Mold system and method

Abstract

A mold (102, 103, 15, 201, 25) system for molding a container (22) is described. The mold (102, 103, 15, 201, 25) system comprises: a mold (102, 103, 15, 201, 25), the mold comprising a mold cavity (115, 203) and an opening (117); and a mandrel (123, 125, 403) system, the mandrel system comprising a reference point (133), a mandrel (123, 125, 403), and an expandable member (123, 125). The mandrel (123, 125, 403) is at least partially located or at least partially loadable inside the expandable member (123, 125), and includes one or more apertures (135) through which a fluid, in use, can flow from the inside of the mandrel (123, 125, 403) to the outside of the mandrel (123, 125, 403) to expand the expandable member (123, 125). When the mandrel (123, 125, 403) is at least partially inside the expandable member (123, 125), the system of mandrels (123, 125, 403) is positionable relative to the mold (102, 103, 15, 201, 25) such that the reference point (133) is in a fixed position relative to the mold (102, 103, 15, 201, 25), and the mandrel (123, 125, 403) and the expandable member (123, 125) extend through the opening (117) into the mold cavity (115, 203), the expandable member (123, 125) is configured such that there is a gap between the expandable member (123, 125) and a base (119) of the mold cavity (115, 203) opposite the opening (117). At least a portion of the expandable member (123, 125) and the mandrel (123, 125, 403) is movable relative to the reference point (133) to vary the gap.

Description

Technical Field

[0001] The present invention relates to a mold system for molding a container and a method for molding a container. Background Art

[0002] The mandrel system can be inserted into a mold of the mold system so that the expandable member of the mandrel system expands, thereby applying a forming operation to a container (e.g., a bottle) located in the mold. In some examples, after the forming operation has been applied, the mandrel system can be removed from the mold. Summary of the invention

[0003] According to a first aspect of the present invention, there is provided a mold system for molding a container, the mold system comprising: a mold including a mold cavity and an opening; and a mandrel system, the mandrel system comprising a reference point, a mandrel and an expandable member, wherein: the mandrel is at least partially located or at least partially locatable inside the expandable member and comprises one or more holes through which a fluid can flow from the inside of the mandrel to the outside of the mandrel to expand the expandable member when in use; when the mandrel is at least partially located inside the expandable member, the mandrel system can be positioned relative to the mold so that the reference point is in a fixed position relative to the mold and the mandrel and the expandable member extend through the opening into the mold cavity so that there is a gap between the expandable member and a base of the mold cavity opposite to the opening; and at least a portion of the expandable member and the mandrel can be moved relative to the reference point to change the gap. The expandable member can be considered an inflatable member or a bladder. Therefore, the expandable member can be appropriately positioned relative to the base. If the expandable member is improperly positioned (e.g., too far from the base), during expansion, the expandable member may contact the upper portion of the container in the mold cavity before the expandable member has filled the lower portion of the container. Then, further expansion of the expandable member in the downward direction may be inhibited by friction between the expandable member and the upper portion of the container. Inhibiting expansion may cause the expandable member to fail to completely fill the lower portion of the container. This may result in incorrect pressure being applied to the lower portion of the container (e.g., the base of the container). Therefore, this portion of the container may not be fully compacted, resulting in a fragile container and / or poor container quality. Alternatively, inhibiting expansion may cause the expandable member to overstretch and fail to completely fill the lower portion of the container. Overstretching may reduce the uniformity of the pressure applied by the expandable member to the container. This reduction in uniformity may have an adverse effect on the quality of the container, for example, causing the container to become fragile or thickness changes. In addition, overstretching may fatigue the expandable member, thereby shortening the life of the expandable member, or causing the expandable member to rupture. Making at least a portion of the mandrel movable enables the expandable member to be properly positioned in the mold cavity. Therefore, the quality of the container manufactured in the mold system can be improved and / or the life of the expandable member can be improved. Optionally, the expandable member and the entire mandrel can be moved relative to the reference point to change the gap. The mandrel can be single. In examples where the mold is one of multiple molds with cavities of different geometries, particularly different heights, it may be particularly advantageous to make at least a portion of the mandrel movable. In these examples, the gap can be changed based on the specific geometry of each mold cavity to appropriately position the expandable member within each mold. Advantageously, this may eliminate the need for each mold to have a customized mandrel system. In some examples, the container is a bottle, such as a fiber-based bottle.Alternatively, fluid may flow from the outside of the mandrel to the inside of the mandrel through the apertures in use.

[0004] The spindle system may include a connector for connecting the spindle system to the mold, and the reference point may consist of the connector. The connector may provide a convenient way to position the spindle system relative to the mold and to fix the reference point relative to the mold.

[0005] The spindle system may include a controller configured to move the expandable member and at least a portion of the spindle relative to a reference point. Thus, the amount of operator input required to operate the mold system may be reduced compared to, for example, a mold system in which an operator manually moves the spindle and the expandable member. This in turn may improve overall product quality and consistency. Additionally, this may result in reduced processing time and increased throughput.

[0006] The controller can be configured to move at least a portion of the expandable member and the mandrel relative to the reference point so that the gap has a predetermined value. The predetermined value can advantageously specify the required gap. Specifically, as described above, if the gap is too large, the expandable member may be inhibited from expanding downward. On the contrary, if the gap is too small (i.e., the expandable member is too close to the base), a suboptimal expansion of the expandable member may occur. Specifically, the expandable member may contact the base of the container prematurely, which may inhibit the expandable member from subsequently expanding outward to the corner of the container. This may cause the quality of the container to decrease and / or shorten the life of the expandable member, also as described above. The mold can be one of a plurality of molds having cavities of different geometries, particularly different heights. Regardless of the geometry of the mold cavity, the controller moves the mandrel and the expandable member so that the gap between the expandable member and the mold base is the same predetermined value. Therefore, the expandable member can be appropriately positioned for each mold without the need for a custom mandrel and expandable member for each mold. Since there is no need to switch the mandrel and the expandable member when switching the mold, this can reduce the cost of the system and reduce processing time.

[0007] The predetermined value may be no less than 2 mm. Thus, the expandable member may be appropriately positioned to reduce the likelihood of suboptimal expansion of the expandable member, as discussed above.

[0008] The predetermined value may be no greater than 11 mm. Thus, the expandable member may be appropriately positioned to reduce the likelihood that downward expansion of the expandable member may be inhibited, as discussed above.

[0009] The controller may be configured to determine the predetermined value based on a characteristic of the mold. Thus, the expandable member may be appropriately positioned for a particular mold. Additionally, since the operator is not required to determine and input the predetermined value, the amount of operator input required to operate the mold system may be further reduced. Optionally, the characteristic of the mold may be one of: a height of the mold, a width of the mold, and a geometry of the mold. Optionally, the controller may be configured to determine the predetermined value based on a characteristic of the expandable member. The characteristic of the expandable member may be one of: for example, a height of the expandable member, a width of the expandable member, a geometry of the expandable member, and a material of the expandable member.

[0010] The controller may store a lookup table of different predetermined values ​​associated with respective different mold characteristics; and the controller may be configured to select the predetermined value from the lookup table using the characteristics of the mold. This may eliminate the requirement for an operator to calculate a gap when switching from one mold to another mold having a different geometry. Thus, downtime incurred when switching between molds may be reduced. Optionally, the predetermined value may be associated with respective different mold characteristics and respective different expandable member characteristics. The controller may be configured to select the predetermined value from the lookup table using the characteristics of the mold and the characteristics of the expandable member.

[0011] The end of the mandrel may be attachable or attached to the expandable member. For example, the end of the mandrel may be removably attachable or removably attached to the expandable member. Therefore, during different stages of the manufacturing process, the end of the mandrel may be attached or detached from the expandable member. For example, when attached to the mandrel, the expandable member may be more easily positioned and moved. This may be beneficial to position the expandable member in the mold before expansion and / or during the insertion of the mandrel system into the mold or removal from the mold. When separated from the mandrel, the expandable member may expand without being inhibited by the end of the mandrel, which may otherwise inhibit the expansion. The uninhibited expansion of the expandable member may improve the size and uniformity of the pressure applied by the expandable member to the container in the mold. Therefore, due to the improved size and uniformity of the applied pressure, the compaction degree may be improved, and therefore the quality of the container may be improved. In addition, the uninhibited expansion may reduce the stress concentration in the expandable member, which may damage the expandable member or fatigue the expandable member. Therefore, the life of the expandable member may be improved.

[0012] When the end of the mandrel is attached to the expandable member, the end of the mandrel can be movable relative to the reference point in response to the expansion of the expandable member. Therefore, the expandable member can be expanded relatively uninhibited by the mandrel while still attached to the mandrel. Attachment to the mandrel can advantageously enable the mandrel to manipulate the expandable member, which can improve the functionality of the mandrel system. For example, the mandrel can be used to properly position the expandable member within the mold, twist the expandable member around the mandrel and / or change the length of the expandable member and thus change the width of the expandable member. Optionally, the mandrel includes a first portion and a second portion, the second portion including the end of the mandrel, and the second portion is movable relative to the first portion, such as telescopically, in response to the expansion of the expandable member. Optionally, the mandrel system includes an actuator that can operate in the following modes: a first mode, in which the actuator moves the end of the mandrel relative to the reference point to change the length of the expandable member, thereby changing the width of the expandable member; and a second mode, in which the actuator allows the end of the mandrel to move relative to the reference point or moves the end of the mandrel relative to the reference point in response to the expansion of the expandable member. The actuator may include one of a rack and pinion system, a pneumatic system, and a hydraulic system.

