SHIELD POSITIONING MECHANISM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation under 35 U.S.C. § 120 of International Application No. PCT/GB2024/051778, filed Jul. 8, 2024, which claims priority to United Kingdom Application No. GB 2310462.3, filed Jul. 7, 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 systems for 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.

Published patent document EP1195466 describes forming a pulp moulded article. The document describes forming a precursor in a mould. To achieve this, a fibre suspension (pulp slurry) is introduced into a cavity of the mould and “dewatered” using a vacuum and an inflatable pressing member (such as a bladder). The pressing member is introduced into the mould after the fibre suspension, and is expanded to press the fibre suspension against an inner surface of the cavity.

SUMMARY

As mentioned, it is known to use an inflatable member to press a fibre suspension against the inner surface of a cavity of a mould. However, due to the delicate nature of the fibre suspension, it is important to ensure that the inflatable member does not contact the fibre suspension as the inflatable member enters the cavity. For example, the inflatable member may cause some of the fibre suspension to come away from the inner surface of the cavity, if the inflatable member rubs the fibre suspension as the inflatable member is moved into the cavity. The risk of damaging the fibre suspension (or indeed any product contained within the cavity) may be greater when manufacturing products with necks. For example, in such cases, there is a need to pass a relatively wide portion of the inflatable member (which is subsequently expanded to form a main body portion of the product) through a relatively narrow neck portion of the product.

Accordingly, described herein are systems and methods for reducing the likelihood of inflatable (or more generally expandable) members from coming into contact with the fibre suspension during insertion of the expandable member into the cavity. As will become apparent, this protection or prevention of contact is provided by use of a protective barrier, such as a “shield”, which is placed between the expandable member and the fibre suspension contained with the cavity of the mould. The shield can also be used during further, downstream moulding processes, such as when a precursor (formed from the fibre suspension in the mould) is pressed in a second mould. As such, the shield can therefore be used to protect any product that is being moulded. The shield provides a barrier between the expandable member and the product to protect the product (such as a neck portion of a product) during the insertion of the expandable member. The shield therefore mitigates the risk of contact between the expandable member and the product.

As such, according to a first aspect of the present invention, there is provided a moulding system, comprising a mould defining a cavity, the cavity configured to receive a product for moulding therein, wherein the system is configured to insert a shield at least partially into the cavity, and insert an expandable member at least partially into the cavity through the shield, whereby in use the shield protects at least part of the product from contacting the expandable member during the insertion of the expandable member into the cavity, wherein the expandable member is expandable to urge the product against an inner surface of the cavity. In some examples, the shield prevents at least part of the product from contacting the expandable member during the insertion of the expandable member into the cavity.

In an example, the system comprises a shield positioning mechanism configured to insert the shield at least partially into the cavity. In an example, the system comprises an expandable member positioning mechanism configured to insert the expandable member at least partially into the cavity through the shield. In certain examples, the shield positioning mechanism and the expandable member positioning mechanism are parts of the same component or device. It will be appreciated that any reference to a part of the system being configured to perform an action can be considered an action performed by the system, rather than by the particular part of the system. For example, if the expandable member positioning mechanism or the shield positioning mechanism perform an action, those actions may be said to be performed by the system itself.

In an example, the product is a hollow moulded fibre product. The product may be a precursor or a bottle precursor, for example. For example, the shield may be used in a thermoforming mould. In some examples, the moulding system may be a thermoforming system. For example, the cavity may be heated to apply heat to the product during moulding.

In another example, the product is a fibre suspension. For example, the shield may be used in a primary mould for initially forming a precursor from the fibre suspension.

In certain examples, the expandable member is an inflatable member, also known as a bladder.

The system may comprise the expandable member. The system may comprise the shield.

In some examples, the shield is inserted after the product has been received in the cavity. For example, the shield is inserted after the fibre suspension has been introduced into the cavity, such as sprayed and/or drawn into the cavity, or after a previously formed precursor has been introduced into the cavity.

In a particular example, the shield is only partially inserted into the cavity.

In some arrangements, the shield defines an opening through which the expandable member can be inserted into the cavity.

In some examples, the shield/expandable member positioning mechanism may be known as a shield/expandable member insertion mechanism, respectively.

Urging the product against the inner surface of the cavity moulds the product in the cavity (thereby forming a pressed product). For example, the expandable member compacts the fibre suspension or the fibrous material forming the precursor. In use, the expandable member is expanded inside the cavity. As such, the expandable member is in a non-expanded (or collapsed) state during insertion into the cavity through the shield.

In examples, the product defines a hollow interior, the shield positioning mechanism is configured to insert the shield at least partially into the hollow interior of the product, and the expandable member positioning mechanism is configured to insert the expandable member at least partially into the hollow interior of the product through the shield. Positioning the shield at least partially inside the product allows the product to be protected as the expandable member is guided inside the product. In one example, the shield positioning mechanism is configured to insert the shield partially into the hollow interior of the product, such that the shield extends from outside of the hollow interior through an opening of the product, and into the hollow interior when the expandable member positioning mechanism inserts the expandable member at least partially into the hollow interior of the product through the shield. In a particular example, the product has a neck portion, the neck portion having the opening.

In certain examples, the precursor may be known as a hollow moulded fibre product, a partially formed hollow moulded fibre product, a partially formed receptacle, a partially formed article, a partially formed bottle, a partially formed container, etc. A precursor may be moulded from a fibre suspension, including constituents such as paper pulp. A fibre suspension may contain, amongst other things, cellulose fibres and a liquid, such as water. Additives may be present in the fibre suspension. In any of the examples described herein, the product may be referred to as a necked product. A hollow product is a product that has an empty space or void inside. A moulded product is a product that is made within a mould. A fibre product is one that is formed from a fibre suspension, such as a fibre suspension comprising paper pulp.

As mentioned, the mould defines a cavity (also known as a “mould cavity”), and in examples where the product is fibre suspension, a layer or coating of the fibre suspension can be applied to an inner surface of the cavity. Similarly, in examples where the product is a precursor, the precursor may abut the inner surface of the cavity. The layer or coating of the fibre suspension, as well as a wall of the precursor, may have a first thickness, and after being urged against the inner surface (and therefore compressed) by the expandable member, the layer, coating or wall may have a second thickness that is less than the first thickness owing to the compaction of the fibres and in some cases, removal of some of the liquid.

In certain examples, the mould has an opening into the cavity. In some examples, the cavity has a main body portion (also known as a first portion) and a neck portion (also known as a second portion). Both portions of the cavity together form the cavity. The neck portion may be used to form the neck of the product. The main body portion has a cross-sectional width that is larger than the cross-sectional width of the neck portion (the cross-section being taken in a plane parallel to a longitudinal axis of the product).

