Molding of hollow-formed textile products

Abstract

The present invention relates to a method and system for forming hollow molded textile products from a fiber suspension, such as a fiber suspension containing paper pulp. In one embodiment, a method for forming hollow molded textile products from a fiber suspension is provided. The method includes at least partially filling a cavity of a mold with a prefilling liquid to form a mass of prefilling liquid within the cavity, wherein the cavity is defined by one or more inner surfaces of the mold, and the mold has a plurality of passages that provide fluid communication between the cavity and the outside of the mold, and subsequently introducing a fiber suspension into the at least partially filled cavity, such that at least a portion of the fiber suspension collides with the mass of prefilling liquid.

Description

Technical Field

[0001] The present invention relates to a method and system for forming hollow molded fiber products from fiber suspensions such as fiber suspensions containing paper pulp. The product can be further processed to form containers, such as bottles, jars, or certain types of vases, which are consumer packages useful for holding liquids, powders, other flowable materials, one or more solids, or combinations thereof.

Background Art

[0002] It is desirable to reduce the use of glass and plastic in consumables, particularly in packages. Containers without necks, such as trays, bowls, and other simple shapes, as well as containers with necks, such as bottles, jars, or certain types of vases, can be formed from paper pulp and other more environmentally considerate recyclable materials.

[0003] During certain stages of the formation of hollow molded fiber products, particularly in the initial stages, the hollow molded fiber products may be formed non-uniformly. Containers manufactured from hollow molded fiber products may have structural weaknesses or poor finishes.

Summary of the Invention

[0004] According to a first aspect of the present invention, a molding system is provided for forming a hollow molded textile product from a fiber suspension. The molding system comprises a mold having one or more inner surfaces defining a cavity in which a hollow molded textile product is formed when in use, and a plurality of passages providing fluid communication between the cavity and the outside of the mold; a fiber suspension supply system; a prefilling liquid supply system; and a control system configured to control the prefilling liquid supply system and the fiber suspension supply system to at least partially fill the cavity with the prefilling liquid from the prefilling supply system to form a mass of prefilling liquid, and subsequently to introduce the fiber suspension from the fiber suspension supply system into the at least partially filled cavity, where at least a portion of the fiber suspension is to collide with the mass of prefilling liquid. The presence of the prefilling liquid in the cavity of the mold acts as a liquid buffer for the colliding fiber suspension (also known as "fiber slurry"), thereby reducing the velocity of the fibers colliding with the mold. This reduces or eliminates fiber sticking in the passages of the mold, resulting in a reduced need for mold cleaning and reduced fluffing of the hollow molded textile product.

[0005] In some cases, hollow molded fiber products can serve as precursors, such as bottle precursors. In some cases, the fiber suspension contains pulp fibers suspended in water (or an aqueous liquid). In some cases, the prefilling liquid contains water or "white water," which is filtered wastewater from a previous molding operation and may contain fewer fibers or a lower concentration compared to the fiber suspension.

[0006] In some examples, the mass of prefilled liquid may be allowed to settle in an upright pool before the fiber suspension is introduced into the cavity. In other examples, the mass of prefilled liquid may be in a dynamic or turbulent state when the fiber suspension is introduced. The shape of the liquid mass may be defined by gravity, the shape of the cavity, and any hydrodynamic forces arising from filling the cavity with the prefilled liquid. In some examples, the level of turbulence present in the mass of prefilled liquid when the fiber suspension impacts can be controlled by controlling one or more of the following: the rate at which the cavity is filled with the prefilled liquid, the amount of prefilled liquid added to the cavity and / or the volume of prefilled liquid held in the cavity before the fiber suspension is introduced, the delay between at least partially filling the cavity with the prefilled liquid and introducing the fiber suspension, and the discharge of the mass of prefilled liquid before or during the introduction of the fiber suspension.

[0007] Optionally, the control system is configured to at least partially fill the cavity with a pre-filling liquid during a first period, introduce a fiber suspension into the at least partially filled cavity during a second period, and remove the liquid from the cavity during a third period. Period-based control of the molding system allows for optimization of various outcomes related to hollow molded fiber products, such as increased molding speed and / or throughput, improved surface finish such as smoothness, and improved uniformity of fiber deposition.

[0008] In some examples, parts of the periods may overlap and / or be separated by delays. For example, the liquid may begin to be removed from the cavity by the action of a negative pressure source (during the third period) while the fiber suspension is being introduced into the cavity (during the second period), but not until the pre-filling of the cavity is complete. In another example, the first and second periods may overlap so that the introduction of the fiber suspension begins before the cavity is filled with the pre-filling liquid. In yet another example, the delay between the completion of the pre-filling of the cavity (end of the first period) and the start of the introduction of the fiber suspension (start of the third period) may be set to allow the mass of pre-filling liquid to settle to a substantially static state.

[0009] Optionally, the second and third periods overlap, while the first period does not overlap with the third period. This configuration prevents the liquid from being discharged from the cavity while the cavity is still filled with the pre-filling liquid. This can increase the size, reduce turbulence in the existing clumps of pre-filling liquid, and improve the smoothness and / or uniformity of the fiber density characteristics of the hollow molded fiber product.

[0010] Optionally, the mold includes an inlet to the cavity for receiving a prefilling liquid or fiber suspension, with the inlet located above the cavity. This configuration allows the prefilling liquid or fiber suspension to flow into the cavity from the respective prefilling liquid supply system or fiber suspension supply system, with the assistance of gravity. The inlet can be used to introduce either the prefilling liquid or the fiber suspension, or both, into the cavity. This improves the flow of the prefilling liquid and / or fiber suspension, allowing them to be controlled more easily and / or precisely, thereby improving the overall quality of the hollow molded fiber product. This also eliminates the need to apply positive pressure to push the prefilling liquid and / or fiber suspension into the cavity, resulting in a simplification of the control system and the entire molding system.

[0011] In some embodiments, separate inlets may be used to introduce pre-filling liquid and fiber suspension into the cavity. For example, a first inlet located above the cavity may be provided for introducing the fiber suspension into the cavity, and a second inlet located below the cavity may be provided for introducing the liquid to be pre-filled into the cavity. For example, if the mold is split in half to be joined in use for molding hollow molded fiber products, multiple inlets may be provided for introducing the pre-filling liquid.

[0012] Optionally, the cavity has an elongated shape and is provided with an inlet located at one of the longitudinal ends of the elongated shape. Such a device can improve the effectiveness of the prefilling liquid, which acts as a liquid buffer for the introduction of the fiber suspension, and / or improve the distribution of fibers in the hollow molded fiber product. In some examples, separate inlets are provided for introducing the prefilling liquid and the fiber suspension into the cavity, and the separate inlets may be located at opposing longitudinal ends of the cavity.

[0013] In some examples, the mold may be oriented vertically or substantially vertically. For example, if the hollow molded fiber product is a precursor to a bottle, the mold may be oriented such that the neck of the formed bottle precursor is above the mold and the base of the formed bottle precursor facing the neck is at the bottom of the mold. In some examples, a bleed valve is provided in the conduit between the fiber suspension supply system and / or the prefill liquid supply system to the cavity, so that the cavity may be positioned under atmospheric pressure. This facilitates the flow of the respective fiber suspension and / or prefill liquid from the fiber suspension supply system and / or prefill liquid supply system into the cavity, with or without the application of positive pressure to the fiber suspension and / or prefill liquid. In some examples, one or more pumps may be used to push the prefill liquid and / or fiber suspension into the cavity.

[0014] Optionally, the elongated main shaft of the cavity is oriented vertically.

[0015] Optionally, the molding system includes a negative pressure source, and the control system is configured to control the negative pressure source to apply negative pressure outside the mold when controlling the fiber suspension supply system to introduce the fiber suspension into at least partially filled cavities. The use of negative pressure applied outside the mold accelerates the removal of liquid from the mold cavity, which may result in a shorter molding process, improved fiber distribution, and / or improved surface finish of the hollow molded fiber product.

[0016] Optionally, the control system is configured to control the amount of fiber suspension introduced into the partially filled cavity using the flow rate of the fiber suspension introduced into the partially filled cavity. Using the flow rate of the fiber suspension into the partially filled cavity simplifies the supply of the fiber suspension required for molding hollow molded fiber products. Otherwise, supply can be difficult in the presence of a pre-filling liquid that adds mass to the mold, which can complicate other supply methods such as metering.

[0017] In some cases, a flow meter may be installed between the fiber suspension supply system and the mold cavity to measure the flow rate of the fiber suspension into the partially filled cavity.

[0018] Optionally, the molding system includes conduit networks between the fiber suspension supply system and the cavity, and between the prefill liquid supply system and the cavity, and the control system is configured to control the prefill liquid supply system and the fiber suspension supply system so that the volume of prefill liquid in the cavity is greater than the volume of air in the conduit network between the cavity and the fiber suspension supply system. This ensures that sufficient prefill liquid is retained in the cavity when the fiber suspension is introduced.

