Method and system for forming containers

Abstract

A method of forming a molded container is disclosed, the method comprising applying a fibrous suspension to a mold cavity wall of a container mold, the fibrous suspension at least partially coating the mold cavity wall. The method further includes supplying a fluid at a pressure between about 3.5 bar and about 10 bar in direct contact with the fiber suspension on the mold cavity wall for a period of less than about 60 seconds such that the fluid presses the fiber suspension against the mold cavity wall, liquid is thus removed from the fiber suspension and passed through holes formed in the mold cavity wall to form the molded container on the mold cavity wall.

Description

Technical Field

[0001] The present invention relates to a method and system for forming a molded container from a fiber suspension (eg, containing pulp). The container may form a consumer package, such as a bottle, for containing liquids, powders, other flowable materials or solid objects. Background Art

[0002] Bottles made from fiber suspensions are well known and can be used to replace plastic bottles. Thus, these slurry-molded bottles can reduce the amount of plastic used in disposable consumer products.

[0003] Published patent document WO2018 / 020219A1 describes forming a bottle from pulp in a mold. A fiber suspension is introduced into the mold and a layer is deposited inside the mold. From here, a "bladder" is placed into the mold and inflated. The expansion of the bladder presses the fiber suspension toward the mold to help squeeze water out of the fiber suspension, thus forming the bottle. This process of removing water is generally called "dewatering." A further drying process can then be carried out to make the bottle completely dry. Summary of the invention

[0004] As described above, the use of inflatable bladders to form slurry molded containers is known. However, when these bladders are first placed in the mold, they sometimes damage the fragile slurry layer inside the mold. In addition, these bladders have a limited service life and are prone to rupture after repeated expansion and contraction, requiring frequent replacement. In addition, due to manufacturing defects, the material from which the bladder is made may have uneven thickness and / or elasticity across the surface of the bladder, which may cause the molded bottle to be unevenly compressed. In addition, the shape of the bladder is limited by the limited size of the opening through which the bladder is inserted into the mold, and therefore, the shape of the container formed using the bladder is also limited.

[0005] To alleviate the problems caused by the use of such bladders, the inventors have discovered that the bladders can be replaced with high pressure fluids applied directly to the slurry. Such high pressure fluids can be air (e.g., compressed air), steam, or superheated steam. When the fluid is supplied to the mold, the force applied to the fiber suspension inside the coating mold is sufficient to form the container and remove liquid from the fiber suspension) without the need for a bladder.

[0006] Therefore, according to a first aspect of the present invention, there is provided a method of forming a moulded container, the method comprising: (i) applying a fibre suspension to a mould cavity wall of a container mould, the fibre suspension at least partially coating the mould cavity wall, and (ii) supplying a fluid at a pressure between about 3.5 bar and about 10 bar to directly contact the fibre suspension on the mould cavity wall for a period of less than about 60 seconds, so that liquid is removed from the fibre suspension through holes formed in the mould cavity wall to form a moulded container on the mould cavity wall.

[0007] The inventors have found that applying a pressure within this specific range for less than 60 seconds can achieve the desired level of dewatering of the fiber suspension during this initial manufacturing process. For example, it has been found that these pressures and times can remove more than 5% of the liquid, such as more than 8% or more than 10% of the liquid content. Reducing the moisture content by at least 5% can reduce the time and / or energy required for subsequent drying processes. In a specific example, the pressure is between about 3.5 bar and about 9 bar.

[0008] In some examples, the flow rate of the fluid is selected to achieve sufficient dehydration. In a specific example, supplying the fluid includes supplying the fluid at a flow rate greater than about 3 liters per minute (l / min). It has been found that when the fluid is air, a flow rate greater than 3 l / min can provide the desired amount of dehydration while avoiding damage to the container.

[0009] In some examples, the flow rate of the fluid can be controlled or regulated. In some examples, the flow rate is regulated when the fluid is supplied to the mold, but in other examples, the flow rate remains constant when the fluid is supplied (but it can be regulated before the fluid is supplied). For example, the fluid supply system that supplies the fluid to the mold can include a flow device that allows the fluid flow rate to be regulated. The flow device can include one or more holes through which the fluid flows, and in order to control the flow rate, a certain number of holes can be blocked or closed to stop the fluid from passing through these holes. Additionally or alternatively, the size of these holes can be adjusted / controlled by at least partially blocking one or more holes to regulate the flow rate. Therefore, in some examples, the method further includes regulating the flow rate of the fluid entering the container mold.

[0010] In certain examples, the method includes supplying the fluid at a temperature between about 10° C. and about 180° C. Temperatures within this particular range may help control how much liquid is removed from the fiber suspension.

[0011] In one example, supplying the fluid includes supplying the fluid at a pulsed / variable pressure over time. Thus, the pressure may periodically vary (or alternately vary) between a maximum pressure and a minimum pressure over time. The pressure curve that varies over time may take the form of a square wave, a sine wave, a half-wave rectified sine wave, a full-wave rectified sine wave, or a triangular wave. In other examples, the pressure may remain relatively constant over time and thus have a continuous curve over time. In either case, the pressure may also be gradually increased when first applied (as described below).

[0012] When at least partially coating the mold cavity wall, the fiber suspension may have a first liquid content percentage L1 by weight, and the molded container may have a second liquid content percentage L2 by weight (i.e., after applying the fluid). Preferably, the pressure and timing are selected so that the liquid content reduction percentage R is greater than about 5%, where R=(L1-L2) / L1. In a specific example, the first liquid content percentage L1 is between about 80% and about 90% by weight. In an example, the second liquid content percentage L2 is between about 60% and about 80% by weight. More specifically, the first liquid content percentage L1 is between about 80% and about 83%, such as about 82%. In an example, the second liquid content percentage L2 is between about 60% and about 70%, such as between about 71% and about 74%, such as about 72% or 73%. In an example, L1=82%, L2=73%, and R=11%.

[0013] In a particular configuration, the fluid may be air (eg, compressed air), and the pressure may be between about 5 bar and about 10 bar, such as between about 7 bar and about 9 bar. In a particular example, the pressure is about 8 bar.

[0014] In some examples, a receptacle may be referred to as a molded container, an article, a bottle, a container, a container for holding a fluid (e.g., a liquid) or a solid (e.g., a drug or other tablet / capsule), an article for holding a fluid, a bottle for holding a fluid, a container for holding a fluid, etc. The container may be molded from a fiber suspension, including ingredients such as pulp. The fiber suspension may contain cellulose fibers and a liquid (e.g., water), etc. Additives may be present in the fiber suspension.

[0015] The container may have a longitudinal axis along its length. The length / height of the container may be greater than the width and / or depth of the container. In some examples, because the container is generally cylindrical (at least along a portion of its length), the container may have a generally circular footprint. In some examples, the container may have a square or rectangular footprint.

