MOULDING SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation under 35 U.S.C. § 120 of International Application No. PCT/GB2024/051615, filed June 25, 2024, which claims priority to United Kingdom Application No. GB 2309875.9, filed June 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 methods and moulding systems for use in manufacturing receptacles from a fibre suspension, such as a fibre suspension comprising paper pulp. The receptacles may be consumer packaging, such as bottles, jars or certain types of vases, useful for holding liquids, powders, other flowable materials, one or more solid objects, or a combination thereof.

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.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product.

SUMMARY

According to a first aspect of the present invention, there is provided a moulding system for providing a hollow moulded fibre product, the moulding system comprising: a first mould comprising first and second mould parts separable from one another along a first split plane wherein, when the first mould is placed in a closed position, in which the first and second mould parts abut one another, the first and second mould parts define a first mould cavity therebetween, the first mould being configured to provide a hollow moulded fibre product precursor. There is also a second mould comprising third and fourth mould parts separable from one another along a second split plane wherein, when the second mould is placed in a closed position in which the third and fourth mould parts abut one another, the third and fourth mould parts define a second mould cavity therebetween, the second mould being configured to receive the hollow moulded fibre product precursor in the second mould cavity and to provide the hollow moulded fibre product from the hollow moulded fibre product precursor, wherein a width of the first mould cavity, in a direction across the first split plane, is smaller than a width of the second mould cavity, in a direction across the second split plane.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product.

In use of the moulding system, the hollow moulded fibre product precursor is formed by moulding in the first mould. The hollow moulded fibre product precursor has a geometry corresponding to the first mould cavity, and thus an outer width, in the direction across the first split plane, corresponding to the width of the first mould cavity. The hollow moulded fibre product precursor is then transferred to the second mould. The second mould has a greater width, in the direction across the second split plane, than the width of the hollow moulded fibre product precursor. Accordingly, a chance of damage being imparted to the hollow moulded fibre product precursor during its transfer to the second mould may be reduced compared with a moulding system in which the width of the first mould cavity, in the direction across the first split plane, is equal to the width of the second mould cavity, in the direction across the second split plane. This is because the greater width of the second mould cavity provides a clearance for receiving the hollow moulded fibre product precursor of smaller width.

The hollow moulded fibre product precursor is then moulded by the second mould to provide the hollow moulded fibre product, which has an outer width, in the direction across the second split plane, corresponding to the width of the second mould cavity. Accordingly, during moulding by the second mould, side walls of the hollow moulded fibre product precursor are stretched and/or re-shaped to increase, in the direction across the second split plane, the outer width of the hollow moulded fibre product precursor to the width of the second mould cavity. This may result in a relatively small amount of thinning of the side walls of the hollow moulded fibre product precursor, compared to a full thickness of the side walls, in regions of the side walls that are stretched and/or re-shaped.

In some examples, the moulding system comprises a transferrer configured to move the hollow moulded fibre product precursor from the first mould to the second mould. In some examples, the transferrer is a mechanical transfer system.

In some examples, the transferrer is configured to demould the hollow moulded fibre product precursor from the first mould and/or to insert the hollow moulded fibre product precursor into the second mould. This may help to reduce the number of handling operations applied to the hollow moulded fibre product precursor between being formed in the first mould and being inserted into the second mould, which may reduce a chance of damage being caused to the hollow moulded fibre product precursor.

In some examples, the moulding system comprises a vacuum retention system configured to retain the hollow moulded fibre product precursor and the hollow moulded fibre product, once formed, in the second mould cavity by generating a vacuum between the hollow moulded fibre product precursor and the second mould. This may help to retain the hollow moulded fibre product precursor more securely in the second mould compared with a moulding system that does not comprise the vacuum retention system. This may also help to retain the hollow moulded fibre product precursor in a correct position within the second mould cavity, which may reduce a chance of damage being caused to the hollow moulded fibre product precursor, for example by catching on an edge of the second mould.

In some examples, the width of the first mould cavity and the width of the second mould cavity are each measured at the same predetermined distance from an uppermost surface of the respective cavity.

In some examples, the width of the first mould cavity and the width of the second mould cavity are each measured at a widest point across the split plane and in a direction orthogonal to a height of the respective cavity.

In some examples, the first and second mould cavities are shaped to form necked bottles, and the width of each cavity is measured at a predetermined position between a shoulder and a base of the respective cavity. The predetermined position may be a predetermined percentage of a distance between the shoulder and the base.

In some examples, the width of the first mould cavity and the width of the second mould cavity are each measured in a direction orthogonal to a height of the respective mould cavity.

In some examples, the width of the first mould cavity and the width of the second mould cavity are measured at the same height percentage of an overall height of the respective cavity. In some examples, the height percentage is between 30% and 70% of the overall height of the respective cavity.

In some examples, the first mould cavity is discorectangle-shaped, or obround-shaped, in cross-section, on a plane orthogonal to the first split plane and at a height of the first mould cavity corresponding to a height at which the width of the first mould cavity is measured. In some examples, the second mould cavity is circular in cross-section, on a plane orthogonal to the second split plane and at a height of the second mould cavity corresponding to a height at which the width of the second mould cavity is measured.