[0019] Optionally, the fiber suspension supply system comprises a fiber suspension valve coupled to a conduit network, the prefill liquid supply system comprises a prefill liquid valve coupled to a conduit network, the molding system further comprises a drain conduit system coupled to the outside of the mold and having a drain valve coupled between the outside of the mold and a drain outlet, and the control system is configured to open the prefill liquid valve, allowing the prefill liquid supply system to at least partially fill the cavity with prefill liquid, close the prefill liquid, open the drain valve and open the fiber suspension valve, introduce the fiber suspension into the cavity and allow the prefill liquid to be removed from the cavity.

[0020] A second aspect of the present invention provides a method for forming a hollow molded textile product from a fiber suspension. The method includes: at least partially filling a cavity of a mold with a prefilling liquid to form a mass of prefilling liquid within the cavity, wherein the cavity is defined by one or more inner surfaces of the mold, and the mold has a plurality of passages that provide fluid communication between the cavity and the outside of the mold; and subsequently introducing a fiber suspension into the at least partially filled cavity, wherein at least a portion of the fiber suspension collides with the mass of prefilling liquid. The presence of the prefilling liquid in the cavity of the mold acts as a liquid buffer for the colliding fiber suspension, thereby reducing the velocity of the fibers colliding with the mold. This reduces or eliminates fiber sticking in the passages of the mold, resulting in a reduced need for mold cleaning and reduced fluffing of the hollow molded textile product.

[0021] In some examples, the hollow molded fiber product may be a precursor, such as a bottle precursor. In some examples, the fiber suspension contains pulp fibers suspended in water (or an aqueous liquid). In some examples, the prefilling liquid contains water or "white water," which is filtered wastewater from a previous molding operation and may contain fewer fibers or a lower concentration compared to the fiber suspension.

[0022] In some examples, a mass of prefilled liquid can be allowed to settle in an upright pool before the fiber suspension is introduced into the cavity. In other examples, the mass of prefilled liquid may be in a dynamic or turbulent state when the fiber suspension is introduced. The shape of the liquid mass may be defined by gravity, the shape of the cavity, and any hydrodynamic forces arising from filling the cavity with the prefilled liquid. In some examples, the level of turbulence present in the mass of prefilled liquid when the fiber suspension collides can be controlled by controlling one or more of the following: the rate at which the cavity is filled with the prefilled liquid, the amount of prefilled liquid added to the cavity and / or the volume of prefilled liquid held in the cavity before the fiber suspension is introduced, the delay between at least partially filling the cavity with the prefilled liquid and introducing the fiber suspension, and the discharge of the mass of prefilled liquid before or during the introduction of the fiber suspension.

[0023] Optionally, the method includes at least partially filling the cavity with a pre-filling liquid during a first period, introducing a fiber suspension into the at least partially filled cavity during a second period, and removing the liquid from the cavity during a third period. Period-based control of the molding system allows for optimization of various results related to hollow molded fiber products, such as increased molding speed and / or throughput, improved surface finish such as smoothness, and improved uniformity of fiber deposition.

[0024] In some examples, some of the periods may overlap and / or be separated by delays. For example, the liquid may begin to be removed from the cavity by the action of a negative pressure source (during the third period) while the fiber suspension is being introduced into the cavity (during the second period), but not until the pre-filling of the cavity is complete. In another example, the first and second periods may overlap so that the introduction of the fiber suspension begins before the cavity is fully filled with the pre-filling liquid. In yet another example, the delay between the completion of the pre-filling of the cavity (end of the first period) and the start of the introduction of the fiber suspension (start of the third period) may be set to allow the mass of pre-filling liquid to settle to a substantially static state.

[0025] Optionally, the second and third periods overlap with each other, while the first period does not overlap with the third period. This configuration prevents the liquid from being discharged from the cavity while the cavity is still filled with the pre-filling liquid. This increases the size and reduces turbulence of the existing clumps of pre-filling liquid, which can improve the smoothness and / or uniformity of the fiber density characteristics of the hollow molded fiber product.

[0026] Optionally, the prefill liquid or fiber suspension is received into the cavity through an inlet located above the cavity. This configuration allows the prefill liquid or fiber suspension to flow into the cavity from the respective prefill liquid supply system or fiber suspension supply system with the assistance of gravity. This improves the flow of the prefill liquid and / or fiber suspension, making them easier and / or more precisely controlled, and improving the overall quality of the hollow molded fiber product. This also eliminates the need to apply positive pressure to push the prefill liquid and / or fiber suspension into the cavity, resulting in a simplification of the control system and the entire molding system.

[0027] In some examples, separate inlets may be used to introduce the pre-filled liquid and the fiber suspension into the cavity. For example, a first inlet disposed above the cavity may be provided to introduce the fiber suspension into the cavity, and a second inlet disposed below the cavity may be provided to introduce the liquid to be pre-filled into the cavity. For example, when a mold that is joined during use is split into half molds to form a hollow molded fiber product, a plurality of inlets may be provided to introduce the pre-filled liquid.

[0028] Optionally, the cavity has an elongated shape and includes an inlet disposed at one end of the longitudinal direction of the elongated shape. Such an arrangement can improve the effectiveness of the pre-filled liquid that functions as a liquid buffer against the introduction of the fiber suspension and / or can improve the distribution of the fibers within the hollow molded fiber product. In some examples, separate inlets are provided for introducing the pre-filled liquid and the fiber suspension into the cavity, and these separate inlets may be disposed at opposite longitudinal ends of the cavity.

[0029] In some examples, the mold may be oriented in a vertical or substantially vertical direction. For example, when the hollow molded fiber product is a precursor of a bottle, the mold may be oriented such that the neck of the formed bottle precursor is above the mold and the base of the bottle precursor facing the neck is at the bottom of the mold. In some embodiments, a bleed valve is provided in the conduit to the cavity between the fiber suspension supply system and / or the pre-filled liquid supply system, whereby the cavity can be disposed under atmospheric pressure. This promotes the flow of the fiber suspension and / or the pre-filled liquid from the fiber suspension supply system and / or the pre-filled liquid supply system into the cavity, regardless of the application of positive pressure to the fiber suspension and / or the pre-filled liquid. In some examples, one or more pumps may be used to push the pre-filled liquid and / or the fiber suspension into the cavity.

[0030] Optionally, the major axis of the elongated shape of the cavity is oriented in the vertical direction.

[0031] In some examples, the method may include applying a negative pressure outside the mold while introducing a fiber suspension into the at least partially filled cavity. The use of the negative pressure applied outside the mold accelerates the removal of liquid from the mold cavity, and as a result, the molding process can be shortened, the fiber distribution can be improved, and / or the outer surface finish of the hollow molded fiber product can be improved.

[0032] Optionally, the method includes controlling the amount of fiber suspension introduced into the at least partially filled cavity using the flow rate of the fiber suspension introduced into the at least partially filled cavity. The use of the flow rate of the fiber suspension into the at least partially filled cavity simplifies the provision of the fiber suspension required to form the hollow molded fiber product. Otherwise, the provision can be difficult in the presence of a prefill liquid that adds mass to the mold, which can disrupt other provision methods such as metering.

[0033] In some examples, a flow meter may be provided between the fiber suspension supply system and the mold cavity to measure the flow rate of the fiber suspension into the at least partially filled cavity.

[0034] Optionally, the method includes controlling such that the volume of the prefill liquid in the cavity is greater than the volume of air in the conduit network between the cavity and the fiber suspension supply system used to supply the fiber suspension for introduction into the cavity. This ensures that sufficient prefill liquid is retained in the cavity when the fiber suspension is introduced.

[0035] According to a third aspect of the present invention, a control system is provided that is configured to cause a molding system to perform the method according to the second aspect. The molding system may be a molding system according to the first aspect.

[0036] According to a fourth aspect of the present invention, a non-temporary storage medium for storing machine-readable instructions is provided, which, when executed by a processing unit of a control system, controls the molding system to perform the method of the second aspect.

[0037] In some examples of any of the above embodiments, the hollow molded textile product is a hollow molded textile product with a neck, such as a bottle, jar, or vase. In some embodiments of any of the above embodiments, the hollow molded textile product is a bottle.

[0038] According to a fifth aspect of the present invention, a container manufacturing line is provided, which includes a molding system for forming a hollow molded fiber product according to the first aspect, and an apparatus for performing at least one additional processing on the hollow molded fiber product to provide a container.

[0039] The apparatus may include an internal coating machine, and at least one additional process may include the internal coating machine coating at least a portion of the inside of a product in order to produce an internally coated product. The apparatus may include a closing portion applicator, and at least one additional process may include the closing portion applicator applying a closing portion to a product or an internally coated product in order to produce a closureable or closed product. The apparatus may include an external coating machine, and at least one additional process may include the external coating machine coating at least a portion of the outside of a product, or an internally coated product, or a closureable or closed product, in order to produce an externally coated product. The apparatus may include a decorating machine, and at least one additional process may include the decorating machine decorating a product, or an internally coated product, or a closureable or closed product, or an externally coated product, in order to produce a decorated product. The apparatus may include a dryer, and at least one additional process may include the dryer drying a product, or an internally coated product, or a closureable or closed product, or an externally coated product, or a decorated product, in order to produce a dried product. The apparatus may include an evaluation machine, and at least one additional process may include the evaluation machine evaluating a product, an internally coated product, a resealable or sealed product, an externally coated product, a decorated product, or a dried product in order to produce an evaluated product. In some examples, the container is the product, an internally coated product, a resealable or sealed product, an externally coated product, a decorated product, a dried product, or an evaluated product.

