GB2634549A

GB2634549A - Expandable member for receptacle moulding

Info

Publication number: GB2634549A
Application number: GB2315655.7A
Authority: GB
Inventors: George Prozesky Daniel
Original assignee: Pulpex Ltd
Current assignee: Pulpex Ltd
Priority date: 2023-10-12
Filing date: 2023-10-12
Publication date: 2025-04-16
Also published as: WO2025078822A1; GB202315655D0

Abstract

A reusable expandable member 100 for use in processing a hollow moulded fibre product. The reusable expandable member comprises a neck portion 102 defining an opening 107, the neck portion 102 having a first width A and a main body portion 104 having a second width greater D than the first width A. The main body portion comprises a wall, at least a portion of the wall has a thickness E less than 1.2 mm. The wall thickness may be greater than 0.15 mm, the wall may vary in thickness along a portion of the wall, it may vary constantly along at least a portion of the wall. The main body 104 may comprise a shoulder portion 108 proximal to the neck portion 102 and a lower portion 110 distal from the neck portion 102, the shoulder portion 108 and lower portion 110 each have a wall thickness that differ. Further disclosed is a method of processing a hollow moulded fibre product, a processing system for processing a hollow moulded fibre product, a method of manufacturing a receptacle and a receptacle obtainable or obtained by the processing of a hollow moulded fibre product.

Description

EXPANDABLE MEMBER FOR RECEPTACLE MOULDING

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, and to expandable members for use in such methods and systems. 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. For example, it may be difficult to ensure compaction of paper pulp within a mould to form a bottle with sufficient wall thickness and strength.

SUMMARY

According to a first aspect of the present invention, there is provided a reusable expandable member for use in processing a hollow moulded fibre product, the reusable expandable member comprising a neck portion defining an opening of the reusable expandable member, the neck portion having a first width; and a main body portion having a second width greater than the first width; wherein the main body portion comprises a wall, and at least a portion of the wall has a wall thickness less than 1.2 mm.

It has been found that when at least a portion of the wall of the main body portion has a wall thickness less than 1.2mm, that portion of the wall may expand more easily than if it were to have a wall thickness of greater than 1.2mm As the wall may expand more easily, when the reusable expandable member is expanded inside the hollow moulded fibre product when processing the hollow moulded fibre product, the reusable expandable member may be able to apply a greater and/or more uniform pressure to an interior of the hollow moulded fibre product, when compared with a corresponding reusable expandable member where the portion of the wall has a wall thickness of greater than 1.2mm. This may result in improved consistency of compaction of the hollow moulded fibre product by the reusable expandable member, which may result in fewer weak spots in the processed hollow moulded fibre product, and/or may provide improved internal and/or external surface finish for the processed hollow moulded fibre product.

As at least the portion of the wall has a wall thickness less than 1.2 mm, the reusable expandable member may be expanded with a lower pressure when compared with reusable expandable members with main body portions comprising a wall having a wall thickness greater than I.2mm. Use of a lower pressure in processing a hollow moulded fibre product may provide for increased energy efficiency when compared to use of a higher pressure.

The reusable expandable member may be inserted into and withdrawn from the hollow moulded fibre product in a fully or partially deflated state. In the fully or partially deflated state the reusable expandable member may be manipulated to change shape, such as by folding, twisting or stretching, in order to be inserted into and subsequently withdrawn from the hollow moulded fibre product through a relatively small opening without deforming the hollow moulded fibre product. The relatively small opening is relative to the size of the expanded or unfolded reusable expandable member and may be for example a neck of a bottle. As at least the portion of the wall has a wall thickness less than 1.2 mm, the reusable expandable member may collapse easily when deflated, meaning that it can be more quickly and readily inserted into and withdrawn from the hollow moulded fibre product before and after processing compared with the portion of the wall having a wall thickness of greater than 1.2mm.

As at least the portion of the wall has a wall thickness less than 1 2mm, the reusable expandable member may also lend itself better to twisting and stretching than thicker-walled reusable expandable members. This may provide for improved manoeuvrability of the reusable expandable member into and out of the hollow moulded fibre product.

Optionally, the wall thickness is greater than 0.15 mm. A wall thickness greater than 0.15mm may provide increased resilience to wear, more use cycles to failure and greater shape retention than a comparable wall with a wall thickness of less than 0.15mm.

Optionally, the wall thickness is greater than 0.2 mm, greater than 0.3mm, greater than 0.4mm, greater than 0.5mm, greater than 0.6mm, greater than 0.7mm, greater than 0.8 mm, greater than 0.9mm, greater than lmm, or greater than 1.1 mm.

Optionally, the wall thickness is less than 1.1 mm, less than 1mm, less than 0.9mm, less than 0.8mm, less than 0.7 mm, less than 0.6mm, less than 0.5mm, less than 0.4 mm, less than 0.3mm or less than 0.2mm.

Optionally, the neck portion comprises a neck portion wall that has a further wall thickness greater than the wall thickness. By having a relatively greater further wall thickness in comparison with the wall thickness, increased strength may be provided in the region of the opening of the reusable expandable member, for example in a region where the reusable expandable member is connectable to an expansion fluid source in use. A relatively greater further wall thickness in comparison with the wall thickness may also encourage expansion of the main body portion in preference to the neck portion. This may be beneficial where, for example, the main body portion has a width greater than the neck portion.

Optionally, the further wall thickness is greater than 0.2 mm, greater than 0.3mm, greater than 0.4mm, greater than 0.5mm, greater than 0.6mm, greater than 0.7mm, greater than 0.8 mm, greater than 0.9mm, greater than lmm, greater than 1.1 mm, or greater than 1.2mm.