[0013] The expandable member can be arranged to separate from the end of the mandrel in response to the expansion of the expandable member. Therefore, the expandable member can move freely relative to the end of the mandrel during expansion, and thus expand without being inhibited by the end of the mandrel. As discussed above, the uninhibited expansion of the expandable member can improve the magnitude and uniformity of the pressure applied by the expandable member to the container in the mold. In addition, the uninhibited expansion may reduce stress concentrations in the expandable member, which may damage the expandable member or fatigue the expandable member. Therefore, the life of the expandable member can be improved.

[0014] The mandrel and the expandable member may be movable relative to the reference point to change the width of the expandable member. Therefore, the width of the expandable member may be changed to best suit the requirements of the manufacturing process using the mandrel system. For example, reducing the width of the expandable member may be beneficial to facilitate the expansion member to pass through the opening of the mold, which may occur when the mandrel system is inserted into the mold and then removed from the mold. Reducing the width can enable the expandable member to pass through the opening without contacting the mold and thus damaging the expandable member. In addition, in the case where the container is located in the mold and the expandable member is inserted into the container to apply a forming operation to the container, reducing the width can reduce the possibility of the expandable member contacting and damaging the container during insertion and / or removal. Increasing the width of the expandable member during the expansion of the expandable member may be advantageous because the expandable member may be able to expand relatively uninhibited by the mandrel. The uninhibited expansion of the expandable member can improve the size and uniformity of the pressure applied to the container by the expandable member during the forming operation. In addition, the uninhibited expansion may reduce the stress concentration in the expandable member, which may damage the expandable member or fatigue the expandable member, and thus the life of the expandable member can be improved. Optionally, the spindle system may include a connector for connecting the spindle system to the mold, the expandable member may be attached to the connector, and the spindle may be movable relative to the connector. Optionally, the base of the mold is a fixed distance from the opening of the mold. Therefore, the mold can be stronger and cheaper to manufacture than a mold in which the mold base is movable relative to the opening, which can achieve mold cavities of different heights.

[0015] The mold system may include another mold; the other mold may include another mold cavity and another opening; the other mold cavity may have a geometry different from the geometry of the mold cavity; the mandrel system may be positionable relative to the other mold when the mandrel is at least partially located inside the expandable member so that the reference point is in a fixed position relative to the other mold and the mandrel and the expandable member extend through the other opening into the other mold cavity so that there is another gap between the expandable member and a base of the other mold cavity opposite the other opening; the mandrel and the expandable member may be movable relative to the reference point to change the other gap; and the mandrel system may include a controller configured to: move the mandrel and the expandable member relative to the reference point so that the gap and the other gap have the same value. Thus, containers of different geometries (e.g., different heights) may be manufactured using the same mandrel system while also ensuring proper positioning of the expandable member.

[0016] According to a second aspect of the present invention, a method for molding a container is provided, the method comprising: providing a mold system of the first aspect of the present invention; when the mandrel is at least partially located inside the expandable member, moving at least a portion of the expandable member and the mandrel relative to a reference point to change the gap; and positioning the mandrel system relative to the mold so that the reference point is in a fixed position relative to the mold and the mandrel and the expandable member extend into the mold cavity through the opening. Therefore, the expandable member can be properly positioned relative to the base. If the expandable member is improperly positioned (e.g., too far from the base), during expansion, the expandable member may contact the upper portion of the container in the mold cavity before the expandable member has filled the lower portion of the container. Then, further expansion of the expandable member in a downward direction may be inhibited by friction between the expandable member and the upper portion of the container. Inhibiting expansion may cause the expandable member to fail to completely fill the lower portion of the container. This may result in incorrect pressure being applied to the lower portion of the container (e.g., the base of the container). Therefore, this portion of the container may not be fully compacted, resulting in a fragile container and / or poor container quality. Alternatively, inhibiting expansion may cause the expandable member to overstretch and fail to completely fill the lower portion of the container. Overstretching may reduce the uniformity of the pressure applied by the expandable member to the container. This reduction in uniformity may have an adverse effect on the quality of the container, for example, causing the container to become fragile or thickness variation. In addition, overstretching may fatigue the expandable member, thereby shortening the life of the expandable member, or causing the expandable member to break. Making at least a portion of the mandrel movable enables the expandable member to be properly positioned in the mold cavity. Therefore, the quality of the container manufactured in the mold system can be improved and / or the life of the expandable member can be improved. Optionally, the movement includes moving the expandable member and the entire mandrel relative to a reference point to change the gap. The mandrel can be single. In examples where the mold is one of multiple molds with cavities of different geometries, particularly different heights, making at least a portion of the mandrel movable may be particularly advantageous. In these examples, the gap can be changed based on the specific geometry of each mold cavity to properly position the expandable member in each mold. Advantageously, this may eliminate the need for each mold to have a customized mandrel system. Optionally, the method may include extending the expandable member to apply a forming operation to the container located in the mold cavity. In some examples, the container is a bottle, such as a fiber-based bottle.

[0017] The mandrel system may include a connector, the connector may include a reference point, and positioning the mandrel system may include connecting the connector to the mold. The connector may provide a convenient way to position the mandrel system relative to the mold and to fix the reference point relative to the mold.

[0018] The movement may include moving at least a portion of the expandable member and the mandrel relative to the reference point so that the gap has a predetermined value. The predetermined value may advantageously be able to specify the desired gap. Specifically, as described above, if the gap is too large, the expandable member may be inhibited from expanding downward. On the contrary, if the gap is too small (i.e., the expandable member is too close to the base), suboptimal expansion of the expandable member may occur. Specifically, the expandable member may contact the base of the container prematurely, which may inhibit the expandable member from subsequently expanding outward to the corner of the container. This may result in a decrease in the quality of the container and / or shorten the life of the expandable member, also as described above. The mold may be one of a plurality of molds having cavities of different geometries, particularly different heights. Regardless of the geometry of the mold cavity, the mandrel and the expandable member may be moved so that the gap between the expandable member and the mold base is the same predetermined value. Therefore, the expandable member can be appropriately positioned for each mold without the need for a custom mandrel and expandable member for each mold. Since there is no need to switch the mandrel and the expandable member when switching the mold, this can reduce the cost of the system and reduce processing time. Optionally, the predetermined value may be not less than 2 mm. Optionally, the predetermined value may be not more than 11 mm.

[0019] The method may include determining the predetermined value based on a characteristic of the mold. Thus, the expandable member can be appropriately positioned for a particular mold. Optionally, the characteristic of the mold can be one of: a height of the mold, a width of the mold, and a geometry of the mold. Optionally, the method includes determining the predetermined value based on a characteristic of the expandable member. The characteristic of the expandable member can be one of: for example, a height of the expandable member, a width of the expandable member, a geometry of the expandable member, and a material of the expandable member. Optionally, the spindle system includes a controller, and the determining includes the controller determining the predetermined value based on the characteristic of the mold.

[0020] Determining the predetermined value may include selecting the predetermined value from a lookup table of different predetermined values ​​associated with corresponding different mold characteristics using the characteristics of the mold. This may eliminate the requirement for an operator to calculate a gap when switching from one mold to another mold having a different geometry. Thus, downtime incurred when switching between molds may be reduced. Alternatively, selecting the predetermined value may include selecting the predetermined value from a lookup table of different predetermined values ​​associated with corresponding different mold characteristics and corresponding different expandable member characteristics using the characteristics of the mold and the characteristics of the expandable member.

[0021] The method may include at least one of: separating the end of the mandrel from the expandable member, and attaching the end of the mandrel to the expandable member. Thus, during different stages of the manufacturing process, the end of the mandrel may be attached to or detached from the expandable member. For example, when attached to the mandrel, the expandable member may be more easily positioned and moved. This may be advantageous for positioning the expandable member within the mold prior to expansion and / or during insertion of the expandable member into or removal from the mold. When separated from the mandrel, the expandable member may expand without being inhibited by the end of the mandrel, which may otherwise inhibit expansion. The uninhibited expansion of the expandable member may improve the magnitude and uniformity of the pressure applied by the expandable member to the container within the mold. Thus, due to the improved magnitude and uniformity of the applied pressure, the compaction may be improved, and thus the quality of the container may be improved. In addition, the uninhibited expansion may reduce stress concentrations in the expandable member, which may damage or fatigue the expandable member. Thus, the life of the expandable member may be improved. Alternatively, the method may include extending the expandable member to apply a forming operation to a container located within the mold cavity, and moving the end of the mandrel relative to a reference point during the expansion of the expandable member. Optionally, the end of the mandrel is attached to the expandable member, or the method includes attaching the end of the mandrel to the expandable member, and the method includes moving the end of the mandrel relative to the reference point in response to expansion of the expandable member.

