the one or more additives are mixed with the water, and the water and one or more additives subsequently mixed with the processed pulp; in other examples, the processed pulp and water are mixed, and the one or more additives subsequently mixed with the processed pulp and water. The fibre suspension typically comprises Polymin® SK in an amount of 0.3wt % with respect to the total dry mass of the solid fibres. Mixing of the fibre suspension at the mixing station 13 helps to homogenise the fibre suspension. In other examples, the processed pulp or the fibre suspension may be provided in other ways, such as being supplied ready-made.

Downstream of the vat 12 and the mixing station 13 is a first moulding station that comprises a porous first mould 15. In this example, the porous first mould 15 comprises two half-moulds 14 that are movable towards and away from each other, in this case using a hydraulic ram. In this example, each of the half-moulds 14 is a monolithic or unitary tool formed by additive manufacturing (for example, 3D-printing) that defines a mould profile, and, when the half-moulds 14 are brought into contact with each other, their respective mould profiles cooperate to define the mould cavity in which the hollow moulded fibre product is to be formed. Each half-mould 14 itself defines a smaller moulding cavity and, when brought into cooperation with a second half-mould 14, the smaller moulding cavities combine to provide the overall mould cavity. The two half-moulds 14 may themselves be considered “splits” or “moulds” and the overall porous first mould 15 may be considered a “split-mould” or, again, a “mould”. In other examples, the porous first mould 15 may comprise more than two splits 14, such as three, four or six splits, that cooperate to define the moulding cavity.

In FIG. 1, the fibre suspension (also known as slurry) is top-filled into the porous first mould 15, in contrast to moulding processes that dip a mould in slurry. The fibre suspension is drawn under vacuum via a line 16 and into the porous first mould 15, with excess suspending liquid being drawn through the porous first mould 15 under vacuum via a line 18 into a tank 17. Shot mass may be controlled by measuring (for example, weighing) the amount of liquid drawn into the tank 17. A weight scale platform supporting the tank 17 is visible in FIG. 1. Once a required amount (for example, a predetermined volume, such as 10 litres, or a predetermined mass, such as 10 kilograms) of liquid has been collected in the tank 17, suction of the suspending liquid through the porous first mould 15 is stopped and the first mould 15 is opened to ambient air. In this example, the suspending liquid drawn with the fibre suspension in line 16 is water, or predominantly water (as additives may also be present). The liquid drawn under vacuum via the line 18 and into the tank 17 is substantially free of fibres, since these are left behind against the walls of the porous first mould 15 to form the hollow moulded fibre product.

In one example, in order to remove further suspending liquid (for example, water) from the hollow moulded fibre product, and form or consolidate the three-dimensional shape of the product, high pressure fluid (such as compressed air) is introduced into the first mould 15 to compress the fibre suspension against the cavity wall of the first mould 15. This process strengthens the product so that it can be handled, and displaces water from in between the fibres, thereby increasing the efficiency of a subsequent drying process. The fluid is regulated using a hydraulic pump 20. The pump 20 has a cylinder that displaces the fluid in a line 21 into the first mould 15. In an alternative example, an impermeable inflation element in the form of a collapsible bladder is inserted into the first mould 15 and expanded, by introduction of a fluid into the bladder from the line 21, to act as an internal high-pressure core structure for the first mould 15. In such an alternative, the fluid within the line 21 is preferably non-compressible, such as water or oil, although in other examples it could be a compressible fluid, such as air. Water has the advantage over other non-compressible liquids that any leaking or bursting of the bladder will not introduce a new substance to the system (since the suspending liquid is already water, or predominantly water).