Optionally, the wall thickness varies along a length of the at least a portion of the wall. As the wall thickness varies along a length of the at least a portion of the wall, expansion of the main body portion of the reusable expandable member may be controlled. For example, thinner regions of the at least a portion of the wall may expand in preference to thicker regions of the at least a portion of the wall. Therefore, by varying the thickness of the at least a portion of the wall of the main body portion, contact of the main body portion with the hollow moulded fibre product upon expansion of the reusable expandable member may be controlled. Such control of contact may facilitate moulding of the hollow moulded fibre product.

In particular, contact points of the reusable expandable member with a hollow moulded fibre product may, as a result of friction, impact upon subsequent expansion of the reusable expandable member within the hollow moulded fibre product. Thus, by controlling which region of the at least a portion of the wall of the main body portion of the reusable expandable member contacts the hollow moulded fibre product first, subsequent expansion and contact points of the reusable expandable member may be controlled. This may ensure that the reusable expandable member is able to contact particular regions of the hollow moulded fibre product with sufficient pressure to ensure sufficient compaction of the material from which the hollow moulded fibre product is made. The reusable expandable member may thereby provide the hollow moulded fibre product with more uniform strength when compared with, for example, hollow moulded fibre products formed by use of a reusable expandable member having a main body portion with constant wall thickness.

Widths as discussed herein may comprise maximal widths between two opposing points on an outer surface of a relevant portion of the reusable expandable member.

Widths as discussed herein may comprise widths as measured when the reusable expandable member is supported with the opening exposed to ambient external atmosphere, for example with substantially no radially inward or outward pressure applied to the reusable expandable member.

Optionally, the wall thickness varies along a length of the wall for substantially a whole length of the main body portion. Optionally, the wall thickness vanes from 1 mm to 1.2 mm. Optionally, the main body portion has a minimal thickness of 1mm and a maximal thickness of 1.3mm.

Optionally, the wall thickness varies constantly along the length of the at least a portion of the wall. This may provide more desirable expansion characteristics than, for example, a wall having one or more discrete changes or step-changes in wall thickness along the length of the portion of the wall.

Optionally, the wall thickness tapers along the length of the at least a portion of the wall, for example along substantially the entirety of the length of the wall. Optionally, the wall thickness varies constantly along a length of the wall for substantially the whole length of the main body portion. Optionally, the wall thickness varies constantly from 1 mm to 1.2 mm.

Optionally, the main body portion comprises a shoulder portion proximal to the neck portion and a lower portion distal from the neck portion, wherein the shoulder portion comprises a shoulder portion wall having a shoulder portion wall thickness, the lower portion comprises a lower portion wall having a lower portion wall thickness that differs from the shoulder portion wall thickness. The shoulder portion and the lower portion may require different inflation properties and this may be achieved by these portions having different wall thicknesses.

Optionally, at least one of the lower portion and the shoulder portion comprises the at least a portion of the wall.

Optionally, the shoulder portion wall thickness varies along a length of the shoulder portion wall. Optionally, the shoulder portion wall thickness varies along a length of the shoulder portion wall for substantially the whole length of shoulder portion of the main body portion. Optionally, the shoulder portion wall thickness varies from 1 mm to 2.3 mm. Optionally, the shoulder portion wall thickness varies constantly from lmm to 2.3 mm. Optionally, the shoulder portion wall thickness varies from a minimum at a point where the shoulder portion meets the lower portion to a maximum at a point where the shoulder portion meets the neck portion. Optionally, the shoulder portion wall thickness varies from lmm at a point where the shoulder portion meets the lower portion to 2.3mm at a point where the shoulder portion meets the neck portion.

Optionally, the lower portion wall thickness varies along a length of the lower portion wall. Optionally, the lower portion wall thickness varies along a length of the lower portion wall for substantially the whole length of the shoulder portion of the main body portion. Optionally, the shoulder portion wall thickness varies from I mm to 1.3 mm. Optionally, the lower portion wall thickness varies constantly from lmm to 1.3mm. Optionally, the lower portion wall thickness varies from a minimum at a point where the lower portion meets the shoulder portion to a maximum at an end of the main body portion distal from the shoulder portion. Optionally, the lower portion wall thickness varies from lmm at a point where the lower portion meets the shoulder portion to 1.3mm at an end of the main body portion distal from the shoulder portion.

Optionally, at least a portion of the shoulder portion wall has a shoulder portion wall thickness which is smaller than the lower portion wall thickness.

By having a relatively smaller shoulder portion wall thickness and a relatively greater lower portion wall thickness, contact of the main body of the reusable expandable member with a hollow moulded fibre product, upon expansion of the reusable expandable member, may be controlled such that the shoulder portion contacts the receptacle before the lower portion. Friction may then lock the shoulder portion in place relative to the hollow moulded fibre product, with the rest of the main body portion of the reusable expandable member then expanding to fill and make contact with the hollow moulded fibre product.

Optionally, the at least a portion of the shoulder portion wall thickness is greater than 0.2 mm, greater than 0.3mm, greater than 0.4mm, greater than 0.5mm, greater than 0.6mm, greater than 0.7mm, greater than 0.8 mm, greater than 0.9mm, greater than 1mm, greater than 1.1 mm or greater than 1.2mm.

Optionally, at least a portion of the lower portion wall thickness is greater than 0.2 mm, greater than 0.3mm, greater than 0.4mm, greater than 0.5mm, greater than 0.6mm, greater than 0.7mm, greater than 0.8 mm, greater than 0.9mm, greater than lmm, greater than 1.1 mm or greater than 1.2mm.

Optionally, the at least a portion of the shoulder portion wall thickness is less than 1.2mm, less than 1.1 mm, less than 1mm, less than 0.9mm, less than 0.8mm, less than 0.7 mm, less than 0.6mm, less than 0.5mm, less than 0.4 mm, less than 0.3mm or less than 0.2mm.