In some examples, the cavity has apertures formed on/through the inner surface of the cavity. This allows liquid to pass from within the cavity to outside of the mould. The apertures may therefore extend from the cavity to an outer surface of the mould.

In particular examples, the moulding system further comprises the shield, wherein the shield is connected to, or connectable to, a shield positioning mechanism. This allows different shields, such as differently dimensioned shields, to be used with the same shield positioning mechanism. For example, the shield to be used can be selected from a plurality of shields depending upon the particular product to be moulded.

In some examples, the shield comprises (or is formed from) a metal, a metal alloy or plastic. The expandable member may, for example, comprise (or be formed from) rubber.

In certain arrangements, the moulding system further comprises the shield, the system (such as the shield positioning mechanism) is configured to position the shield such that the shield extends through an opening of the product during the insertion of the expandable member into the cavity, and optionally the shield is dimensioned to extend around at least 90% of the opening. This ensures a high proportion of the opening is protected during insertion of the expandable member.

The shield is preferably dimensioned to extend around at least 95%, or 100% of the opening. In a particular example, the product has a neck portion, the neck portion having the opening. The opening may define a perimeter (or circumference), such that the shield extends around at least 90% of the perimeter. In examples where the shield extends around 100% of the opening, the shield may be “ring” shaped.

In some examples, the moulding system comprises the product. In some examples, the shield positioning mechanism is configured to position the shield such that it extends through the opening after the product has been received within the cavity.

In particular examples, the moulding system further comprises the shield, the shield defines a channel with a first end and a second end, the first end being wider than the second end, and the system (such as the expandable member positioning mechanism) is configured to insert the expandable member at least partially into the cavity by passing the expandable member through the first end, along the channel, and then out of the second end. Having the expandable member initially pass through a wider end of the shield helps “funnel” the expandable member into the cavity, which reduces the likelihood of the expandable member contacting the product.

The shield may be funnel-shaped. The shield may funnel the expandable member at least partially through a neck portion of the product.

The channel may be open or closed.

The first end has a first cross-sectional width that is wider than a second-cross sectional width of the second end. The cross-section is taken in a plane perpendicular to a longitudinal axis of the shield.

In use, the second end of the channel is positioned within the cavity of the mould. In use, the first end of the channel is positioned external to (i.e., outside of) the cavity.

In some cases, the moulding system further comprises the shield, the cavity has a first interior portion and a second interior portion, the first interior portion having a narrower cross-sectional width than the second interior portion, the shield has a length that is greater than a length of the first interior portion of the cavity, and the system (such as the shield positioning mechanism) is configured to position the shield such that the shield extends completely through the first interior portion of the cavity (during the insertion of the expandable member).

The narrower portion of the cavity (and therefore product) is more likely to come into contact with the expandable member during insertion of the expandable member. As such, having the shield have a length greater than the length of the narrower portion ensures that the first (narrower) portion of the product is well protected by the shield.

The length is measured parallel to a longitudinal axis of the cavity. The longitudinal axis is parallel to an insertion axis—that is, the axis along which the expandable member is inserted into the cavity/product. The first and second interior portions contact the product once the product is received in the cavity. The product has a first portion and a second portion, the first portion having a narrower cross-sectional width than the second portion, where the first interior portion of the cavity has a cross-sectional width corresponding to the first portion of the product and the second interior portion of the cavity has a cross-sectional width corresponding to the second portion of the product. In some examples, the first portion is a neck portion and the second portion is a body portion.

In some examples, the system (such as the shield positioning mechanism) is further configured to remove the shield from the cavity. Removing the shield allows the product to be moulded within the cavity without interference from the shield. For example, the shield may be removed before the expandable member urges the product against the inner surface of the cavity. As such, in one example, the system (such as the expandable member positioning mechanism) is configured to: (i) insert a portion of the expandable member into the cavity before the system (such as the shield positioning mechanism) has removed the shield from the cavity, and (ii) insert a further portion of the expandable member into the cavity after the system (such as the shield positioning mechanism) has been removed the shield from the cavity. This allows the expandable member to be fully inserted before it is expanded, without interfering with and contacting the shield.

In some examples, the expandable member is expanded after the expandable member positioning mechanism has inserted the further portion of the expandable member. A greater proportion of the expandable member is inserted into the cavity after the expandable member positioning mechanism has inserted the further portion of the expandable member into the cavity, than before the expandable member positioning mechanism has inserted the further portion of the expandable member into the cavity. The further portion of the expandable member may have a narrower cross-sectional width than the portion of the expandable member already inserted into the cavity.

In certain examples, the shield comprises a first shield part and second shield part, wherein the second shield part is discrete or separate from the first shield part, and the system (such as a shield positioning mechanism) comprises: a first positioning component configured to insert the first shield part at least partially into the cavity, and a second positioning component configured to insert the second shield part at least partially into the cavity. In some examples, the first and second positioning components are separate from each other. In other examples, the first and second positioning components are not separate, and are part of the same mechanism.

The shield may therefore be formed in two or more parts, which, when brought together by the positioning components of the shield positioning mechanism, allows the shield to be formed. This can allow the expandable member to be inserted through the shield, and then allow the shield to be removed from around the expandable member (by moving the two shield parts away from each other). Furthermore, having two or more positioning components of the shield positioning mechanism can allow the shield to be held stable during the insertion of the expandable member. For example, the two positioning components can hold the shield on opposite sides. In some cases, the first and second positioning components of the shield positioning mechanism are separate from each other. In other cases, however, they may be connected to each other, such as forming part of the same piece of equipment.

The shield positioning mechanism is thereby configured to position the first and second shield parts adjacent each other.

In some cases, the shield positioning mechanism is configured to position the first and second shield parts such that they abut each other.

In some cases, there may be a gap/space between the first and second shield parts when the first and second shield parts are inserted/positioned at least partially into the cavity. As such, it will be appreciated that the expandable member may still be said to be inserted “through the shield” despite the shield being open at least at one location around its perimeter.

The first shield part may define a first half of the shield, and the second shield part may define a second half of the shield. In other examples, the shield comprises more than two shield parts and, in some examples, the shield positioning mechanism comprises more than two positioning components, each positioning component configured to insert a respective one of the shield parts. In some examples, each shield part defines a channel. In some examples, the channel of each shield part has a first end and a second end, the first end being wider than the second end.

In some examples, the shield comprises a first shield part and second shield part, wherein the second shield part is discrete or separate from the first shield part, and the shield positioning mechanism is configured to: (i) insert the first shield part at least partially into the cavity and (ii) insert the second shield part at least partially into the cavity.