[0016] The container mold (also referred to as the mold) defines a cavity therein (also referred to as the "mold cavity"), and a layer or coating of a fiber suspension may be applied to the inner wall of the mold ("mold cavity wall"). This initial layer / coating may have a first thickness, and after supplying the fluid, the container may have a second thickness that is less than the first thickness due to compaction of the fibers and removal of some of the liquid. Thus, applying the fiber suspension to the mold cavity wall includes introducing the fiber suspension into the cavity of the mold.

[0017] In some examples, the mold has an opening to the cavity through which the fiber suspension can be supplied. In some examples, the cavity has a body portion (also referred to as the first portion) and a neck portion (also referred to as the second portion). The two portions of the cavity together form the cavity. The neck can be used to form the neck of a container / bottle. For example, a cap can be added to one end of the container neck. In examples where the container is used to store / hold liquids, other fluids or powders, the body portion can hold most of the contents of the container when in use. In some examples, the cross-sectional width of the body portion is greater than the cross-sectional width of the neck (the cross section is taken on a plane parallel to the longitudinal axis of the container).

[0018] In some examples, the mold is part of a split mold that is made from two or more molds. For example, the mold may form half (or a third, a quarter, etc.) of a split mold and be put together with at least one other mold before receiving the fiber suspension therein. Thus, the cavity of the mold may form only a portion of the entire cavity of the split mold, and the mold cavity wall may therefore only serve to form a portion of the outer surface of the molded container. In some examples, the molds that form the split mold may be identical, but in other examples, they may be different.

[0019] As described above, the cavity has holes formed on / through the mold cavity wall. This allows liquid to flow from the inside of the cavity to the outside of the mold (and can be collected by a liquid measurement system, as described below). Therefore, the hole can extend from the cavity to the outer surface of the mold. In a specific example, the mold cavity wall of the container mold has a smooth surface, and the hole extends from the smooth surface. Therefore, applying the fiber suspension to the mold cavity wall includes applying the fiber suspension to form a coating on the surface. In some examples, the mold / mold cavity does not have a grid or net. This means that the molded container can be relatively easily detached from the mold, and the outer surface of the container molded in the mold can be smoother than when a grid or net is included in the mold.

[0020] In examples, the mold is formed by 3D printing or other additive manufacturing techniques.

[0021] As described above, in some examples, the fluid in direct contact with the fiber suspension distributed on the inner wall of the cavity is air. For example, using air instead of steam may be less dangerous and have lower energy requirements (because the air does not necessarily need to be heated to the same extent). In other examples, the fluid is steam or superheated steam. The use of steam can provide additional heating and drying effects, thereby reducing the overall time required to produce the container. For example, when steam is used, the container can be heated by warm air during one or more further drying processes, and the heating period is shorter than when the fluid is air.

[0022] In a particular example, the container has a width (e.g., diameter) between about 65 mm and 70 mm, a height between about 190 mm and about 200 mm, and a volume between about 500 ml and 600 ml. In a further example, the container has a diameter of about 68 mm, a height of about 196 mm, and a volume of about 550 ml.

[0023] In some examples, the period of time for applying pressure is less than about 35 seconds. In a specific configuration, the period of time for applying pressure is between about 25 seconds and about 35 seconds. The inventors have found that the pressure within the above-mentioned specific range applied during this period is sufficient to remove the required amount of liquid from the fiber suspension while achieving a good balance between energy costs and manufacturing efficiency. In some examples, the period is about 30 seconds. In some examples, the period depends on the pressure. In the example, the inventors found that when L1=82%, compressed air (applied at a pressure of about 4 bars) for about 30 seconds forms a molded container with L2=73%. In such examples, the container can have the width, height and volume dimensions mentioned above.

[0024] In some examples, the length of time that the fluid (e.g., air or steam) is applied depends on the amount of liquid / water removed from the mold / fiber suspension (i.e., via the holes in the cavity). For example, the weight or volume of liquid removed while the fluid is applied can be measured, and the supply of the fluid can be stopped when the desired amount is measured.

[0025] In other examples, other factors are used to control the supply of fluid. For example, the fluid can be stopped after a predetermined time period has passed. In another example, the volume / amount of the fluid supplied to the mold can be measured (for example, this can be inferred by measuring the volume remaining in the storage tank), and when the volume reaches a predetermined amount / volume, the fluid can be stopped. In another example, the temperature of the fluid can be measured, and when the measured fluid temperature has reached a predetermined temperature, the fluid supply can be stopped. The temperature can be, for example, the temperature of the fluid inside the mold, the temperature of the fluid inside the fluid storage tank, the temperature of the fluid between the storage tank and the mold, or the temperature of the fluid extracted from the mold via a hole or other opening. In a further example, the pressure of the fluid can be measured over time, and when the pressure has dropped / reduced by a predetermined amount, the fluid supply can be stopped. The pressure can be, for example, the pressure of the fluid inside the mold, the pressure of the fluid inside the fluid storage tank, the pressure of the fluid between the storage tank and the mold, or the pressure of the fluid extracted from the mold via a hole or other opening. Thus, in some examples, the method includes at least one of: (i) measuring the weight or volume of liquid removed from the fiber suspension, and stopping the supply of fluid when the weight or volume of the liquid has reached a predetermined amount; (ii) stopping the supply of fluid after a predetermined time period; (iii) measuring the volume of fluid supplied to the mold, and stopping the supply of fluid when the measured fluid volume has reached a predetermined amount; (iv) measuring the temperature of the fluid, and stopping the supply of fluid when the measured fluid temperature has reached a predetermined temperature; and (v) measuring the pressure drop of the fluid, and stopping the supply of fluid when the pressure drop has reached a predetermined amount.

[0026] In some examples, a vacuum may be applied to the mold while the fiber suspension is poured / sucked / inserted / introduced into the mold cavity. The vacuum may draw liquid through holes in the cavity wall and help coat the wall with the fiber suspension (forming a loose / wet container). In some examples, it may be useful to stop applying the vacuum when applying the fluid (air, steam), which can provide a smoother exterior finish to the molded container and improve energy efficiency (since applying a vacuum can consume a lot of energy). In some configurations, stopping the application of the vacuum can avoid fluid-vacuum interaction. Therefore, the method may also include at least one of the following: (i) applying a vacuum to the container mold while applying the fiber suspension to the mold cavity wall, and terminating the application of the vacuum before supplying the fluid, and (ii) terminating the application of the vacuum after a predetermined period of time.

[0027] As described above, it may be useful to measure the weight or volume of liquid removed from the mold / fiber suspension. This may also be done while applying a vacuum during application of the fiber suspension to the cavity. When the desired amount of liquid has been measured, the vacuum may be turned off and the fluid applied. By measuring the weight or volume of liquid removed from the mold, a consistent method is provided for determining when to proceed to the next stage of the molded container forming process. This may also improve consistency between different containers. Thus, the method may further include: (i) measuring the weight or volume of liquid extracted from the container mold while applying the vacuum, and (ii) terminating the application of the vacuum when the weight or volume of liquid extracted from the container mold has reached a predetermined amount.