Demoulding occurs when the first mould 15 opens for removal of the self-supporting hollow moulded fibre product 22. Mould cleaning 23 is preferably performed subsequently, to remove any remaining small fibres and/or other debris and maintain a porosity of the porous first mould 15. In this example, a radially firing high-pressure jet is inserted into the mould cavity while the first mould 15 is open. This dislodges debris from the wall of the mould cavity. Alternatively, or in addition, water from the tank 17 is pressurised through the back of the porous first mould 15 to dislodge entrapped fibres and/or other debris. Water is drained for recycling back to an upstream part of the system. It is noteworthy that cleaning is important for conditioning the first mould 15 for re-use. The first mould 15 may appear visibly clean after removal of the receptacle, but its performance could be compromised without cleaning.

According to FIG. 1, the hollow moulded fibre product 22 is subsequently transported to a second moulding station where, in a, for example, aluminium, mould 25, pressure and heat are applied for thermoforming a desired neck and surface finish, optionally including embossed and/or debossed surface features. After two halves of the mould 25 have closed around the product 22, a pressuriser is engaged. For example, a bladder 26 (for example, a thermoforming bladder 26) is inserted into the product 22. The bladder 26 is inflated with a pressurised fluid supplied via a line 27 by a pump 28. The pressurised fluid is preferably a non-compressible fluid such as water or oil, although in other examples it could be a compressible fluid such as air. In other examples, during supply, the pressurised fluid is heated with, for example, a heater or, alternatively, is cooled with, for example, a heat exchanger. An external mould block 24 of the mould 25, and/or the mould 25 itself, is also, or alternatively, heated in some examples. After thermoforming, a state of the product 22, which may now be considered a hollow further-moulded fibre product, is considerably more rigid, with more compressed side walls, as compared with the state of the product 22 at demoulding from the first mould 15.

A drying stage 30 (for example, a microwave drying process or other drying process) is performed on the product 22 downstream of the thermoforming, as shown, to provide a dried product. In one example, the drying stage 30 is performed before thermoforming to provide a dried product. However, moulding in the mould 25 requires some water content to assist with bonding during the compression process. The drying may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying.

The product 22 is then subjected to an internal-coating stage during which, in this example, an interior coater in the form of a spray lance 31 is inserted into the product 22 and applies one or more surface coatings to internal walls of the product 22 to produce an internally coated product. In another example, the product 22 is instead filled with and subsequently drained of a liquid that coats the internal walls of the product 22. In practice, such coatings provide a protective layer to prevent egress of contents into the bottle wall, which may permeate and/or weaken it. Coatings will be selected dependent on the intended contents of finished receptacle, for example, a beverage, foodstuff, detergent, lubricant, pharmaceutical product, etc. In this example, the internally coated product 22 is then subjected to a curing or drying process 32, which can be configured or optimised dependent on the internal coating, for example, drying for twenty-four hours at ambient conditions or by a flash drying method. The drying again may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying. Following the drying, the coated product 22 is considered another dried product.

A closure or mouth forming process is then performed on the product 22 by a closure-part applicator to produce a closable or closed product. For example, as shown in FIG. 1, a neck fitment 33 is affixed to the dried product. This results in the product being closable subsequently by positioning of a cap, lid or other closure relative to the neck fitment. An exterior coating and/or decoration is then applied to the product 22 by an exterior coater and/or a decorator, respectively, as shown in the further stage 34, to produce an externally coated and/or decorated product. In one example, the product 22 is dipped into a liquid to coat its outer surface, as shown in FIG. 1. In another example, the outer surface receives the external coating in a different manner. The coating and/or decoration may cover all or only part of an external surface of the product. The product 22 is then allowed to dry in warm air to produce another dried product. In other examples, the drying may be performed using a dryer such as one of those discussed above.

The product 22 may therefore be fully formed, considered the end “receptacle”, and ready to accept contents therein. In other examples, the receptacle may be fully formed without the neck fitment 35 being affixed and/or without the interior coating being applied and/or without the exterior coating being applied and/or without the decoration being applied and/or immediately after one of the drying processes or one of the inspecting and/or evaluating processes. For example, in some cases, the product is provided with the closure part by moulding the closure part during moulding of the product at the first moulding station and/or the second moulding station.