In some examples, the width of the first mould cavity is at least 0.25% smaller than the width of the second mould cavity. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the second mould.

In some examples, the width of the first mould cavity is not more than 6% smaller than the width of the second mould cavity. This may limit an amount of stretching and/or re-shaping required to form the hollow moulded fibre product from the hollow moulded fibre product precursor. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness.

In some examples, the width of the first mould cavity is at least 0.5 mm smaller than the width of the second mould cavity. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the second mould. The difference in width between the first mould cavity and the second mould cavity may be split between opposing sides of the first and second mould cavities, the opposing sides being sides that intersect the respective first or second split plane. The split may be substantially even.

In some examples, the width of the first mould cavity is no more than 5 mm smaller than the width of the second mould cavity. This may limit an amount of stretching and/or re-shaping required by the second mould to form the hollow moulded fibre product from the hollow moulded fibre product precursor. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness.

In some examples, the first mould cavity has a first depth at a predetermined distance from an uppermost surface of the first mould cavity, the first depth being in a direction normal to the first split plane, and the second mould cavity has a second depth at the predetermined distance from an uppermost surface of the second mould cavity, the second depth being in a direction normal to the second split plane, and wherein the first depth is equal to the second depth. Accordingly, when in the second mould cavity, the hollow moulded fibre product precursor may fit snugly against a rear wall of each of the third and fourth mould parts. This may help to reduce an amount of stretching and/or re-shaping required by the second mould in the direction normal to the second split plane, to form the hollow moulded fibre product from the hollow moulded fibre product precursor.

In examples in which the moulding system comprises the vacuum retention system, this may increase the stability and/or security with which the hollow moulded fibre product precursor is retained by the vacuum retention system in the second mould.

In some examples, the first depth is measured at the same height of the first cavity as the width of the first cavity, and the second depth is measured at the same height of the second mould cavity as the width of the second mould cavity.

In some examples, the first mould cavity is of the same size and shape as the second mould cavity, except for the width of the first mould cavity being smaller than the width of the second mould cavity. Accordingly, when in the second mould cavity, the hollow moulded fibre product precursor may fit snugly against walls of the third and fourth mould parts that define the second mould cavity, except at portions of the walls of the third and fourth mould parts that are adjacent to the second split plane. This may help to reduce an amount of stretching and/or re-shaping required by the second mould to form the hollow moulded fibre product from the hollow moulded fibre product precursor.

In examples in which the moulding system comprises the vacuum retention system, this may increase the stability and/or security with which the hollow moulded fibre product precursor is retained by the vacuum retention system in the second mould.

In some examples, the first mould part and the second mould part comprise a plurality of dewatering apertures. In use of the first mould, water (optionally containing additives) from a fibre slurry is drawn through the one or more dewatering apertures. Such a process may be referred to as dewatering. During dewatering, fibres from the fibre slurry may be drawn, at least partially, into the plurality of dewatering apertures and may subsequently inhibit demoulding of the hollow moulded fibre product precursor from the first mould cavity due to additional force being required to release the stray fibres from the dewatering apertures. Such stray fibres can become trapped between the mould parts of a subsequent mould, for example the second mould of the moulding system, which may be a thermoforming mould, and can damage contacting surfaces of the mould parts of the subsequent mould.

Providing the second mould with a second mould cavity having a greater width than the width of the first mould cavity may result in a smaller portion of the hollow moulded fibre product precursor contacting the third and/or fourth mould part of the second mould, as the hollow moulded fibre product precursor is inserted into the second mould, compared with a system in which the first and second moulds have equal width. This may reduce the number of stray fibres that may become trapped between the third and fourth mould parts in use of the second mould.

In some examples, the second mould is configured to hold the third and fourth mould parts together with a pressure of at least 15 bar. This may help to overcome pressure exerted against internal surfaces of the second mould, for example by a bladder or other expandable member inserted within the hollow moulded fibre product precursor during use of the second mould.

At such pressures, stray fibres that are trapped between the third and fourth mould parts may damage contacting surfaces of the third and fourth mould parts during moulding by the second mould. Accordingly, moulding a hollow moulded fibre product precursor formed in the first mould, and thus with a smaller outer width than the width of the second mould in the direction normal to the second split plane, may reduce a chance of damage to the contacting surfaces because the chance of stray fibres becoming trapped between the third and fourth mould parts may be lessened.

In some examples, the second mould is configured to hold the third and fourth mould parts together with a pressure of at least 20 bar.

In some examples, the second mould is a thermoforming mould.