Optionally, at least a portion of the lower portion wall thickness is less than 1.2mm, less than 1.1 mm, less than 1mm, less than 0.9mm, less than 0.8mm, less than 0.7 mm, less than 0.6mm, less than 0.5mm, less than 0.4 mm, less than 0.3mm or less than 0.2mm.

Optionally, the lower portion wall thickness is between 1.2 and 2.0 times the shoulder portion wall thickness. Such a ratio may provide desirable expansion characteristics of the reusable expandable member whilst ensuring that the wall thickness does not vary to too great a degree. This may, for example, facilitate manufacturing of the reusable expandable member.

Optionally, the lower portion wall thickness is between 1_4 and 1.8 times the shoulder portion wall thickness. Optionally, the lower portion wall thickness is around 1.6 times the shoulder portion wall thickness.

Optionally, the lower portion wall thickness is constant along a length of the lower portion wall, and the shoulder portion wall thickness varies along a length of the shoulder portion wall.

This may enable the lower portion of the main body to be expanded at a constant rate throughout the length of the lower portion if the lower portion wall thickness is constant along that length.

Optionally, the shoulder portion wall thickness varies constantly along a length of the shoulder portion wall. This may provide more desirable expansion characteristics than, for example, a shoulder portion wall having one or more discrete changes or step-changes in shoulder portion wall thickness along the length of the shoulder portion.

Optionally, the shoulder portion wall thickness tapers along the length of the shoulder portion wall, for example along substantially the entirety of the length of the shoulder portion wall.

Optionally, the shoulder portion wall thickness tapers along the length of the shoulder portion wall in a direction towards the lower portion, reaching a minimum thickness where the lower portion meets the shoulder portion.

Optionally, the shoulder portion wall thickness is constant along a length of the shoulder portion wall, and the lower portion wall thickness varies along a length of the lower portion wall. This may enable the shoulder portion of the main body to be expanded at a constant rate throughout the length of the shoulder portion if the shoulder portion wall thickness is constant along that length.

Optionally, the lower portion wall thickness varies constantly along a length of the lower portion wall. This may provide more desirable expansion characteristics than, for example, a lower portion wall having one or more discrete changes or step-changes in lower portion wall thickness along the length of the lower portion wall.

Optionally, the lower portion wall thickness tapers along the length of the lower portion wall, for example along substantially the entirety of the length of the lower portion wall.

Optionally, the lower portion wall thickness tapers along the length of the lower portion wall in a direction towards the shoulder portion, reaching a minimum thickness where the lower portion meets the shoulder portion.

Optionally, the lower portion wall thickness varies along a length of the lower portion wall and the shoulder portion wall thickness varies along a length of the shoulder portion wall.

Optionally, the lower portion wall thickness tapers along the length of the lower portion wall, for example along substantially the entirety of the length of the lower portion 25 wall.

Optionally, the lower portion wall thickness tapers along the length of the lower portion wall in a direction towards the shoulder portion, reaching a minimum thickness where the lower portion meets the shoulder portion. This may provide more desirable expansion characteristics than, for example, a shoulder portion wall having one or more discrete changes or step-changes in shoulder portion wall thickness along the length of the shoulder portion.

Optionally, the reusable expandable member comprises a base portion located at an opposite end of the main body portion to the neck portion, the base portion comprising a third width, the third width being greater than the second width. I5

By providing the reusable expandable member with a base portion wider than the main body portion, the base portion may be more likely to be encouraged to move toward a periphery of a base of the hollow moulded fibre product upon expansion of the reusable expandable member when compared with, for example, a reusable expandable member comprising a main body portion and a base portion of the same width. This may ensure that the reusable expandable member is able to contact regions of the periphery of the base width more than 70% greater than the first width, no more than 60% greater than the first width of the hollow moulded fibre product with sufficient pressure to ensure sufficient compaction of the material from which the hollow moulded fibre product is made.

For a reusable expandable member comprising a main body portion and a base portion of the same width, in use the reusable expandable member may first contact the base of the hollow moulded fibre product, creating friction that hinders subsequent expansion of the expansion member toward the periphery of the base of the hollow moulded fibre product. As a result, the periphery of the hollow moulded fibre product may be insufficiently compacted, and therefore a weak spot in the finished hollow moulded fibre product may occur. The internal and external surface finish of the hollow moulded fibre product may also be unacceptably rough. Providing a reusable expandable member with a base portion wider than the main body portion may mitigate for these factors.

Optionally, a difference between the third width and the first width is greater than a maximal wall thickness of the main body portion.

Optionally, the third width is in the region of 25mm to 70mm, for example in the region of 40mm to 55mm.

Optionally, the third width is no more than 10% greater than the second width, no more than 5% greater than the second width, or no more than 1% greater than the second 15 width.

Optionally, the second width is no more than 80% greater than the first width, no more than 70% greater than the first width, no more than 60% greater than the first width, or no more than 50% greater than the first width.

Optionally, the first width is in the region of 23mm to 68mm, for example in the region of 26mm to 40mm. This may encourage movement of the base portion toward the periphery of the base of the hollow moulded fibre product. This may be to enable movement of the base portion toward the periphery of the base of the receptacle prior to the adjacent region of the main body portion contacting, and potentially becoming frictionally engaged with, the hollow moulded fibre product.

Optionally, the adjacent region of the main body portion is a region of maximal wall thickness of the wall of the main body portion. Optionally, an adjacent region of the main body portion is a region of the main body portion that is within 5% of a total length of the main body portion away from the transition region.

Optionally, the base portion is rounded. Optionally, the base portion has the form of a spherical dome. Such a shape may encourage movement of the base portion toward the periphery of the base of the hollow moulded fibre product, for example in comparison with a base portion having a planar lower surface. Such a minimal base portion wall thickness location may facilitate expansion of the base portion toward a periphery of the hollow moulded fibre product upon expansion of the reusable expandable member in use.