FIG. 2 shows a forming station 101 which may be used to form the product 22 discussed above. The forming station 101 comprises: a first interface arrangement 103, a second interface arrangement 105, a first expandable member 107, a second expandable member 109, a first mould 111, a second mould 113, a reservoir system 115, a first fluidic loop 117, a second fluidic loop 119, a vacuum generator 121, a cooling system 123, and a controller 125.

The first interface arrangement 103 (shown in FIG. 3) comprises an interface 127, an interface fluidic flow path 129, and an interface arrangement valve 131. The interface 127 comprises a connector to which the first expandable member 107 is detachably connected. The interface fluidic flow path 129 comprises a first end 102 which is connected to the connector, and a second end 104 which is connected to the first fluidic loop 117.

The interface arrangement valve 131 is located along the interface fluidic flow path 129 and selectively inhibits or allows fluid flow along the interface fluidic flow path 129. Specifically, the interface arrangement valve 131 is switchable between being open and being closed. The interface arrangement valve 131 may be switched to being closed to facilitate the replacement of the first expandable member 107, which may be required if the first expandable member 107 becomes damaged.

The second interface arrangement 105 is identical to the first interface arrangement 103 except that the connector of the second interface arrangement 105 is detachably connected to the second expandable member 109, and the second end of the interface fluidic flow path of the second interface arrangement 105 is connected to the second fluidic loop 119.

The first expandable member 107 comprises an inflatable member in the form of an elastomeric bladder. The bladder comprises a neck portion and a body portion. The neck portion has a smaller diameter than the body portion. In other examples, the bladder may comprise a single portion of constant diameter. The second expandable member 109 is identical to the first expandable member 107.

The first mould 111 (which is shown open in FIG. 3 and closed in FIG. 2) comprises a first part 112 and a second part 114. In other examples, the first mould 111 may comprise more than two parts. The two parts 112,114 are separable so as to open the first mould 111. The first part 112 comprises a cavity 116, a surface 118, and a heater assembly 133. In this example, the cavity 116 has the shape of half a bottle. The surface 118 defines the cavity 116 and has a concave shape. The second part 114 is a mirror image of the first part 112. The second part 114 is moveable relative to the first part 112 to close the first mould 111. When the first mould 111 is closed, a mould cavity 135 (shown in FIG. 2) is created within the first mould 111 that comprises the cavities 116 of the first part 112 and the second part 114. The second part 114 is moved by a hydraulic ram (not shown). The second mould 113 is identical to the first mould 111 and thereby comprises a second mould cavity 137 which is identical to the first mould cavity 135.

The reservoir system 115 (shown in FIG. 4) comprises a return reservoir 139, an output reservoir 141, a reservoir fluidic flow path 143 and a reservoir valve 145. The return reservoir 139 is a tank which retains fluid in use. The output reservoir 141 is a tank which retains fluid in use. The output reservoir 141 has a volume of 35 L. The volume of the output reservoir 141 is no less than 1.1 times greater, and no greater than 4 times greater, than the volume of a first portion of fluid (discussed below in more detail) supplied to the second expandable member 109 to change the second expandable member 109 from a collapsed state to an expanded state. The volume of the output reservoir being no less than 2 times greater and no greater than 4 times greater, than the volume of a first portion of fluid supplied to the second expandable member 109 to change the second expandable member 109 from the collapsed state to the expanded state is also envisaged.

The reservoir fluidic flow path 143 comprises a first end 142 which is connected to the return reservoir 139 and a second end 144 which is connected to the output reservoir 141. The return reservoir 139 is located above the output reservoir 141 such that fluid in the return reservoir 139 may flow under gravity from the return reservoir 139 to the output reservoir 141 along the reservoir fluidic flow path 143.

The reservoir valve 145 is located along the reservoir fluidic flow path 143 and selectively inhibits or allows fluid flow along the reservoir fluidic flow path 143. Specifically, the reservoir valve 145 is switchable between being open and being closed.