According to a second aspect of the present invention, there is provided a moulding system for providing a hollow moulded fibre product, the moulding system comprising: a first mould comprising first and second mould parts separable from one another along a first split plane wherein, when the first mould is placed in a closed position, in which the first and second mould parts abut one another, the first and second mould parts define a first mould cavity therebetween, the first mould being configured to provide a hollow moulded fibre product precursor; a second mould comprising third and fourth mould parts separable from one another along a second split plane wherein, when the second mould is placed in a closed position in which the third and fourth mould parts abut one another, the third and fourth mould parts define a second mould cavity therebetween, the second mould being configured to receive the hollow moulded fibre product precursor in the second mould cavity and to provide the hollow moulded fibre product from the hollow moulded fibre product precursor, and a transferrer configured to move the hollow moulded fibre product precursor from the first mould to the second mould. The first mould cavity is dimensioned to give the hollow moulded fibre product precursor a precursor width that is smaller than a width of the second mould cavity in a direction across the second split plane, and the transferrer is configured to place the hollow moulded fibre product precursor in the second mould cavity in an orientation in which the precursor width of the hollow moulded fibre product precursor is aligned with the second split plane.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product precursor. The hollow moulded fibre product precursor having a precursor width that is smaller than the width of the second mould cavity in the direction across the second split plane may help to reduce a chance of damage being imparted to the hollow moulded fibre product precursor during its transfer to the second mould. This is because the greater width of the second mould cavity provides a clearance for receiving the hollow moulded fibre product precursor of smaller precursor width.

A hollow moulded fibre product precursor provided from the first mould may have fibres extending from outer surfaces of the hollow moulded fibre product precursor. The hollow moulded fibre product precursor having a precursor width that is smaller than the width of the second mould cavity in the direction across the second split plane may help to reduce a chance of such fibres accumulating at a rim of the third and fourth mould parts. Fibre accumulation at the rims of the third and fourth mould parts may result in damage to the second mould during use of the second mould. For example, in use with the third and fourth mould parts held together with a pressure of at least 15 bar.

The term ‘aligned with’ is to be understood as the precursor width being coplanar with the second split plane, or extending across the split plane in a direction along the split plane, when the hollow moulded fibre product precursor is placed in the second mould.

In some examples, the precursor width is at least 0.25% smaller than the width of the second mould cavity. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the second mould by the transferrer, and to avoid fibres accumulating at a rim of the third and fourth mould parts as a result of the transferrer placing the hollow moulded fibre product precursor in the second mould.

In some examples, the precursor width is not more than 6% smaller than the width of the second mould cavity. This may limit an amount of stretching and/or re-shaping required to form the hollow moulded fibre product from the hollow moulded fibre product precursor. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness. This may also help to avoid fibres accumulating at a rim of the third and fourth mould parts as a result of the transferrer placing the hollow moulded fibre product precursor in the second mould

In some examples, the precursor width is at least 0.5 mm smaller than the width of the second mould cavity. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the second mould and avoid fibres accumulating at a rim of the third and fourth mould parts as a result of the transferrer placing the hollow moulded fibre product precursor in the second mould. The difference in width between the first mould cavity and the second mould cavity may be split between opposing sides of the first and second mould cavities, the opposing sides being sides that intersect the respective first or second split plane. The split may be substantially even.

In some examples, the precursor width is no more than 5 mm smaller than the width of the second mould cavity. This may limit an amount of stretching and/or re-shaping required by the second mould to form the hollow moulded fibre product from the hollow moulded fibre product precursor. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness. This may also help to avoid fibres accumulating at a rim of the third and fourth mould parts as a result of the transferrer placing the hollow moulded fibre product precursor in the second mould

In some examples, the transferrer is a mechanical transfer system. In other examples, the transferrer is a human being.

The moulding system of the second aspect may have any suitable features of the optional features described above with reference to the first aspect.

According to a third aspect of the present invention, there is provided a method of providing a hollow moulded fibre product with a mould defining a mould cavity having a mould width in a direction across a split plane of the mould, the method comprising: placing a hollow moulded fibre product precursor in the mould cavity, the hollow moulded fibre product precursor having a precursor width in the direction across the split plane of the mould, the mould width being greater than the precursor width; and with the hollow moulded fibre product precursor in the mould cavity, increasing the precursor width in the direction across the split plane of the mould by urging the hollow moulded fibre product precursor against the mould, thereby to provide the hollow moulded fibre product from the hollow moulded fibre product precursor.

The disclosed method provides the advantage of helping to reduce, compared with a method in which the precursor width is equal to the mould width, the chance of damage to the hollow moulded fibre product precursor caused by the hollow moulded fibre product precursor catching on the mould as the hollow moulded fibre product is placed into the mould cavity.

The disclosed method may also reduce a chance of stray fibres extending from an outer surface of the hollow moulded fibre product precursor from becoming trapped between mould parts of the mould, where the stray fibres may damage contacting surfaces of the mould parts during use of the mould.

In some examples, the mould is the second mould as described with reference to the first aspect or the second aspect.

The precursor width is an outer width of the hollow moulded fibre product precursor. The precursor width is measured in a direction orthogonal to a height of the hollow moulded fibre product precursor. The mould width is measured in a direction orthogonal to a height of the mould cavity.

In some examples, the precursor width is measured at a predetermined height percentage of an overall height of the precursor, and the mould width is measured at the same predetermined height percentage of an overall height of the mould cavity. In some examples, the height percentage is between 30% and 70%.