[0022] The method may include: expanding an expandable member to apply a forming operation to a container located within a mold cavity; and separating an end of a mandrel from the expandable member during expansion of the expandable member. Thus, the expandable member may be free to move relative to the end of the mandrel during expansion and thus expand without being inhibited by the end of the mandrel. As discussed above, uninhibited expansion of the expandable member may improve the magnitude and uniformity of the pressure applied by the expandable member to the container within the mold. Additionally, uninhibited expansion may reduce stress concentrations in the expandable member that may damage or fatigue the expandable member. Thus, the life of the expandable member may be improved.

[0023] At least a portion of the expandable member and the mandrel can be moved relative to the reference point to vary the width of the expandable member. Thus, the width of the expandable member can be varied to best suit the requirements of a manufacturing process employing a mandrel system. For example, reducing the width of the expandable member may be advantageous in facilitating the passage of the expandable member through the opening of the mold, which may occur when the mandrel system is inserted into the mold and subsequently removed from the mold. Reducing the width may enable the expandable member to pass through the opening without contacting the mold and thereby damaging the expandable member. In addition, in the case where the container is located within the mold and the expandable member is inserted into the container to apply a forming operation to the container, reducing the width may reduce the likelihood that the expandable member contacts and damages the container during insertion and / or removal. Increasing the width of the expandable member during the expansion of the expandable member may be advantageous because the expandable member may be able to expand relatively uninhibited by the mandrel. The uninhibited expansion of the expandable member may improve the size and uniformity of the pressure applied by the expandable member to the container during the forming operation. In addition, the uninhibited expansion may reduce stress concentrations in the expandable member, which may damage the expandable member or fatigue the expandable member, and thus may improve the life of the expandable member.

[0024] The method may include positioning a container in a mold, the container being formed at least in part from paper pulp; and expanding an expandable member to apply a forming operation to the container. Paper is a more environmentally friendly choice than plastic. However, because the container is made of paper, the quality of the container is particularly sensitive to poor compaction. For example, poor compaction may result in increased liquid permeability and / or excessive fragility of the container. The effects of such poor quality may be reduced by varying the gap between the expandable member and the base of the mold and thereby achieving proper positioning of the expandable member. In some examples, the container is a bottle, such as a fiber-based bottle.

[0025] The method may include extending the expandable member to a container located in a mold cavity as part of a thermoforming operation. Thermoforming may improve mechanical properties of the container, such as stiffness and surface finish of the container. Optionally, moving the mandrel and the expandable member relative to a reference point may include moving the mandrel and the expandable member relative to the reference point so that the gap has a predetermined value. The method may include providing another mold, the other mold including another mold cavity and another opening, the other mold cavity having a geometry different from the geometry of the mold cavity. The method may include moving the mandrel and the expandable member relative to the reference point to change the gap between the expandable member and another base of the other mold cavity opposite to the other opening so that the other gap has a predetermined value. The method may include positioning the mandrel system relative to the other mold so that the reference point is in a fixed position relative to the other mold and the mandrel and the expandable member extend into the other mold cavity through the other opening. Thus, containers of different geometries (e.g., different heights) may be manufactured using the same mandrel system while also ensuring proper positioning of the expandable member. In some examples, the container is a bottle, such as a fiber-based bottle.

[0026] According to a third aspect of the present invention there is provided a container obtainable or obtained from a method of manufacture comprising the method of the second aspect.

[0027] The container may be a bottle, such as a fiber-based bottle. For example, the container may be obtainable or obtained from the method of the third aspect of the invention. The manufacturing method may include at least one additional process. At least one additional process may include coating the container to produce a coated container. At least one additional process may include drying the container or the coated container to produce a dry container. At least one additional process may include applying a closure to the container, the coated container or the dry container.

[0028] According to a fourth aspect of the present invention, there is provided a mandrel system for use with a mold to mold a container, the mandrel system comprising: a reference point and a mandrel, wherein: the mandrel comprises a plurality of holes through which a fluid can flow from the inside of the mandrel to the outside of the mandrel when in use; and at least a portion of the mandrel can be moved relative to the reference point to change the distance between the reference point and the end of the mandrel.

[0029] Optionally, the mandrel system comprises a connector for connecting the mandrel system to the mould, and the reference point consists of the connector.

[0030] Optionally, the spindle system comprises a controller configured to move at least a portion of the spindle relative to the reference point.

[0031] Optionally, the controller is configured to cause movement of at least a portion of the spindle relative to the reference point such that the distance has a predetermined value.

[0032] Optionally, the controller is configured to determine the predetermined value based on a characteristic of the mold.

[0033] Optionally, the controller stores a lookup table of different predetermined values ​​associated with corresponding different mold characteristics; and the controller is configured to select the predetermined value from the lookup table using the characteristics of the mold.

[0034] Optionally, the mandrel system includes an expandable member, and the ends of the mandrel may be attached or attached to the expandable member.

[0035] Optionally, when the end of the mandrel is attached to the expandable member, the end of the mandrel may move relative to the reference point in response to expansion of the expandable member.

[0036] Optionally, the expandable member is arranged to separate from the end of the mandrel in response to expansion of the expandable member.

[0037] Optionally, the mandrel and expandable member may be moved relative to a reference point to change the width of the expandable member.

[0038] Where appropriate, optional features of one aspect of the invention may be equally applied to other aspects of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0040] Figure 1 A schematic diagram showing an example process for making a bottle from pulp;

[0041] Figure 2 shows a simplified cross-sectional view of an example mold system;

[0042] Figure 3 The various stages of inserting a mandrel system into and removing a mandrel system from a mold of a mold system are illustrated by simplified cross-sections, wherein (a) the mandrel system is located outside the mold; (b) the mandrel is moved relative to the connector to reduce the width of an expandable member of the mandrel system; (c) the mandrel system is inserted into the mold; (d) the mandrel system is extended into the mold; (e) the expandable member is expanded to apply a forming operation to a container located in the mold; (f) the expandable member is collapsed; (g) the connector and mandrel are moved to reduce the width of the expandable member; and (h) the mandrel system is removed from the mold;

[0043] Figure 4 is a simplified cross-sectional view of a die and another die of a die system with a central axis system extending into each die;

[0044] Figure 5 A simplified cross-sectional view showing an alternative example mandrel system;

[0045] Figure 6 The various stages of inserting and removing an alternative example mandrel system from a mold are illustrated by simplified cross-section, wherein (a) the alternative example mandrel system is located outside the mold; (b) the mandrel is moved relative to the connector to reduce the width of an expandable member of the alternative example mandrel system; (c) the alternative example mandrel system is inserted into the mold; (d) the alternative example mandrel system is extended into the mold; (e) the expandable member is expanded to apply a forming operation to a container located within the mold; (f) the expandable member is collapsed; (g) the connector and mandrel are moved to reduce the width of the expandable member; and (h) the alternative example mandrel system is removed from the mold;

[0046] Figure 7 a simplified cross-sectional view showing another example mandrel system; and

[0047] Figure 8 Different stages of inserting another example spindle system into and removing another example spindle system from a mold are shown by simplified cross-sections, wherein (a) the other example spindle system is located outside the mold; (b) the spindle is moved relative to the connector to reduce the width of the expandable member of the other example spindle system; (c) the other example spindle system is inserted into the mold; (d) the other example spindle system is extended into the mold; (e) the expandable member is expanded to apply a forming operation to a container located within the mold; (f) the expandable member is collapsed; (g) the connector and spindle are moved to reduce the width of the expandable member; and (h) the other example spindle system is removed from the mold. DETAILED DESCRIPTION

[0048] The following description presents exemplary embodiments and, together with the accompanying drawings, serves to explain principles of embodiments of the present invention.

[0049] Figure 1A 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 merely exemplary and is provided to provide context for an example of the invention. Broadly speaking, the exemplary process includes providing a fiber suspension, introducing the fiber suspension into a mold cavity of a porous first mold and draining a liquid (such as water) from the fiber suspension using the porous first mold to produce a wet precursor or embryo (which itself may be considered a molded container), further molding the wet precursor in the mold to produce a further molded container, coating the further molded container to produce a coated molded container, drying the coated molded container to produce a dry container, and applying a closure to the dry container. As will be apparent at least from the following description, the exemplary process may be modified to provide variations thereof in which other examples of the invention may be embodied.