[0028] However, in some cases it may still be useful to apply a vacuum while supplying fluid to form the container. Applying a vacuum during this process may help remove extra liquid from the molded container, thereby reducing production time. Thus, the method may include applying a vacuum to the container mold while applying the fiber suspension to the mold cavity wall and supplying fluid.

[0029] The inventors have found that as the fluid (air / steam) escapes from the mold, the amount of liquid removed from the fiber suspension / container reaches a steady state as the pressure increases. Therefore, excessive pressure may be unnecessary. In order to determine the optimal pressure, it may be useful to perform a pressure determination process, during which fluids of different pressures are applied to the mold and the pressure within the container / cavity is measured to determine the maximum pressure maintained within the container. For example, despite a fluid delivery pressure of 8 bar, a pressure of 4 bar may still be maintained inside the container. Therefore, in the subsequent formation of the container, it may be desirable to use a pressure of about 4 bar (or slightly above 4 bar, such as 5 bar) to improve efficiency and reduce production costs. Therefore, in the above method, the pressure can be about 1 bar or less higher than the maximum pressure determined to be maintained in the previously molded container when the fluid is supplied to the container mold to press the fiber suspension against the mold cavity wall during the previous execution of the method. In some examples, the method may include determining a maximum pressure maintained within a previously molded container when supplying fluid into the container mold to press the fiber suspension fluid against the mold cavity wall, and wherein the pressure is less than about 1 bar above the maximum pressure. This process ensures that the pressure used is high enough to remove the desired amount of liquid, but not too high.

[0030] As described above, after the container is formed in the mold, one or more additional drying / heating processes may be performed. In one example, the container is moved to a second heated mold, which helps to further evaporate the liquid from the container. In another example, the container is removed from the mold and placed in warm air. Therefore, the method can further include applying heat to the molded container to remove liquid from the molded container.

[0031] In some embodiments, fluid pressure is gradually increased to required pressure. For example, initially apply low pressure fluid, and gradually increase pressure within a certain period of time (for example, about 5 seconds). This avoids or reduces the rupture / damage of the fiber suspension layer in the cavity caused by suddenly supplying relatively high pressure fluid to the fiber suspension. Therefore, pressure can be final pressure, and the supply fluid can include: (i) supplying fluid under initial pressure, and (ii) increasing pressure from initial pressure to final pressure within a specific time period. The time period can be, for example, about 0.5 seconds, 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, etc. In a specific example, the time period is between about 0.5 seconds and about 5 seconds.

[0032] In some examples, the pressure at which the fluid is applied is selected based on one or more factors (e.g., the size / volume of the container). A lookup table or other database may store different pressures associated with different container types or other standards, and when the manufacturing process is started, the correct pressure is selected based on the type of container being molded. The container type may be defined based on one or more parameters, such as the size and / or volume of the container, and / or the composition of the fiber suspension, etc. Therefore, in some examples, the pressure is a specific pressure, and the method includes determining the specific pressure based on the type of container being molded and / or one or more other standards, and supplying the fluid includes supplying the fluid at a specific pressure. In some examples, the specific pressure is determined before the fluid is supplied.

[0033] According to a second aspect of the present invention, there is provided a moulded container produced by a method according to any one of the methods described in the first aspect.

[0034] According to a third aspect of the present invention, a system for forming a molded container is provided, the system comprising: (i) a container mold having a mold cavity wall, the mold cavity wall being configured to receive a fiber suspension coating thereon and to form holes therein, (ii) a fiber suspension application system, which is configured to apply a fiber suspension to the mold cavity wall to at least partially coat the mold cavity wall, and (iii) a fluid supply system, which is configured to supply fluid at a pressure between about 3.5 bar and about 10 bar to directly contact the fiber suspension on the mold cavity wall for a period of less than about 60 seconds, so that liquid is removed from the fiber suspension through the holes to form a molded container on the mold cavity wall.

[0035] In some examples, the fluid supply system is configured to supply fluid at a pulsed pressure over time.

[0036] In certain examples, the fluid supply system is configured to supply the fluid at a flow rate greater than about 3 liters / minute. In some examples, the fluid supply system is configured to control the flow rate of the fluid into the container mold.

[0037] In some examples, the system further includes at least one of the following: (i) a liquid measuring system configured to measure the weight or volume of liquid removed from the fiber suspension, wherein the fluid supply system is configured to stop the supply of fluid when the liquid measuring system determines that the weight or volume of the liquid has reached a predetermined amount, (ii) a timing system configured to measure the time that the fluid supply system supplies the fluid, wherein the fluid supply system is configured to stop the supply of fluid when the timing system determines that the time has reached a predetermined period of time, (iii) a fluid measuring system configured to measure the volume of fluid supplied by the fluid supply system, wherein the fluid supply system is configured to stop the supply of fluid when the fluid measuring system determines that the volume of the fluid has reached a predetermined amount, (iv) a temperature measuring system configured to measure the temperature of the fluid, wherein the fluid supply system is configured to stop the supply of the fluid when the temperature measuring system determines that the temperature of the fluid has reached a predetermined temperature, and (v) a pressure measuring system configured to measure a pressure drop of the fluid, wherein the fluid supply system is configured to stop the supply of the fluid when the pressure measuring system determines that the pressure drop of the fluid has reached a predetermined amount.

[0038] In some examples, the system further includes: a vacuum application system configured to: (i) apply vacuum to the container mold while the fiber suspension application system applies the fiber suspension to the mold cavity wall, and (ii) stop applying vacuum before the fluid supply system supplies the fluid.

[0039] In some examples, the system further includes at least one of: (i) a liquid measuring system configured to measure the weight or volume of liquid removed from the container mold while the vacuum is being applied, and wherein the vacuum application system is configured to stop applying the vacuum when the liquid measuring system determines that the weight or volume of the liquid has reached a predetermined amount; and (ii) a timing system configured to measure the time that the vacuum application system applies the vacuum, wherein the vacuum application system is configured to stop applying the vacuum when the timing system determines that the time has reached a predetermined period of time.

[0040] In some examples, the system further includes a vacuum application system configured to apply vacuum to the container mold while the fiber suspension application system applies the fiber suspension to the mold cavity wall and the fluid supply system supplies the fluid.

[0041] In some examples, the fluid supply system is configured to supply fluid at a pressure that is less than about 1 bar higher than a maximum pressure determined to be maintained within a previously molded container when the fluid supply system supplied fluid into the container mold to press the fiber suspension fluid against the mold cavity wall during molding of the previously molded container. Therefore, in some examples, the system further includes a pressure measurement device configured to determine a maximum pressure maintained within the previously molded container when the fluid supply system supplies fluid into the previously molded container at a range of different pressures.

[0042] In some examples, the pressure is a final pressure, and the fluid supply system is configured to: (i) supply the fluid at an initial pressure, and (ii) increase the pressure from the initial pressure to the final pressure within a specific period of time.

[0043] In some examples, the fluid supply system is configured to: (i) determine a specific pressure based on the type of container being molded and / or one or more other criteria; and (ii) supply fluid at the specific pressure.