In some examples, the precursor width is measured at a predetermined distance from an uppermost surface of the hollow moulded fibre product precursor, and the mould width is measured at the predetermined distance from an uppermost surface of the mould cavity.

In some examples, the precursor width is smaller than the mould width by at least two times an average length of fibres forming the hollow moulded fibre product precursor. This may help to reduce a chance of stray fibres extending from an outer surface of the hollow moulded fibre product precursor from becoming trapped between mould parts of the mould as the hollow moulded fibre product precursor is placed in the mould.

In some examples, the method comprises, prior to placing the hollow moulded fibre product precursor in the mould cavity of the mould: forming the hollow moulded fibre product precursor in a further mould cavity of a further mould, the further mould cavity having a further mould width in a direction across a split plane of the further mould, the further mould width being substantially the same as the precursor width; and demoulding the hollow moulded fibre product precursor from the further mould cavity.

In some examples, the further mould width is smaller than the mould width by at least two times an average length of fibres forming the hollow moulded fibre product precursor. This may help to reduce a chance of stray fibres extending from an outer surface of the hollow moulded fibre product precursor from becoming trapped between mould parts of the mould as the hollow moulded fibre product precursor is placed in the mould.

In some examples, the further mould is the first mould as described with reference to the first aspect or the second aspect.

In some examples, the method comprises transferring the hollow moulded fibre product precursor from the further mould to the mould.

In some examples, the increasing the precursor width in the direction across the split plane of the mould comprises expanding an expandable member within the hollow moulded fibre product precursor to urge the hollow moulded fibre product precursor against the mould. This may help to form the hollow moulded fibre product without imparting relatively high localised pressures to the hollow moulded fibre product precursor, which may cause damage to the hollow moulded fibre product precursor.

In some examples, the expandable member comprises an inflatable bladder.

The method may result in a relatively small amount of thinning of side walls of the hollow moulded fibre product precursor, compared to a full thickness of the side walls, in regions of the hollow moulded fibre product precursor that are stretched and/or re-shaped during the increasing the precursor width in the direction across the split plane of the mould by urging the hollow moulded fibre product precursor against the mould.

In some examples, the method comprises increasing the precursor width in the direction across the split plane of the mould by at least 0.25%. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the mould.

In some examples, the method comprises increasing the precursor width in the direction across the split plane of the mould by no more than 6%. This may limit an amount of stretching and/or re-shaping required to form the hollow moulded fibre product from the hollow moulded fibre product precursor compared to greater percentages. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness.

In some examples, the method comprises increasing the precursor width in the direction across the split plane of the mould by at least 0.5 mm. This may be a sufficient width difference to help avoid damage to the hollow moulded fibre product precursor during transfer to the mould.

In some examples, the method comprises increasing the precursor width in the direction across the split plane of the mould by no more than 5 mm. This may limit an amount of stretching and/or re-shaping required by the mould to form the hollow moulded fibre product from the hollow moulded fibre product precursor compared to greater distances. Excessive stretching and/or re-shaping may detrimentally affect properties of the hollow moulded fibre product, such as strength, porosity and uniformity of wall thickness.

According to a fourth aspect of the present invention, there is provided a moulding system controller configured to cause a moulding system to perform a method of the third aspect.

According to a fifth aspect of the present invention, there is provided a non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a moulding system controller, cause the processor to cause a moulding system to perform the method of the third aspect.

In some examples of any of the above aspects, the hollow moulded fibre product is a necked hollow moulded fibre product, such as 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 sixth aspect of the present invention, there is provided a receptacle manufacturing line comprising the moulding system of the first aspect or the second aspect, for providing the hollow moulded fibre product and apparatus for performing at least one additional process on the 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 product to produce an internally coated 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 product or the internally coated product to produce a closable or closed 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 product or the internally coated product or the closable or closed product to produce an externally coated product. The apparatus may comprise a decorator and the at least one additional process may comprise the decorator decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The apparatus may comprise a dryer and the at least one additional process may comprise the dryer drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The apparatus may comprise an evaluator and the at least one additional process may comprise the evaluator evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product.

In some examples, the receptacle is a necked receptacle, such as a bottle, jar or a type of vase, and the receptacle manufacturing line is a necked-receptacle manufacturing line. In some examples, the receptacle is a bottle.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a receptacle, the method comprising performing the method of the third aspect to provide the hollow moulded fibre product, and then performing at least one additional process on the 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 product to produce an internally coated product. The at least one additional process may comprise applying a closure part to the product or the internally coated product to produce a closable or closed product. The at least one additional process may comprise coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product. The at least one additional process may comprise decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The at least one additional process may comprise drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The at least one additional process may comprise evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product.

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

According to an eighth 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 seventh aspect and providing contents in the receptacle to provide the content-containing receptacle.

In some examples, the providing 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 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 necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

In some examples, the method 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 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 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 ninth aspect of the present invention, there is provided use of a receptacle obtained by the method of the seventh aspect 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 necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

According to a tenth aspect of the present invention, there is provided a receptacle obtainable or obtained from a fabrication method comprising the method of any one of the third, seventh or eighth aspects.