In some examples, the shield is rigid.

In some examples, the moulding system further comprises the shield, and the shield is expandable, such that when the expandable member is expanded to urge the product against the inner surface of the cavity, the expansion of the expandable member causes the shield to expand. The shield may therefore be expandable itself, and be expanded by the expansion of the expandable member. This allows the shield to be retained in place during expansion of the expandable member, meaning that it does not need to be removed after insertion of the expandable member and before expansion of the expandable member. This can simplify the manufacturing process, and reduce complexity of having the shield formed in two or more shield parts.

In some examples, the shield is stretchable. For example, the shield is made from a resilient material, such as silicon or rubber.

The shield may be made from a low friction and/or heat resistant material.

In some examples, the shield positioning mechanism is configured to insert the shield at least partially into the cavity in an unexpanded or collapsed state, and the expansion of the expandable member causes the shield to expand into an expanded state. In the unexpanded state, the shield has an outer perimeter that has a narrower cross-section than the outer perimeter in the expanded state. The shield expands around the outer surface of the expandable member.

In an example, the expandable member positioning mechanism is configured to remove the expandable member from the cavity, which causes the shield to be removed from the cavity with the expandable member (for example, the shield may be abutting the outer surface of the expandable member). In an example, the system further comprises a shield extraction mechanism configured to decouple the shield from the expandable member, such that the shield is available for a subsequent insertion into the cavity. Decoupling the shield may comprise separating the shield from the expandable member (which may comprise turning the shield inside out) and subsequently adjusting the shield such that it is no longer inside out.

According to a second aspect of the present invention, there is provided a receptacle manufacturing line comprising the moulding system of the first aspect for moulding the product, and apparatus for performing at least one additional process on the product to provide a 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 third aspect of the present invention, there is provided shield positioning mechanism, configured to: insert a shield at least partially into a cavity of a mould, whereby in use the shield protects at least part of a product contained within the cavity from contacting an expandable member during insertion of the expandable member into the cavity through the shield, wherein the expandable member is expandable to urge the product against an inner surface of the cavity.

The shield positioning mechanism may comprise any or all the features of the shield positioning mechanism described above.

In certain examples, the shield positioning mechanism comprises a connector for connecting the shield to the shield positioning mechanism. The shield may comprise a complementary connector for engagement with the connector on the shield positioning mechanism.

In some examples, the shield positioning mechanism is further configured to remove the shield from the cavity.

In some arrangements, the shield positioning mechanism comprises a first positioning component configured to insert a first shield part of the shield at least partially into the cavity and a second positioning component configured to insert a second shield part of the shield at least partially into the cavity.

According to a fourth aspect of the present invention, there is provided a method comprising: causing a shield to be at least partially inserted into a cavity of a mould, such that the shield protects at least part of a product contained within the mould from contacting an expandable member during subsequent insertion of the expandable member through the shield and into the cavity.

The method may be a method for a moulding system. Causing the shield to be at least partially inserted into the cavity of the mould may be performed by a shield positioning mechanism. The method may comprise, before causing the shield to be at least partially inserted into the cavity, causing a previous shield to be decoupled from a shield positioning mechanism and causing the shield to be coupled with the shield positioning mechanism. The previous shield may be a differently dimensioned (or damaged) shield. In some examples, the product defines an opening having a perimeter and causing the shield to be at least partially inserted comprises protecting at least 90% of the perimeter of the opening. In one example, the perimeter is circular. In some examples, causing the shield to be at least partially inserted into the cavity comprises causing the shield to be at least partially inserted into the cavity after the product has been received in the cavity.

In some examples, causing the shield to be at least partially inserted into the cavity comprises causing the shield to be positioned such that it extends through an opening of the product during the insertion of the expandable member into the cavity.

Causing the shield to be positioned such that it extends through an opening of the product during the insertion of the expandable member into the cavity may be performed by a shield positioning mechanism. In an example, the product has a first portion and a second portion, the first portion having a narrower cross-sectional width (such as an outer cross-sectional width) than the second portion, wherein the shield has a length that is greater than a length of the first portion of the product and wherein causing the shield to be at least partially inserted into the cavity comprises causing the shield to be positioned such that the shield extends completely through a first portion of the product.

In certain examples, causing the shield to be at least partially inserted into the cavity comprises causing the shield to be positioned such that it extends at least partially into a hollow interior of the product after the product has been received within the cavity. Positioning the shield at least partially inside the product allows the product to be protected as the expandable member is guided inside the product.

Causing the shield to be positioned such that it extends at least partially into a hollow interior of the product may be performed by a shield positioning mechanism. In a particular case, the method comprises causing the shield to be inserted partially into the hollow interior of the product, such that the shield extends from outside of the hollow interior through an opening of the product, and into the hollow interior when the expandable member is inserted at least partially into the hollow interior of the product through the shield.

In some examples, the method further comprises causing the shield to be removed from the cavity. Causing the shield to be removed from the cavity may be performed by a shield positioning mechanism.

The method may further comprise causing a portion of the expandable member to be inserted into the cavity before causing the shield to be removed from the cavity, and causing a further portion of the expandable member to be inserted into the cavity after causing the shield to be removed from the cavity. Such actions may be performed by an expandable member positioning mechanism.

In some cases, causing the shield to be at least partially inserted into the cavity comprises causing a first shield part to be at least partially inserted into the cavity and causing a second shield part to be at least partially inserted into the cavity, wherein the second shield part is separate from the first shield part. Causing the first shield part of the shield to be at least partially inserted into the cavity and causing the second shield part of the shield to be at least partially inserted into the cavity may be performed by a shield positioning mechanism. For example, a first positioning component of the shield positioning mechanism may cause the first shield part to be at least partially inserted into the cavity and a second positioning component of the shield positioning mechanism may cause the second shield part to be at least partially inserted into the cavity.

The method may further comprise causing the product to be introduced into the cavity, causing the expandable member to be at least partially inserted into the cavity through the shield, and causing the expandable member to expand and thereby urge the product against an inner surface of the cavity to form the product into a pressed product. Causing the expandable member to be at least partially inserted may be performed by an expandable member positioning mechanism. Causing the expandable member to expand may be performed by an expandable member positioning mechanism. Causing the product to be introduced may be performed by a transfer mechanism.

According to a fifth aspect of the present invention, there is provided a control system configured to cause a shield positioning mechanism to perform the method of the fourth aspect (such as those actions performed by the shield positioning mechanism), or to cause a moulding system to perform the method of the fourth aspect.

According to a sixth aspect of the present invention, there is provided a non-transitory storage medium storing machine-readable instructions that, when executed by one or more processors of a control system, cause the one or more processors to perform the method of the fourth aspect.