[0044] In some arrangements, venting the mold cavity from high pressure to atmospheric pressure can help to quickly reduce the internal pressure and speed up the process. Thus, in some examples, the container mold includes a cavity (or "mold cavity") and an opening through which the fluid can escape from the cavity while the fluid supply system supplies the fluid. Thus, the mold cavity wall is the wall of the mold cavity.

[0045] According to a fourth aspect of the invention, there is provided a method of forming a molded container, the method comprising: applying a fiber suspension to a mold cavity wall of a container mold, the fiber suspension at least partially coating the mold cavity wall; and supplying a fluid at a specific pressure to directly contact the fiber suspension on the mold cavity wall so that the fluid presses the fiber suspension against the mold cavity wall to help remove liquid from the fiber suspension by forcing the liquid through holes formed in the mold cavity wall, thereby forming a molded container on the mold cavity wall. The pressure may be less than about 1 bar higher than the maximum pressure determined to be maintained in a previously molded container when the fluid was supplied to the container mold to press the fiber suspension against the mold cavity wall during a previous execution of the method. The fourth aspect may additionally include any of the methods or features described above in relation to the first aspect.

[0046] According to a fifth aspect of the present invention, there is provided a system for forming a molded container, the system comprising: a container mold having a mold cavity wall, the mold cavity wall being configured to receive a fiber suspension coating thereon and forming holes therein; a fiber suspension application system, which is configured to apply a fiber suspension to the mold cavity wall to at least partially coat the mold cavity wall; and a fluid supply system, which is configured to supply a fluid at a specific pressure to directly contact the fiber suspension on the mold cavity wall, so that the fluid presses the fiber suspension against the mold cavity wall to help remove liquid from the fiber suspension and cause it to pass through the holes formed in the mold cavity wall to form a molded container on the mold cavity wall. The fluid supply system may be configured to supply the fluid at a pressure that is about 1 bar or less higher than the maximum pressure determined to be maintained in the previously molded container when the fluid supply system supplies the fluid into the container mold to press the fiber suspension against the mold cavity wall during the molding of the previously molded container. The fifth aspect may additionally include any of the features described above with respect to the third aspect.

[0047] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

[0049] Figure 1 An example of a process for producing a container at least partially molded from a fiber suspension is shown;

[0050] Figure 2 An example container mold is shown;

[0051] Figure 3 Shown in Figure 2 An example container molded in a container mold;

[0052] Figure 4A shows a cross section of an example mold prior to introduction of a fiber suspension into the mold cavity;

[0053] Figure 4B shows a cross section of an example mold after applying a fiber suspension to the inner wall of the cavity;

[0054] Figure 4C shows a cross section of an example die after a fiber suspension is pushed toward the inner wall of the cavity by a pressurized fluid;

[0055] Figure 5A and 5B An example system for forming a molded container is shown;

[0056] Fig. 6Aa graph showing variable fluid pressure according to a first example;

[0057] Figure 6B a graph showing variable fluid pressure according to a second example; and

[0058] Figure 7 An example flow chart illustrating a method of forming a molded container. DETAILED DESCRIPTION

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

[0060] Figure 1 A process for making a bottle from pulp (i.e., pulp that may form the basis of an example fiber suspension) is shown. The process is exemplary only and is provided to give context to examples of the invention. Broadly speaking, the exemplary process includes providing a fiber suspension, introducing the fiber suspension into a porous first mold, and draining a liquid (e.g., water) from the fiber suspension using the porous first mold to produce a wet precursor (which may be considered a molded container), further molding the wet precursor in the mold to produce a further molded container / article, coating the interior and exterior surfaces of the further molded container to produce a coated molded container, drying the coated molded container to produce a dry container / article, and applying a closure to the dry container. As will be apparent from the following description, the exemplary process may be modified to provide variations thereof in which other examples of the invention may be embodied.

[0061] In this example, providing a fiber suspension includes preparing a fiber suspension according to its composition. More specifically, the preparation includes providing pulp fibers, such as pulp fibers, and mixing the pulp fibers with a liquid to provide hydrated pulp fibers. In this example, the pulp fibers are provided by a supplier in sheet form, and the liquid includes water and one or more additives. The hydrated pulp fibers are passed between the plates of a valley beater 11 or a refiner that move relative to each other. This causes part or all of the fibers to fibrillate, meaning that the cell walls of these fibers are partially layered, so that the wetted surfaces of these fibers include protruding hairs or fibrils. These fibrils will help increase the bonding strength between the fibers in the dry final product. In other examples, the valley beater or refiner can be omitted. The obtained treated pulp is stored in a barrel 12 in a relatively concentrated form to reduce the required storage space. At an appropriate time, the treated pulp is conveyed to a mixing station 13, where the treated pulp is further diluted with water to provide a fiber suspension that can be molded. In this example, the solid fibers account for 0.7%wt of the resulting fiber suspension, but in other examples, the proportion of solid fibers in the fiber suspension may be different, for example other values ​​in the range of 0.5%wt to 5%wt of the fiber suspension. Mixing the fiber suspension at the mixing station 13 helps to homogenize the fiber suspension. In other examples, the processed pulp or fiber suspension may be provided in other ways, for example in a ready-to-use form.

[0062] The porous first mold 15 includes two mold halves that can be moved toward and away from each other using hydraulic cylinders. In this example, each of the mold halves is an integral or single 3D printed tool that defines a mold curve, and when the mold halves contact each other, their respective mold curves cooperate to define a mold cavity. Each mold half can define a smaller cavity by itself, and can provide a larger molding cavity when mated with a second mold half. The two mold halves themselves can be considered "molds", and the integral porous first mold 15 can be considered a "split mold" or again considered a "mold".

[0063] exist Figure 1 In the process, a fiber suspension (also called slurry) is filled into the porous mold 15 from the top, unlike the molding process where the mold is immersed in the slurry. The fiber suspension is then sucked through the porous mold 15 through the pipeline 16 under vacuum, similar to an injection molding machine. The injection mass can be controlled by measuring (e.g. weighing) the mass / volume of water in the suction tank 17. Once the desired mass is reached, the porous mold 15 is opened to the ambient air. In Figure 1 The weighing platform supporting the tank 17 can be seen in FIG.

[0064] The suspension liquid drawn off in line 16 together with the fiber suspension is water, or mainly water (since additives may also be present). The liquid sucked under vacuum through line 18 and into tank 17 is substantially free of fibers, since these fibers remain on the walls of the porous die 15. By way of example, the suspension liquid 18 is continuously drawn through the porous die 15 until a predetermined volume of water (e.g. 10 liters) is collected in tank 17.

[0065] At this stage, the "container" within the porous mould 15 takes on a wet form or shape that fits snugly against the inner walls of the mould.