For example, the receptacle may be obtainable or obtained from the method of the third, seventh or eighth aspect of the present invention.  The fabrication method may comprise at least one additional process.  The at least one additional process may comprise coating at least a portion of an interior of the product to produce an internally coated product.  The at least one additional process may comprise applying a closure part to the product or the internally coated product to produce a closable or closed product.  The at least one additional process may comprise coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product.  The at least one additional process may comprise decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product.  The at least one additional process may comprise drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product.  The at least one additional process may comprise evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product.  In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product.

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

Receptacles obtainable or obtained from such a fabrication method may be discernible from receptacles made by other methods; such receptables may comprise features indicative of the increasing of the precursor width that took place to thereby provide the hollow moulded fibre product from the hollow moulded fibre product precursor. Indicative features may comprise, for example, fibres that are aligned in a direction in which the hollow moulded fibre product precursor was stretched to increase the precursor width, and/or fibres that are teased away from one another in the direction in which the hollow moulded fibre product precursor was stretched to increase the precursor width, albeit to a degree that is acceptable given the intended function of the end product.

It will be appreciated that 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 a moulding system according to an example;

FIG. 3 is a perspective view of a mould part of a mould of the moulding system of FIG. 2, according to an example;

FIG. 4 is a slice plan view of a part of a mould of the moulding system of FIG. 2, according to an example, across plane A-A of FIG. 2;

FIG. 5 is a plan view of a receptacle according to an example;

FIG. 6 is a perspective view of a mould part of a mould of the moulding system of FIG. 2, according to an example;

FIG. 7 is a slice plan view of a part of a mould of the moulding system of FIG. 2, according to an example, across plane B-B of FIG. 2;

FIG. 8 is a plan view of a receptacle according to an example;

FIGS. 9a and 9b show a receptacle at various stages of manufacture, according to an example;

FIG. 10 shows a method according to an example;

FIG. 11 shows a non-transitory computer-readable storage medium according to an example;

FIG. 12 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and

FIG. 13 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. It will be appreciated that, in other examples, the receptacle manufacturing line could be for making non-necked receptacles (i.e., receptacles without such a neck), such as bowls or trays.

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 “mould parts”, “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 moulding system 100, according to an example, for forming a hollow moulded fibre bottle 22b. The moulding system 100 comprises a moulding station 110 comprising a first mould 111, a second mould 120, and a transfer mechanism 130. The first mould 111 has a pair of mould parts 112 that are co-operable with each other along a split plane 113 to define a first mould cavity 114. In some examples, the first mould 111 is the mould 15 described with reference to FIG. 1. The second mould 120 comprises a pair of mould parts 122 that are co-operable with each other along a split plane 123 to define a second mould cavity 124. In some examples, the second mould 120 is the mould 25 described with reference to FIG. 1.

A shape of the first mould cavity 114 of the first mould 111 differs from a shape of the second mould cavity 124 of the second mould 120, as will be described in more detail herein.

FIG. 3 is a perspective view of one of the mould parts 112 of the first mould 111. FIG. 4 is a view of an inner wall 142 of the first mould 111 across the line A-A shown in FIG. 2. Each mould part 112 has an inner wall 142 that defines the shape of the mould cavity 114, and an outer wall 144 separated from the inner wall 142 by a void. In this example, the inner wall 142 and the outer wall 144 have geometries such that the void has a substantially even thickness.

Each mould part 112 has a split face 150 that seals the void at the split plane 113. When the mould parts 112 are cooperating with one another to define the first mould cavity 114, as shown in FIG. 4, the split face 150 of one of the mould parts 112 contacts the split face 150 of the other mould part 112. Each mould part 112 is substantially identical, but opposite, in shape to the other. Accordingly, the first mould cavity 114 is bisected by the split plane 113.

The inner wall 142 of each mould part 112 has a body portion 152, a base portion 154, a shoulder portion 156 and a neck portion 158. The body portion 152, shoulder portion 156 and neck portion 158 are all upstanding from the base portion 154 and form side walls of the mould part 112. The base portion 154 of each mould part 112 has a positive draft angle A1, which in this example is around 2.5 degrees. Accordingly, a distance, in a direction parallel to the split plane 113, from an upper edge 160 of the mould part to the base portion 152 is greater along the split plane 113 than towards an edge 153 of the base portion 154 that is most distal from the split plane 113. The base portion 154 is substantially planar such that the draft angle A1 is uniform across the base portion 154 from the edge 153 to the split plane 113.

The body portion 152 is upstanding from the base portion 154, and thus includes walls upstanding from the base portion 154 of each mould part 112. At the split plane 113, the walls extend perpendicularly away from the split plane 113. In plan view, the body portion 152, shoulder portion 156 and neck portion 158 of the inner wall 142 of each mould part 112 are each semi-obround in cross-sectional profile at any given point along the length of the mould part 112. That is, the mould parts are generally semi-circular in cross-sectional profile, but have straight edges 151 towards either side of the mould part 112. The straight edges 151 extend more perpendicularly relative to the split plane 113 than the rest of the semi-circular cross-sectional profile. In this example, the straight edges 151, as viewed along a central axis of the mould 111, of the semi-obrounds extend from the split plane 113 in a direction normal to the split plane 113. Accordingly, a depth D1 of the first mould cavity 114 in a direction normal to the split plane 113 is greater than a width W1 of the first mould cavity 114 in a direction across the split plane 113. It will be appreciated that in other examples, the straight edges of the semi-obrounds may have a positive draft angle, for example of around 3 degrees, from a direction normal to the split plane 113 to assist in demoulding the bottle 22a from the first mould 111.