The first fluidic loop 117 (shown in FIG. 5) comprises a first output fluidic flow path 147, a first return fluidic flow path 149, a first output fluid movement device 151, a first output valve 153, a first return valve 155, a first divert fluidic flow path 157, and a first divert valve 159.

The first output fluidic flow path 147 comprises a first end 146 and a second end 148. The first end 146 is connected to the output reservoir 141. The second end 148 is connected to the first interface arrangement 103 and the first return fluidic flow path 149.

The first return fluidic flow path 149 comprises a first end 150 and a second end 152. The first end 150 is connected the first output fluidic flow path 147 and the first interface arrangement 103. The second end 152 is connected to the return reservoir 139.

The first output fluid movement device 151 is located along the first output fluidic flow path 147 between the output reservoir 141 and the first output valve 153. The first output fluid movement device 151 is operable to move fluid along the first output fluidic flow path 147 and the first divert fluidic flow path 157. The first output fluid movement device 151 comprises a pump.

The first output valve 153 is located along the first output fluidic flow path 147 between the first output fluid movement device 151 and the first interface arrangement 103. The first output valve 153 selectively inhibits or allows fluid flow along the first output fluidic flow path 147. Specifically, the first output valve 153 is switchable between being open and being closed.

The first return valve 155 is located along the first return fluidic flow path 149 between the first interface arrangement 103 and the return reservoir 139. The first return valve 155 selectively inhibits or allows fluid flow along the first return fluidic flow path 149. Specifically, the first return valve 155 is switchable between being open and being closed.

The first divert fluidic flow path 157 comprises a first end and a second end. The first end connects to the first output fluidic flow path 147 between the first output fluid movement device 151 and the first output valve 153. The second end connects to the output reservoir 141.

The first divert valve 159 is located along the first divert fluidic flow path 157 and selectively inhibits or allows fluid flow along the first divert fluidic flow path 157. Specifically, the first divert valve 159 is switchable between being open and being closed.

The second fluidic loop 119 (shown in FIG. 6) comprises a second output fluidic flow path 161, a second return fluidic flow path 163, a second output fluid movement device 165, a second output valve 167, a second return valve 169, a second divert fluidic flow path 171, and a second divert valve 173.

The second output fluidic flow path 161 comprises a first end 160 and a second end 162. The first end 160 is connected to the output reservoir 141. The second end 162 is connected to the second interface arrangement 105 and the second return fluidic flow path 163.

The second return fluidic flow path 163 comprises a first end 164 and a second end 166. The first end is connected to the second output fluidic flow path 161 and the second interface arrangement 105. The second end 166 is connected to the return reservoir 139.

The second output fluid movement device 165, the second output valve 167, the second return valve 169, the second divert fluidic flow path 171, and the second divert valve 173 are identical to the corresponding element of the first fluidic loop 117.

The vacuum generator 121 is connected to the return reservoir 139. The vacuum generator 121 is operable to apply a vacuum to the return reservoir 139.

The cooling system 123 (shown in FIG. 7) comprises a cooling system fluidic flow path 177, a cooling system fluid movement device 179, and a heat exchanger 181. The cooling system fluidic flow path 177 comprises a first end 176 connected to the output reservoir 141 and a second end 178 connected to the output reservoir 141. The cooling system fluid movement device 179 is operable to move fluid along the cooling system fluidic flow path 177. The cooling system fluid movement device 179 comprises a pump. The heat exchanger 181 is located along the cooling system fluidic flow path 177. The heat exchanger 181 is operable to remove heat from fluid flowing over the heat exchanger 181.

The controller 125 is connected via control lines to, and controls the operation of, the heater assemblies 133, the fluid movement devices 151,165,179, the vacuum generator 121, the hydraulic rams, the heat exchanger 181, and a robotic arm (not shown).