Optionally, the base portion wall thickness substantially corresponds to the maximal wall thickness of the main body portion. Optionally, the base portion wall thickness is less than a maximal wall thickness of the main body portion.

Optionally, the third width is no more than 1.2 times the second width. This may encourage the base portion to move toward the periphery of the base of the hollow moulded fibre product upon expansion of the reusable expandable member, whilst avoiding formation of a friction lock between the base portion and the base of the hollow moulded fibre product.

Optionally, the reusable expandable member comprises a monolithic component, for example such that the main body portion and the neck portion are integrally formed.

For example, the reusable expandable member may comprise a single wall structure shaped to define the various portions of the reusable expandable member described herein.

Optionally, the reusable expandable member comprising a resiliently deformable material Optionally, the reusable expandable member comprises or is made from an elastomeric material. Optionally, the reusable expandable member comprises or is made from a rubber material. Optionally, the reusable expandable member comprises or is made from a silicone material. Optionally, the reusable expandable member is formed from a material comprising a Shore A hardness of between 20 and 50, for example around 45.

Optionally, shapes and dimensions of the reusable expandable member discussed above comprise shapes and dimensions of the reusable expandable member in a partially expanded configuration, for example where sufficient fluid is contained within a hollow interior of the reusable expandable member for the reusable expandable member to have a defined shape without deformation of the wall structure of the reusable expandable member.

According to a second aspect of the present invention, there is provided a moulding system for processing a hollow moulded fibre product, the moulding system comprising: a hollow moulded fibre product mould comprising a mould cavity for receiving a component, wherein the component is a fibre suspension or a partially formed hollow moulded fibre product; and the reusable expandable member of the first aspect, the reusable expandable member being expandable in the mould cavity so as to urge the component against an inner surface of the mould cavity during a process to form the hollow moulded fibre product from the component. Such a system permits the processing of a hollow moulded fibre product, in line with the benefits outlined with respect to the novel reusable expandable member according to the first aspect Optionally, the moulding system comprises an expansion fluid source fluidically connectable to the reusable expandable member, such that expansion fluid can be selectively supplied to an interior of the reusable expandable member when the reusable expandable member is inserted into the mould cavity. Thus, the reusable expandable member may be expanded when in the mould cavity in use to contact, and apply a pressure to, the fibre suspension or the partially formed hollow moulded fibre product held within the mould cavity.

Optionally, the moulding system comprises a heat source for supplying heat to the component when the component is held within the mould cavity. Such a system may thereby be used to provide a thermoforming process on the component when the component is held within the mould cavity.

Optionally, the hollow moulded fibre product moulding system comprises a bottle moulding system for moulding a bottle, for example from a fibre suspension.

According to a third aspect of the present invention, there is provided a method processing a hollow moulded fibre product, the method comprising: providing a component in a mould cavity of a mould, wherein the component is a fibre suspension or a partially formed hollow moulded fibre product; providing the reusable expandable member of the first aspect in the mould cavity; and expanding the reusable expandable member so as to urge the component against an inner surface of the mould cavity during a process to form the hollow moulded fibre product from the component.

By expanding the reusable expandable member such that regions of the main body portion with relatively small wall thickness expand prior to regions of the main body portion with a relatively great wall thickness, expansion of the main body portion of the reusable expandable member may be controlled. For example, the regions of the main body portion with a relatively small wall thickness may expand in preference to regions of the main body portion with a relatively great wall thickness. Therefore, by varying the wall thickness, contact of the main body portion with the hollow moulded fibre product upon expansion of the reusable expandable member may be controlled. Such control of contact may facilitate moulding of the hollow moulded fibre product.

Optionally, the method comprises applying heat to component in the mould cavity. Such a method may thereby be used to provide a thermoforming process on the component when the component is held within the mould cavity.

Optionally, the component is a first component, and the method comprises: subsequently providing a second component in the mould cavity of the mould, wherein the component is a fibre suspension or a partially formed hollow moulded fibre product; providing the reusable expandable member of the first aspect in the mould cavity; and expanding the reusable expandable member so as to urge the second component against the inner surface of the mould cavity during a further process to form a further hollow moulded fibre product from the second component.

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

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

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

According to a sixth aspect of the present invention, there is provided a receptacle 20 manufacturing line comprising the moulding system of the second aspect for processing the hollow moulded fibre product and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle.

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

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

According to a seventh aspect of the present invention, there is provided a method of manufacturing a receptacle, the method comprising performing the method of the third aspect to process the hollow moulded fibre product, withdrawing the reusable expandable member from the hollow moulded fibre product, and then performing at least one additional process on the hollow moulded fibre product to provide the receptacle.

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

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

According to an eighth aspect of the present invention, there is provided a method I5 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 receptacle is a necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

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

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

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

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

According to a ninth aspect of the present invention, there is provided a 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 I5 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.

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

A receptacle formed by the process herein has benefits over a receptacle formed by a known process in that the uniformity of the receptacle walls in terms of properties in improved and occurrence of weak points is reduced. I5

In some examples, the receptacle is obtainable or obtained from the method of the seventh aspect.

The fabrication method may comprise at least one additional process. The at least one additional process may comprise coating and drying the receptacle to produce a coated receptacle. The at least one additional process may comprise applying a closure to the receptacle or the coated receptacle.

It will be appreciated that optional features of aspects of the present invention may be equally applied to other aspects of the present invention, where appropriate.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic view of an example receptacle manufacturing line for performing a method of manufacturing receptacles from paper pulp; Figure 2 is a schematic view of an example bladder for use in the example receptacle manufacturing line of Figure 1; Figure 3 is a schematic view of a second example bladder for use in the example receptacle manufacturing line of Figure 1; Figure 4 is a schematic illustration of expansion of the second example bladder of Figure 3; Figure 5 shows a moulding system comprising the second bladder of Figure 3 according to an example; Figure 6 is a flow diagram illustrating an example method in accordance with use of the second example bladder of Figure 3 in the example receptacle manufacturing line of Figure 1; Figure 7 shows a non-transitory computer-readable storage medium according to an example; Figure 8 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and Figure 9 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.