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: (i) causing the product to be introduced into the cavity, (ii) causing the expandable member to be at least partially inserted into the cavity through the shield, and (iii) causing the expandable member to expand and thereby urge the product against an inner surface of the cavity, thereby to provide a pressed product, and then performing at least one additional process on the pressed 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 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 method further 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 a 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.

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 THE 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 perspective view of an example shield positioning mechanism;

FIGS. 3A to 3M show respective cross-sections of an example mould at different points in time according to a first example;

FIGS. 4A to 4C show respective cross-sections of an example mould at different points in time according to a second example;

FIGS. 5A and 5B show respective cross-sections of an example mould at different points in time according to a third example;

FIGS. 6A to 6C show top down views of example shields;

FIG. 7 is a flow diagram of a first example method;

FIG. 8 is a flow diagram of a second example method;

FIG. 9 shows a computer-readable storage medium according to an example;

FIG. 10 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and

FIG. 11 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 “splits” or “moulds” or “mould parts” 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 or mould parts 14, such as three, four or six splits or mould parts, 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). The bladder may be referred to as an expandable member, in some examples. The fibre suspension contained within the cavity of the mould 15 may be referred to as a “product” in some examples, which is urged against the inner surface of the cavity by the bladder.

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.

As discussed earlier, the use of a bladder (referred to as an expandable member in some examples) can damage the “product” contained in the mould 15, 25, whether that be the fibre suspension or the preform. To stop or reduce the damage, a shield can be introduced into the mould through which the expandable member is inserted. The shield can be moved into place by a shield positioning mechanism.

FIG. 2 depicts part of an example shield positioning mechanism. In this particular example, the shield positioning mechanism has two positioning components, each positioning component configured to position part of a shield at least partially within a cavity of a respective mould. FIG. 2 depicts just one of the two positioning components of the shield positioning mechanism; however, it will be appreciated that another positioning component will be present to position another part of the shield within the cavity of the mould. The two parts of the shield therefore form a “complete” shield, as will become apparent. Together, the two positioning components of the shield positioning mechanism are configured to insert the shield at least partially into the cavity of the mould (and therefore insert both parts of the shield into the cavity), to protect at least part of a product contained within the cavity.

FIG. 2 therefore depicts a first positioning component 202 of the shield positioning mechanism. The shield positioning mechanism may form part of a moulding system, the moulding system comprising at least the first positioning component 202 and a second positioning component (not shown in FIG. 2). In certain examples, the moulding system may additionally comprise any or all of the manufacturing stages or stations depicted in FIG. 1.

As shown in the particular example of FIG. 2, a first shield part 204 is coupled to the shield positioning mechanism (and in particular the first positioning component 202). For example, the first positioning component 202 of the shield positioning mechanism comprises a connector 206a (such as a threaded hole, as in this example) and the first shield part 204 comprises a complimentary connector 206b (such as a hole and screw) for engagement with the connector 206a on the first positioning component 202. In some cases, further connectors and complementary connectors may additionally be used to further secure the first shield part 204 to the first positioning component 202. Allowing the first shield part 204 to be decoupled from the first positioning component 202 enables the first shield part 204 to be replaced when it is damaged, or allows differently dimensioned shield parts to be used with the same positioning component. For example, different sized shields may be used depending upon the size of the mould and/or the particular type of product being moulded in the mould.

In other examples, the first shield part 204 is integrally formed with the first positioning component 202 of the shield positioning mechanism.

In the example of FIG. 2, the first positioning component 202 is coupled to a further shield part 214 which is for insertion into a different mould to that into which the first shield part 204 is inserted. In other examples, each positioning component 202 may be coupled or be couplable to a single shield part, or two or more shield parts, each shield part being insertable into a different mould cavity.

In embodiments where the shield positioning mechanism comprises two or more positioning components, it will be understood that features of each positioning component (such as the first positioning component 202) may also be referred to as being features of the shield positioning mechanism. Similarly, in embodiments where the shield comprises two or more shield parts, it will be understood that features of each shield part (such as the first shield part 204) may also be referred to as being features of the shield. As such, any features of the first positioning component 202 may be present in embodiments where the shield positioning mechanism is not formed from two or more components and any features of the first shield part 204 may be present in embodiments where the shield is not formed from two or more shield parts.

Furthermore, although FIG. 2 depicts just one positioning component of the shield positioning mechanism and a corresponding shield part, features discussed in respect of FIG. 2 may also be present in other positioning components of the shield positioning mechanism (such as the second positioning component mentioned above) and other shield parts (such as a second shield part).

As also shown in the particular example of FIG. 2, the first positioning component 202 comprises a moveable arm 208 that is movable to position the first shield part 204 at least partially into the cavity of the mould. The moveable arm 208 is connected to a main body 212 of the first positioning component 202 by a pivoting assembly 210 about which the moveable arm 208 pivots with respect to the main body 212. A drive mechanism (not shown) is arranged to control movement of the first shield part 204 via movement of the moveable arm 208.

In other examples, movement and positioning of the first shield part 204 may be achieved by mechanisms other than a moveable arm 208 and a pivoting assembly 210. For example, a drive mechanism may move a moveable arm and/or the first shield part along one or more axes, rather than via a pivoting action. An example of such a mechanism is shown in FIGS. 3A-3M.

The first shield part 204 defines a channel (in this case an open channel) along its length, where the length is measured along a longitudinal axis 220 of the first shield part 204. The channel (and therefore the first shield part 204) has a first end 216 and a second, opposite, end 218, where the first end 216 has a first cross-sectional width (such as an outer or external cross-sectional width) and the second end 218 has a second cross-sectional width (such as an outer or external cross-sectional width), where the first and second cross-sectional widths are measured in a direction perpendicular to the longitudinal axis 220. As shown in FIG. 2, the first cross-sectional width is wider than the second cross-sectional width. The shield, when formed from the first and second shield parts, therefore has a funnel shape to funnel the expandable member into the product contained within the cavity of the mould. The longitudinal axis 220 is moveable by the first positioning component 202 to be parallel to a longitudinal axis of the second shield part and a longitudinal axis of the mould cavity. To ensure that the shield can be inserted into an opening of the product, where the opening of the product has a third cross-sectional width, the second cross-sectional width must be less than the third cross-sectional width.