Although not shown, the inner wall 142 has a number of dewatering apertures extending therethrough. The dewatering apertures are distributed substantially uniformly across an inner surface (a surface facing the mould cavity 114) of the inner wall 142. The apertures each define a respective conduit that fluidly connects the mould cavity 114 to the void between the inner and outer walls 142, 144 of the mould part 112.

Each mould part 122 of the second mould 120 has an inner wall 162 that defines the shape of the mould cavity 114, and an outer wall 164 separated from the inner wall 162 by a void. In this example, the inner wall 162 and the outer wall 164 have geometries such that the void has a substantially even thickness. The mould parts 122 of the second mould 120 also each have a split face 170 that contacts the split face 170 of the other mould part 122. The inner wall 162 of each mould part 122 comprises a body portion 172, a base portion 174, a shoulder portion 176 and a neck portion 178. The body portion 172 of the mould parts 122 of the second mould 120 is longer than the body portion 152 of the mould parts 112 of the first mould 111.

Unlike the mould parts 112 of the first mould 111, the base portion 174 of each mould part 122 has a negative draft angle. This is best shown in FIG. 6, which shows a perspective view of one of the mould parts 122 of the second mould 120. Accordingly, a distance, in a direction parallel to the split plane 123, from an upper edge 180 of the second mould part 122 to the base portion 174 when measured along the split plane 123 is less than the distance when measured from an edge 173 of the base portion 174 that is most distal from the split plane 123. It will be appreciated that, in other examples, the base portion 154 of each of the mould parts 112 of the first mould 111 has the same draft angle as the base portion 174 of each of the mould parts 122 of the second mould 120, for example both moulds 111, 120 have base portions 154, 174 with a draft angle of zero.

Unlike the mould parts 112 of the first mould 111, the body portion 172, shoulder portion 176 and neck portion 178 of the inner wall 162 of each mould part 122 are each semi-circular in cross-sectional profile at any given point along the length of the mould part 122, as best shown in FIG. 7 which is a view of the inner wall 162 across the line B-B shown in FIG. 2. Accordingly, a depth D2 of the second mould cavity 124 in a direction normal to the split plane 123 is equal to a width W2 of the second mould cavity 124 in a direction across the split plane 123. In addition, the depth D2 of the second mould cavity 124 is equal to the depth D1 of the first mould cavity, whilst the width W2 of the second mould cavity 124 is greater than the width W1 of the first mould cavity 114. The difference in magnitude between the width W1 of the first mould cavity 114 and the width W2 of the second mould cavity 124 is exaggerated in FIG. 7, for clarity. In this example, the width W1 of the first mould cavity 114 is around 2% smaller than the width W2 of the second mould cavity 124.

The first mould 111 and the second mould 120 are configured for use in a manufacturing line configured to form a necked-receptacle, in this example a bottle. The manufacturing line may be the receptacle manufacturing line described with reference to FIG. 1. The first mould 111 is configured to form a hollow moulded fibre bottle precursor 22a, and the second mould 120 is configured to form a hollow moulded fibre bottle 22b, as best shown in FIGS. 9a and 9b and described in more detail hereinafter.

In use of the moulding system 100, with the pair of mould parts 112 of the first mould 111 cooperating with each other to define the first mould cavity 114, a fibre slurry is supplied to the first mould cavity 114 of the first mould 111. In use of the first mould 111, water (optionally containing additives) from the fibre slurry is drawn from the mould cavity 114 via the apertures. The fibre slurry is moulded by the first mould 111 to the shape of the first mould cavity 114 of the first mould 111 to provide a hollow moulded fibre bottle precursor 22a (illustrated in FIG. 9a and in plan view in FIG. 5).

The hollow moulded fibre bottle precursor 22a corresponds in shape to the mould cavity 114 of the first mould 111. Due to the obround cross-sectional profile of the inner wall 142 of the mould parts 112, the body portion 132, shoulder portion 136 and neck portion 138, the hollow moulded fibre bottle precursor 22a is generally obround, or discorectangle-shaped. The hollow moulded fibre bottle precursor 22a has: a body portion 132; a base portion 134 that seals a lower end of the body portion 132; a shoulder portion 136 at an opposite end of the body portion 132 to the base portion; and a neck portion 138. The shoulder portion 136 is between the main body portion 132 and the neck portion 138. The body portion 132, shoulder portion 136 and neck portion 138 each have an obround outer shape, with straight edges 131 that extend normal to and across the split plane 113, as beset shown in FIG. 5. When formed in the first mould 111, a central longitudinal axis 140 of the hollow moulded fibre bottle precursor 22a lies on the split plane 113.