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

Broadly speaking, the exemplary process comprises providing a fibre suspension, introducing the fibre suspension into a mould cavity of a porous first mould and expelling a liquid (such as water) from the fibre suspension to produce a hollow moulded fibre product (which may be called a wet precursor or embryo) in the mould cavity, further moulding the hollow moulded fibre product to produce a hollow further-moulded fibre product, drying and then internally-coating the hollow further-moulded fibre product to produce an internally coated product, drying the internally coated product to produce a dried product, applying a closure part to the dried product to produce a closable or closed product, externally-coating and/or decorating the closable or closed product to produce an externally coated and/or decorated product, and then drying the externally coated or decorated product to produce another dried product. As will be apparent at least from the following description, modifications may be made to the exemplary process to provide variants thereof in which other examples of the present invention may be embodied. For example, in some cases, either the internal coating or the external coating and/or decorating may be omitted. Moreover, in the present case and as indicated by the stars labelled Ins. 1 to Ins. 5 in Figure 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 I wt% 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 II 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 l wt% 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 0.5wtYci to 5wt%, or 0.lwt% to lwt%, 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 b comprises two half-moulds 14 that are movable towards and away from each other, in this case using a hydraulic ram. In this example, each of the half-moulds 14 is a monolithic or unitary tool formed by additive manufacturing (for example, 3D-printing) that defines a mould profile, and, when the half-moulds 14 are brought into contact with each other, their respective mould profiles cooperate to define the mould cavity in which the hollow moulded fibre product is to be formed. Each half-mould 14 itself defines a smaller moulding cavity and, when brought into cooperation with a second half-mould 14, the smaller moulding cavities combine to provide the overall mould cavity. The two half-moulds 14 may themselves be considered "splits" or "moulds" and the overall porous first mould 15 may be considered a "split-mould" or, again, a "mould". In other examples, the porous first mould 15 may comprise more than two splits 14, such as three, four or six splits, that cooperate to define the moulding cavity.

In Figure 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 Figure 1. Once a required amount (for example, a predetermined volume, such as 10 litres, or a predetermined mass, such as 10 kilograms) of liquid has been collected in the tank 17, suction of the suspending liquid through the porous first mould 15 is stopped and the first mould 15 is opened to ambient air. In this example, the suspending liquid drawn with the fibre suspension in line 16 is water, or predominantly water (as additives may also be present). The liquid drawn under vacuum via the line 18 and into the tank 17 is substantially free of fibres, since these are left behind against the walls of the porous first mould 15 to form the hollow moulded fibre product.

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

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

According to Figure 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. In this 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. During supply, the pressurised fluid may be 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 Figure 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 Figure 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.

A first example bladder 100 is shown in Figure 2. The bladder 100 is a reusable thermoforming bladder, and is as an example of a thermoforming bladder 26 for repeated use at the second moulding station as described in reference to Figure 1. A bladder according to the present invention may be used at other processing stages of the hollow moulded fibre product or the receptacle, such as the first moulding station as described with reference to Figure 1.

The bladder 100 is a one-piece construction, formed of silicone having a Shore A hardness in the region of 45, and is substantially hollow. The bladder 100 has a neck portion 102 and a main body portion 104 The neck portion comprises a mouth portion 112 and an elongate portion 116. The mouth portion 112 defines an opening 107 into the interior of the bladder. The mouth portion 112 has a maximal width W at the opening 107 of about 68.1mm. The mouth portion 112 has a lip 114 of substantially constant width extending about 5.35 mm from the opening 107 with wall thickness Y of up to 3mm. The mouth portion 112 narrows inwardly from the lip 114 to where the mouth portion 112 meets the elongate portion 116, where the width W is about 28.6 mm. The mouth portion 112 past the lip 114 has a wall thickness X of about 3.25 mm which is approximately constant.

The elongate portion 116 is generally cylindrical in form and is intermediate to the main body portion 104 and the mouth portion 112. The elongate portion 116 has a width A, measured between two diametrically opposite points on an outer surface of the elongate portion 116, that varies from a maximum of around 28.6 mm at the point where the elongate portion 116 meets the mouth portion 112 to a minimum of about 26.0 mm at the point where the elongate portion 116 meets the main body portion 104. The elongate portion 116 has a wall thickness B that varies from a maximum around 2 mm at the point where the elongate portion 116 meets the mouth portion 112 to a minimum of about 1 mm at the point where the elongate portion 116 meets the main body portion 104.

The main body portion 104 begins at an opposite end of the elongate portion 116 to the mouth portion 112, and includes a shoulder portion 108 proximal to the neck portion 102, and a lower portion 110 distal from the neck portion 102. The shoulder portion 108 flares outwardly from the neck portion 102, and has a substantially constant wall thickness C of around 1 mm. The interface between the shoulder portion 108 and the lower portion 110 occurs at a width D of about 44 mm from which the lower portion 110 extends at substantially constant width. The lower portion 110 also has substantially the same wall thickness E as the wall thickness C of the shoulder portion 108, of about lmm.

In use, the bladder 100 is, for example, utilised as the thermoforming bladder 26, and is inserted into the hollow moulded fibre product 22, i.e. a partially formed receptacle, held within the aluminium mould 25. The bladder 26 is inflated via the line 27 by the pump 28 to supply pressurised fluid, e.g., air, water, or oil, to the interior of the bladder 26, such that the bladder 26 expands to apply a pressing force to the hollow moulded fibre product 22 as part of a thermoforming process.