In certain examples, the channel of the first shield part 204 has a non-constant surface gradient along its length. As shown in FIG. 2, the surface gradient has a discontinuity along the length of the channel. For example, at a first point (such as near to the first end 216 or at the first end 216), the channel has a first surface gradient relative to an axis that is perpendicular to the longitudinal axis 220 of the first shield part 204. Similarly, at a second point (such as near to or at the second end 218), the channel has a second surface gradient relative to an axis that is perpendicular to the longitudinal axis 220 of the first shield part 204. Here the first point is closer to the first end 216 than the second point as measured in a direction along the longitudinal axis 220. As shown, the first surface gradient is shallower than the second surface gradient (so an angle between the axis that is perpendicular to the longitudinal axis 220 and the first point is less than an angle between the axis that is perpendicular to the longitudinal axis 220 and the second point). Although the surface gradient of the channel has a discontinuity, and therefore abruptly changes (such as by more than 10 or 20 degrees) as seen at point 222 (which is between the first and second points), in other examples, the surface gradient may smoothly vary along the length of the channel, rather than having a discontinuity.

In some examples, the first surface gradient is about 45 degrees, and the second surface gradient is greater than 45 degrees, such as about 50, 60, 70, 80 or 90 degrees. In this particular case, the first surface gradient is about 70 degrees, and the second surface gradient is about 90 degrees (i.e., the second surface is substantially parallel to the longitudinal axis 220). The shallower gradient eases the transition of the expandable member into the channel, and the steeper (second) surface gradient controls the placement and the trajectory of the expandable member into the centre of the cavity, reducing the likelihood that the expandable member contacts the product in the cavity of the mould.

To illustrate more clearly how the shield protects a product contained within the cavity of mould during insertion of an expandable member, FIGS. 3A-3M depict schematic drawings of at least part of a moulding system 300 comprising an example shield positioning mechanism at various points in time. As in the example of FIG. 2, the shield positioning mechanism has two positioning components, including the first positioning component 202 of FIG. 2 and a second positioning component 202′ that is substantially the same as the first positioning component 202. For brevity, features of the first positioning component 202 and the first shield part 204 have the same reference numbers as those in FIG. 2 and corresponding features of the second positioning component 202′ and the second shield part 204′ have the same reference numbers as those in FIG. 2, but with primes.

In contrast to the example of FIG. 2, however, rather than having a pivoting mechanism to move the moveable arms 208, 208′, the first and second positioning components 202, 202′ each have a drive mechanism (not shown), to move the moveable arms 208, 208′ along one or more axes, in one or more dimensions. As will become apparent, in the examples of FIGS. 3A-3M, the drive mechanisms are configured to move the moveable arms 208, 208′ along two perpendicular axes in two dimensions, such as parallel and perpendicular to a longitudinal axis of a cavity of a mould.

FIG. 3A therefore depicts a cross-section through a mould 302 (which may correspond to either of moulds 15, 25 of FIG. 1), where the mould 302 defines a cavity 304 therein for moulding a product 306. In this example, the cavity 304 has a first interior portion 304a and a second interior portion 304b, the first interior portion 304a having a narrower cross-sectional width than the second interior portion 304b, where the cross-sectional widths are measured perpendicular to a longitudinal axis 308 of the mould 302 and/or cavity 304. The cavity 304 also comprises an inner surface 304c against which a product is mouldable using an expandable member.

At the time shown in FIG. 3A, the product 306 is already contained within the cavity 304, having been introduced during an earlier process. The product 306 may be a loose coating of fibre suspension that has been sprayed and/or drawn against the inner surface 304c, or may be a precursor, like the hollow moulded fibre product 22 discussed in FIG. 1.

The first and second interior portions 304a, 304b of the cavity 304 contact the product 306 once the product 306 is received in the cavity 304. Due to the nature of the cavity 304, the product 306 has a first portion (formed by the first interior portion 304a) and a second portion (formed by the second interior portion 304b), where the first portion has a narrower cross-sectional width than the second portion. In this particular example, the first portion is a neck portion of the product 306 and the second portion is a body portion of the product 306.

Once the product 306 has been introduced into the cavity 304, and before an expandable member is introduced to urge or force the product 306 against the inner surface 304c of the cavity 304, a shield is inserted at least partially into the cavity 304.

As previously described, the shield of this example is formed from two shield parts, each of which are separately introduced into the cavity 304 by respective positioning components of the shield positioning mechanism. As such, in this example, the first positioning component 202 is configured to insert the first shield part 204 at least partially into the cavity 304, and the second positioning component 202′ is configured to insert the second shield part 204′ at least partially into the cavity 304. As mentioned, movement is facilitated by the drive mechanisms causing the moveable arms 208, 208′, and therefore the shield parts 204, 204′, to move.

FIG. 3B therefore shows the moulding system 300 of FIG. 3A at a moment in time later than that shown in FIG. 3A. Here, the first and second positioning components 202, 202′ have moved the respective first and second shield parts 204, 204′ to a position in which they are closer together, by moving the first and second shield parts 204, 204′ in a direction perpendicular to the longitudinal axis 308 of the cavity 304. From this position, the first and second shield parts 204, 204′ are insertable along the longitudinal axis 308 and into the cavity 304.

FIG. 3C therefore shows the moulding system 300 of FIG. 3B at a moment in time later than that shown in FIG. 3B. Here, the first and second shield parts 204, 204′ have been moved to a position inside the cavity 304, by moving the first and second shield parts 204, 204′ in a direction parallel to the longitudinal axis 308 of the cavity 304. It will be appreciated that other mechanisms can be used to position the first and second shield parts 204, 204′ in the cavity 304, in other examples.

FIG. 3C therefore depicts the shield (formed by both the first and second shield parts 204, 204′ being brought together) positioned such that it extends through an opening 310 (such as a top opening) of the product 306. The shield remains in this position during insertion of the expandable member into the cavity 304. As will be described, in some examples, the shield is withdrawn from the opening 310 and cavity 304 before the expandable member is fully inserted into the cavity 304 and before it is caused to expand and urge the product 306 against the inner surface 304c. In alternative examples, however, the shield may be positioned such that it does not extend through the opening 310 during the insertion of the expandable member. For example, it may be positioned further inside a hollow interior of the product 306 (such as within a neck portion of the product 306).

Furthermore, the shield is positioned such that it extends at least partially into the cavity 304. For example, as shown, the first ends 216, 216′ of the first and second shield parts 204, 204′ are positioned outside of the cavity 304 (where the cavity 304 is defined by the part of the mould 302 that contacts the product 306) and in this case, outside of the mould 302 itself. In some cases, the first ends 216, 216′ of the first and second shield parts 204, 204′ are positioned outside of the cavity 304 but within the mould 302 (such as within an entrance cavity, which does not contact the product 306). The second ends 218, 218′ of the first and second shield parts 204, 204′ are positioned inside the cavity 304 and inside the product 306 itself (such as within a hollow interior of the product 306).