[0040] In some examples, the container is a necked container such as a bottle, jar, or vase, and the container manufacturing line is a necked container manufacturing line. In some examples, the container is a bottle.

[0041] A sixth aspect of the present invention provides a method for manufacturing a container, which comprises performing the method of the second aspect to form a hollow molded fiber product, and then performing at least one additional process on the hollow molded fiber product to provide a container.

[0042] At least one additional process may include coating at least a portion of the interior of a product in order to manufacture an internally coated product. At least one additional process may include applying a closing portion to a product or an internally coated product in order to manufacture a closureable or closed product. At least one additional process may include coating at least a portion of the exterior of a product, or an internally coated product, or a closureable or closed product, in order to manufacture an externally coated product. At least one additional process may include decorating a product, or an internally coated product, or a closureable or closed product, or an externally coated product, in order to manufacture a decorated product. At least one additional process may include drying a product, or an internally coated product, or a closureable or closed product, or a decorated product, or a decorated product, in order to manufacture a dried product. At least one additional process may include evaluating a product, an internally coated product, a closureable or closed product, an externally coated product, a decorated product, or a dried product, in order to manufacture an evaluated product. In some examples, the container is a product, an internally coated product, a resealable or sealed product, an externally coated product, a decorated product, a dried product, or an evaluated product.

[0043] In some examples, the container is a container with a neck, such as a bottle, jar, or a type of vase. In some examples, the container is a bottle.

[0044] According to a seventh aspect of the present invention, a method for providing a contents-containing container is provided, which includes providing a container obtained by the method of the sixth aspect, and providing a contents-containing container by providing contents to the container.

[0045] In some examples, providing contents into a container includes putting contents into the container. In contrast, in some examples, providing a container includes providing contents that are already present in the container into the container, thereby providing the contents within the container.

[0046] The contents may be, for example, liquids, powders, other fluid materials, one or more solids, or combinations thereof. For example, the contents may be food products such as condiments, beverages such as alcoholic beverages, home care products such as detergents or other cleaning products, personal care products such as hair care products or personal cleansing products, or health products, or pharmaceuticals, or fragrance products such as cosmetics or perfumes, vehicle products such as engine oil, or industrial products. Other suitable contents will be apparent to those skilled in the art in consideration of the subject matter of this application and general knowledge.

[0047] In some examples, the container is a container with a neck, such as a bottle, jar, or a type of vase. In some examples, the container is a bottle.

[0048] Optionally, the method may include closing the opening of the container after dispensing the contents into the container, and / or labeling or marking the container.

[0049] In some examples, closing involves applying a closure (such as a lid or cap or heat seal) to the container to close the opening. In some examples, closing involves applying a heat seal to the container and (for example, then) applying a lid or cap to the container.

[0050] In some cases, the application of a label or mark to a container occurs after the contents have been placed in the container (i.e., the label or mark is applied to the container containing the contents). In other cases, the application of a label or mark to a container occurs before or during the placement of the contents into the container.

[0051] In some cases, the application occurs before closure. In some cases, the application occurs after closure. In some cases, the application occurs during closure.

[0052] According to an eighth aspect of the present invention, a container obtained by the method of the sixth aspect is provided for containing contents.

[0053] The container is used, for example, by a person (such as a natural person or a company) who puts contents into the container, or by a person who transports the contents, or by a person who wishes to dispose of the contents (for example, to a consumer or end user), offers to dispose of the contents (for example, to a consumer or end user), disposes of them, or imports or stores the contents for other purposes.

[0054] The contents may take any of the above forms, for example.

[0055] In some examples, the container is a container with a neck, such as a bottle, jar, or a type of vase. In some examples, the container is a bottle.

[0056] It will be understood that the feature of optional embodiments of the present invention can be equally applied to other embodiments of the invention where appropriate.

[0057] Herein, embodiments of the present invention will be described with reference to the accompanying drawings, merely as examples. [Brief explanation of the drawing]

[0058] [Figure 1]This is a schematic diagram of an exemplary container manufacturing line for carrying out a method of manufacturing containers from paper pulp. [Figure 2] This is a schematic diagram of an exemplary molding system for forming hollow-molded textile products. [Figure 2A] This is a schematic diagram of another exemplary molding system for forming hollow-molded textile products. [Figure 3] Figures A and B are cross-sectional views of the mold shown in Figure 2, illustrating the pre-filling of the mold and the subsequent introduction of fiber slurry into the mold using different examples. [Figure 4] Figures A and B are cross-sectional and enlarged cross-sectional views of the mold shown in Figure 2, respectively, illustrating an example of the formation of a hollow molded fiber product and the removal of excess liquid from the mold. [Figure 5] This document describes a method for forming a hollow-molded fiber product as an example. [Figure 6] Another example of a method for forming hollow-molded textile products is shown. [Figure 7] An example of a non-temporary computer-readable storage medium is shown. [Figure 8] A schematic cross-sectional view of a container holding its contents is shown as an example. [Figure 9] This document describes a method for providing a container for holding contents. [Modes for carrying out the invention]

[0059] The following description presents exemplary embodiments and, together with the drawings, serves to explain the principles of the embodiments of the present invention.

[0060] Figure 1 shows a container manufacturing line for carrying out a method of manufacturing a container, in this case a necked container from paper pulp (i.e., which can form the basis of an exemplary fibrous suspension), more specifically, in this case in the form of a bottle. “Necked container” means that the container has an internal constriction, or “neck,” between a main body portion where most or all of the container’s contents are stored during use, and an opening from which the contents can enter and exit the container during use. The internal width of the container at the neck may be the same as or different from the internal width of the opening. However, since the internal width of the neck is smaller than the internal width of the main body portion, a shoulder is defined by and between the neck and the main body portion. This shoulder complicates the manufacturing of the container because it interferes with the subsequent removal (and, in some cases, insertion) of any mold tools inserted into the container to form the internal shape of the container. Examples of necked containers are bottles, jars, and certain types of vases. This process is merely illustrative and is provided to give context to the examples of the present invention. In other examples, it will be understood that a container manufacturing line may be for producing neckless containers (i.e., such neckless containers) such as bowls or trays.

[0061] Broadly speaking, the exemplary process includes supplying a fiber suspension, introducing the fiber suspension into the mold cavity of a porous first mold, draining the liquid (such as water) from the fiber suspension to produce a hollow molded fiber product (sometimes called a wet precursor or embryo) in the mold cavity, further molding the hollow molded fiber product to produce a hollow, further molded fiber product, drying the hollow, further molded fiber product and then internally coating it to produce an internally coated product, drying the internally coated product to produce a dried product, applying a closure component to the dried product to produce a closureable or closed product, externally coating and / or decorating the closureable 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. Modifications to the exemplary process can be provided, at least as will be apparent from the following description, in which other embodiments of the present invention may be embodied. For example, in some cases, either the internal coating or the external coating and / or decoration may be omitted. Furthermore, in this example, as indicated by the asterisks labeled Inspection 1 to Inspection 5 in Figure 1, the process involves inspecting or evaluating hollow, further molded textile products, internally coated products, closureable or closed products, externally coated or decorated products, and dried products to produce each evaluated product. In some examples, the container is one of the hollow molded textile products, hollow, further molded textile products, internally coated products, closureable or closed products, externally coated or decorated products, dried products, or one of each evaluated product.

[0062] In this example, supplying a fiber suspension includes preparing a fiber suspension from its components. More specifically, preparation includes supplying pulp fibers, such as paper pulp fibers, and mixing the pulp fibers with a liquid to supply hydrated pulp fibers. In this example, the pulp fibers are supplied from a supplier in the form of sheets, and the liquid contains water and one or more additives. In this example, the liquid is mixed with the pulp fibers to supply hydrated pulp fibers having a solid fiber content of 1 wt% to 5 wt% (depending on the dry mass of the fibers). In this example, one or more additives include a sizing agent such as alkyl ketene dima (AKD). The hydrated pulp fibers typically contain 0.4 wt% of AKD relative to the total dry mass of solid fibers in the hydrated pulp fibers. In some examples, one or more additives are present in the liquid at the time the pulp fibers are mixed with the liquid. In some examples, one or more additives are added to the hydrated pulp fibers after they have been mixed with a liquid (for example, the pulp fibers are hydrated for a certain period, e.g., 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fibers). The hydrated pulp fibers pass between the plates of the valley beater 11 or the purifier, which are moving relative to each other. This causes some or all of the fibers to fibrillate, i.e., the cell walls of these fibers are partially delaminated, and the wet surface of these fibers has protruding hairs or fibrillation. These fibrillations help to increase the bonding strength between fibers in the dried final product. In other examples, the valley beater 11 or the purifier may be omitted.