The controller 125 switches the valves 131,155,159,167,169,173 between being open and being closed. In practice, each valve 131,155,159,167,169,173 is coupled to a respective actuator, and the controller 125 controls the operation of the actuators to cause each valve 131,155,159,167,169,173 to switch between being open and being closed. Such actuators are not shown here for the sake of clarity. In other examples, the controller 125 could be replaced with multiple controllers.

The controller 125 controls the expansion and contraction of the first expandable member 107 according to a first cycle of operations, and the second expandable member 109 according to a second cycle of operations, as will now be explained with reference to FIGS. 8 to 17b. The first cycle is different to the second cycle. Specifically, the operations of the first cycle occur at different times to the operations of the second cycle.

Although there are small gaps shown in FIGS. 8 to 17b between the expandable members 107,109 in the expanded state, the formed products 183,187, the product 185, and the moulds 111,113, in practice these small gaps would not be present. The small gaps are merely shown for clarity.

FIGS. 8, 9a, and 9b show the first expandable member 107 at the start of the first cycle, whilst the second expandable member 109 is mid-way through the second cycle. At this stage, a first formed product 183 is located in the second mould 113, and the second expandable member 109 is located inside the first formed product 183. The second expandable member 109 has just completed forming the first formed product 183 and is in the expanded state. In the expanded state, the second expandable member 109 contains a first portion of fluid, and the volume of the second expandable member 109 is greater than 95 % of the volume of the second mould cavity 137. The volume of the first portion of fluid is 94 % of the volume of the second mould cavity 137.

The first expandable member 107 is located outside of the first mould 111 and is in the collapsed state. The first mould 111 does not contain any products.

The output valves 153,167, return valves 155,169, and reservoir valve 145 are closed, and the divert valves 159,173 and interface arrangement valves 131 are open. Additionally, the output fluidic movement devices 151,165 are moving fluid around the loops 117, 119. Fluid flows in the first fluidic loop 117 from the output reservoir 141, along the part of the first output fluidic flow path 147 located between the output reservoir 141 and the point where the first output fluidic flow path 147 connects to the first divert fluidic flow path 157, along the first divert fluidic flow path 157, and back into the output reservoir 141. Fluid flows in the second fluidic loop 119 in a corresponding manner.

The cooling system fluid movement device 179 is moving fluid in the cooling system 123. The cooling system fluid movement device 179 moves fluid from the output reservoir 141, over the heat exchanger 181 (where heat is removed from the fluid), and back into the output reservoir 141 via the cooling system fluidic flow path 177. The heater assemblies 133 are heating the moulds.

The controller 125 then controls the robotic arm to place a first product 185 (such as the product 22 discussed above) into the first mould 111. The controller 125 then controls the hydraulic ram to move the second part 114 of the first mould 111 towards the first part of the first mould 111 such that the two parts 112,114 are closed around the first product 185. Thereby, the first product 185 is located inside the mould cavity 135 of the first mould 111. The controller 125 controls the robotic arm to insert the first expandable member 107 into the first product 185.

The controller 125 then switches the first divert valve 159 to being open and the first output valve 153 to being closed (FIGS. 10, 11a, and 11b). The first fluidic movement device 151 moves a second portion of fluid from the output reservoir 141, along the first output fluidic flow path 147, and into the first expandable member 107 via the first interface arrangement 103. This causes the first expandable member 107 to expand from the collapsed state to the expanded state. The expanded state of the first expandable member 107 is identical to the expanded state of the second expandable member 109, and the volume of the second portion of fluid is identical to the volume of the first portion of fluid. In the expanded state, the first expandable member 107 applies pressure to an inside of the first product 185, which urges the first product 185 against the surfaces of the parts of the first mould 111. As the heater assemblies 133 of the first mould 111 have previously heated the first mould 111, the mould cavity 135 of the first mould 111, and thereby the first product 185, is heated to a temperature of 200° C. Temperatures of no less than 90° C., or no less than 100° C., or no less than 200° C. are also envisaged. The first product 185 is thereby heated and compressed such that, after the pressure is maintained for a period of time (discussed below), a second formed 187 product is produced from the first product 185.