[0066] In the prior art process, to further remove the suspending liquid (water) and form / consolidate the 3D container shape, a water-impermeable inflatable element (e.g., a collapsible bladder 19) is inserted into the porous mold 15 to act as the internal high-pressure core structure of the mold. As described above, this process consolidates the wet 'embryo' bottle so that it can be handled (or transported by mechanized means) before drying, and displaces moisture between the fibers, thereby improving the efficiency of the drying process. The bladder 19 is actuated / regulated using a hydraulic pump 20 with a cylinder, which discharges fluid in a pipeline 21 into the bladder 19 so that the bladder 19 expands radially and fits the mold cavity. The fluid in the pipeline 21 is preferably incompressible, such as water. Water also has the advantage over other incompressible liquids that any leakage or rupture of the bladder 19 will not introduce new substances into the system (because the suspending liquid is already water or mainly water).

[0067] Figure 2 and 3 The appearance of a two-part block 14 housing a porous mold 15 is shown diagrammatically (the non-porous mold 25 described below has a similar appearance). A passage through the block 14 communicates with the porous mold 15, thereby providing a path for the suspension liquid to be drawn through the porous mold 15 and providing reverse flow during mold cleaning (described below).

[0068] Demolding occurs when the porous die 15 is opened to remove the self-supporting (hence "formed") container 22. It is preferably followed by die cleaning 23 to remove small fibers and maintain the porosity of the porous die 15. In the form shown, a radially ejecting high pressure jet is inserted into the die cavity when the die is opened. This causes the fibers to fall off the cavity walls. Alternatively or additionally, water from a tank 17 is pressurized through the back of the porous die 15 to break off trapped fibers. The water is drained and circulated back to the upstream part of the system. It is worth noting that cleaning is very important to condition the tool for reuse. After removing the container, the tool may appear clean, but if it is not cleaned, its performance may be affected.

[0069] according to Figure 1The formed but unfinished container 22 is then transported to a second or additional molding station where pressure and / or heat are applied in, for example, an aluminum tool / mold 25 to thermoform the desired neck and surface finish. After the two halves of the mold 25 (optionally including negative surface features for debossing / embossing, etc.) are closed around the container 22, a pressurizer is engaged. For example, a bladder 26 (e.g., a thermoformed bladder 26) is inserted into the container 22. A pump 28 with a heater inflates the bladder 26 through a line 27 to supply a pressurized fluid, such as air, water, or oil. The outer mold block 24 of the mold 25 and / or the mold 25 itself may also or alternatively be heated.

[0070] The state of the molded container 22 after thermoforming is more rigid and the sidewalls are more compressed than when it was released from the porous mold 15 .

[0071] As shown, a drying stage 29 (microwave or other means) may be applied downstream of thermoforming. However, some moisture content is required when molding in the mold 25 to aid bonding during compression. In some forms, microwave or other drying options may be applied at multiple stages of the process. In one example, the drying stage 29 is performed prior to thermoforming.

[0072] Figure 1 A further drying stage 30 is shown, which may be performed prior to a coating stage using hot air circulated over the bottle, for example in a "hot box", in which a surface coating is applied to the inner wall of the bottle 22, for example by a spray gun 31 inserted into the bottle 22. In another example, the container 22 may be filled with a liquid that coats the inner surface of the container 22. In practice, the coating provides a protective layer to prevent the liquid contents from entering the bottle wall, which may penetrate and / or weaken the bottle wall. The choice of coating depends on the intended contents of the bottle 22, such as beverages, detergents, medicines, etc. In some examples, a further drying stage 30 is performed after the coating stage (or before and after the coating stage).

[0073] The subsequent curing process 34 may be optimized depending on the coating, for example drying under ambient conditions for twenty-four hours or by flash drying. In examples where a further drying phase occurs after the coating phase, the curing process 34 may be omitted.

[0074] At an appropriate stage of production (eg, during thermoforming, before or after coating), the container may be subjected to a closure or finish forming process. The container 22 may thus be fully formed and ready to receive contents therein.

[0075] In some examples, an outer coating is applied to the container, as shown in further coating stage 32. In one example, Figure 1As shown, the container 22 is immersed in the liquid on the outer surface of the container in the figure. Then one or more further drying or curing processes can be performed. For example, the container can be dried in warm air.

[0076] Figures 4A-4C Schematic examples of a porous mould 15 are shown at different times during the moulding process. Figure 4A depicts the mold 15 before the fiber suspension is introduced into the mold 15, Figure 4B depicts the mold 15 after the fiber suspension has been introduced into the mold 15, and Figure 4C The die 15 is depicted after high pressure fluid is supplied into the die 15 to directly contact the fiber suspension to press the fiber suspension against the cavity walls of the die 15 .

[0077] In more detail, Figure 4A A mold 15 is depicted that is formed from two separate mold halves. In some examples, each mold half can itself be referred to as a mold, and each mold half can define a cavity having mold cavity walls to which the fiber suspension is applied. When the two mold halves are brought together, the two cavities form a larger cavity 36 in the mold 15. In other examples, the mold 15 can be made from a single piece.

[0078] Figure 4A Depicted are holes 38 in / through the mold cavity wall 40. As previously described, these holes 38 allow liquid to pass through. Figure 4A In the embodiment shown in FIG. 1 , the cavity 36 is “empty” because the fiber suspension has not yet been supplied to the mold 15 . The mold 15 is shaped so that an opening 42 leading to the cavity 36 is present.

[0079] like Figure 4A As shown, mold cavity wall 40 (ie, the inner wall of cavity 36) has a surface, and holes 38 extend from the surface through mold 15 to the outer surface of the mold. In some examples, the cavity has no mesh or grid, and thus has a generally smooth surface from which holes 38 extend.

[0080] exist Figure 4A In the example of FIG. 1 , cavity 36 (and each cavity of the mold half) has a body portion 36a (also referred to as a first portion) and a neck portion 36b (also referred to as a second portion). Neck portion 36b can be used to form the neck of a container / bottle.

[0081] Figure 4BDepicts the mold 15 at a later time. Here, the fiber suspension has been poured / sucked into the cavity 36 through the cavity opening 42 (in some cases under vacuum), and the fiber suspension coats the mold cavity wall 40 to form a loose container shape. The liquid can be drawn out or drained through the hole 38. At this point, the fiber suspension coating / layer 44 has an initial thickness on the cavity wall 40, and the fiber suspension layer 44 has a liquid content percentage L1 by weight, which can be between about 80% and about 90%.

[0082] Regarding the above Figure 1 In contrast to the example process described above using the bladder 19, the following example dispenses with the bladder 19 and instead uses a high pressure fluid to assist in dewatering the container 22 within the mold 15. Thus, after the fiber suspension is applied to the mold cavity wall 40, the fluid supply system (e.g. Figure 5A and 5B The mold cavity wall 40 is provided with a mold (as shown) to supply a fluid (e.g., compressed air, steam, or superheated steam) at a specific pressure and for a specific period of time to directly contact the fiber suspension layer 44 on the mold cavity wall 40. This high pressure fluid squeezes / compacts the fiber suspension layer 44 and helps to drain the liquid. This liquid can then pass through the holes 38, in some cases under vacuum.