[0050] In this example, providing a fiber suspension includes preparing a fiber suspension by its components. More specifically, the preparation includes providing a pulp fiber, such as a pulp fiber, and mixing the pulp fiber with a liquid to provide a hydrated pulp fiber. In this example, the pulp fiber is provided by a supplier in the form of a sheet, and the liquid includes water and one or more additives. In this example, the liquid is mixed with the pulp fiber to provide a hydrated pulp fiber with a solid fiber content of 1wt% to 5wt% (based on the dry mass of the fiber). In an example, one or more additives include a shorting agent, such as an alkyl ketene dimer (AKD). The hydrated pulp fiber generally includes an AKD accounting for 0.4wt% of the total dry mass of the solid fibers in the hydrated pulp fiber. In some examples, when the pulp fiber is mixed with the liquid, one or more additives are present in the liquid. In some examples, after the pulp fiber is mixed with the liquid, one or more additives are included in the hydrated pulp fiber (e.g., the pulp fiber is hydrated for a period of time, such as from 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fiber). The hydrated pulp fibers pass between the plates of a grain beater 11 or refiner that move relative to each other. This fibrillates some or all of the fibers, meaning that the cell walls of the fibers are partially delaminated so that the wetted surfaces of the fibers include protruding hairs or fibrils. These fibrillated structures will help increase the bond strength between the fibers in the dry final product. In other examples, the grain beater 11 or refiner may be omitted.

[0051] The resulting treated pulp is stored in a relatively concentrated form (e.g., 1 wt% to 5 wt% solid fiber content) in barrels 12 to reduce required storage space. At an appropriate time, the treated pulp is transferred to a mixing station 13 where it is diluted in more water and optionally mixed with one or more additives (in addition to or in place of one or more additives provided with the hydrated pulp fibers) to provide a fiber suspension ready for molding.

[0052] In this example, the porous first mold 15 includes two half molds that can be moved toward and away from each other, in this case using hydraulic cylinders. In this example, each of the half molds is an integral or single tool that defines a mold contour formed by additive manufacturing (e.g., 3D printing), and when the half molds contact each other, their corresponding mold contours cooperate to define a mold cavity in which a wet precursor or molded container is to be formed. Each half mold itself can define a smaller molding cavity, and when matched with the second half mold, the smaller molding cavity can be combined to provide an overall mold cavity. The two half molds themselves can be considered as "splits" or "molds", and the overall porous first mold 15 can be considered as a "split mold" or again considered as a "mold". In other examples, the porous first mold 15 can include more than two splits, such as three, four or six splits, which cooperate to define a molding cavity.

[0053] exist Figure 1 In the present invention, the fiber suspension (also called slurry) is filled into the porous mold 15 from the top, which is different from the molding process in which the mold is immersed in the slurry. The fiber suspension is sucked into the porous mold 15 through the pipeline 16 under vacuum conditions, wherein the excess suspension liquid is sucked into the tank 17 through the porous mold 15 through the pipeline 18 under vacuum conditions. The injection quality can be controlled by measuring (e.g., weighing) the amount of liquid sucked into the tank 17. Figure 1 17. The weighing platform supporting the tank 17 can be seen in the figure. Once the desired amount of liquid (e.g., a predetermined volume, such as 10 liters, or a predetermined mass, such as 10 kg) has been collected in the tank 17, the suction of the suspension liquid through the porous mold 15 is stopped and the porous mold 15 is vented to the surrounding air. In this example, the suspension liquid sucked together with the fiber suspension liquid in the pipeline 16 is water, or mainly water (because additives may also be present). The liquid sucked into the tank 17 under vacuum conditions via the pipeline 18 is substantially free of fibers, because these fibers remain on the walls of the porous mold 15 to form the embryo of the molded container.

[0054] In one form, in order to further remove the suspension liquid (e.g., water) from the embryo and form or consolidate the three-dimensional shape of the container, an impermeable inflatable element 19 (e.g., a collapsible bladder) is inserted into the porous mold 15 and expanded to act as the internal high-pressure core structure of the porous mold 15. This process can enhance the strength of the wet embryo so that it can be handled and drain water between the fibers, thereby improving the efficiency of the subsequent drying process. The inflatable element 19 is actuated and regulated using a hydraulic pump 20. The pump 20 has a cylinder that moves the fluid in the pipeline 21 into the inflatable element 19 so that the inflatable element 19 expands radially and conforms to the mold cavity. The fluid in the pipeline 21 is preferably incompressible, such as water. The advantage of water over other incompressible liquids is that any leakage or rupture of the bladder 19 will not introduce new substances into the system (because the suspension liquid is already water or mainly water).

[0055] Demolding occurs when the porous mold 15 is opened to remove the self-supporting molded container 22. Mold cleaning 23 is preferably performed afterwards to remove small fibers and maintain the porosity of the porous mold 15. In this example, when the mold 15 is opened, a radially emitted high-pressure jet is inserted into the mold cavity. This will cause the fibers to fall off the mold cavity wall. Alternatively or in addition, water from a tank 17 is pressurized through the back of the porous mold 15 to cause trapped fibers to fall off. The water is drained to circulate back to the upstream part of the system. It is worth noting that cleaning is important to condition the porous mold 15 for reuse. After removing the container, the porous mold 15 may appear clean, but its performance may be compromised if it is not cleaned.

[0056] according to Figure 1 , the formed but unfinished container 22 is then transported to a second molding station where pressure and heat are applied in, for example, an aluminum mold 25 to thermoform to a desired neck and surface finish, optionally including embossed and / or intaglio surface features. After the two halves of the mold 25 have been closed around the container 22, a pressurizer is engaged. For example, a bladder 26 (e.g., a thermoforming bladder 26) is inserted into the container 22. The bladder 26 is inflated by a pump 28 supplying a pressurized fluid (e.g., air, water, or oil) via a pipeline 27. Optionally, during supply, the pressurized fluid is heated, for example, by a heater, or alternatively cooled, for example, by a heat exchanger. The outer mold block 24 of the mold 25 and / or the mold 25 itself may also or alternatively be heated. The state of the molded container 22 after thermoforming is significantly harder and the sidewalls are more compressed than when it was demolded from the porous mold 15.

[0057] As shown, a drying stage 29 (e.g., a microwave drying process or other drying process) is performed downstream of the thermoforming. In one example, the drying stage 29 is performed before the thermoforming. However, some moisture is required when molding in the mold 25 to assist bonding during the compression process. Figure 1 Drying stage 29 is followed by a further drying stage 30, which may utilize hot air circulated over the molded container 22, such as in a "hot box." In some examples, microwave or other drying processes may be performed at multiple stages throughout the manufacturing process.

[0058] Then, the molded container 22 passes through a coating phase, during which, in this example, a spray gun 31 is inserted into the molded container 22 and applies one or more surface coatings to the inner wall of the molded container 22. In another example, the molded container 22 is instead filled with a liquid that coats the inner wall of the molded container 22. In fact, such a coating can provide a protective layer to prevent the contents from penetrating the bottle wall, thereby preventing it from penetrating or weakening the bottle wall. The choice of coating depends on the expected contents of the container 22, such as beverages, detergents, medicines, etc. In some examples, a further drying phase 30 is performed after the coating phase (or before and after the coating phase). In this example, the molded container 22 then passes through a curing process 34, which can be configured or optimized according to the coating, such as drying for twenty-four hours under ambient conditions or by a rapid drying method. In some examples, such as when the further drying phase 30 occurs after the coating phase, the curing process 34 can be omitted.

[0059] At an appropriate stage of production (e.g., during thermoforming, or before or after coating), the molded container 22 may be subjected to a closure or finish forming process. Figure 1 As shown, the neck fitting 35 can be secured. In some examples, an exterior coating is applied to the molded container 22, as shown in the further coating stage 32. In one example, the molded container 22 is immersed in a liquid that coats its exterior surface, such as Figure 1 As shown. One or more further drying or curing processes may then be performed. For example, the molded container 22 may be allowed to dry in warm air. Thus, the molded container 22 may be fully formed and ready to receive contents therein.

[0060] Figure 2 A mold system 101 is shown which may be used to thermoform the self-supporting molded container 22 discussed above. The mold system 101 includes a mold 103, a spindle system 105, a pump 107, and a line 109.

[0061] The mold 103 includes a first portion 111 and a second portion 113. In other examples, the mold 103 may include more than two portions. The two portions 111, 113 may be separated to open the mold 103. Each portion includes a cavity. When the two portions 111, 113 are brought together to close the mold 103, a mold cavity 115 is formed in the mold 103, the mold cavity including the cavities of the first portion 111 and the second portion 113. In this particular example, the mold cavity 115 has the shape of a bottle and includes a body portion and a neck portion. The diameter of the neck portion is smaller than the diameter of the body portion and extends to the top of the mold 103. The mold 103 includes an opening 117 leading to the mold cavity 115. In addition, the mold cavity 115 includes a base 119 opposite to the opening 117. The base 119 is a fixed distance from the opening 117, that is, the base 119 does not move relative to the opening 117. Compared with a mold having a base that is movable relative to the opening, this can provide a relatively sturdy and inexpensive mold.

[0062] The spindle system 105 includes a connector 121, a spindle 123, an expandable member 125, a first actuator 127, a second actuator 129, a controller 131, and a control panel (not shown).

[0063] The connector 121 includes a bore 122 extending through the connector 121 from the top to the bottom of the connector 121. An annular seal is located within the bore 122 and provides a seal between the connector 121 and the mandrel 123 extending through the bore 122. The seal is a low friction seal and allows the mandrel 123 to move relative to the connector 121. In this example, the connector 121 includes a reference point 133. As described in more detail below, when the mandrel 123 and the expandable member 125 are inserted into and removed from the mold 102, the mandrel 123 moves relative to the reference point 133. In other examples, the reference point 133 can be composed of other components of the mandrel system 105.