In the example of FIG. 3C, the first and second shield parts 204, 204′ have lengths 312, 312′ that are greater than a length 314 of the first interior portion 304a of the cavity (and also a length of the first/neck portion of the product 306), where the lengths 312, 312′, 314 are all measured parallel to the longitudinal axis 308 of the cavity 304 and/or the longitudinal axes 220, 220′ of the shield parts 204, 204′. The length of the first interior portion 304a is measured between the part of the cavity 304 where the opening 310 of the product 306 is located, and the part of the cavity 304 where the cavity 304 begins to widen in cross-section (i.e., where the neck portion of the product 306 ends). The length of the first/neck portion of the product 306 is measured between the opening 310 of the product 306 and where the product 306 begins to widen in cross-section (i.e., where the neck portion of the product 306 ends). Accordingly, the first interior portion 304a of the cavity 304 and the first/neck portion of the product 306 are equal in length. The lengths 312, 312′ of the first and second shield parts 204, 204′ are measured between the first 216, 216′ and second 218, 218′ ends. As shown, the first and second shield parts 204, 204′ are dimensioned and positioned such that they extend completely through the first interior portion 304a of the cavity (and therefore completely through the neck portion of the product 306). This protects the neck portion from damage by the expandable member as the expandable member is being inserted through the neck portion of the product 306.

Once the shield has been moved into the position shown in FIG. 3C, the expandable member is insertable into the cavity 304 (and therefore into the hollow interior of the product 306). FIG. 3D therefore shows the moulding system 300 of FIG. 3C at a moment in time later than that shown in FIG. 3C. Here, the expandable member 316 has begun to move in a direction 318 towards the cavity 304 and along an insertion axis that is parallel to a longitudinal axis of the shield (and therefore the longitudinal axes of the first and second shield parts 204, 204′), as well as the longitudinal axis 308 of the cavity 304. As the expandable member 316 is being inserted into the cavity 304, the expandable member 316 is in a collapsed state (so has a narrower cross-sectional width than in an expanded state), so that it can fit through the opening 310 of the product 306.

FIG. 3E shows the moulding system 300 of FIG. 3D at a moment in time later than that shown in FIG. 3D. Here, the expandable member 316 has continued to move along the insertion axis, and is now partially inserted into the cavity 304 so that a distal end of the expandable member 316 is within the cavity 304. As shown, the expandable member 316 has passed through the shield (and therefore along the channels defined by each of the first and second shield parts 204, 204′) and into the cavity 304. At the time shown in FIG. 3E, the expandable member 316 is still surrounded by the shield. Due to the shield, the expandable member 316 cannot come into contact with the neck portion of the product 306.

FIG. 3E additionally shows a line 320 that is connected to the expandable member 316 and a fluid storage tank (not shown) through which a fluid, such as water, oil or a gas is able to be introduced to cause the expandable member 316 to expand.

FIG. 3E also shows an expandable member positioning mechanism 322 which controls and therefore causes movement of the expandable member 316. In some cases, the expandable member positioning mechanism 322 also controls the flow of fluid along the line 320 and therefore also controls the expansion of the expandable member 316. In other cases, the fluid flow may be controlled by another part of the system 300.

As mentioned previously, both the first and second shield parts 204, 204′ define channels along their lengths 212, 212′. Accordingly, the expandable member 316 is inserted into the cavity 304 by passing through the first ends 216, 216′ of the first and second shield parts 204, 204′, along the channels, and then out of the second ends 218, 218′ of the first and second shield parts 204, 204′. In some examples, only some parts of the expandable member 316 pass through the shield. For example, a proximal end of the expandable member 316 (which is connected to line 320) may never pass through the first ends 216, 216′ of the first and second shield parts 204, 204′.

Once at least a portion of the expandable member 316 has been inserted into the cavity 304, as depicted in FIG. 3E, the first and second positioning components 202, 202′ are configured to remove the respective first and second shield parts 204, 204′ from the cavity 304. This allows the expandable member 316 to be expanded and thereby urge the product 306 against the inner surface 304c of the cavity without the first and second shield parts 204, 204′ being positioned between the expandable member 316 and the product 306. After the shield has been removed, a further portion of the expandable member 316 is inserted into the cavity 304. That is, the expandable member 316 becomes fully inserted into the cavity 304. In some cases, as will be described below, the expandable member 316 may already be fully inserted into the cavity 304 at the point in time when the shield is removed from the cavity 304. As will also become apparent, in some examples, the shield may not be removed from the cavity 304 while the expandable member 316 is expanded.

FIG. 3F shows the moulding system 300 of FIG. 3E at a moment in time later than that shown in FIG. 3E. Here, the first and second positioning components 202, 202′ have removed the respective first and second shield parts 204, 204′ from the cavity 304, for example, by moving the first and second shield parts 204, 204′ away from the cavity 304, in a direction parallel to the longitudinal axis 308 of the cavity 304.

FIG. 3G shows the moulding system 300 of FIG. 3F at a moment in time later than that shown in FIG. 3F. Here, the first and second positioning components 202, 202′ have continued to move the respective first and second shield parts 204, 204′, for example, by moving the first and second shield parts 204, 204′ in a direction perpendicular to the longitudinal axis 308 of the cavity 304. This action could be omitted in other examples.

FIG. 3H shows the moulding system 300 of FIG. 3G at a moment in time later than that shown in FIG. 3G. Here, the expandable member 316 has been caused to continue to move towards the cavity 304 and along the insertion axis, such that a further portion of the expandable member 316 is also contained within the cavity 304. As previously mentioned, movement of the expandable member 316 is controlled and facilitated by the expandable member positioning mechanism 322. At this moment, the expandable member 316 is still in a collapsed state. As is clear from comparing FIG. 3H with FIG. 3G, a greater proportion (such as a greater length) of the expandable member 316 is contained within the cavity 304 at the time shown in FIG. 3H. FIG. 3H therefore depicts the expandable member 316 as fully inserted.

After the expandable member 316 has been fully inserted into the cavity 304, the expandable member 316 is caused to expand to urge the product 306 against the inner surface 304c of the cavity 304, and therefore compress the product 306 against the inner surface 304c. As mentioned, this is achieved by causing fluid to be pumped into the expandable member 316 via the line 320. The expandable member 316 therefore changes from the collapsed state to an expanded or partially expanded state. FIG. 3I therefore shows the moulding system 300 of FIG. 3H at a moment in time later than that shown in FIG. 3H. Here, the expandable member 316 is in a partially expanded state, since it is not yet urging the whole outer surface of the product 306 against the inner surface 304c of the cavity 304. As the fluid continues to flow into the expandable member 316, the cross-sectional width of the expandable member 316 continues to increase until the expandable member 316 is fully expanded (that is, expanded to the point required to urge the product 306 against the inner surface 304c of the cavity 304 with the required force). FIG. 3J therefore shows the moulding system 300 of FIG. 3I at a moment in time later than that shown in FIG. 3I. Here, the expandable member 316 is fully expanded and occupies the majority of the space in the cavity 304 (less the volume occupied by the product 306).