[0083] Figure 4C The container 22 formed inside the cavity 36 of the mold 15 after the high pressure fluid is supplied is shown. The high pressure fluid compacts and dehydrates the fiber suspension layer 44, so that the layer 44 is thicker than Figure 4B At this point, the fiber suspension has a liquid content percentage L2 by weight, which may be between about 60% and about 80%, depending on the fluid pressure and the length of time the fluid is supplied.

[0084] Figure 5A An example system 100 is depicted for forming a molded container 22. The system 100 includes a container mold 15 for receiving a fiber suspension and a fiber suspension application system 50 for introducing / supplying a fiber suspension 52 into the cavity 36 and onto the mold cavity wall 40.

[0085] In this example, the fiber suspension application system 50 includes a tank 56 that temporarily holds the fiber suspension 52 before it is introduced into the mold 15. The fiber suspension application system 50 may be used with Figure 1 The fiber suspension application system 50 can be used together with the mixing station 13 of the mixing station 13, or the fiber suspension application system 50 itself can perform the mixing function of the mixing station 13. The fiber suspension application system 50 of this example also includes a pipeline 54 along which the fiber suspension 52 can flow from the tank 56 into the mold 15. In some examples, the pipeline 54 can be flexible.

[0086] The fiber suspension application system 50 of this particular example also includes an arm 58 and a connecting portion 60. The line 54 extends through the arm 58 and into the connecting portion 60. The fiber suspension 52 exits the fiber suspension application system 50 and enters the mold 15 through the connecting portion 60 and the opening 42. In some examples, the connecting portion 60 is shaped to fit the top of the mold 15 and / or the block 14 containing the mold. In a particular example, the arm 58 is static and the mold 15 is moved to the appropriate position below the connecting portion 60. In another example, the arm 58 can be moved (by an operator or another machine) so that the connecting portion 60 can be connected to the mold 15. In another example, the arm 58 is mechanical (that is, it can move to the desired position by itself).

[0087] The system 100 also includes a fluid supply system 62 for supplying a fluid 64 (e.g., compressed air or steam) to directly contact the fiber suspension (i.e., the fiber suspension layer 44) that at least partially coats the mold cavity wall 40. The pressure at which the fluid 64 can be applied can be controlled by a control system (not shown). In an example, the pressure is between about 3.5 bar and about 10 bar. Similarly, the time at which the fluid 64 can be applied can be controlled by a control system. In an example, the period of time for which the fluid is supplied is less than about 60 seconds, such as about 30 seconds. The fluid enters the cavity 36 and presses the fiber suspension 44 against the mold cavity wall 40, thereby facilitating the removal of liquid from the fiber suspension and urging the liquid to pass through the holes 38 formed in the mold cavity wall 40. After this process, a molded container 22 is formed on the mold cavity wall 40.

[0088] The fluid supply system 62 of this example also includes a line 66 along which the fluid 64 can flow from the tank 68 into the mold 15. In some examples, the line 66 can be flexible. In this example, the fluid supply system 62 also includes an arm 70 and a connecting portion 72. The line 66 extends through the arm 70 and enters the connecting portion 72. The fluid 64 leaves the fluid supply system 62 and enters the mold 15 through the connecting portion 72 and the opening 42. In some examples, the shape of the connecting portion 72 is designed to cooperate with the top of the mold 15 and / or the block 14 containing the mold. In a specific example, the arm 70 is static, and the mold 15 moves to the appropriate position below the connecting portion 72. In another example, the arm 70 can be moved (by an operator or another machine) so that the connecting portion 72 can be connected to the mold 15. In another example, the arm 70 is mechanical (that is, it can move to the desired position by itself).

[0089] exist Figure 5BIn some examples shown, both lines 54 and 66 extend to a single connection 80, so that two separate connection parts 60, 72 are not required. A single connection 80 for supplying fluid 64 and fiber suspension 52 to the mold 15 may be preferred because the mold 15 and / or arms 58, 70 may not need to move. In addition to the single connection 80, Figure 5B The system is based on Figure 5A The system operates in the same manner.

[0090] As described above, the fluid supply system 62 supplies the fluid 64 to the mold 15 at high pressure to assist in squeezing the liquid in the fiber suspension 44, thereby dehydrating the container 22. In some examples, the fluid supply system 62 supplies the fluid 64 at a variable pressure during the molding process. For example, the pressure can be gradually increased from an initial lower pressure to a final higher pressure. The control system can control the pressure ramp and the time for applying each pressure within this pressure ramp.

[0091] In some examples, the fluid pressure additionally or alternatively pulses over time (ie, the pressure varies periodically). Fig. 6A An example of a fluid pressure pulsating according to a square wave curve is shown. Similarly, Figure 6B The fluid pressure is shown to pulsate according to a half-wave rectified sinusoidal curve. In some examples ( Fig. 6A Each time the fluid pressure increases to a maximum pressure, the pressure gradually increases over a specific period of time, as described above. Fig. 6A and 6B The fluid pressure is shown to pulsate at a constant frequency, but in other examples, the frequency is not constant over time. In another example (not shown), the pressure can vary over time, rather than having periods of time where the pressure remains constant for a particular period of time (e.g., Fig. 6A and 6B For example, the pressure can pulsate according to a sine wave.

[0092] In some examples, the pressure (or pressures) of the supplied fluid 64 depends on the type of container being molded (or other criteria). For example, a container with thicker walls may require a higher pressure fluid to fully compact the pulp fibers. Therefore, the control system can also supply fluid 64 based on the type of container currently being molded. For example, a human operator can provide a user input indicating the type of container to the control system. Based on this input, the control system can select an appropriate pressure. In some examples, the control system can automatically detect the type of container, for example based on data measured by one or more sensors. Alternatively, a human operator can directly select a specific pressure. Once the specific pressure is determined, the fluid supply system 62 supplies the fluid 64 at the determined pressure.

[0093] In some examples, it may be useful to allow some of the pressurized fluid to escape from the mold 15 when the fluid supply system 62 supplies the pressurized fluid 64. Venting the cavity 36 may help to quickly reduce the internal pressure of the mold cavity 36 and reduce the time required to form the container 22. To achieve this, the cavity 36 can be open to the atmosphere through a channel or opening through which some of the pressurized fluid can escape. For example, when the fluid supply system 62 supplies the fluid 64, the opening 42 to the cavity can be at least partially maintained open. In one example, the connecting portions 72, 80 have holes formed therethrough so that the fluid 64 can escape from the cavity 36 through the opening 42.

[0094] In some arrangements, the system 100 may further include a liquid measurement system 74 configured to measure the weight or volume of liquid removed from the fiber suspension / mold 15. In one example, the liquid measurement system 74 may include Figure 1 In another example, the liquid measuring system 74 is connected to the weighing table and tank 17 as depicted in FIG. Figure 1 is different from that depicted in the figure and can be used instead of the weighing table and tank 17.