[0064] The mandrel 123 includes a cylindrical tube 134 and a first portion 137 of an attachment mechanism of the mandrel system 105. A plurality of holes 135 are formed along the length of the tube 134. The holes 135 are located along the lower portion of the tube 134 and extend radially through the tube 134 to allow fluid to flow from the interior of the mandrel 123 to the exterior of the mandrel 123. The first portion 137 of the attachment mechanism includes a magnet located at the lower end of the mandrel 123, i.e., the end of the mandrel 123 located within the expandable member 125. The mandrel 123 extends through the bore 122 in the connector 121 and into the expandable member 125, such that the lower portion of the mandrel 123 is located within the expandable member 125. In some examples, the mandrel 123 may be located entirely within the expandable member 125, and a different connector 121 may be used. The upper portion of the mandrel 123 is connected to the pipeline 109. The mandrel 123 is free to move relative to the connector 121, and therefore, relative to the reference point 133. Specifically, the spindle 123 is free to move up and down within the bore 122 and is free to rotate within the bore 122 in the connector 121 .

[0065] The expandable member 125 includes an inflatable member in the form of an elastic bladder 138. The bladder 138 includes a neck portion and a body portion. The neck portion is sealingly connected to the bottom of the connector 121. The diameter of the neck portion is smaller than the diameter of the body portion. In other examples, the bladder 138 may include a single portion with a constant diameter. The second portion 139 of the attachment mechanism includes a metal plate 139 formed of a ferromagnetic metal such as iron. The metal plate 139 is attached to the bottom of the bladder 138. The metal plate 139 cooperates with the magnet 137 of the spindle 123 to removably connect the expandable member 125 to the spindle 123.

[0066] The first actuator 127 is located on the connector 121 and is coupled to the spindle 123. The operation of the first actuator 127 causes the spindle 123 to move linearly along the longitudinal axis of the spindle 123 relative to the reference point 133. In this example, the first actuator 127 includes a motor and a transmission device (e.g., a gear, a friction wheel, and / or a rack and pinion) for transmitting the torque generated by the motor to the spindle 123. In other examples, the first actuator 127 may include a hydraulic or pneumatic system for moving the spindle 123 relative to the reference point 133.

[0067] The second actuator 129 is located at the top end of the spindle 123 and is coupled to the spindle 123. The operation of the second actuator 129 rotates the spindle 123 about the longitudinal axis of the spindle 123 relative to the reference point 133. In this example, the second actuator 129 includes a motor and a transmission device (e.g., a gear, a friction wheel, and / or a rack and pinion) for transmitting the torque generated by the motor to the spindle 123. In other examples, the second actuator 129 may include a hydraulic or pneumatic system for rotating the spindle 123 relative to the reference point 133.

[0068] In this example, the spindle system 105 includes separate actuators 127, 129 for linearly moving the spindle 123 and for rotating the spindle 123. This subsequently provides improved control of the linear and rotational movement of the spindle 123, and enables independent control of the rotational and linear movement. In other examples, the spindle system 105 may include a single actuator that is operable to move the spindle 123 linearly and rotate simultaneously. In a further example, the actuator may include a single motor, and one or more transmissions may be connected by a clutch. In this way, the benefits of independent control of the linear and rotational movement of the spindle can be achieved using a single motor. The controller 131 controls the operation of the actuators 127, 129, thereby controlling the movement of the spindle 123 relative to the reference point 133. The controller 131 also controls a robotic arm (not shown) that moves the connector 121 relative to the mold 103 and the pump 107.

[0069] A control panel (not shown) is connected to the controller 131 and is used to receive instructions and data related to the mold 103 and the expandable member 125 .

[0070] The pump 107 includes a cylinder that discharges fluid in the pipeline 109. In some examples, the fluid is one of air, water, or oil. Since the pipeline 109 is connected to the top of the mandrel 123, discharging the fluid causes the pump 107 to supply pressurized fluid to the interior of the mandrel 123. The pressurized fluid then flows through the hole 135 in the conduit 134 and enters the expandable member 125. Thus, the pump 107 is used to expand the expandable member 125. The pump 107 can also be operated in the opposite direction to extract fluid from the expandable member 125, thereby collapsing and contracting the expandable member 125.

[0071] Now it will pass Figure 3 The use of the mold system 101 is provided. Figure 3 As shown in (a), the two parts 111, 113 of the mold 103 are closed around the container 22 so that the container 22 is located inside the mold cavity 115. At this stage, the mandrel system 105 is located outside the mold cavity 115. The magnet 137 is attached to the magnetic plate 139, which attaches the expandable member 125 to the end of the mandrel 123.

[0072] Now go to Figure 3 (b), the controller 131 controls the first actuator 127 to move the spindle 123 downward relative to the reference point 133. When the spindle 123 moves downward, the end of the spindle 123 forces the bottom of the expandable member 125 downward, which increases the length of the expandable member 125. This increase in the length of the expandable member 125 causes the width of the expandable member 125 to decrease accordingly. At the same time, the controller 131 operates the second actuator 129 to rotate the spindle 123 relative to the reference point 133. Since the expandable member 125 is attached to the end of the spindle 123 by a connecting mechanism (i.e., the magnet 137 and the metal plate 139), the rotation causes the expandable member 125 to twist around the spindle 123. By twisting and stretching the expandable member 125, a greater width reduction of the expandable member 125 can be achieved compared to twisting or stretching alone.

[0073] Then, the controller 131 controls the actuators 127, 129 to stop the downward movement and rotation of the mandrel 123. At this stage, the width of the expandable member 125 is no greater than the width of the opening 117 of the mold 103. Therefore, the mandrel 123 and the expandable member 125 can pass through the opening 117 of the mold 103 without the expandable member 125 contacting the mold 103 or the container 22. Advantageously, this can reduce the possibility that the container 22 can be damaged by the expandable member 125 and the expandable member 125 can be damaged by the mold 103.

[0074] Now go to Figure 3 (c), the controller 131 then controls the robot arm to move the connector 121 downward toward the mold 103 until the connector 121 contacts the top of the mold 103 and connects thereto ( Figure 3 (d)). When the connector 121 moves downward, the mandrel 123 and the expandable member 125 are inserted into the mold cavity 115 through the opening 117. Due to the previous downward movement of the mandrel 123 relative to the connector 121 (refer to Figure 3 (b) Discussion), the length of the mandrel 123 is too large to fit within the mold cavity 115. Therefore, once the predetermined length of the mandrel 123 has been inserted into the mold cavity 115, the controller 131 operates the first actuator 127 to move the mandrel 123 upward relative to the connector 121. This upward movement of the mandrel 123 occurs simultaneously at the same rate of travel as the connector 121 moves downward toward the mold 103. Therefore, the position of the mandrel 123 within the mold appears to be stationary. The upward movement of the mandrel 123 relative to the connector 121 causes the length of the expandable member 125 to decrease and the width of the expandable member 125 to increase.

[0075] When the connector 121 contacts and connects to the top of the mold 103, the controller 131 controls the robot arm to stop the downward movement of the connector 121. In addition, the controller 131 controls the first actuator 127 to stop the upward movement of the mandrel 123 relative to the connector 121. Figure 3 (d) shows that when the connector 121 is connected to the top of the mold 103, the reference point 133 is in a fixed position relative to the mold 103. At this stage, the gap between the base 119 of the mold cavity 115 and the bottom of the expandable member 125 is determined by the length of the mandrel 123 extending below the connector 121. When the reference point 133 is in a fixed position relative to the mold 103, the gap is the minimum separation distance between the base 119 of the mold cavity and the expandable member 125. By changing the length of the mandrel 123 extending below the connector 121, the controller 131 can change the gap. The controller 131 controls the first actuator 127 (and therefore controls the length of the mandrel 123 extending below the connector 121) so that the gap has a predetermined value. Therefore, the bottom of the expandable member 125 can be appropriately positioned relative to the base 119. This is discussed in more detail below.

[0076] Then, the controller 131 operates the second actuator 129 to rotate the spindle 123 relative to the reference point 133 to unwind the expandable member 125 from around the spindle 123. This then causes the width of the expandable member 125 to further increase.

[0077] With the expandable member 125 now positioned within the mold cavity 115, a forming operation is performed on the container 22 ( Figure 3 (e)). The controller 131 controls the pump 107 to supply pressurized fluid to the mandrel 123, which flows through the hole 135 in the mandrel 123 and enters the expandable member 125 to expand the expandable member 125. The expansion of the expandable member 125 applies a force to the bottom of the expandable member 125, which overcomes the magnetic attraction between the magnet 137 and the metal plate 139, thereby separating the expandable member 125 from the end of the mandrel 123. The expandable member 125 continues to expand within the container. When fully expanded, the expandable member 125 contacts the container 22 and compresses the container against the mold 103 to form the container 22.