As a result of the positive draft angle of the base portion 154 of the mould parts 112 of the first mould 111, the base portion 134 of the hollow moulded fibre bottle precursor 22a is convex. That is, the base portion 134 protrudes from the body portion 132 in a direction along the longitudinal central axis 140 and away from the body portion 132, as best shown in FIG. 9a. Accordingly, a length L1 of the hollow moulded fibre bottle precursor 22a at the longitudinal central axis 140 of the hollow moulded fibre bottle precursor 22a is greater than a length L2 of the hollow moulded fibre bottle precursor 22a at an edge that is distal from the longitudinal central axis 140 and the split plane 113.

Returning to use of the moulding system 100, the mould parts 112 are separated from one another to permit demoulding of the hollow moulded fibre bottle precursor 22a from the first mould 111. The hollow moulded fibre bottle precursor 22a is demoulded from the mould part 112 in a direction that is normal to the split plane 113, as illustrated by arrow A in FIG. 9a.

The transfer mechanism 130 is configured to transfer the hollow moulded fibre bottle precursor 22a from the first mould 111 to one of the mould parts 122 of the second mould 120. The mould parts 122 are subsequently moved together so that the hollow moulded fibre bottle precursor 22a is in the second mould cavity 124. Due to the difference in cross-sectional shape between the body portion 152, 172, shoulder portion 156, 176 and neck portion 158, 178 of the mould parts 112 of the first mould 11 and the mould parts 122 of the second mould 120, voids 182 are formed between an outer surface of the hollow moulded fibre bottle precursor 22a and an inner surface of the inner wall 162 of the second mould 120 when the transfer mechanism 130 inserts the hollow moulded fibre bottle precursor 22a into the second mould 120 and the mould parts 122 are brought together to form the second mould cavity 124.

The voids 182 extend along the length of the mould cavity 124 on opposing sides of the hollow moulded fibre bottle precursor 22a at the split plane 123. At the split plane 123, a distance between the outer surface of the hollow moulded fibre bottle precursor 22a and the inner surface of the inner wall 162 is greater than an average length of the fibres in the fibre slurry used to form the hollow moulded fibre bottle precursor 22a. Such clearance between the outer surface of the bottle 22a and the inner surface of the inner wall 162 can help prevent fibres extending outwardly from the outer surface of the hollow moulded fibre bottle precursor 22a from catching on the mould part 122 of the second mould 120 as the hollow moulded fibre bottle precursor 22a is inserted into the second mould 120.

Due to the positive draft angle of the base portion 154 of the mould parts 112 of the first mould 111, and the body portion 152 of the mould parts 112 of the first mould 111 being shorter than the body portion 172 of the mould parts 122 of the second mould 120, the risk of base portion 134 of the hollow moulded fibre bottle precursor 22a catching on the base portion 174 of the mould parts 122 of the second mould 120 is reduced.

With the mould parts 122 held together with a pressure of around 19.5 bar, a bladder, such as the thermoforming bladder 26 described with reference to FIG. 1, is inserted into the hollow moulded fibre bottle precursor 22a and inflated to a pressure of around 17 bar. The hollow moulded fibre bottle precursor 22a is urged against the inner surface of the inner walls 162 of the second mould 120 by the bladder, to substantially eradicate the voids 182 between the outer surface of the bottle 22a and the inner surface of the inner wall 162, thus to form the hollow moulded fibre bottle 22b.

FIG. 8 shows a plan view and FIG. 9b shows a side view of the hollow moulded fibre bottle 22b after being moulded by the second mould 120. Compared with the hollow moulded fibre bottle precursor 22a, the straight edges 131 have been eradicated so that the body portion 132, shoulder portion 136 and neck portion 138 are substantially circular in outer profile, and the body portion 132 of the hollow moulded fibre bottle precursor 22a has been stretched to the length of the body portion 172 of the mould parts 122 of the second mould 120 so that the base portion 134 of the hollow moulded fibre bottle 22b comprises a punt, as indicated by the dashed line 134a in FIG. 9b. Accordingly, a distance L3, in a direction parallel to the split plane 123, from an upper edge of the thermoforming mould part 122 to the base portion 174 when measured along the split plane 123 is less than the distance L4 when measured from an edge 173 of the base portion 174 that is most distal from the split plane 123.

It will be appreciated that there is provided a control system 104 that is configured to cause the moulding system 100 to: supply a fibre slurry to the mould cavity 114 of a mould 111; and mould, using the mould 111, the fibre slurry in the mould cavity 114 to provide the hollow moulded fibre bottle precursor 22a, the hollow moulded fibre bottle precursor 22a having a precursor width; transfer the hollow moulded fibre bottle precursor 22a to the second mould cavity 124 of the second mould 120, the second mould cavity 124 being defined by mould parts 122 having a mould width that is greater than the precursor width; and increase the precursor width of the hollow moulded fibre bottle precursor 22a in a direction across a split plane 123 of the second mould 120 by urging the hollow moulded fibre bottle precursor 22a against the second mould 120 to provide a hollow moulded fibre bottle 22b.