[0095] The liquid measuring system 74 can weigh or measure the volume of liquid extracted from the mold 15. For example, the liquid measuring system 74 can weigh or measure the volume of liquid 76 extracted from the mold 15 during the process of supplying the fiber suspension 52 into the mold 15 and / or during the process of applying a vacuum (described below) and / or during the process of supplying the fluid 64 into the mold 15. The liquid measuring system 74 can be communicatively coupled to the control system and / or other components of the system 100 so that an action can be stopped or performed or changed when the measured weight / volume reaches a certain threshold amount (or one or more different threshold amounts).

[0096] For example, when the liquid measuring system 74 determines that the weight or volume of the liquid 76 has reached a predetermined amount, the fluid supply system 62 may be controlled to terminate / stop the supply of the fluid 64. The predetermined amount may be the amount removed from the mold 15 during the supply of the fluid, or may be the amount removed from the mold 15 during the entire molding process up to that point in time (and thus may include liquid removed during the process of supplying the fiber suspension into the mold and / or applying a vacuum to the mold).

[0097] In some examples, the system 100 further includes a vacuum application system 78 configured to apply a vacuum to the container mold 15 (and / or the block 14). In one particular example, the vacuum is applied when the fiber suspension application system 50 supplies the fiber suspension 52 into the mold 15 (and possibly after the fiber suspension has been supplied), but is no longer applied when the fluid supply system 62 supplies the fluid 64. In one example, the vacuum may be removed when the desired weight or volume of the liquid 76 is extracted from the mold 15. In this case, the liquid measurement system 74 may determine that the weight or volume of the liquid has reached a predetermined amount, and the vacuum application system 78 terminates the application of the vacuum when the weight or volume of the liquid has reached a predetermined amount (wherein the predetermined amount may be different from the amount used to control the application of the fluid 64). Data or instructions indicating the volume or weight of the liquid and / or indicating when the volume or weight reaches the predetermined amount may be sent from the liquid measurement system 74 to the vacuum application system 78. The vacuum application system 78 may then operate according to the data / instructions. Similarly, the fiber suspension application system 50 may also be controlled when the liquid measurement system 74 determines that the weight or volume of the liquid 76 has reached a predetermined amount.

[0098] In another example, vacuum is applied while the fiber suspension application system 50 supplies the fiber suspension 52 into the mold 15 and while the fluid supply system 62 supplies the fluid 64 .

[0099] In some examples, the system 100 further includes a timing system (not shown) configured to measure the time that the fluid supply system 62 supplies the fluid 64. In some examples, the timing system can be part of the fluid supply system. The fluid supply system 62 can be configured to stop the supply of the fluid 64 when the timing system determines that the time has reached a predetermined time period. For example, the timing system can control the fluid supply system 62 to stop the supply of the fluid when the time reaches 30 seconds.

[0100] In some examples, the system 100 further includes a fluid measurement system (not shown) configured to measure the volume of the fluid 64 supplied by the fluid supply system 62. In some examples, the fluid measurement system can be part of the fluid supply system 62. The fluid supply system 62 can be configured to stop the supply of the fluid 64 when the fluid measurement system determines that the volume of the fluid has reached a predetermined amount. For example, the volume of the fluid 64 can be determined / inferred based on the volume of the fluid contained in the tank 68.

[0101] In some examples, the system 100 further includes a temperature measurement system (not shown) configured to measure the temperature of the fluid 64. The temperature may be the temperature of the fluid in the tank 68, the temperature at a point between the tank 68 and the connection portions 72, 80, the temperature within the mold 15, or the temperature at the outlet of the mold (e.g., near the hole 38). The fluid supply system 62 may be configured to stop the supply of the fluid 64 when the temperature measurement system determines that the temperature of the fluid has reached a predetermined temperature. For example, as the fluid is supplied to the mold 15, the temperature of the fluid in the tank 68 may decrease, and when the temperature or temperature change reaches a predetermined temperature or temperature change, the fluid supply may be stopped.

[0102] In another example, the system 100 further includes a pressure measurement system (not shown) configured to measure a pressure drop of the fluid 64. The pressure drop may be a pressure drop of the fluid in the tank 68, a pressure drop at a point between the tank 68 and the connection portions 72, 80, a pressure drop within the mold 15, or a pressure drop at an outlet of the mold (e.g., near the hole 38). The fluid supply system 62 may be configured to stop the supply of the fluid 64 when the pressure measurement system determines that the pressure drop of the fluid has reached a predetermined amount. For example, when the fluid is supplied to the mold 15, the pressure of the fluid in the tank 68 may decrease, and when the pressure change / decrease reaches a predetermined amount, the fluid supply may be stopped.

[0103] In a particular example, the fluid supply system 62 is configured to supply fluid at a specific flow rate. Therefore, the fluid supply system 62 can include a flow device that can adjust or control the flow rate based on specific requirements. The flow device can be located at the connection portion 72, 80 or other locations within the fluid supply system 62. The flow device may include a hole (or multiple holes) through which the fluid flows, and the size of the hole can be adjusted to adjust the flow rate (e.g., using a valve). In an example where multiple holes are present, one or more holes can be blocked or closed to adjust the flow rate.

[0104] As previously mentioned, in some examples, the fluid supply system 62 can be configured to supply fluid at a certain pressure, which is about 1 bar or less higher than the maximum pressure maintained in the previously molded container when the fluid supply system 62 supplies the fluid to the container mold. Therefore, in some examples, there is a pressure measuring device (not shown) that measures the fluid pressure inside the previously molded container during molding. During this pressure determination process, the fluid supply system 62 can apply fluid at different pressures (e.g., 4 bar, 5 bar, 6 bar, 7 bar, 8 bar, 9 bar, 10 bar, etc.), and the pressure in the container can be determined by the pressure measuring device. The inventors found that under certain conditions, despite the increase in fluid pressure, the pressure measured in the cavity remains stable. This "stable pressure" indicates the maximum pressure maintained inside the container. Therefore, excessive pressure can leak out from the container mold. Therefore, when molding subsequent containers, the fluid pressure supplied by the fluid supply system can be set to this maximum pressure (or slightly higher than this maximum pressure) (assuming that the same type of container is molded). In some examples, setting the fluid supply pressure to be 1 bar or less above the maximum pressure may help improve efficiency.

[0105] Figure 7 An example method 200 for forming a molded container is depicted. In a first frame 202, the method includes applying a fiber suspension to a mold cavity wall of a container mold, the fiber suspension at least partially coating the mold cavity wall. In a second frame 204, the method further includes supplying a fluid at a pressure between about 3.5 bar and about 10 bar to directly contact the fiber suspension on the mold cavity wall for a period of less than about 60 seconds. This high pressure fluid presses the fiber suspension against the mold cavity wall, thereby causing liquid to be removed from the fiber suspension and pass through holes formed in the mold cavity wall to form a molded container on the mold cavity wall.