[0078] Now go to Figure 3 (f), once the forming operation is complete, the controller 131 controls the pump 107 to extract the pressurized fluid from the expandable member 125, which causes the expandable member 125 to collapse and shrink. When the expandable member 125 shrinks, the attractive force between the magnet 137 and the metal plate 139 is sufficient to reattach the expandable member 125 to the end of the mandrel 123.

[0079] Then, the controller 131 controls the robot arm to move the connector 121 upward relative to the mold 103 ( Figure 3 (g)). At the same time, the controller 131 controls the first actuator 127 to move the mandrel 123 downward relative to the reference point 133 at the same rate as the rate of moving the connector 121 upward, so that the end of the mandrel 123 is stationary relative to the mold 103. Therefore, the length of the expandable member 125 increases, which causes the width of the expandable member 125 to decrease. The controller 131 also controls the second actuator 129 to rotate the mandrel 123 relative to the reference point 133, so that the expandable member 125 twists around the mandrel 123 to further reduce the width of the expandable member 125. In the case where the expandable member 125 is extended and twisted around the mandrel 123, the controller 131 controls the actuators 127, 129 to stop the movement of the mandrel 123 relative to the reference point 133.

[0080] Now go to Figure 3 (h), the controller 131 controls the robot to move the connector 121 upward relative to the mold 103 to remove the mandrel 123 and the expandable member 125 from the mold 103 through the opening 117. Once the mandrel 123 and the expandable member 125 are removed from the mold 103, the mold 103 is opened by separating the two parts 111, 113 and removing the container 22 for further processing. For example, the container 22 can be dried in the drying stage 29, as described above with reference to Figure 1 described.

[0081] By moving the mandrel 123 and the expandable member 125 relative to the reference point 133, the bottom of the expandable member 125 can be properly positioned relative to the base 119. If the bottom of the expandable member 125 is improperly positioned (for example, if the bottom is positioned too far from the base 119 of the mold), during expansion, the expandable member 125 may contact the upper portion of the container 22 before the expandable member 125 has filled the lower portion of the container 22. Then, further expansion of the expandable member 125 in the downward direction may be inhibited due to friction between the expandable member 125 and the upper portion of the container 22. Inhibiting expansion may cause the expandable member 125 to fail to completely fill the lower portion of the container 22. This may result in incorrect pressure being applied to the lower portion of the container 22 (for example, the base of the container 22). Therefore, this portion of the container 22 may not be fully compacted, resulting in the container 22 being fragile. Alternatively, inhibiting expansion may cause the expandable member 125 to overstretch and fail to completely fill the lower portion of the container 22. Overstretching may reduce the uniformity of the pressure applied by the expandable member 125 to the container 22. This reduction in uniformity may adversely affect the quality of the container 22, for example, causing the container 22 to become brittle or to vary in thickness. In addition, overstretching may fatigue the expandable member 125, thereby shortening the life of the expandable member 125, or causing the expandable member 125 to break. The movable mandrel 123 enables the expandable member 125 to be properly positioned within the mold cavity 115. Therefore, the quality of the container manufactured in the mold system 101 can be improved and / or the life of the expandable member 125 can be improved.

[0082] By moving the mandrel 123 relative to the connector 121 to change the length of the expandable member 125, thereby changing the width of the expandable member 125, the width of the expandable member 125 can be changed to best suit the requirements of the manufacturing process using the mandrel system 105. For example, reducing the width of the expandable member 125 may be advantageous in facilitating the passage of the expandable member 125 through the opening 117 of the mold 103, which may occur when the mandrel system 105 is inserted into the mold 103 and then removed from the mold 103. Reducing the width may enable the expandable member 125 to pass through the opening 117 without contacting the mold 103 and thereby damaging the expandable member 125. In addition, reducing the width may reduce the likelihood that the expandable member 125 will contact and damage the container 22 during insertion and / or removal. During expansion of the expandable member 125, increasing the width of the expandable member 125 may be advantageous because the expandable member 125 may be able to expand relatively uninhibited by the mandrel 123. The uninhibited expansion of the expandable member 125 may improve the magnitude and uniformity of the pressure applied by the expandable member 125 to the container 22 during the forming operation. Additionally, the uninhibited expansion may reduce stress concentrations in the expandable member 125 that may damage or fatigue the expandable member 125, and thus may increase the life of the expandable member 125. Additionally, increasing the length of the expandable member 125 may place the expandable member 125 under tension, which may reduce the amount of slack in the expandable member 125. Thus, the expandable member 125 is less likely to contact and damage the container 22 during the insertion and / or removal process.

[0083] In the above example, the end of the mandrel 123 is removably attached to the expandable member 125. Therefore, during different stages of the manufacturing process, the end of the mandrel 123 can be attached or detached from the expandable member 125. For example, when attached to the mandrel 123, the expandable member 125 can be more easily positioned and moved. This may be advantageous for positioning the expandable member 125 within the mold 103 before expansion and / or during the insertion of the expandable member 125 into or removal from the mold 103. When separated from the mandrel 123, the expandable member 125 can expand without being inhibited by the mandrel 123. The uninhibited expansion of the expandable member 125 can improve the magnitude and uniformity of the pressure applied by the expandable member 125 to the container 22 within the mold 103. Therefore, due to the improved magnitude and uniformity of the applied pressure, the compaction can be improved, and thus the quality of the container 22 can be improved. In addition, the uninhibited expansion can reduce stress concentrations in the expandable member 125, which may damage the expandable member 125 or fatigue the expandable member 125. Therefore, the life of the expandable member 125 can be improved.

[0084] In the example above, after insertion but before expansion, the gap between the bottom of the expansion member and the base of the mold has a predetermined value of 8mm. However, other values ​​of the gap can be used. As previously discussed, as the gap between the bottom of the expandable member and the base of the mold decreases, the possibility of the downward expansion of the expandable member 125 being suppressed is reduced. This can reduce the possibility that insufficient compaction causes the container 22 to be fragile and / or the overstretching of the expandable member 125 causes the fatigue of the expandable member 125. However, as the gap decreases, the possibility of suboptimal expansion of the expandable member 125 increases. Specifically, the expandable member 125 may contact the base of the container 22 prematurely, which may inhibit the expandable member 125 from subsequently expanding outward to the corner of the container 22. This may cause the quality of the container 22 to decline and / or shorten the life of the expandable member 125, also as described above. By a gap of not more than 11mm and not less than 2mm, a good balance can be provided between the competing demands of reducing the possibility of suppressing downward expansion and reducing the possibility of suboptimal expansion.

[0085] Although the user can manually input the desired gap (e.g., via the control panel), in this example, the controller 131 is configured to select or determine the predetermined gap based on the characteristics of the mold 103 and the characteristics of the expandable member 125. In the example, the controller 131 receives the characteristics of the mold 103 and the characteristics of the expandable member 125 via the control panel. Then, the controller 131 selects the predetermined gap from a lookup table, which is indexed using the received characteristics of the mold 103 and the received characteristics of the expandable member 125. Therefore, if a different mold or a different expandable member is used, there is no need for the operator to calculate a new gap. Therefore, the downtime generated when switching between molds can be reduced. The lookup table may have been previously generated through experiments and process modeling to determine the optimal predetermined values ​​of different characteristics. The characteristic of the mold 103 can be one of the height, width, and geometry of the mold 103. The characteristic of the expandable member 125 can be one of the height, width, geometry, and elasticity of the expandable member 125.

[0086] Now go to Figure 4, the mold system 101 further includes another mold 201. The other mold 201 includes another mold cavity 203, which has a different geometry from the mold cavity 115. Specifically, the height of the other mold cavity 203 is less than the height of the mold cavity 115. Therefore, the mold system 101 can be used to form a range of container sizes. Regardless of the geometry of the mold cavities 115, 203, the controller 131 moves the mandrel 123 and the expandable member 125 so that the gap between the bottom of the expandable member 125 and the base 119, 205 of the mold cavities 115, 203 is the same predetermined value. Therefore, the expandable member 125 can be appropriately positioned for each mold 103, 201 without the need for a customized mandrel and expandable member for each mold 103, 201. Since there is no need to switch the mandrel 123 and the expandable member 125 when switching molds 103, 201, this can reduce the cost of the mold system 101 and reduce processing time.

[0087] In the above example, the first portion 137 of the attachment mechanism includes a magnet 137, while the second portion 139 of the attachment mechanism includes a magnetically attractive element in the form of a metal plate 139. Likewise, in other examples, the first portion 137 and the second portion 139 may include a plug and a socket, or a clamp and a clampable structure. In fact, it is contemplated that the attachment mechanism is a single part located on the mandrel 123 or the expandable member 125, for example, a clamp on the mandrel 123 that clamps a portion of the expandable member 125.

[0088] In the above example, connector 121 contacts and connects to the top of mold 103. However, in other examples, connector 121 may not contact and connect to the top of mold 103. Instead, connector 121 may be moved downward until connector 121 is in a prescribed position above the top of mold 103 with central axis 123 and expandable member 125 extending into mold 103. In this example, when connector 121 is in the prescribed position, reference point 133 is in a fixed position relative to mold 103.