The wall thickness C of the shoulder portion 108 and the thickness E of the lower portion of the bladder 100 being around 1 mm is beneficial during insertion of the bladder into the hollow moulded fibre product 22. This is because the bladder may be collapsed and folded, stretched or twisted as required to fit through an opening in the hollow moulded fibre product 22 which may be relatively narrow compared to the unfolded, unstretched and/or untwisted bladder dimensions. This is relatively easier to do for the bladder 100 than for a comparable bladder with a main body portion wall thickness of 1.2 mm or more.

A comparable benefit is derived from the relatively thin walls of the main body portion 104 of the bladder 100 during withdrawal of the bladder 100 from the hollow moulded fibre product 22 or hollow further-moulded fibre product after processing, as the bladder 100 may be easily folded, stretched or twisted to be removed via a narrow opening, as during insertion.

During processing, the bladder 100 is inflated and the relatively thin walls of the main body portion 104 expand easily under pressure from the received fluid, compared with a bladder with greater thickness of main body portion wall, such as more than 1.2 mm thick, resulting in lower pressure fluid being required for the processing and an associated increase in energy efficiency and decrease of equipment wear. A pressure exerted to the inside walls of the hollow moulded fibre product 22 by the bladder 100 when inflated may be more uniform throughout the main body section 104 than during processing using a comparable bladder with a thicker main body portion, such as with a wall thickness of more than 1.2 mm. A more uniform pressure may enable greater compaction and relative reduction in weak spots, and thus increased overall integrity of the finished receptacle.

A second example bladder 200 is shown in Figure 3, and comprises a neck portion 202, a main body portion 204 and a base portion 206. The bladder 200 is a one-piece construction, formed of silicone having a Shore A hardness in the region of 30, and is substantially hollow. The bladder 200 is a reusable thermoforming bladder, and is an example of a thermoforming bladder 26 for repeated use at the second moulding station as described in reference to Figure 1. A bladder according to the present invention may be used at other processing stages of the hollow moulded fibre product or the receptacle, such as at the example first moulding station as described with reference to Figure 1.

The neck portion 202 comprises a mouth portion 212 and an elongate portion 216. The mouth portion 212 defines an opening 207 into the interior of the bladder 200. The mouth portion 212 has a maximal width Rat the opening 207 of about 68.1 mm. The mouth portion 212 has a lip 214 of substantially constant width extending about 5.35 mm from the opening 207 with wall thickness P of up to 3 mm. The mouth portion 212 narrows inwardly from the lip 214 to where the mouth portion 212 meets the elongate portion 216, where the width W is about 28.6 mm. The mouth portion 212 past the lip 214 has a wall thickness X of about 3.25 mm which is approximately constant.

The elongate portion 216 is generally cylindrical in form. The elongate portion 216 has a maximal width F, measured between two diametrically opposite points on an outer surface of the elongate portion 216, of around 28.6 min at a point where the elongate portion 216 meets the mouth portion 212. The neck portion 202 narrows towards the main body portion 204, having a minimal width H at a point where the neck portion 202 meets the main body portion of around 28.2mm. The elongate portion 216 wall thickness G varies from a minimal thickness of about 1.3 mm at an end of the elongate portion 216 distal from the main body portion 204 (where the width is the maximal width F), to a maximal thickness of about 2.3 mm at the point where the neck portion meets the main body portion (at the minimal width H).

The main body portion 204 begins at an opposite end of the elongate portion 216 to the mouth portion 212 and includes a shoulder portion 208 proximal to the neck portion 202, and a lower portion 210 distal from the neck portion 202.

The shoulder portion 208 flares outwardly from the neck portion 202. The interface between the shoulder portion 208 and the lower portion 210 occurs at a point of maximal width J of the main body portion 204. The maximal width J of the main body portion 204, measured between two diametrically opposite points on an outer surface of the main body portion 204, is around 40.8 mm. The wall thickness I of the shoulder portion 208 varies from a maximal thickness of about 2.3 mm at a point where the neck portion 202 meets the shoulder portion 208 (at the minimal width H) to a minimal thickness of about 1 mm at a point where the shoulder portion 208 meets the lower portion 210 (at the maximal width J).

The lower portion 210 tapers inwardly from the maximal width J of the main body portion 204 toward the base portion 206. A minimal width L of the lower portion 210, measured between two diametrically opposite points on an outer surface of the lower portion 208, is around 37.3mm. A wall thickness K of the lower portion 210 increases gradually, without a step-change in thickness, along the length of the lower portion 210, from the minimal wall thickness I of the shoulder portion 208 of 1 mm, to a maximal wall thickness K of the main body portion 204 of around 1.3 mm. The maximal wall thickness K of the main body portion 204 occurs at a distal most end of the main body portion 204 from the neck portion 202 where the lower portion 210 meets the base portion 206.

The base portion 206 has the form of a spherical dome located at an opposite end of the main body portion 204 to the neck portion 202, such that the main body portion 204 lies intermediate the neck portion 202 and the base portion 206. The base portion 206 has a maximal width M, measured between two opposing points on an outer surface of the base portion 206, of around 44 mm. The base portion 206 has a wall thickness N that varies from the maximal wall thickness K of the lower portion of the main body portion of about 1.3 mm at the point where the base portion 206 meets the lower body portion 210 to a maximal thickness of about 2.4 mm at an extreme end 209 of the base portion 206 that is most distal from the opening 207.

Like the first example bladder 100, the second example bladder 200 is, for example, utilised as the thermoforming bladder 26, and is inserted into the hollow moulded fibre product 22, as previously described. In other examples, the bladder 200 may be a part of the first moulding station in mould 15.