[0106] The above embodiments are to be understood as illustrative examples of the present invention. Additional embodiments of the present invention are contemplated. It should be understood that any feature described with respect to any one embodiment may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other embodiment or any combination of any other embodiment. In addition, equivalents and modifications not described above may also be employed without departing from the scope of the present invention as defined by the appended claims.

Claims

1. A method of forming a molded container, the method comprising: applying a fiber suspension to a mold cavity wall of a container mold, the fiber suspension at least partially coating the mold cavity wall; as well as Fluid is supplied at a pressure of between about 3.5 bar and about 10 bar to be in direct contact with the fiber suspension on the mold cavity wall for a period of less than about 60 seconds so that liquid is removed from the fiber suspension through holes formed in the mold cavity wall to form the molded container on the mold cavity wall.

2. The method of claim 1, wherein the fluid is air or superheated steam.

3. The method of claim 1 or 2, wherein the pressure is a final pressure, and wherein supplying the fluid comprises: supplying the fluid at an initial pressure; as well as The pressure is increased from the initial pressure to the final pressure within a specific period of time.

4. The method of any one of claims 1 to 3, wherein the supplying the fluid comprises supplying the fluid at a temperature between about 10°C and about 180°C.

5. The method of any one of claims 1 to 4, wherein the supplying the fluid comprises supplying the fluid under a pulsed pressure over time.

6. The method of any one of claims 1 to 5, wherein the supplying the fluid comprises supplying the fluid at a flow rate greater than about 3 liters / minute.

7. The method of any one of claims 1 to 6, wherein the period of time is less than 35 seconds.

8. The method of any one of claims 1 to 7, further comprising at least one of the following: measuring the weight or volume of said liquid removed from said fiber suspension and stopping the supply of said fluid when said weight or volume of said liquid has reached a predetermined amount; stopping the supply of the fluid after a predetermined period of time; measuring a volume of a fluid supplied into the mold, and stopping the supply of the fluid when the measured volume of the fluid has reached a predetermined amount; measuring the temperature of the fluid, and when the measured temperature of the fluid has reached a predetermined temperature, stopping the supply of the fluid; as well as The pressure drop of the fluid is measured, and when the pressure drop has reached a predetermined amount, the supply of the fluid is stopped.

9. The method of claim 8, wherein: When at least partially coating the mold cavity wall, the fiber suspension has a first liquid content percentage L1 by weight; The molded container has a second liquid content percentage L2 by weight; and The liquid content reduction percentage R is greater than about 5%, where R = (L1 - L2) / L1.

10. The method of any one of claims 1 to 9, further comprising applying the fiber suspension to the mold cavity wall and applying a vacuum to the container mold while supplying the fluid.

11. The method of any one of claims 1 to 9, further comprising applying a vacuum to the container mold while applying the fiber suspension to the mold cavity wall; and Applying the vacuum is terminated prior to supplying the fluid.

12. The method of claim 11, further comprising at least one of the following: measuring the weight or volume of liquid extracted from the container mold while applying the vacuum, and terminating the applying of the vacuum when the weight or volume of the liquid extracted from the container mold has reached a predetermined amount; and The applying of the vacuum is terminated after a predetermined period of time.

13. The method of any one of claims 1 to 12, further comprising applying heat to the molded container to remove liquid from the molded container.

14. A method as claimed in any one of claims 1 to 13, wherein the pressure is a specific pressure, and the method includes determining the specific pressure based on the type of the container being molded and / or one or more other criteria, and the supplying the fluid includes supplying the fluid at the specific pressure.

15. A moulded container produced by the method according to any one of claims 1 to 14.

16. A system for forming a molded container, the system comprising: a container mold having a mold cavity wall configured to receive a fiber suspension coating thereon and to form apertures therein; a fiber suspension application system configured to apply the fiber suspension to the mold cavity wall to at least partially coat the mold cavity wall; and a fluid supply system configured to supply fluid at a pressure between about 3.5 bar and about 10 bar into direct contact with the fiber suspension on the mold cavity wall for a period of less than about 60 seconds such that liquid is removed from the fiber suspension through the apertures to form the molding vessel on the mold cavity wall.

17. The system of claim 16, wherein the pressure is a final pressure, and wherein the fluid supply system is configured to: supplying the fluid at an initial pressure; and The pressure is increased from the initial pressure to the final pressure within a specific period of time.

18. A system as claimed in claim 16 or claim 17, wherein the fluid supply system is configured to supply the fluid under a pulsed pressure over time.

19. The system of any one of claims 16 to 18, wherein the fluid supply system is configured to supply the fluid at a flow rate greater than about 3 liters per minute.

20. The system of any one of claims 16 to 19, further comprising at least one of the following: a liquid measuring system configured to measure the weight or volume of said liquid removed from said fiber suspension, wherein said fluid supply system is configured to stop said supply of said fluid when said liquid measuring system determines that said weight or volume of said liquid has reached a predetermined amount; a timing system configured to measure the time that the fluid supply system supplies the fluid, wherein the fluid supply system is configured to stop the supply of the fluid when the timing system determines that the time has reached a predetermined period of time; a fluid measurement system configured to measure a volume of a fluid supplied by the fluid supply system, wherein the fluid supply system is configured to stop the supply of the fluid when the fluid measurement system determines that the volume of the fluid has reached a predetermined amount; a temperature measurement system configured to measure a temperature of the fluid, wherein the fluid supply system is configured to stop the supply of the fluid when the temperature measurement system determines that the temperature of the fluid has reached a predetermined temperature; as well as A pressure measurement system is configured to measure a pressure drop of the fluid, wherein the fluid supply system is configured to stop the supply of the fluid when the pressure measurement system determines that the pressure drop of the fluid has reached a predetermined amount.

21. The system of any one of claims 16 to 20, further comprising: A vacuum application system configured to: The fiber suspension application system applies the fiber suspension to the mold cavity wall and a vacuum is applied to the container mold while the fluid supply system supplies the fluid.

22. The system of any one of claims 16 to 20, further comprising: A vacuum application system configured to: applying a vacuum to the container mold while the fiber suspension application system applies the fiber suspension to the mold cavity wall; as well as Application of the vacuum is stopped before the fluid supply system supplies the fluid.

23. The system of claim 22, further comprising at least one of the following: a liquid measuring system configured to measure the weight or volume of the liquid removed from the container mold while the vacuum is being applied, wherein the vacuum application system is configured to stop applying the vacuum when the liquid measuring system determines that the weight or volume of the liquid has reached a predetermined amount; and A timing system is configured to measure the time that the vacuum application system applies the vacuum, wherein the vacuum application system is configured to stop the application of the vacuum when the timing system determines that a predetermined period of time has elapsed.

24. The system of any one of claims 16 to 23, wherein the fluid supply system is configured to: determining a specific pressure based on the type of container being molded and / or one or more other criteria; and The fluid is supplied at the specific pressure.

25. The system of any one of claims 16 to 24, wherein the container mold comprises: a mold cavity, the mold cavity wall being a wall of the mold cavity; and an opening through which the fluid can escape from the cavity while the fluid supply system is supplying the fluid.

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