[0089] In the above example, the movement of the connector 121 and the spindle 123 is controlled by the controller 131. However, it is conceivable that the operator can manually control the movement. However, the use of a controller can improve the overall product quality and can result in reduced processing time and increased production.

[0090] In the above example, mandrel 123 and expandable member 125 of mandrel system 105 are inserted into and removed from mold cavity 115 through opening 117. It should be understood that the entire mandrel system 105 need not be inserted.

[0091] In the above examples, the spindle system 123 includes attachment mechanisms 137, 139 for removably attaching the expandable member 125 to the spindle 123. However, in other examples, the attachment mechanism may be omitted. For example, Figure 5 An example of a spindle system 301 is shown in which the expandable member 125 is fixedly attached to the spindle 123. The spindle system 301 and Figure 2 The spindle system is the same as that of the , but with the following differences.

[0092] The attachment mechanisms 137 , 139 are omitted, and the bottom of the main body portion of the expandable member 125 is fixedly attached to the lower end of the spindle 123 .

[0093] The first actuator 303 can operate in a first mode and a second mode. In the first mode, the first actuator 303 causes the spindle 123 to move linearly along the longitudinal axis of the spindle 123 relative to the reference point 133. In the second mode, the first actuator 303 allows the spindle 123 to move freely relative to the reference point 133. For example, the first actuator 303 can be decoupled from the spindle 123 in the second mode (for example, using a clutch) to allow the spindle 123 to move freely. In another example, the first actuator 303 can be set to an idle mode, in which the first actuator 303 remains coupled to the spindle 123, but there is little resistance to the movement of the spindle 123. In an example where the first actuator 303 includes a hydraulic system, the hydraulic system can be exhausted to the atmosphere in the idle mode.

[0094] Now go to Figure 6 , the operation mode of the spindle system 301 is similar to Figure 2 The spindle system is the same as that of the , but with the following differences.

[0095] The expandable member 123 remains attached to the spindle 125 during all stages of operation. The controller 131 operates the first actuator 127 in a first mode to move the spindle 123 up and down relative to a reference point 133.

[0096] To perform a forming operation ( Figure 6(e)), the controller 131 controls the pump 107 to supply pressurized fluid to the mandrel 123, which flows through the hole 135 in the mandrel 123 and enters the expandable member 125 to expand the expandable member 125. At the same time, the controller 131 operates the first actuator 303 in the second operating mode, which allows the mandrel 123 to move freely relative to the reference point 133. Therefore, the mandrel 123 does not inhibit the expansion of the expandable member 125. The expansion of the expandable member 125 causes the mandrel 123 to move downward toward the base 119 of the mold 103. The expandable member 125 continues to expand within the container 22. When fully expanded, the expandable member 125 contacts the container 22 and compresses the container against the mold 103 to form the container 22.

[0097] Now go to Figure 6 (f), once the forming operation is completed, the controller 131 controls the pump 107 to extract the pressurized fluid from the expandable member 125, which causes the expandable member 125 to collapse and shrink. The first actuator 303 continues to operate in the second mode. Therefore, as the expandable member 125 shrinks, the mandrel 123 moves upward with the bottom of the expandable member 125.

[0098] exist Figure 5 In the example of FIG. 301 , the mandrel 123 can move relative to the connector 121 in response to the expansion of the expandable member 125. Thus, the expandable member 125 can expand relatively uninhibited by the mandrel 123 while also being attached to the mandrel 123. Attachment to the mandrel 123 can advantageously enable the mandrel 123 to manipulate the expandable member 125, which can improve the functionality of the mandrel system 301.

[0099] exist Figure 5 In the example of FIG. 1 , when operating in the second mode, the first actuator 303 allows the mandrel 123 to move freely relative to the reference point 133. However, in other examples, when operating in the second mode, the first actuator 303 may instead actively move the mandrel 125 in response to the expansion of the expandable member 125. Specifically, during the expansion of the expandable member 125, the first actuator 303 may move the mandrel 123 downward toward the base 119 of the mold 103, and the movement rate may be as fast as Figure 3 During the subsequent collapse of the expandable member 125, the first actuator 303 can move the mandrel 123 upwardly away from the base 119 of the mold 103, thereby causing the expandable member 125 to collapse.

[0100] exist Figure 5 In the example of the embodiment, the mandrel 125 is one-piece, which can provide a relatively simple and strong mandrel. However, in other examples, the mandrel can be a multi-part mandrel. For example, Figure 7An example of a spindle system 401 comprising a two-part spindle 403 is shown. The spindle system 401 and Figure 5 The spindle system 105 is the same as that of FIG. 1 , but has the following differences.

[0101] The mandrel 403 includes a first portion 405 and a second portion 407. The first portion 405 has the form of a cylindrical tube and includes a plurality of holes 135 formed along the length of the first portion 405. The holes 135 are located along a lower portion of the first portion 405 and extend radially through the first portion 405 to allow fluid to flow from the interior of the mandrel 403 to the exterior of the mandrel 403.

[0102] The second portion 405 has a cylindrical shape and has an outer diameter that is smaller than the inner diameter of the first portion 409. The second portion 407 is located inside the first portion 405 at the lower end of the first portion 405. The end of the second portion 407 is attached to the main body of the expandable member 125. The second portion 407 is keyed to the first portion 405 so that the second portion 407 moves linearly relative to the first portion 405 but is prevented from rotating relative to the first portion 405. For example, the first portion 405 may include a channel extending parallel to the longitudinal axis of the first portion 405, and the second portion 407 may include a protrusion received in the channel. The second portion 407 moves between a retracted position and an extended position along the longitudinal axis of the first portion 405. The length of the mandrel 403 in the extended position is greater than the length in the retracted position.

[0103] The first actuator 409 and the second actuator 411 are similar to Figure 5 129, except that the first actuator 409 operates only in the first mode. The actuators 409, 411 are each coupled to the first portion 405 of the spindle. The first actuator 409 is operable to linearly move the first portion 405 of the spindle 403 along the longitudinal axis of the spindle 403 relative to the connector 121 and the reference point 133. The second actuator 411 is operable to rotate the first portion 405 of the spindle 403 relative to the connector 121 and the reference point 133. Since the first portion 405 is keyed to the second portion 407 of the spindle 403, rotation of the first portion 405 causes the second portion 407 to also rotate.

[0104] Now go to Figure 8 , the operation mode of the spindle system 401 is similar to Figure 5 The spindle system is the same as that of the , but with the following differences.

[0105] like Figure 8As shown in (a), the operation of the mandrel system 401 begins with the two parts 111, 113 of the mold 103 being closed around the container 22, so that the container 22 is located inside the mold cavity 115. At this stage, the mandrel system 401 is located outside the mold cavity 115 and the expandable member 125 is in a collapsed state. In the collapsed state, the length of the mandrel 403 extending below the connector 121 is the same as the natural (unstretched) length of the expandable member 125. Therefore, when the expandable member 125 is in the collapsed state, the second portion 407 of the mandrel 403 is biased by the expandable member 125 toward the retracted position. Specifically, the elasticity of the expandable member 125 biases the second portion 407 toward the retracted position.

[0106] To perform a forming operation ( Figure 8 (e)), the controller 131 controls the pump 107 to supply pressurized fluid to the mandrel 403, which flows through the hole 135 in the mandrel 403 and enters the expandable member 125 to expand the expandable member 125. As the expandable member 125 expands, the bottom of the expandable member 125 moves downward toward the base 119 of the mold 103. The downward movement of the bottom of the expandable member 125 causes the second portion 407 of the mandrel 403 to move from the retracted position to the extended position. The expandable member 125 continues to expand within the container 22. When fully expanded, the expandable member 125 then contacts the container 22 and applies pressure to compress the container against the mold 103 to form the container 22.

[0107] Now go to Figure 8 (f), once the forming operation is complete, the controller 131 controls the pump 107 to extract the pressurized fluid from the expandable member 125, which causes the expandable member 125 to collapse and contract. As the expandable member 125 contracts, the bottom of the expandable member 125 moves upward away from the base 119 of the mold 103. This upward movement of the bottom of the expandable member 125 causes the second portion 407 of the mandrel 403 to move from the extended position to the contracted position.

[0108] exist Figure 7 In the example of the embodiment of the present invention, the expandable member 125 is attached to the second portion 407 of the mandrel 403, and the second portion 407 moves relative to the first portion 405 in response to the expansion of the expandable member 125. Therefore, the above-mentioned benefits of relatively uninhibited expansion of the expandable member 125 while still being attached to the mandrel 403 can be achieved. In addition, providing a two-part mandrel 403 can provide a convenient means for enabling the end of the mandrel 403 to move relative to the connector 121 in response to the expansion of the expandable member.