[0063] The resulting processed pulp is stored in tank 12 in a relatively concentrated form (e.g., with a solid fiber content of 1 wt% to 5 wt%) to reduce the required storage space. At an appropriate time, the processed pulp is transferred to mixing station 13, where it is diluted with further water and optionally mixed with one or more additives (in addition to or in place of one or more additives supplied with the hydrated pulp fibers) to supply a fiber suspension ready for molding. In this example, solid fibers account for 0.7 wt% (by dry weight of fibers) of the resulting fiber suspension, but in other examples, the proportion of solid fibers in the fiber suspension may vary, such as 0.5 wt% to 5 wt% (by dry weight of fibers) of the fiber suspension, or another value in the range of 0.1 wt% to 1 wt%. In some examples, the one or more additives mixed with the processed pulp and water include dehydrating agents such as modified and / or unmodified polyethyleneimine (PEI), such as modified PEI sold under the trademark Polymin® SK. In some examples, one or more additives are mixed with water, and the water and one or more additives are then mixed with the treated pulp. In other examples, the treated pulp is mixed with water, and then one or more additives are mixed with the treated pulp and water. The fiber suspension typically contains 0.3 wt% of Polymin® SK relative to the total dry mass of solid fibers. Mixing the fiber suspension at the mixing station 13 helps to homogenize the fiber suspension. In other examples, the treated pulp or fiber suspension may be supplied in other ways, such as being supplied as a ready-made product.

[0064] Downstream from the tank 12 and mixing station 13 is a first molding station containing a porous first mold 15. In this example, the porous first mold 15 includes two half molds 14, which are movable to move closer to or away from each other, in this case using a hydraulic ram. In this example, each half mold is a monolithic or integrated tool formed by additive manufacturing (e.g., 3D printing) that defines the mold contour, and when the half molds 14 are in contact with each other, their respective mold contours cooperate to define a mold cavity where a hollow molded textile product is formed. Each half mold 14 itself defines a smaller mold cavity, and when in cooperation with the second half mold 14, the smaller mold cavities combine to provide an overall mold cavity. The two half molds 14 can be considered as “split molds” or “molds” themselves, and the overall porous first mold 15 can be considered as “split molds” or similarly “molds”. In other examples, the porous first mold 15 may have three or more split molds 14, such as three, four, or six split molds, which cooperate to define the mold cavity.

[0065] In Figure 1, the fibrous suspension (also known as slurry) is filled from above into a porous first mold 15, unlike a molding process in which the mold is immersed in the slurry. The fibrous suspension is drawn into the porous first mold 15 via line 16 under vacuum, and any excess suspension is drawn through the porous first mold 15 into a tank 17 via line 18 under vacuum. The injection mass can be controlled by measuring (e.g., by gravimetric measurement) the amount of liquid drawn into the tank 17. A gravimetric platform supporting the tank 17 can be seen in Figure 1. Once the required amount of liquid (e.g., a predetermined volume such as 10 liters, or a predetermined mass such as 10 kilograms) has been collected in the tank 17, the suction of the suspension through the porous first mold 15 is stopped, and the first mold 15 is opened to ambient air. In this example, the suspension drawn in along with the fibrous suspension in line 16 is water, or mostly water (additives may also be present). Since the fibers remain on the walls of the porous first mold 15 to form a medium-sized molded fiber product, the liquid drawn into the tank 17 via the line 18 under vacuum is substantially fiber-free.

[0066] In one example, a high-pressure fluid (such as compressed air) is introduced into a first mold 15 to further remove the suspension (e.g., water) from a hollow molded fiber product and to form or strengthen the three-dimensional shape of the product, compressing the fiber suspension against the cavity walls of the first mold 15. This process strengthens the product, making it more manageable, and replaces water from between the fibers, thereby increasing the efficiency of the subsequent drying process. The fluid is regulated using a hydraulic pump 20, which has a cylinder that moves the fluid in line 21 into the first mold 15. In an alternative example, an impermeable expansion element in the form of a foldable bladder is inserted into the first mold 15 and expands by introducing fluid from line 21 into the bladder, functioning as an internal high-pressure core structure for the first mold 15. In such an alternative configuration, the fluid in line 21 is preferably incompressible, such as water or oil, but in other examples, the fluid may be a compressible fluid, such as air. Water has an advantage over other incompressible liquids in that any leakage or rupture of the bladder does not introduce new material into the system (since the suspension is already water, or primarily water).

[0067] Demolding occurs when the first mold 15 is opened to remove the self-supporting hollow molded fiber product 22. Subsequently, it is preferable to perform mold cleaning 23 to remove any remaining small fibers and / or other debris and maintain the porosity of the porous first mold 15. In this example, while the first mold 15 is open, a radially fired high-pressure jet is inserted into the mold cavity. This removes debris from the walls of the mold cavity. Alternatively or additionally, water from the tank 17 is pressurized through the back of the porous first mold 15 to remove any stuck fibers and / or other debris. The water is discharged and returned to the upstream part of the system for recycling. It should be noted that cleaning is important to prepare the first mold 15 for reuse. After the container is removed, the first mold 15 may appear clean, but its performance may be impaired if it is not cleaned.

[0068] As shown in Figure 1, the hollow molded fiber product 22 is then transferred to a second molding station, where pressure and heat are applied for thermoforming of a desired neck finish and surface finish in, for example, an aluminum mold 25, the surface finish optionally including embossed and / or debossed surface features. After the two halves of the mold 25 are closed around the product 22, a pressurizer is engaged. For example, a bladder 26 (e.g., a thermoforming bladder 26) is inserted into the product 22. The bladder 26 is inflated with pressurized fluid supplied via line 27 by a pump 28. The pressurized fluid is preferably an incompressible fluid such as water or oil, but in other examples it may be a compressible fluid such as air. In other examples, during supply, the pressurized fluid is heated, for example by a heater, or alternatively, cooled, for example by a heat exchanger. The external mold block 24 of the mold 25 and / or the mold 25 itself are also heated, or alternatively, in some examples. After thermoforming, the state of product 22, which can be considered here as a hollow, further molded textile product, is considerably more rigid and has more compressed side walls compared to the state of product 22 when demolded from the first mold 15.

[0069] The drying step 30 (e.g., microwave drying or other drying treatment) is performed on the product 22 downstream of thermoforming, as shown in the figure, to provide a dried product. In one example, the drying step 30 is performed before thermoforming to provide a dried product. However, molding in the mold 25 requires some moisture content to aid in bonding during the compression process. Drying may be performed using a dryer, such as a machine that functions to dry the product, or using a shelf or other support on which the product 22 is simply placed during drying.

[0070] Next, product 22 is subjected to an internal coating stage, during which an internal coating device in the form of a spray lance 31 is inserted into product 22 to apply one or more surface coatings to the inner wall of product 22 in order to produce an internally coated product. In another example, product 22 is instead filled with a liquid that coats the inner wall of product 22 and then discharged. In practice, such a coating provides a protective layer to prevent contents that could penetrate and / or weaken the bottle wall from being released into the bottle wall. The coating will be selected according to the intended contents of the finished container, for example, beverages, food, detergents, lubricants, pharmaceuticals, etc. In this example, the internally coated product 22 is then subjected to a curing or drying process 32, which can be configured or optimized according to the internal coating, for example, by drying for 24 hours under ambient conditions or by a rapid drying method. Drying may also be performed using a dryer, such as a machine that functions to dry the product, or simply using a shelf or other support on which product 22 is placed during drying. After drying, the coated product 22 is considered a separate dried product.

[0071] Next, a closure component application device performs a closure or mouth-forming process on the product 22 to produce a closureable or closed product. For example, as shown in Figure 1, a necking device 33 may be attached to the dried product. This makes the product closureable by positioning a cap, lid, or other closure relative to the necking device. Next, as shown in a further step 34, an external coating device and / or decoration device applies an external coating and / or decoration to the product 22, respectively, to produce an externally coated and / or decorated product. In one example, as shown in Figure 1, the product 22 is immersed in a liquid to coat its outer surface. In another example, the outer surface receives external coating in a different manner. The coating and / or decoration may cover all or only part of the outer surface of the product. Next, the product 22 is dried in warm air to produce another dried product. In another example, drying may be performed using a drying device such as one of those discussed above.

[0072] Thus, product 22 is fully formed and considered a final “container” ready to receive contents therein. In other examples, the container may be fully formed without the necking fixture 35 being attached, and / or without the internal coating being applied, and / or without the external coating being applied, and / or without the decoration being applied, and / or immediately after one of the drying processes or one of the inspection and / or evaluation processes. For example, in some cases, the product is provided with a closure by forming the closure during the molding of the product at a first molding station and / or a second molding station.

[0073] Herein, we refer to Figure 2, which is a schematic diagram of the mold system 100 according to an embodiment. The illustrated molding system 100 is configured to mold a hollow molded textile product 22 (indicated by a dashed outline) from a fiber suspension during use of the system 100. The hollow molded textile product 22 and / or fiber suspension may be, for example, those described above with reference to Figure 1. In this embodiment, the hollow molded textile product 22 is a bottle or (after further processing) becomes a bottle. However, by making appropriate modifications to the system, such as using a different mold, the hollow molded textile product 22 may be, for example, a jar, a vase, or another container with or without a neck, or may be used to make (further process) them.