Once the product 306 has been sufficiently compressed by the expandable member 316, the fluid is withdrawn from within the expandable member 316, so that the cross-sectional width of the expandable member 316 decreases again. FIG. 3K therefore shows the moulding system 300 of FIG. 3J at a moment in time later than that shown in FIG. 3J. Here, the expandable member 316 is no longer fully expanded, and is in a partially expanded (or partially collapsed) state. As the fluid continues to be removed from the expandable member 316, the cross-sectional width of the expandable member 316 continues to decrease until the expandable member 316 is fully collapsed (that is, collapsed to a desired point). FIG. 3L therefore shows the moulding system 300 of FIG. 3K at a moment in time later than that shown in FIG. 3K. Here, the expandable member 316 is in the collapsed state, and is removable from the cavity 304. FIG. 3M shows the moulding system 300 of FIG. 3L at a moment in time later than that shown in FIG. 3L. Here, the expandable member 316 has been removed from the cavity 304 (and from within the pressed product 306). From here, the pressed product 306 is removable from the cavity 304, for further processing, for example.

As mentioned briefly, instead of the shield being formed from two or more shield parts, a single shield part may be used instead. Furthermore, in some cases, rather than removing the shield from within the cavity 304 before the expandable member is expanded, the shield may remain in place and expand with the expandable member. To illustrate, FIGS. 4A-4C describe an example in which the shield is expandable such that when the expandable member is expanded to urge the product against the inner surface of the cavity, the expansion of the expandable member causes the shield itself to expand. The shield may therefore contact the product during the expansion of the expandable member.

FIG. 4A therefore depicts another example moulding system 400 comprising the mould 302 and the product 306 discussed earlier, along with a shield positioning mechanism 402. As shown in the particular example of FIG. 4A, a shield 404 is coupled to the shield positioning mechanism 402.

As also shown in the particular example of FIG. 4A, the positioning mechanism 402 comprises a moveable arm 408 that is arranged to be moved to position the shield 404 at least partially into the cavity 304 of the mould 302. The moveable arm 408 is connected to a main body 412 of the positioning mechanism 402. A drive mechanism (not shown) is arranged to control movement of the shield 404 via movement of the moveable arm 408. In other examples, movement and positioning of the shield 404 may be achieved by other types of movement and/or other mechanisms.

The shield 404 of this example is expandable. More particularly, it is formed from a resilient material, more specifically rubber. The shield 404 therefore stretches as the expandable member 316 is expanded. The shield 404 of this example is formed from, or as, a single piece.

As with the previously described examples, the shield 404 defines a channel (in this case a closed channel) along its length, where the length is measured along a longitudinal axis of the shield 404. The channel (and therefore the shield 404) has a first end and a second, opposite, end.

Once the shield 404 has been positioned by the shield positioning mechanism 402 (for example, in the same manner and/or location as described in FIGS. 2-3M), and the expandable member 316 has been fully inserted into the cavity 304 through the shield 404, the expandable member 316 is caused to expand. As mentioned, this is achieved by causing fluid to be pumped into the expandable member 316 via the line 320. The expandable member 316 therefore changes from a collapsed state to an expanded or partially expanded state. FIG. 4B therefore shows the moulding system 400 of FIG. 4A at a moment in time later than that shown in FIG. 4A. Here, the expandable member 316 is in a partially expanded state, since it is not yet urging the whole outer surface of the product 306 against the inner surface 304c of the cavity 304. In addition, the shield 404 has also been caused to expand by the expansion of the expandable member 316. For example, the second end of the shield 404 is wider than before the expandable member 316 was caused to expand.

As the fluid continues to flow into the expandable member 316, the cross-sectional width of the expandable member 316 continues to increase until the expandable member 316 is fully expanded (that is, expanded to the point required to urge the product 306 against the inner surface 304c of the cavity 304 with the required force).

FIG. 4C therefore shows the moulding system 300 of FIG. 4B at a moment in time later than that shown in FIG. 4B. Here, the expandable member 316 is fully expanded and occupies the majority of the space in the cavity 304 (less the volume occupied by the product 306). In addition, the shield 404 has also continued to expand due to the expansion of the expandable member 316. As shown, the shield 404 is contacting the product 306, and is urged against the product 306 by the expandable member 316. The shield 404 therefore remains in situ during moulding of the product 306 (i.e., during expansion of the expandable member 316).

Once the product 306 has been sufficiently compressed by the expandable member 316, the fluid is withdrawn from within the expandable member 316, so that the cross-sectional width of the expandable member 316 (and shield 404) decreases again. Once the expandable member 316 is in a collapsed state again (i.e., sufficient fluid has been removed), the expandable member 316 can be withdrawn from the cavity 304. The shield 404 is also removed from within the cavity and pressed product 306. The shield 404 and pressed product 306 therefore remain separate. In some cases, the shield is withdrawn from the cavity as a result of withdrawing the expandable member 316.

It will be appreciated that some of the actions, processes and features described in FIGS. 2-3M may also be applicable to the embodiment of FIGS. 4A-4C to form further embodiments.

As mentioned briefly, instead of the shield being formed from two or more shield parts, a single shield part may be used instead. Furthermore, in some cases, rather than having the shield remain in situ during moulding (and therefore being formed from a material allowing the shield to expand with the expandable member), the single shield part can be removed from within the cavity 304 before the expandable member is expanded.

FIG. 5A therefore depicts another example moulding system 500 comprising the mould 302 and product 306 discussed earlier, along with a shield positioning mechanism 502. As shown in the particular example of FIG. 5A, a shield 504 is coupled to the shield positioning mechanism 502, and formed from a single piece of material, rather than from separable shield parts.

As also shown in the particular example of FIG. 5A, the positioning mechanism 502 comprises a moveable arm 508 that is arranged to be moved to position the shield 504 at least partially into the cavity 304 of the mould 302. The moveable arm 508 is connected to a main body 512 of the positioning mechanism 502. A drive mechanism (not shown) is arranged to control movement of the shield 504 via movement of the moveable arm 508. In other examples, movement and positioning of the shield 504 may be achieved by other types of movement and/or other mechanisms.

As with the previously described examples, the shield 504 defines a channel (in this case a closed channel) along its length, where the length is measured along a longitudinal axis of the shield 504. The channel (and therefore the shield 504) has a first end and a second, opposite, end.