Simultaneously, the controller 125 switches the second return valve 169 to being open and controls the vacuum generator 121 to apply a vacuum to the return reservoir 139. As the return reservoir 139 is connected to the second return fluidic flow path 163, the first portion of fluid is drawn from the second expandable member 109, along the second return fluidic flow path 163, and into the return reservoir 139. Thereby, the second expandable member 109 is collapsed from the expanded state to the collapsed state.

At this stage, the reservoir system 115 is supplying the second portion of fluid to the first expandable member 107 (via the first interface arrangement 103) whilst simultaneously receiving the first portion of fluid from the second expandable member 109 (via the second interface arrangement 105).

The controller 125 then switches the first output valve 153 to being closed and the first divert valve 159 to being open (FIGS. 12, 13a, and 13b). Thereby, the first expandable member 107 remains in the expanded state, and the pressure applied by the first expandable member 107 on the inside of the first product 185 maintained. After the period of time, the second formed product 187 is produced from the first product 185. The period of time is 90 s. Periods of time no less than 10 s, or no less than 90 s are also envisaged. Additionally, fluid flows in the first fluidic loop 117 from the output reservoir 141, along the part of the first output fluidic flow path 147 located between the output reservoir 141 and the point where the first output fluidic flow path 147 connects to the first divert fluidic flow path 157, along the first divert fluidic flow path 157, and back into the reservoir.

The controller 125 controls the robotic arm to withdraw the second expandable member 109, in the collapsed state, from the first formed product 183 and the second mould 113. The controller 125 also controls the hydraulic ram to move the second part of the second mould 113 away from the first part of the second mould 113 such that the two parts are separated and the first formed product 183 can be removed from the second mould 113. The controller 125 then controls the robotic arm to withdraw the first formed product 183 from the second mould 113.

Once the first portion of fluid has been moved from the second expandable member 109 into the return reservoir 139, the controller 125 controls the vacuum generator 121 to halt applying the vacuum to the return reservoir 139. The controller also switches the second return valve 169 to being closed and the reservoir valve 145 to being open. The first portion of fluid then moves from the return reservoir 139 into the output reservoir 141, where it subsequently flows through the cooling system 123.

At this stage, the first expandable member 107 is mid-way through the first cycle (i.e., the point in the second cycle that the second expandable member 109 was at in FIGS. 8 and 9b), and the second expandable member 109 has completed the second cycle (i.e., the point in the first cycle that the first expandable member 107 was at in FIGS. 8 and 9a). To complete the first cycle, the first expandable member 107 is operated in an identical manner to the second expandable member 109 described above with reference to FIGS. 8-13b. Similarly, to start a subsequent second cycle, the second expandable member 109 is operated in an identical manner to the first expandable member 107 described above with reference to FIGS. 8-13b. This is shown in FIGS. 14 to 17b.

The first and second cycles are repeated to produce additional formed products. When performing subsequent first cycles, the controller 125 controls the duration of the operations of the first cycles such that a time period between the second portion of fluid being received by the return reservoir 139 during the first cycle and the second portion of fluid being supplied to the first expandable member 107 during a subsequent first cycle, is 2 s. Time periods of no less than 5s, or no less than 30 s are also envisaged. When performing subsequent second cycles, the controller 125 controls the duration of the operations of the second cycles such that a time period between the first portion of fluid being received by the return reservoir 139 during the second cycle and the first portion of fluid being supplied to the second expandable member 109 during a subsequent second cycle, is 2 s. Time periods of no less than 5 s, or no less than 30 s are also envisaged.

By having a reservoir system 115 with a greater volume than a volume of the first portion of fluid, the reservoir system 115 may contain more fluid than is required to change the first 107 or second expandable member 109 from the collapsed state to the expanded state. This may improve the functionality of the reservoir system 115 when compared with a reservoir system having a lesser volume.