FIG. 10 shows a method 200 of providing a hollow moulded fibre product. The method 200 may be known as a fabrication method, in some examples. The hollow moulded fibre product may be the bottle 22b provided by the moulding system 100 described above with reference to FIGS. 2-9. The method 200 comprises forming a hollow moulded fibre product precursor in a first mould cavity of a first mould, as denoted by block 210. The first mould cavity has a first mould width in a direction across a split plane of the first mould. The hollow moulded fibre product precursor may be the bottle 22a provided by the moulding station 110 described above with reference to FIGS. 2-9.

The method 200 further comprises demoulding the precursor from the first mould cavity, as denoted by block 220. The precursor may be demoulded by the transfer mechanism 130 described above with reference to FIG. 2. The precursor has a precursor width in a direction across the split plane of the first mould, and the precursor width is equal to the first mould width.

The method 200 further comprises placing the precursor in a second mould cavity of a second mould, different to the first mould, as denoted by block 230. The second mould cavity has a second mould width, in a direction across a split plane of the second mould, that is greater than the first mould width and the precursor width. The placing may be performed by the transfer mechanism 130 described above with reference to FIG. 2. The second mould may be the second mould 120 described above with reference to FIGS. 2-9.

The method 200 further comprises, with the precursor in the second mould cavity, increasing the precursor width in the direction across the split plane of the second mould by urging the precursor against the mould, thereby to provide the hollow moulded fibre product from the precursor, as denoted by block 240. In this example, the mould parts of the second mould are held together with a pressure of around 19.5 bar during the increasing of the precursor width. In this example, the method 200 comprises increasing the precursor width by expanding an expandable member to a pressure of around 17 bar within the precursor to urge the precursor against the second mould, as denoted by block 242. In this example, the precursor width is increased by around 2% to the second mould width. It will be appreciated that, in other examples, the precursor width may be increased in any other suitable way and thus that block 242 may be omitted.

The method 200 therefore forms a receptacle. For example, FIG. 12 depicts a receptacle 900 that is obtained from the fabrication method.

Blocks 210, 220 are shown with dashed lines to indicate that, in other examples, blocks 210, 220 may be omitted from the method 200.

FIG. 11 shows a schematic diagram of a non-transitory computer-readable storage medium 800 according to an example. The non-transitory computer-readable storage medium 800 stores instructions 830 that, if executed by a processor 820 of a control system 810 of a moulding system, cause the moulding system to perform a method according to an example. In some examples, the control system 810 is or comprises the control system 104 as described above. The instructions 830 comprise: causing the moulding station to place a hollow moulded fibre precursor in a mould cavity of a mould 831, the precursor having a precursor width in a direction across a split plane of the mould and the mould cavity having a mould width in the direction across the split plane, the mould width greater than the precursor width; and causing the moulding station to increase the precursor width in the direction across the split plane by urging the precursor against the mould 832.

It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in FIG. 1) comprising a moulding station for providing/processing a hollow moulded fibre product and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle. Similarly, also provided is a method of manufacturing a receptacle, the method comprising: placing a hollow moulded fibre product precursor in a mould cavity, the hollow moulded fibre product precursor having a precursor width in a direction across a split plane of the mould, the mould defining a mould cavity having a mould width in the direction across the split plane of the mould, the mould width being greater than the precursor width; and with the hollow moulded fibre product precursor in the mould cavity, increasing the precursor width in the direction across the split plane of the mould by urging the hollow moulded fibre product precursor against the mould to provide a hollow moulded fibre product, and then performing at least one additional process on the hollow moulded fibre product to provide the 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 900, in the form of a necked receptacle and specifically a bottle, containing contents 910 is shown in FIG. 12. 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 1000 is shown in FIG. 13. The method 1000 comprises providing 1010 the receptacle, in the form of a necked receptacle and specifically a bottle, and then providing 1020 the contents in the receptacle. In this example, block 1020 follows block 1010, so that block 1020 comprises putting the contents into the receptacle that has been provided at block 1010. However, in some other examples, blocks 1010 and 1020 are performed concurrently, so that the providing 1010 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 1000 also comprises closing 1030 an opening of the receptacle after block 1020, and applying 1040 a label or indicia to the receptacle after block 1030. In this example, block 1030 involves applying a heat seal to the opening and then screwing a cap or lid onto the receptacle, and block 1040 comprises adhering a label onto the receptacle.

In respective other examples, the order of blocks 1030 and 1040 is reversed, blocks 1030 and 1040 are performed concurrently, block 1030 is omitted, and block 1040 is omitted. In some examples, block 1040 occurs before block 1020, or block 1040 occurs during block 1020. 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 1000 could be performed by the same party that manufactures the receptacle, for example so that block 1010 comprises the method discussed above with reference to the manufacturing line shown in FIG. 1. Alternatively, the method 1000 could be performed by a different party to that which manufactures the receptacle. In such an alternative, the different party performs block 1010 by way of obtaining the receptacle from the party that manufactures the receptacle (such as by way of the method discussed above with reference to 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.