[0074] As shown in Figure 2, the system 100 includes a mold 110 having a cavity 112, in which a hollow molded fiber product 22 is formed during use of the system 100. As also shown in the figure, the mold includes an inner surface 114 that together defines the cavity 112. As will be described later, the mold 110 further includes a plurality of passages or pores 111, 111A (not shown in Figure 2), each of which provides fluid communication between one of the inner surfaces 114 of the mold 110 and the outer surface 113 of the mold. This allows the liquid in the cavity 112 to be removed to the outside of the mold 113. For example, after introducing a fiber suspension containing pulp fibers held in a liquid medium such as water into the cavity, the passages in the mold can remove the liquid medium from the cavity, leaving pulp fiber deposits on the inner surface of the mold.

[0075] The mold 110 also includes an inlet 116 that opens into the cavity 112 to allow for the introduction of a fiber suspension. In this example, the inlet 116 is located in the neck portion 115 of the mold, facing the base portion 117 of the mold. The cavity 112 has an elongated shape and includes the inlet 116 located at one of the longitudinal ends of this elongated shape. The mold 110 is configured to mold a hollow molded fiber product with a neck as a precursor for a bottle. However, other molds with differently shaped cavities may be used instead to mold different types of precursors. In some examples, multiple inlets may be available, in which case the fiber suspension can be delivered into the cavity 112 through one or more of these inlets.

[0076] The mold 110 may also be associated with structural components 119, such as a frame, to provide structural support and precise positioning of the mold 110. In this example, the elongated main axis of the cavity 112 is oriented vertically, but other orientations may be employed instead. Structural components may house the exterior of the mold 113 to collect the liquid received from the cavity 112 through passages 111, 111A. The mold 110 may be formed from two separate half-molds or parts, similar to the mold 15 shown in Figure 1. However, this is by no means mandatory, and in other examples, the mold 110 may be formed from three, four, or so parts.

[0077] The molding system 100 includes a drain conduit 170 having a drain valve 172 and a negative pressure source 174 such as a vacuum pump. The drain conduit is positioned to drain liquid from outside the mold 113. The use of the vacuum pump 174 increases the rate of liquid removal from outside the mold, and consequently the rate of liquid removal from the cavity 112. This helps ensure that the liquid is substantially removed from the cavity in order to form the hollow molded textile product 22. In an alternative example, the negative pressure source 174 and / or the drain valve 172 may be omitted, and the molding system 100 relies on gravity to remove liquid from outside the cavity 112 and mold 113.

[0078] The molding system 100 comprises a fiber suspension supply system 130 having a fiber suspension reservoir 132, a flow meter 136, and a fiber suspension valve 138. During use, the fiber suspension reservoir 132 may be supplied with a fiber suspension 134, such as a pulp fiber slurry. The fiber suspension reservoir 132 may be any suitable device or system, such as the tank 12 and mixing station 13 in Figure 1. The fiber suspension valve 138 controls the flow of the fiber suspension toward the mold 110. The flow meter 136 provides an indication of the flow rate of the fiber suspension through the fiber suspension valve 138. By using a device or method for measuring the flow rate of the fiber suspension, the supply or amount of fiber suspension supplied to the mold 110 is simplified. However, in alternative examples, different devices or methods for supplying the fiber suspension may be used. In some examples, the fiber suspension supply system 130 may additionally include a pump (not shown) to apply positive pressure to the fiber suspension supplied to the mold 110.

[0079] The molding system 100 includes a prefilling liquid supply system 140 having a prefilling liquid reservoir 142, a prefilling liquid pump 146, and a prefilling liquid valve 148. When in use, the prefilling liquid reservoir 142 may be supplied with prefilling liquid 144, such as water from the molding system 100 and / or other parts of the container manufacturing line as shown in Figure 1, or recovered wastewater. The recovered wastewater may contain a low concentration of fibers and is known as white water. Using this white water as the prefilling liquid can reduce water waste and improve the overall efficiency of the container manufacturing line. The prefilling liquid valve 148 controls the flow of prefilling liquid toward the mold 110. During use, the prefilling liquid is supplied to the mold 110 before the introduction of the fiber suspension, as will be described in more detail below.

[0080] The molding system 100 includes a conduit network 160 arranged to supply a fiber suspension 134 from a fiber suspension supply system 130 and a prefilling liquid 144 from a prefilling liquid supply system 140 into the cavity 112 of the mold 110. The conduit network 160 is coupled to a fiber suspension valve 138 and a prefilling liquid valve 148. The conduit network 160 may terminate in or around the inlet 116 of the mold 110 and include a plug or other fitting adapted to fit with the neck 115 of the mold 110 to prevent leakage of the fiber suspension or prefilling liquid. The conduit network 160 includes a bleed valve 162 that connects the conduit network to the atmosphere. Opening the bleed valve 162 can facilitate the flow of the fiber suspension and / or prefilling liquid into the cavity 112.

[0081] In an alternative example, if the mold has two or more inlets in its cavity, the prefilling liquid and fiber suspension may be guided to different inlets by a conduit network.

[0082] Figure 2A shows an exemplary molding system 100A having multiple injection ports into the mold cavity. Features common to molding system 100 share the same reference numerals. For simplification, the inner surface 114 and the hollow molded fiber product 22 are not shown but are present in this example as well. For a detailed description of these omitted and common features, refer to the preceding description in Figure 2.

[0083] Example 100A in Figure 2A differs from the example in Figure 2 in that it has half molds 110A and 110B, which, when joined together, form a cavity 112, and are referred to herein as molds 110A and 110B in this state. Example 100A in Figure 2A also differs from the example in Figure 2 in that the prefilling liquid and fiber suspension are supplied into the cavities of molds 110A and 110B via different conduit routes and inlets to the cavities.

[0084] The molding system 100A comprises a modified conduit network having two conduit branches 160A and 160B. The first conduit branch 160A is positioned to deliver the fiber suspension 134 from the fiber suspension supply system 130 into the cavity 112 of the molds 110A and 110B. The first conduit branch 160A is coupled to a fiber suspension valve 138 and terminates in or around the inlet 116 of the molds 110A and 110B. The inlet 116 may be associated with a plug or other fitting adapted to mate with the neck 115 of the molds 110A and 110B to prevent the fiber suspension from flowing out. The first conduit branch 160A comprises a bleed valve 162 that connects the first conduit branch to the atmosphere. Opening the bleed valve 162 can facilitate the flow of the fiber suspension and / or prefilling liquid into the cavity 112.

[0085] A second conduit branch 160B is positioned to deliver pre-filling liquid 144 from the pre-filling liquid supply system 140 into the cavities 112 of the molds 110A and 110B. The conduit branch 160B is coupled to a pre-filling liquid valve 148 and terminates at inlets 118A and 118B of the molds 110A and 110B. Inlets 118A and 118B for the pre-filling liquid may be formed in the respective base portions 117A and 117B of each half of the molds 110A and 110B. In other variations, a single inlet for the pre-filling liquid may be formed in one or both base portions, and / or inlets for the pre-filling liquid may be formed on the sides of the molds 110A and 110B.

[0086] References to molding system 100 and / or mold 110 may be replaced with molding system 100A and / or molds 110A, 110B, respectively.

[0087] The bleed valve 162 in the molding system 100, 100A may be positioned above the fiber suspension valve 138 to facilitate the bleeding of air from this portion of the conduit network 160, 160A.

[0088] The molding system 100 (or 100A) also includes a control system 150 configured to control a prefill liquid supply system 140 and a fiber suspension supply system 130. In one example, the control system 150 may be coupled to control a fiber suspension valve 138, a prefill liquid pump 146, a bleed valve 162, a drain valve 172, and a negative pressure source 174. The control system 150 is also coupled to receive data from a flow meter 136 indicating the flow rate of the fiber suspension. The control system 150 is configured to control the prefill liquid supply system 140 to at least partially fill the cavity 112 with prefill liquid to form a mass of prefill liquid within the cavity. The control system 150 is configured to control the fiber suspension supply system 130 to continue introducing the fiber suspension into the at least partially filled cavity 112, where it collides with the mass of prefill liquid. This combination of operations can be achieved by controlling the opening and closing of the fiber suspension valve 138 and the pre-filled liquid valve 148, as will be described in more detail below. Control by the control system 150 of the pre-filled liquid pump 146, bleed valve 162, drain valve 172 and / or negative pressure source 174 can also facilitate the achievement of this combination of operations.

[0089] By at least partially filling the cavity 112 with a pre-filling liquid before introducing the fiber suspension, the adhesion of fibers to the passages or pores of the mold 110 is reduced or eliminated. The pool of pre-filling liquid acts as a liquid buffer for the injected fiber suspension, slowing the fiber velocity before they collide with the inner surface 114 of the mold. Reducing or eliminating fibers adhering to the pores of the mold reduces the need for mold cleaning and also improves the smoothness of the outer surface of the hollow molded fiber product, which is also known as reducing surface "fuzzing". A smooth outer surface of the hollow molded fiber product improves downstream processing and results in a better finish for the container.