By providing a reservoir system 115 which can supply and receive simultaneously, the expandable members may be expanded and contracted at different times to one another. Specifically, fluid may be removed from the first expandable member 107 and received by the reservoir system 115, along the first return fluidic flow path 149, to contract the first expandable member 107. Simultaneously, fluid may be supplied from the reservoir system 115 to the second expandable member 109, along the second output fluidic flow path 161, to expand the second expandable member 109.

Providing a reservoir system 115 which can supply and receive simultaneously, and thereby expand and contract the expandable members at different times to one another, may be desirable when the station receives products from a preceding manufacturing stage at a greater rate than the rate at which an expandable member can form the products. In this case, if the expandable members were expanded and contracted at the same time, some of the incoming products to the station would need to wait for an expandable member to become available. Waiting may result in a degradation in the mechanical properties of the waiting product. For example, whilst waiting, the waiting product may sag, or, if the waiting product is placed in a waiting area, be deformed due to multiple interactions with the equipment required to move the waiting product to the waiting area and then move the waiting product again to one of the expandable members. Additionally, adapting the station to accommodate a waiting product may complicate the station due to the requirement to incorporate additional equipment and space to store and transfer the waiting product. Instead, by expanding and contracting the expandable members at different times, one of the expandable members may be available to receive the incoming product as soon as the product is produced by the preceding stage. Thereby waiting times may be reduced or removed.

Additionally, having a reservoir system 115 which can operate both expandable members may reduce the complexity of the necked hollow moulded fibre forming station and thereby may increase the reliability of the station and/or reduce the cost of the station when compared with, for example, having a separate reservoir system 115 for each expandable member.

In the above example, each interface arrangement comprises a single interface fluidic flow path 129 which functions as a common inlet and outlet to each expandable member. In other examples, each interface arrangement may comprise two separate interface fluidic flow paths and associated interfaces. One of the interface fluidic flow paths would act as an inlet and have a first end connected to an output fluidic flow path, and a second end connected to an interface connected to an expandable member. The other interface fluidic flow path would act as an outlet and have a first end connected to a return fluidic flow path, and a second end connected to an interface connected to the expandable member. In further examples, each interface arrangement may comprise an interface only.

In some examples the collapsed state may be considered a first configuration of the expandable members and the expanded state may be considered a second configuration of the expandable members.

FIG. 18 shows an alternative forming station 201. The alternative forming station is identical to the forming station 101 except for the following differences.

The alternative forming station 201 comprises a third interface arrangement 203, a third expandable member 205, and a third mould 207, which are identical to the first interface arrangement 103, the first expandable member 107, and the first mould 111 respectively. The third expandable member 205 is operated in an identical first cycle to the first expandable member 107, except that the first output fluid movement device 151 moves a third portion of fluid, identical in volume to the first and second portions of fluid, to the third expandable member 205.

Additionally, the alternative forming station 201 comprises a fourth interface arrangement 211, a fourth expandable member 213, a fourth mould 215, which are identical to the second interface arrangement 105, the second expandable member 109, and the second mould 113 respectively. The fourth expandable member 213 is operated on an identical second cycle to the second expandable member 109 except that the second output fluid movement device provides a fourth portion of fluid, identical to the first, second, and third portions of fluid, to the fourth expandable member 213.

The output reservoir 217 of the alternative forming station has a volume which is no less than 1.1 times greater, and no greater than 4 times greater, than the volume of the first portion of fluid combined with the volume of the third portion of fluid.