As the main body portion 204 has a wall thickness that varies along a length of the wall, expansion of the main body portion 204 of the bladder 200 is controlled such that, upon inflation, thinner regions of the wall expand in preference to thicker regions of the wall. Therefore, by varying the thickness of the wall of the main body portion 204, contact of the main body portion 204 with the hollow moulded fibre product upon expansion of the bladder 200 is controlled. In the example of Figure 3, relatively thicker wall portions of the bladder 200 may expand before the relatively thicker wall portions of the bladder. Such expansion is illustrated schematically in Figure 4 via arrows, with relative sizing of arrows used to indicate likelihood of expansion, and larger arrows indicating those regions likely to expand first.

By controlling such an initial contact point of the main body portion 204 with the hollow moulded fibre product 22, subsequent expansion of the bladder 200 within the hollow moulded fibre product 22 can be controlled. In particular, with the bladder 200 of the example of Figure 3 it has been found that on inflation the shoulder portion 208 can expand initially to come into contact with a corresponding shoulder portion of the hollow moulded fibre product 22, with the remainder of the main body portion 204, and indeed the base portion 206, then subsequently expanding to fill the hollow moulded fibre product 22. This may ensure that the bladder is able to contact the hollow moulded fibre product 22 with sufficient pressure to ensure sufficient compaction of the material of the hollow moulded fibre product 22.

By having a relatively thick wall of the mouth portion 212 in comparison with the wall of the elongate portion 216 and the main body portion 204, increased strength may be provided in the region of the opening 207 of the bladder 200, where the bladder is connectable to the line 27 in use.

Furthermore, the maximal width M of the base portion 206 is greater than the maximal width J of the main body portion 204. This means the base portion 206 may be more likely to be encouraged to move toward a periphery of a base of the hollow moulded fibre product 22 upon expansion of the bladder 200 when compared to, for example, a bladder having a main body portion and a base portion of the same width, such as bladder 100. This may ensure that the bladder 200 is able to contact regions of the periphery of the base of the hollow moulded fibre product 22 with sufficient pressure to ensure sufficient compaction of the hollow moulded fibre product.

An example moulding system 300 for processing a hollow moulded fibre product, such as a hollow moulded fibre product 22, comprising the second example bladder 200 is shown in Figure 5. In this example, the moulding system is a thermoforming system such as the second moulding station of Figure 1. In other examples, the moulding system 300 may be a different part of the production line shown in Figure 1, such as for example the first moulding station. It will be appreciated that in other examples of a moulding system, the moulding system may comprise the first example bladder 100 or another bladder according to the present invention.

The moulding system 300 is a thermoforming apparatus comprising a mould 302 having a mould cavity 304. During processing, the mould cavity receives a component 306, which can be for example the hollow moulded fibre product 22, and the bladder 200. The apparatus further comprises a fluid source 308 connected to the bladder 200 via a fluid connection 310. This is the equivalent to, for example, the line 27 connecting the pump 28 to supply pressurised fluid, e.g., air, water, or oil, to the interior of the bladder 26.

The moulding system 300 further comprises a heat source 312 for applying heat to the component 306 in the mould cavity 304. The heat source may be for example a heater such as the heater described with reference to the second moulding station (thermoforming station) in Figure 1. The heat source may supply heat to the pressurised fluid for pressurising the bladder 200 or an external mould block (not shown) of the mould 302, and/or the mould 302 itself A control system 410 is connected to the moulding system 300 to control the processing of the component 306. A control system 400 is connected to the bladder 200 to control the processing of the component 306 by the bladder 200. The control system 400 and the control system 410 may be separate or combined into a single control system for a processing station comprising the moulding system 300.

Figure 6 shows an example method 600 performable by a moulding system of the present invention, such as for example the moulding system 300 of Figure 5. The method 600 comprises providing 602 a component 3-in a mould cavity of a mould, such as for example the component 306 in the mould cavity 304. The method 600 comprises providing 604 a reusable expandable member in the mould cavity, such as the mould cavity 304. The reusable expandable member may be the second example bladder 200 of the moulding system 300 or the first example bladder 100 as previously described. The method 600 comprises expanding 606 the reusable expandable member so as to urge the component against an inner surface of the mould cavity. This will urge the component to become pressed against the inner surface of the mould cavity.

The method 600 further comprises applying heat 608 to the component in the mould cavity. Applying heat may for example promote the drying of the component. The method 600 comprises removing 610 the expandable member from the mould cavity. The expandable member may need to be fully or partially deflated and/or deformed by stretching, folding, and or twisting in order to be withdrawn from the mould cavity. This may permit the processed component to be demoulded and proceed to further stations of the manufacturing line, as described previously. The method 600 comprises providing 612 a second component in the mould cavity. The method 600 may then be performed on the second component by providing 604 the reusable expandable member in the mould cavity, expanding 606 the reusable expandable member and applying heat 608 to the second component. It will be appreciated that these steps may be repeated numerous times as part of, for example, a production line to process numerous components using the reusable expandable member, such as the bladder 200 of the example apparatus 300.

In other examples of a method according to the present invention, some of the above-described steps such as applying heat to the component 608, providing 610 and processing the second component 612,614 may be omitted. These are shown in dashed lines in Figure 6. This may be the case for a method that is not at the thermoforming stage of the manufacturing line of Figure 1 and is instead, for example, at a previous moulding stage in the first mould 15.

It will be appreciated that there is provided a control system 400 that is configured to cause expansion of a reusable expandable member, such as the bladder 200, to process a component for example by causing expansion of the reusable expandable member so as to urge the component against an inner surface of the mould cavity. Also provided is a control system 410 that is configured to cause a processing system, such as for example the moulding system 300, to process a component for example by the method 600, or another method according to the invention as previously described.

Figure 7 shows a schematic diagram of a non-transitory computer-readable storage medium 700 according to an example. The non-transitory computer-readable storage medium 700 stores instructions 730 that, if executed by a processor 720 of a control system 710, cause the processor 720 to perform a method according to an example. In some examples, the control system 710 is or comprises the control system 400 as described above. The instructions 730 cause expansion of the reusable expandable member so as to expand the reusable member and urge the component against an inner surface of the mould cavity. In other examples, the control system 710 is or comprises the control system 410 of the moulding system 300 as described above, and the instructions 730 cause a processing system, such as for example the moulding system 300, to process a component for example by the method 600, or another method according to the invention as previously described.