[0090] Here, we refer to Figure 3A, a cross-sectional view of the mold 110 shown in Figure 2. For simplicity, a single passage or pore 111 is shown. However, it will be understood that in reality, a number of pores 111 may extend across each inner surface 114 to the outer surface 113 of the mold. In one example, the pores 111 are distributed throughout the mold to provide continuous porosity.

[0091] Figure 3A shows that the cavity 112 is partially filled with prefilling liquid to form a mass of prefilling liquid 180A, and that a flow of fiber suspension 182 is introduced into the cavity 112 through the inlet 116. It will be understood that at least a portion of the flow of fiber suspension 182 collides with the mass of prefilling liquid 180A before it collides with the inner surface 114 of the cavity 112. By colliding with the mass of prefilling liquid 114, the fibers in the flow of fiber suspension are slowed down by their movement through the prefilling liquid, and as a result their velocity is reduced before they collide with the pores 111 on the inner surface 114 of the mold 110.

[0092] The effect of high-speed impact of fibers into the pores 111 may be most pronounced in the base portion 117 of the mold 110, since the corresponding inner surface 114 is directly facing the flow of fiber suspension 182 from the injection port 116. Therefore, in some examples, it may be sufficient to have a mass of pre-filled liquid 180A covering the inner surface of the base portion 117 without requiring it to extend to the inner surface of the sidewall inner surface 114 or the inner surface of the neck portion 115. However, in other examples, the mass of pre-filled liquid 180A may extend to and into the neck portion 115.

[0093] The shape of the prefill liquid mass can be defined by gravity, the shape of the cavity, and the hydrodynamic forces generated by filling the cavity with the prefill liquid. As shown in Figure 3A, the prefill liquid can be allowed to settle in a substantially static or still pool 180A before the fiber suspension is introduced into the cavity. In other examples, as shown in Figure 3B, the prefill liquid mass may be in a dynamic or turbulent state when the fiber suspension is introduced.

[0094] Figure 3B is also a cross-section of the mold shown in Figure 2, and it shows a pool of pre-filled liquid 180B in a turbulent state. This may be a result of the pre-filled liquid having just entered the cavity 112 without any subsequent settling time. However, it can be seen that the flow of the fiber suspension 182 still collides with the pre-filled liquid, thereby reducing the velocity of the fibers that collide with the pores 111 on the inner surface of the mold 110.

[0095] The control system 150 is configured to control the flow of the prefilling liquid and fiber suspension into the cavity in order to provide this liquid buffering effect. In some examples, a sedimentation period may be introduced between the completion of filling the cavity with the prefilling liquid and the start of introducing the fiber suspension into the cavity. Depending on the length of the sedimentation time, the mass of prefilling liquid may be more similar to that shown in Figure 3A or more similar to that shown in Figure 3B. In some examples, the filling of the cavity with the prefilling liquid and the introduction of the fiber suspension may overlap in time, with the start of introduction of the fiber suspension into the cavity occurring after the start of cavity filling with the prefilling liquid but before the completion of cavity filling with the prefilling liquid.

[0096] Figures 4A and 4B are cross-sectional and enlarged cross-sectional views, respectively, of the mold shown in Figure 2. Figure 4A shows an example of the formation of a hollow molded fiber product and the removal of excess liquid from the mold. Figure 4B shows the accumulation of fibers around the pores of the mold.

[0097] Referring to Figure 4A, a liquid mixture 184 remains inside the cavity 112 of the mold 110 after the prefilling liquid has been at least partially filled and the fiber suspension has been introduced. This liquid mixture 184 may be a mixture of the prefilling liquid and the fiber suspension at different relative concentrations depending on factors such as the relative timing of filling the cavity with the prefilling liquid and then filling the cavity with the fiber suspension, as well as the rate and duration of removal of the liquid mixture 184.

[0098] The liquid mixture 184 in the cavity 112 is removed to the outside of the mold 113 through multiple passages or pores 111A within the mold 110 (as shown as removed liquid 186), leaving fibers from the fiber suspension. Again, only a single passage 111A is illustrated for simplification, but it will be understood that the mold may include multiple such passages arranged throughout the inner surface of the cavity 112. The deposition of these fibers against the inner surface of the cavity 112 forms a hollow molded fiber product 22, shown by the dashed contour. The removed liquid 186 is simply shown from a single illustrated passage or pore 111A within the base 117 of the mold. However, it will be understood that such removed liquid may be removed using multiple pores across different parts of the mold 110, including, for example, around and on the sides of the neck 115 of the mold.

[0099] Similarly, referring to Figure 4B, the deposition of fibers 188A, 188B on the inner surface 114 of the mold 110 around the passage or pore 111A is shown. As described above, at least partially filling the cavity 112 with pre-filling liquid before introducing the fiber suspension acts as a liquid buffer for the incoming fiber slurry. This reduces the velocity of the fibers in the fiber suspension as they collide with the inner surface 114 of the mold 110 and the pore 111A. This reduces the retention of fibers 188B within the pore 111A, and instead promotes the deposition of fibers 188A across the pore 111A in a direction substantially parallel to the surface of the inner surface 114 of the mold 110, adhering to the inner wall. In doing so, given their elongated shape, the fibers 188A tend to fold together to form a condensable fiber-based structure defined by the shape of the inner surface of the mold cavity.

[0100] After the liquid mixture 184 has been substantially removed from the cavity 112, the mold can be opened and the newly formed hollow molded fiber product 22 can be removed. After the hollow molded fiber product 22 has been removed, the mold can be closed again to prepare for the next molding cycle, in which the cavity of the mold is again at least partially filled with the pre-filling liquid and the fiber suspension is reintroduced into the partially filled cavity.

[0101] The smoothness of the outer surface of the hollow molded textile product 22 is improved by avoiding or reducing the number of fibers 188B that remain in the pores 111A in a direction substantially not parallel to the inner surface of adjacent cavities. This is because when the hollow molded textile product 22 is removed from the mold 110, there are fewer fibers 188B extending outward perpendicularly from the outer surface of the product 22. Furthermore, the reduction in the number of fibers 188B remaining in the mold pores 111A reduces the need to remove them during the mold cleaning process, or reduces the frequency to which mold cleaning is required.

[0102] Figure 5 shows a method 200 for forming a hollow molded textile product as an example. The hollow molded textile product may be a precursor 22 of a bottle provided by the molding systems 100, 100A described above with reference to Figures 2 to 4B. However, method 200 may be used to form other types of hollow molded textile products and / or to control different molding systems. Method 200 can be carried out in conjunction with the molding system 100 in Figure 2, the molding system 100A in Figure 2A, and / or the mold 15 in Figure 1.

[0103] Method 200 includes, in block 210, at least partially filling the mold cavity with prefilling liquid to form a mass of prefilling liquid within the cavity. This process 210 may be performed within a molding system after closing a multi-part mold to form a cavity that defines the shape of a hollow molded textile product. The mass of prefilling liquid may be static or turbulent and may be defined by gravity, the shape of the cavity, and any fluid forces resulting from the introduction of prefilling liquid into the cavity or the removal of prefilling liquid from the cavity through the mold pores. The liquid level or amount of prefilling liquid in the cavity may be controlled by the rate and duration of the addition of the prefilling liquid to the cavity. In some examples, the liquid level or amount of prefilling liquid in the mass may range from completely filling the cavity to a much smaller non-film mass that covers only a portion of the inner surface of the cavity. In one example, the process of filling the mold cavity at least partially with a pre-filling liquid to form a mass of pre-filling liquid within the cavity may be carried out over a first period, which may be referred to as the pre-filling period.

[0104] A desired amount of pre-filling liquid in the mold cavity, or a desired level of pre-filling liquid, can be achieved by using a pre-filling period along with a predetermined flow rate of the pre-filling liquid. In other examples, a dispensing mechanism may be used to supply a predetermined volume or weight of pre-filling liquid into the mold cavity.

[0105] The method involves introducing a fiber suspension into a cavity that is at least partially filled, such that a portion of the fiber suspension collides with a mass of prefilled liquid in block 220. As previously mentioned, the presence of prefilled liquid between the incoming fiber suspension and the inner surface of the cavity reduces the rate at which the fibers collide with these inner surfaces and the pores they contain. In some examples, only a portion of the cavity may be filled with prefilled liquid so that a mass forms around the inner surface(s) of the cavity at the opposite side of the incoming fiber suspension. In other examples, it may be preferable to substantially fill the cavity with prefilled liquid when introducing the fiber suspension. In one example, the process of introducing the fiber suspension into the cavity may be carried out over a second period.

[0106] The cavity is at least partially filled with prefilling liquid before the introduction of the fiber suspension. In some examples, the prefilling liquid may continue to be added after the introduction of the fiber suspension has begun, i.e., the first and second periods overlap. In other examples, the fiber suspension may be introduced into the cavity immediately after the addition of the prefilling liquid to the cavity has stopped, i.e., the first and second periods are adjacent. In other examples, a delay may be introduced between the completion of block 210 and the start of block 220, i.e., this delay may correspond to a delay period between the first and second periods. This delay allows the mass of prefilling liquid to settle to a more static or stationary state of the liquid in the cavity before the introduction of the fiber suspension.