FIG. 19 shows a schematic diagram of a non-transitory computer-readable storage medium 1900 according to an example. The non-transitory computer-readable storage medium 1900 stores instructions 1930 that, if executed by a processor 1920 of a necked hollow moulded fibre product forming station controller 1910, cause the processor 1920 to cause the necked hollow moulded fibre product forming station to perform a method according to an example. In some examples, the necked hollow moulded fibre product forming station controller 1910 is or comprises the controller 125 as described above. The instructions 1930 comprise: containing 1931 fluid within a reservoir system; inserting 1932 an expandable member in a first configuration into a necked hollow moulded fibre product located within a mould; and retaining 1933 a portion of the fluid within the reservoir system whilst moving a further portion of the fluid from the reservoir system into the expandable member to change the expandable member from the first configuration to a second configuration in which the expandable member urges the necked hollow moulded fibre product against an inner surface of the mould. In other examples, the instructions 1930 comprise instructions to perform any other example methods described herein.

FIG. 20 shows a method 2000 of forming a necked hollow moulded fibre product to provide a formed necked hollow moulded fibre product according to an example. The method 2000 comprising containing 2010 fluid within a reservoir system; inserting 2020 an expandable member in a first configuration into a necked hollow moulded fibre product located within a mould; and retaining 2030 a portion of the fluid within the reservoir system whilst moving a further portion of the fluid from the reservoir system into the expandable member to change the expandable member from the first configuration to a second configuration in which the expandable member urges the necked hollow moulded fibre product against an inner surface of the mould.

It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in FIG. 1) comprising a necked hollow moulded fibre product forming station (such as that shown in FIG. 2) for providing a formed necked hollow moulded fibre product and apparatus for performing at least one additional process on the formed necked hollow moulded fibre product to provide the necked receptacle. Similarly, also provided is a method 2050 of manufacturing a necked receptacle. The method 2050 comprises the method 2000 of FIG. 20 and performing 2040 at least one additional process on the formed necked hollow moulded fibre product to provide the necked receptacle. Examples of the “at least one additional process” are described above with reference to FIG. 1.

Also provided, as a result of the content of the present application, is use of a receptacle obtained by any of the methods described herein to contain contents. An example such receptacle 2100, in the form of a necked receptacle and specifically a bottle, containing contents 2110 is shown in FIG. 21. The use could be, for example, by a person who puts the contents into the receptacle, by a person who transports the contents, or by a person who wishes to dispose of (for example, to a consumer or end user), offer to dispose of (for example, to a consumer or end user), import, or keep the contents whether for disposal or otherwise. The contents could, for example, be any one or more of the example contents described herein.

Also provided is a method of providing a content-containing receptacle. An example such method 2200 is shown in FIG. 22. The method 2200 comprises providing 2212 the receptacle, in the form of a necked receptacle and specifically a bottle, and then providing 2220 the contents in the receptacle. In this example, block 2220 follows block 2210, so that block 2220 comprises putting the contents into the receptacle that has been provided at block 2210. However, in some other examples, blocks 2210 and 2220 are performed concurrently, so that the providing 2210 the receptacle comprises providing the receptacle with the contents already present in the receptacle. The contents could, for example, be any one or more of the example contents described herein. The method 2200 also comprises closing 2230 an opening of the receptacle after block 2220, and applying 2240 a label or indicia to the receptacle after block 2230. In this example, block 2230 involves applying a heat seal to the opening and then screwing a cap or lid onto the receptacle, and block 2240 comprises adhering a label onto the receptacle.

In respective other examples, the order of blocks 2230 and 2240 is reversed, blocks 2230 and 2240 are performed concurrently, block 2230 is omitted, and block 2240 is omitted. In some examples, block 2240 occurs before block 2220, or block 2240 occurs during block 2220. For example, in some cases, the label or indicia is applied to the receptacle, then the contents are provided in the receptacle, and then the receptacle is closed.

It will be appreciated that the method 2200 could be performed by the same party that manufactures the receptacle, for example so that block 2210 comprises the method shown in FIG. 1. Alternatively, the method 2200 could be performed by a different party to that which manufactures the receptacle. In such an alternative, the different party performs block 2210 by way of obtaining the receptacle from the party that manufactures the receptacle (such as by way of the method shown in FIG. 1) or from an intermediary.

Example embodiments of the present invention have been discussed, with reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made without departing from the scope of the invention as defined by the appended claims.