Once the shield 504 has been positioned by the shield positioning mechanism 502 (for example, in the same manner and/or location as described in FIGS. 2-3M), and the expandable member 316 has been fully inserted into the cavity 304 through the shield 504, the shield positioning mechanism 502 is configured to cause the shield 504 to be removed from the cavity 304. FIG. 5B therefore shows the shield 504 having been removed from the cavity 304, by moving the shield 504 in a direction parallel to a longitudinal axis of the cavity 304. Given the single piece nature of the shield 504, and in contrast to the examples discussed in FIGS. 2-3M, the shield 504 may surround part of the expandable member positioning mechanism 322 and/or the line 320, for example.

Once the shield 504 has been removed from the cavity 304, the expandable member 316 is caused to expand in the same way as previously described.

It will be appreciated that some of the actions, processes and features described in FIGS. 2-3M may also be applicable to the embodiment of FIGS. 5A and 5B to form further embodiments.

In any of the previously described examples, in some cases, after moulding, and after the expandable member 316 has been collapsed, the shield may be reintroduced into the cavity 304 to provide additional protection during subsequent extraction of the expandable member from within the hollow interior of the product and the cavity.

As mentioned earlier, the shield (that is, a single piece shield, or a shield formed from two or more shield parts) is preferably dimensioned to extend around at least 90% of the opening 310 of the product 306. This ensures a high proportion of the opening 310 is protected during insertion and/or extraction of the expandable member 316.

To illustrate, FIGS. 6A-6C depict various examples of shields formed so that they protect at least 90% of the opening 310. The opening 310 of a product defines a perimeter (or a circumference, in examples where the opening is circular), and the part of the shield positioned at the opening 310 defines an inner perimeter that extends around at least 90% of the perimeter of the opening 310.

FIG. 6A depicts a top-down view of an example of a shield 604 formed from a single piece, which is positioned to extend through an opening 310 of a product 306. The view is from above a mould 302, looking into the opening 310 of the product 306. As shown, the shield 604 has a closed inner perimeter 604a at a point along its length where it passes through the opening 310. The opening 310 has an inner perimeter and the inner perimeter 604a of the shield 604 extends around 100% of the inner perimeter of the opening 310, thereby fully protecting the opening 310.

FIG. 6B depicts a top-down view of another example of a shield formed from a first shield part 614 and a second shield part 616. The shield is positioned to extend through an opening 310 of a product 306. The view is from above a mould 302, looking into the opening 310 of the product 306. As shown, the shield has an open inner perimeter at a point along its length where it passes through the opening 310. The open inner perimeter of the shield is defined by a first inner perimeter 614a of the first shield part 614 and a second inner perimeter 616a of the second shield part 616. As shown, a small gap separates the two shield parts 614, 616, and as such, the inner perimeter of the shield extends around less than 100% of the inner perimeter of the opening 310, such as about 99%. FIG. 6C depicts another example in which the first and second shield parts 614, 616 are positioned further apart than in FIG. 6B, and as such, the open inner perimeter of the shield extends around less than 100% of the inner perimeter of the opening 310, such as about 90%.

In some cases, despite having two or more shield parts, the shield parts may be positioned to abut each other such that no gap separates the shield parts, and they may therefore extend around 100% of the inner perimeter of the opening 310. In contrast, in some cases, despite a shield being formed from a single part, the shield itself may be open, rather than fully closed, around its perimeter, so may not extend around 100% of the inner perimeter of the opening 310.

FIG. 7 depicts a first example method 650. In block 652, the method comprises causing a shield to be at least partially inserted into a cavity 304 of a mould 302, such that the shield protects at least part of a product 306 contained within the mould 302 from contacting an expandable member 316 during subsequent insertion of the expandable member 316 through the shield and into the cavity 304. Block 652 may be performed by a shield positioning mechanism, for example.

FIG. 8 depicts a second example method 660. In block 662, the method comprises causing the product 306 to be introduced into the cavity 304. Block 652 of FIG. 8 corresponds to block 652 of FIG. 7, and thereby comprises causing a shield to be at least partially inserted into a cavity 304 of mould 302, such that the shield protects at least part of a product 306 contained within the mould 302 from contacting an expandable member 316 during subsequent insertion of the expandable member 316 through the shield and into the cavity 304. In block 664, the method comprises causing the expandable member 316 to be at least partially inserted into the cavity 304 through the shield. In block 666, the method comprises causing the expandable member 316 to expand and thereby urge the product 306 against an inner surface 304c of the cavity 304. A pressed product 306 is therefore formed in the mould.

FIG. 9 shows a schematic diagram of a computer-readable storage medium 700 according to an example. In certain examples, the computer-readable storage medium 700 is non-transitory. The computer-readable storage medium 700 stores instructions 730 that, if executed by one or more processors 720 of a control system 710, cause a shield positioning mechanism to perform a method according to an example. For example, the instructions 730 may cause the control system 710 of the shield positioning mechanism to perform method 650 set out above. In other examples, the computer-readable storage medium 700 stores instructions 730 that, if executed by one or more processors 720 of a control system 710, cause a moulding system to perform a method according to an example. For example, the instructions 730 may cause the control system 710 of the moulding system to perform method 660 set out above.

It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in FIG. 1) comprising a moulding system 100 and apparatus for performing at least one additional process on a product 306 to provide a receptacle. Similarly, also provided is a method of manufacturing a receptacle, the method comprising method 660 to provide a pressed product, and then performing at least one additional process on the pressed 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 800, in the form of a necked receptacle and specifically a bottle, containing contents 810 is shown in FIG. 10. 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 900 is shown in FIG. 11. The method 900 comprises providing 910 the receptacle, in the form of a necked receptacle and specifically a bottle, and then providing 920 the contents in the receptacle. In this example, block 920 follows block 910, so that block 920 comprises putting the contents into the receptacle that has been provided at block 910. However, in some other examples, blocks 910 and 920 are performed concurrently, so that the providing 910 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 900 also comprises closing 930 an opening of the receptacle after block 920, and applying 940 a label or indicia to the receptacle after block 930. In this example, block 930 involves applying a heat seal to the opening and then screwing a cap or lid onto the receptacle, and block 940 comprises adhering a label onto the receptacle.

In respective other examples, the order of blocks 930 and 940 is reversed, blocks 930 and 940 are performed concurrently, block 930 is omitted, and block 940 is omitted. In some examples, block 940 occurs before block 920, or block 940 occurs during block 920. 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 900 could be performed by the same party that manufactures the receptacle, for example so that block 910 comprises the method shown in FIG. 1. Alternatively, the method 900 could be performed by a different party to that which manufactures the receptacle. In such an alternative, the different party performs block 910 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.