[0107] In addition to those illustrated, various other processes may be performed, for example, including one or more of the processes described with respect to the container manufacturing line of Figure 1 and / or Method 300 described below with respect to Figure 6. In some examples, the removal of liquid from the cavity may be performed during a removal period, also called a third period. Due to the porous nature of the mold, the liquid can be removed from the cavity under the influence of gravity. In some examples, negative pressure may be applied to the outside of the mold to increase the rate of liquid removal from the cavity. This negative pressure may be applied between both blocks 210 and 220, or to block 220 or only a portion of these blocks. For example, negative pressure may be applied only when a fiber suspension is introduced, and not when prefill liquid is added.

[0108] The application of negative pressure may be carried out over a fourth period which may be the same as or shorter than the third period. The third period (and the fourth period, if different) may be a predetermined period previously determined experimentally or otherwise, or otherwise may correspond to a cavity from which the liquid exiting the hollow molded textile product has been substantially removed. Following the third period, the mold may be divided into its components, allowing the hollow molded textile product to be removed and a new molding cycle to begin.

[0109] Figure 6 shows a method 300 for forming a hollow molded fiber product according to another example. This method 300 may be carried out using the molding system 100 of Figure 2, and therefore refer to this figure. Method 300 may be carried out by a control system 150 that controls various parts of the aforementioned molding system 100. Method 300 may also be carried out using the mold 15 of the container manufacturing line of Figure 1. One or more blocks of Method 300 may, in some examples, correspond to one or more blocks of Method 200 of Figure 5.

[0110] Method 300 includes opening the bleed valve 162 to the atmosphere in block 310. This means that the conduit network 160 and the cavity 112 are below atmospheric pressure.

[0111] In block 320, the prefilling liquid valve 148 opens and / or the prefilling liquid pump 146 is activated. The prefilling liquid 144 then begins to flow from the prefilling liquid reservoir 142 through the conduit network 160 and into the cavity 112 via the inlet 116, due to gravity and / or the action of the prefilling liquid pump 146. Next, the cavity begins to fill with the prefilling liquid, forming a pool of prefilling liquid that at least partially fills the cavity.

[0112] In block 330, the prefill liquid valve 148 is closed. This process may be performed during a first period after the valve 148 is opened, but other control approaches can be used, such as controlling the opening and closing of the valve 148 based on the rate of prefill liquid flowing into the cavity, or by monitoring the weight of the prefill liquid reservoir 142 and the mold 110. If used, the prefill pump 146 is also stopped at this point.

[0113] In block 340, the bleed valve 162 is closed.

[0114] In some examples, the volume of pre-filled liquid in the cavity can be controlled to be greater than the volume of air in the conduit network 160 between the fiber suspension valve 138 and the inlet 116 of the cavity 112. This ensures that the pre-filled liquid remains in the cavity when the fiber suspension is introduced into the cavity 112.

[0115] In some examples, the volume of air in the conduit network 160 and / or cavity 112 is minimized before the pre-filled liquid is introduced. This can create a vacuum or partial vacuum in these spaces before the pre-filled liquid is introduced.

[0116] The first, second, third, and fourth periods mentioned in relation to Figure 6 correspond to these periods related to Figure 5, although their durations may be the same or different. Some features of method 300 in Figure 6 can be introduced into method 200 in Figure 5, and in some examples, the reverse is also true.

[0117] In some examples, the amount of prefilling liquid introduced into the cavity can be controlled to exceed the volume of the cavity. In some examples, the prefilling liquid may extend into the conduit network 160, 160A above the cavity 112. This allows for a beneficial reduction in the amount of air in this part of the molding system 100, 100A before introducing the fiber suspension. The prefilling liquid may extend to the fiber suspension valve 138. A delay may be introduced between closing the prefilling liquid valve 148 and closing the bleed valve 162 to allow time for any air bubbles introduced into the prefilling liquid to be removed from the molding system 100, 100A via the bleed valve 162. When using the molding system 100A of Figure 2A, the prefilling liquid fills the cavity from the base sections 117A, 117B upwards. Once the cavity is filled, the prefilling liquid may then move into the first conduit branch 160A.

[0118] In block 350, the fiber suspension valve 138 is opened. This may follow immediately after closing the prefill liquid valve 148 (and / or bleed valve 162). Alternatively, a delay may be introduced between closing the prefill liquid valve 148 and opening the fiber suspension valve 138, for example, to allow the prefill liquid in the cavity 112 to reach a proper sedimentation state. By opening the fiber suspension valve 138, the fiber suspension in the fiber suspension reservoir 132 can flow into the cavity 112 through the conduit network 160, 160A and the inlet 116.

[0119] Depending on the amount of prefill liquid held, the fiber suspension may move through the air into the cavity 112 before colliding with the prefill liquid, or the fiber suspension may encounter the prefill liquid in the conduit network 160, 160A before entering the cavity 112. In the latter case, the collision between the fiber suspension and the prefill liquid in the cavity 112 is less turbulent, which can improve the smoothness of the fiber molded product and / or reduce the amount of fiber adhering to the pores of the molds 110, 110A, 110B.

[0120] In block 360, a negative pressure source or vacuum pump 174 is started. If in use, the drain valve 172 is also opened. This places the outside of the mold under negative pressure, facilitating the removal of liquid from inside the cavity toward the drain conduit 170. The liquid removed through the drain conduit 170 may be removed from the molding system 100 or recycled by returning the discharged fluid to the prefill reservoir 142. Filtering may be used to remove fibers that have migrated through the pores of the mold 110. Such prefill liquid 144 may be referred to as white water.

[0121] In other examples, the use of negative and positive pressure may be modified. For example, the negative pressure source 174 may be applied earlier to encourage the prefilling liquid into the cavity, instead of using, or in addition to, the positive pressure from the prefilling liquid pump 146. In other examples, a positive pressure source may be provided above the cavity to place the mold under positive pressure and encourage the removal of liquid from inside the cavity toward the drain conduit 170.

[0122] In block 370, the fiber suspension valve 138 closes. This may be based on a second period after opening the fiber suspension valve 138 to provide an appropriate amount of fiber suspension into the cavity, enabling the molding of a hollow molded fiber product having desired properties such as preferred fiber thickness and distribution. Alternatively, or additionally, precise supply of fiber suspension into the cavity may be achieved by monitoring a flow meter 136 that monitors the flow rate of fiber suspension through the fiber suspension valve 138. The measured flow rate may be used to adjust the second period during which the fiber suspension valve 138 remains open to ensure precise supply. In a further alternative, the weight of the fiber suspension reservoir 132 and / or mold 110 may be monitored and used to control the closing of the fiber suspension valve 138.

[0123] In block 380, the negative pressure source or vacuum pump 174 is stopped and / or the drain valve 172 is closed. This process may be carried out over a predetermined period (e.g., the fourth period described above) after the fiber suspension valve 138 has been closed. This allows time for the liquid to be substantially removed from the cavity while the hollow molded fiber product is being formed, leaving fibers adhering to the inner wall of the cavity. In an alternative example, the flow rate of the removed liquid in the drain conduit 170 may be monitored, and when this flow rate falls below a threshold, the vacuum pump 174 is stopped and / or the drain valve 172 is closed.

[0124] In some examples, a third period may be used to control one or more components of the molding system 100, corresponding to the removal of liquid from the cavity. In some examples, the third period may correspond to the period from opening the pre-filling liquid valve in block 320 to closing the drain valve in block 380. In other examples, the third period may correspond to the period from opening the fiber suspension valve in block 350 to closing the drain valve in block 380.

[0125] By synchronizing the control of various system components above the cavity, such as bleed valves and slurry valves, with the control of system components below the cavity, such as drain valves, a smooth transition from the pre-filled liquid to the fiber suspension is facilitated. This further improves the smoothness of the resulting molded fiber product and reduces the amount of fiber adhering to the mold pores.

[0126] Although the cavity 112 is described as having an elongated shape with an inlet 116 at one of its longitudinal elongated ends, other cavity shapes may be used in other examples. Similarly, although the principal axis of the elongated shape is described as being oriented vertically, other orientations are also possible. In other examples, it will be understood that many other variations are possible, such as using only a positive pressure source for the delivery of the fiber suspension and prefilling liquid, or using only a negative pressure source for the delivery of both the fiber suspension and prefilling liquid.

[0127] It will be understood that the pre-filling liquid supply system 140 is provided with a control system 150 configured to at least partially fill the mold cavity with pre-filling liquid from the pre-filling liquid supply system, thereby forming a mass of pre-filling liquid within the cavity. Also provided is a fiber suspension supply system 130, configured to introduce a fiber suspension from the fiber suspension supply system into the mold cavity, which is at least partially filled with the mass of pre-filling liquid, so that a portion of the fiber suspension collides with the mass of pre-filling liquid.