[0109] exist Figure 7In the example of FIG. 1 , the first portion 405 of the mandrel 403 is movable relative to the connector 121. However, other examples are contemplated in which the first portion 405 of the mandrel 403 is fixedly attached to the connector 121 and is thus immovable relative to the reference point 133. In this example, the connector 121 and the first portion 405 move together during insertion and removal of the mandrel 403 and the expandable member 125. During expansion and collapse of the expandable member 125, the second portion 407 of the mandrel 403 is still able to move relative to the first portion 405 of the mandrel 403, so that expansion and collapse of the expandable member 125 continues to be uninhibited by the mandrel 403.

[0110] In the above example, the movement of the mandrel 123 relative to the reference point 133 changes the length of the expandable member 125, and therefore changes the width of the expandable member. However, it is conceivable that in other examples, the movement of the mandrel 123 relative to the reference point 133 may not change the length of the expandable member 125, and therefore does not change the width of the expandable member. Instead, the movement may only change the gap between the bottom of the expandable member 125 and the base 119 of the mold 103. For example, the top of the expandable member 125 can be sealed to the mandrel 123, rather than being connected to the connector 121. Therefore, when the mandrel 123 moves up and down relative to the reference point 133, the expandable member 125 also moves up and down with the mandrel 123, and the length and therefore the width of the expandable member 125 remain unchanged. This arrangement can achieve the above-mentioned benefits of properly positioning the expandable member 125, but may not achieve the above-mentioned benefits of changing the width of the expandable member 125 to adapt to the requirements of the manufacturing process. In addition, this arrangement can have other benefits, such as simplifying the sealing of the expandable member 125. Specifically, in such an arrangement, an annular seal that permits movement of the spindle 125 relative to the connector 121 may be omitted, and a simpler seal that need not permit significant movement may instead be used to sealingly connect the expandable member 125 to the spindle 123.

[0111] It should be understood that changing the length of the mandrel 123 extending below the connector 121 also changes the length of the mandrel 123 at the lower end (at the Figure 3 a) and the distance 200 (eg, the distance between the first portion 137 of the attachment mechanism and the reference point 133) Figure 3 a).

[0112] In the above examples, the controller 131 is configured to select or determine the predetermined gap based on the characteristics of the mold 103, and the controller 131 selects the predetermined gap from a lookup table indexed using the received characteristics of the mold 103. As discussed above, the gap is determined by the distance 200. Therefore, in some examples, the controller 131 is configured to select or determine the predetermined gap 200 based on the characteristics of the mold 103, and the controller 131 selects the predetermined gap 200 from the lookup table indexed using the received characteristics of the mold 103.

[0113] Exemplary embodiments of the invention have been discussed with reference to the illustrated examples. However, it will be appreciated that changes and modifications may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. A mold system for molding a container, the mold system comprising: a mold, the mold comprising a mold cavity and an opening; as well as a spindle system, the spindle system comprising a reference point, a spindle and an expandable member, in: the mandrel being at least partially located or at least partially locatable within the expandable member and comprising one or more apertures through which fluid can flow from the interior of the mandrel to the exterior of the mandrel in use to expand the expandable member; The mandrel system is positionable relative to the mold when the mandrel is at least partially within the expandable member such that the reference point is in a fixed position relative to the mold and the mandrel and expandable member extend through the opening into the mold cavity such that a gap exists between the expandable member and a seat of the mold cavity opposite the opening; and The expandable member and at least a portion of the mandrel may be movable relative to the reference point to vary the gap.

2. The mold system of claim 1, wherein the spindle system includes a connector for connecting the spindle system to the mold, and the reference point consists of the connector.

3. The mold system of claim 1 or claim 2, wherein the mandrel system includes a controller configured to move the expandable member and the at least a portion of the mandrel relative to the reference point.

4. The mold system of claim 3, wherein the controller is configured to move the expandable member and the at least a portion of the mandrel relative to the reference point such that the gap has a predetermined value.

5. The mold assembly of claim 4, wherein the predetermined value is not less than 4 mm.

6. A mould assembly as claimed in claim 4 or claim 5, wherein the predetermined value is no greater than 11 mm.

7. The mold system of any one of claims 4 to 6, wherein the controller is configured to determine the predetermined value based on a characteristic of the mold.

8. The mold system of claim 7, wherein: The controller stores a lookup table of different predetermined values ​​associated with corresponding different mold characteristics; and The controller is configured to select the predetermined value from the lookup table using the characteristic of the mold.

9. The mould system of any one of claims 1 to 8, wherein an end of the mandrel is attachable or attached to the expandable member.

10. The mold system of claim 9, wherein when the end of the mandrel is attached to the expandable member, the end of the mandrel is movable relative to the reference point in response to expansion of the expandable member.

11. The mold system of claim 9, wherein the expandable member is arranged to separate from the end of the mandrel in response to expansion of the expandable member.

12. The mold system of any one of claims 1 to 11, wherein the mandrel and the expandable member are movable relative to the reference point to change the width of the expandable member.

13. The mold system according to any one of claims 1 to 12, wherein: The mold system includes another mold; The other mold includes another mold cavity and another opening; the other mold cavity having a geometry different from the geometry of the mold cavity; When the mandrel is at least partially located within the expandable member, the mandrel system is positionable relative to the other mold such that the reference point is in a fixed position relative to the other mold and the mandrel and the expandable member extend through the other opening into the other mold cavity such that another gap exists between the expandable member and a seat of the other mold cavity opposite the other opening; The mandrel and the expandable member are movable relative to the reference point to change the another gap; and The mandrel system includes a controller configured to move the mandrel and the expandable member relative to the reference point such that the gap and the further gap have the same value.

14. A method of molding a container, the method comprising: Providing a mold system according to any one of claims 1 to 13; moving the expandable member and the at least a portion of the mandrel relative to the reference point to change the gap when the mandrel is at least partially located within the expandable member; as well as The mandrel system is positioned relative to the mold such that the reference point is in a fixed position relative to the mold and the mandrel and the expandable member extend through the opening into the mold cavity.

15. The method of claim 14, wherein the mandrel system includes a connector, the connector includes the reference point, and the positioning the mandrel system includes connecting the connector to the mold.

16. A method as claimed in claim 14 or claim 15, wherein the moving comprises moving the expandable member and the at least a portion of the mandrel relative to the reference point such that the gap has a predetermined value.

17. The method of claim 16, wherein the method comprises determining the predetermined value based on a characteristic of the mold.

18. The method of claim 17, wherein said determining said predetermined value comprises: The predetermined value is selected from a look-up table of different predetermined values ​​associated with corresponding different mold characteristics using the characteristic of the mold.

19. The method of any one of claims 14 to 18, wherein the method comprises at least one of: detaching the end of the mandrel from the expandable member, and attaching the end of the mandrel to the expandable member.

20. The method of claim 19, wherein the method comprises: expanding the expandable member to apply a forming operation to a container located within the mold cavity; as well as During the expansion of the expandable member, the end of the mandrel is separated from the expandable member.

21. The method of claim 20, wherein said moving said expandable member and said at least a portion of said mandrel relative to said reference point causes a width of said expandable member to vary.

22. The method of any one of claims 14 to 21, wherein the method comprises: positioning a container in the mold, the container being at least partially formed from paper pulp; as well as The expandable member is expanded to apply a forming operation to the container.

23. The method of any one of claims 14 to 22, wherein: The method includes expanding the expandable member into a container positioned within the mold cavity as part of a thermoforming operation.

24. A container obtainable or obtained from a method of manufacture comprising the method of any one of claims 14 to 23.

25. A container as claimed in claim 24, wherein the container is a bottle, such as a fibre bottle.

26. A mandrel system for use with a mold to mold a container, the mandrel system comprising: Reference points and mandrels, in: The mandrel comprises a plurality of apertures through which fluid can flow from an interior of the mandrel to an exterior of the mandrel in use; and At least a portion of the mandrel is movable relative to the reference point to change the distance between the reference point and an end of the mandrel.

27. The mandrel system of claim 26, wherein the mandrel system includes a connector for connecting the mandrel system to a mold, and the reference point consists of the connector.

28. A spindle system as claimed in claim 26 or claim 27, wherein the spindle system comprises a controller configured to move the at least a portion of the spindle relative to the reference point.

29. The spindle system of claim 28, wherein the controller is configured to move the at least a portion of the spindle relative to the reference point such that the distance has a predetermined value.

30. The spindle system of claim 29, wherein the controller is configured to determine the predetermined value based on characteristics of a mold.

31. The spindle system of claim 30, wherein: The controller stores a lookup table of different predetermined values ​​associated with corresponding different mold characteristics; and The controller is configured to select the predetermined value from the lookup table using the characteristic of the mold.

32. A mandrel system as claimed in any one of claims 26 to 31, wherein the mandrel system comprises an expandable member and the end of the mandrel is attachable or attached to the expandable member.

33. The mandrel system of claim 32, wherein when the end of the mandrel is attached to the expandable member, the end of the mandrel is movable relative to the reference point in response to expansion of the expandable member.

34. The mandrel system of claim 32, wherein the expandable member is arranged to separate from the end of the mandrel in response to expansion of the expandable member.

35. The mandrel system of any one of claims 32 to 34, wherein the mandrel and the expandable member are movable relative to the reference point to change the width of the expandable member.

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