It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in Figure 1) comprising a thermoforming bladder 26, for processing a hollow moulded fibre product or a component and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle. The thermoforming bladder 26 is one of the bladder 100, the bladder 200 or another bladder according to the present invention. Similarly, also provided is a method of manufacturing a receptacle, the method comprising a thermoforming bladder to process a hollow moulded fibre product or component, and then performing at least one additional process on the hollow moulded fibre product to provide the receptacle. Examples of the "at least one additional process" are described above with reference to Figure 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 Figure 8. 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 Figure 9. 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 discussed above with reference to the manufacturing line shown in Figure 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 discussed above with reference to Figure 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.

Claims

CLAIMS: 1. A reusable expandable member for use in processing a hollow moulded fibre product, the reusable expandable member comprising a neck portion defining an opening of the reusable expandable member, the neck portion having a first width; and a main body portion having a second width greater than the first width; wherein the main body portion comprises a wall, and at least a portion of the wall has a wall thickness less than 1.2 mm.
2. The reusable expandable member of claim 1, wherein the wall thickness is greater than 0.15 mm.
3. The reusable expandable member of claim I or 2, wherein the wall thickness varies along a length of the at least a portion of the wall.
4. The reusable expandable member of claim 3, wherein the wall thickness varies constantly along the length of the at least a portion of the wall.
5. The reusable expandable member of any one of claims 1 to 4, wherein the main body portion comprises a shoulder portion proximal to the neck portion and a lower portion distal from the neck portion, the shoulder portion comprising a shoulder portion wall having a shoulder portion wall thickness, the lower portion comprises a lower portion wall having a lower portion wall thickness that differs from the shoulder portion wall thickness.
6. The reusable expandable member of claim 5, wherein at least a portion of the shoulder portion wall has a shoulder portion wall thickness which is smaller than the lower portion wall thickness.
7. The reusable expandable member of claim 5 or claim 6, wherein the lower portion wall thickness is constant along a length of the lower portion wall, and the shoulder portion wall thickness varies along a length of the shoulder portion wall.
8. The reusable expandable member of claim 5 or claim 6, wherein the shoulder portion wall thickness is constant along a length of the shoulder portion wall, and the lower portion wall thickness varies along a length of the lower portion wall.
9. The reusable expandable member of claim 5 or claim 6, wherein the lower portion wall thickness varies along a length of the lower portion wall and the shoulder portion wall thickness varies along a length of the shoulder portion wall.
10. The reusable expandable member of any one of claims 1 to 9, wherein the reusable expandable member comprises a base portion located at an opposite end of the main body portion to the neck portion, the base portion comprising a third width, the third width being greater than the second width.
11. The reusable expandable member according to any one of claims 1 to 10, the reusable expandable member comprising a resiliently deformable material. 20
12. A moulding system for processing a hollow moulded fibre product, the moulding system comprising: a hollow moulded fibre product mould comprising a mould cavity for receiving a component, wherein the component is a fibre suspension or a partially formed hollow moulded fibre product; and the reusable expandable member of any one of claims 1 to 11, the reusable expandable member expandable in the mould cavity so as to urge the component against an inner surface of the mould cavity during a process to form the hollow moulded fibre product from the component.
13. The moulding system of claim 12, wherein the moulding system comprises an expansion fluid source fluidically connectable to the reusable expandable member, such that expansion fluid can be selectively supplied to an interior of the reusable expandable member when the reusable expandable member is inserted into the mould cavity.
14. The moulding system of claim 12 or claim 13, wherein the moulding system comprises a heat source for supplying heat to the component when the component is held within the mould cavity.
15. A method of processing a hollow moulded fibre product, the method comprising: providing a component in a mould cavity of a mould, wherein the component s a fibre suspension or a partially formed hollow moulded fibre product; providing the reusable expandable member of any of claim I to I I in the mould cavity; and expanding the reusable expandable member so as to urge the component against an inner surface of the mould cavity during a process to form the hollow moulded fibre product from the component.
16. The method of claim 15, comprising applying heat to component in the mould cavity.
17. The method of claim 15 or claim 16, wherein the component is a first component, and the method comprises: subsequently providing a second component in the mould cavity of the mould, wherein the component is a fibre suspension or a partially formed hollow moulded fibre product; providing the reusable expandable member of any of claims 1 to 11 in the mould cavity; and expanding the reusable expandable member so as to urge the second component against the inner surface of the mould cavity during a further process to form a further hollow moulded fibre product from the second component.
18. A control system configured to cause a moulding system to perform the method of any one of claims 15 to 17.
19. A non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a control system, cause the processor to perform 10 the method of any one of claims 15 to 17
20. A receptacle manufacturing line comprising the moulding system of any one of claims 12 to 14 for processing the hollow moulded fibre product and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle.
21. A method of manufacturing a receptacle, the method comprising performing the method of any of claims 15 to 17 to process the hollow moulded fibre product, withdrawing the reusable expandable member from the hollow moulded fibre product, and then performing at least one additional process on the hollow moulded fibre product to provide the receptacle.
22. A method of providing a content-containing receptacle, the method comprising providing a receptacle obtained by the method of claim 21 and providing the contents in the receptacle to provide the content-containing receptacle.
23. The method of claim 22, comprising: closing an opening of the receptacle after the providing contents in the receptacle, and/or applying a label or indi ci a to the receptacle.
24. Use of a receptacle obtained by the method of claim 21 to contain contents.
25. A receptacle obtainable or obtained from a fabrication method comprising the method of claim 21.