[0128] Figure 7 shows a schematic diagram of an example of a non-temporary computer-readable medium 800. The non-temporary computer-readable storage medium 800 stores instructions 830 that cause the processing unit 820 of the control system 810 to execute the example method when executed by the processing unit 820. In some examples, the control system 810 is or includes the control system 150 described above. The instructions 830 include the following: In -831, the cavity of the mold is at least partially filled with a prefilling liquid to form a mass of prefilling liquid within the cavity. This can be done by controlling a prefilling liquid supply system, the cavity may be defined by one or more inner surfaces of the mold, and the mold has multiple passages that provide fluid communication between the cavity and the outside of the mold. In -832, the fiber suspension is then introduced into a cavity that is at least partially filled, so that at least a portion of the fiber suspension collides with the mass of pre-filled liquid. This can be done by controlling the fiber suspension supply system.

[0129] In other examples, instruction 830 includes instructions for performing any other exemplary methods described herein.

[0130] It will also be understood that a container manufacturing line (as shown in Figure 1) is provided, which includes a molding system for molding hollow molded textile products and an apparatus for performing at least one additional process on the hollow molded textile products to provide a container. Similarly, a method for manufacturing containers is also provided, which includes a method for molding hollow molded textile products and then performing at least one additional process on the hollow molded textile products to provide a container. An example of “at least one additional process” is described above with reference to Figure 1.

[0131] As a result of the content of this application, the use of a container obtained by any of the methods herein for containing contents is also provided. An example of such a container 900 is shown in Figure 8 in the form of a necked container containing contents 910, specifically in the form of a bottle. Its use may be, for example, by a person who puts contents into the container, a person who transports contents, or a person who wishes to dispose of contents (e.g., to a consumer or end user), a person who offers to dispose of contents (e.g., to a consumer or end user), a person who imports contents, or a person who wishes to store contents whether for disposal or not. The contents may be, for example, one or more of the exemplary contents described herein.

[0132] Methods for providing a container containing contents are also provided. An example of such a method 1000 is shown in Figure 9. Method 1000 includes providing a container in the form of a necked container, specifically a bottle 1010, and then providing contents into the container 1020. In this example, block 1020 follows block 1010, and as a result, block 1020 includes placing contents into the container provided in block 1010. However, in some other examples, blocks 1010 and 1020 are performed simultaneously, and as a result, providing the container 1010 includes providing the container along with contents already present in the container. The contents may be, for example, one or more of the exemplary contents described herein. Method 1000 also includes closing the opening of the container after block 1020 1030, and labeling or marking the container after block 1030 1040. In this example, block 1030 includes applying a heat seal to the opening and then screwing a cap or lid onto the container, and block 1040 includes attaching a label to the container.

[0133] In each of the other examples, the order of blocks 1030 and 1040 is reversed, blocks 1030 and 1040 are executed simultaneously, block 1030 is omitted, and block 1040 is omitted. In some examples, block 1040 occurs before block 1020, or block 1040 occurs during block 1020. For example, in some cases, a label or mark is attached to the container, then the contents are placed in the container, and then the container is closed.

[0134] Method 1000 can be performed by the same party manufacturing the container, and as a result, it will be understood that block 1010, for example, includes the method described above with reference to the manufacturing line shown in Figure 1. Alternatively, Method 1000 may be performed by a party different from the party manufacturing the container. In such an alternative, the different party performs block 1010 by obtaining the container from the party manufacturing the container (e.g., via the method described above with reference to Figure 1) or from an intermediary.

[0135] Exemplary embodiments of the present invention have been discussed with reference to the illustrated examples. However, it will be understood that modifications and alterations may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. A molding system for forming hollow molded fiber products from a fiber suspension, A mold comprising one or more inner surfaces defining a cavity in which the hollow molded fiber product is formed during use, and comprising a plurality of passages providing fluid communication between the cavity and the outside of the mold, Fiber suspension supply system, A pre-filled liquid supply system, A control system configured to control the pre-filled liquid supply system and the fiber suspension supply system, The cavity is at least partially filled with the pre-filled liquid from the pre-filled liquid supply system to form a mass of the pre-filled liquid within the cavity. Next, the control system introduces the fiber suspension from the fiber suspension supply system into the at least partially filled cavity so that at least a portion of the fiber suspension collides with the mass of pre-filled liquid, The molding system, including the molding system.

2. The control system, During the first period, the cavity is at least partially filled with the pre-filled liquid. During the second period, the fiber suspension is introduced into the at least partially filled cavity, The molding system according to claim 1, configured to remove the liquid from the cavity during a third period.

3. The molding system according to claim 2, wherein the second period and the third period overlap with each other, and the first period does not overlap with the third period.

4. The molding system according to any one of claims 1 to 3, wherein the mold includes one or more of the following: an inlet for receiving the prefilled liquid or the fiber suspension, the inlet located above the cavity; a first inlet for receiving the fiber suspension, the first inlet located above the cavity; and a second inlet for receiving the prefilled liquid, the second inlet located below the cavity.

5. The molding system according to claim 4, wherein the cavity has an elongated shape and comprises the injection port located at one of the longitudinal ends of the elongated shape.

6. The molding system according to claim 5, wherein the elongated main axis of the cavity is oriented vertically.

7. The molding system according to any one of claims 1 to 6, further comprising a negative pressure source, wherein when the fiber suspension supply system controls the introduction of the fiber suspension into the at least partially filled cavity, the control system is configured to control the negative pressure source to apply negative pressure to the outside of the mold.

8. The molding system according to any one of claims 1 to 7, wherein the control system is configured to control the amount of the fiber suspension introduced into the partially filled cavity using the flow rate of the fiber suspension introduced into the partially filled cavity.

9. A molding system according to any one of claims 1 to 8, comprising a conduit network between the fiber suspension supply system and the cavity, and between the prefill liquid supply system and the cavity, wherein a control system is configured to control the prefill liquid supply system and the fiber suspension supply system so that the volume of the prefill liquid in the cavity is greater than the volume of air in the conduit network between the cavity and the fiber suspension supply system.

10. The fiber suspension supply system includes a fiber suspension valve coupled to the conduit network, the prefill liquid supply system includes a prefill liquid valve coupled to the conduit network, the molding system includes a drain conduit system coupled to the outside of the mold and having a drain valve coupled between the outside of the mold and the drain outlet, and the control system is By opening the pre-filling liquid valve, the pre-filling liquid supply system allows the cavity to be at least partially filled with the pre-filling liquid. Close the pre-filled liquid valve, The molding system according to claim 9, configured to allow the drain valve to open and the fiber suspension valve to open so that the fiber suspension can be introduced into the cavity and the liquid can be removed from the cavity.

11. A method for providing a hollow molded fiber product from a fiber suspension, The process involves filling the cavity of a mold with a pre-filling liquid to form a mass of the pre-filling liquid within the cavity, wherein the cavity is defined by one or more inner surfaces of the mold, and the mold has a plurality of passages that provide fluid communication between the cavity and the outside of the mold. Next, the fiber suspension is introduced into the at least partially filled cavity, wherein at least a portion of the fiber suspension collides with the mass of the pre-filled liquid, Methods that include...

12. During the first period, the cavity is at least partially filled with the pre-filled liquid, During the second period, the fiber suspension is introduced into the at least partially filled cavity, During the third period, the liquid is removed from the cavity, The method according to claim 11, including the method described in claim 11.

13. The method according to claim 12, wherein the second period and the third period overlap with each other, and the first period does not overlap with the third period.

14. The method according to any one of claims 11 to 13, wherein each of the pre-filled liquid and the fiber suspension is received into the cavity through one of the following: an inlet located above the cavity, a first inlet located above the cavity for receiving the fiber suspension, and a second inlet located below the cavity for receiving the pre-filled liquid.

15. The method according to claim 14, wherein the cavity has an elongated shape and is provided with the inlet located at one of the longitudinal ends of the elongated shape.

16. The method according to claim 15, wherein the elongated principal axis of the cavity is oriented vertically.

17. The method according to any one of claims 11 to 16, configured to control the amount of the fiber suspension introduced into the partially filled cavity using the flow rate of the fiber suspension introduced into the partially filled cavity.

18. The method according to any one of claims 11 to 17, comprising controlling the volume of the pre-filled liquid in the cavity to be greater than the volume of air in the conduit network between the cavity and the fiber suspension supply system used to supply the fiber suspension for introduction into the cavity.

19. A control system configured to cause a molding system to perform the method described in any one of claims 11 to 18.

20. A non-temporary storage medium for storing machine-readable instructions that, when executed by a processing unit of a control system, causes the processing unit to control a molding system and perform the method according to any one of claims 11 to 18.

21. A container manufacturing line comprising a molding system according to any one of claims 1 to 10 for molding the hollow molded fiber product, and an apparatus for performing at least one additional process on the hollow molded fiber product to provide a container.

22. A method for manufacturing a container, comprising: performing the method according to any one of claims 11 to 18 to form the hollow molded fiber product; and then performing at least one additional process on the hollow molded fiber product to provide the container.

23. A method for providing a container containing contents, comprising: providing a container obtained by the method described in claim 22; and providing the container containing contents by providing the contents into the container.

24. Closing the opening of the container after providing the contents into the container, and / or The method according to claim 23, comprising applying a label or mark to the container.

25. Use of a container obtained by the method of claim 23 for containing contents.

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