Mandrel system and method

Abstract

A mandrel system for use in conjunction with a mold to mold a container is described. The mandrel system includes an assembly, a mandrel, and an expandable member. The mandrel is at least partially located or may be at least partially located inside the expandable member and includes one or more apertures through which fluid can flow from the inside of the mandrel to the outside of the mandrel in use to expand the expandable member. The expandable member is attached or attachable to the assembly. When the expandable member is attached to the assembly and the mandrel is at least partially located inside the expandable member, an end of the mandrel is movable relative to the assembly to change a length of the expandable member and thereby a width of the expandable member.

Description

Technical Field

[0001] The present invention relates to a mandrel system for use in conjunction with a mold to mold a container and a method of molding a container. Background Art

[0002] The mandrel system can be inserted into the mold to expand the expandable member of the mandrel system to apply a forming operation to a container, such as a bottle, located within the mold. In some examples, the mandrel system can be withdrawn from the mold after the forming operation has been applied. Summary of the invention

[0003] According to a first aspect of the present invention, there is provided a mandrel system for use in conjunction with a mold to mold a container, the mandrel system comprising: an assembly; a mandrel; and an expandable member, wherein: the mandrel is at least partially located or can be at least partially located inside the expandable member, and includes one or more holes, through which a fluid can flow from the inside of the mandrel to the outside of the mandrel when in use to expand the expandable member; the expandable member is attached to or can be attached to the assembly; and when the expandable member is attached to the assembly and the mandrel is at least partially located inside the expandable member, the end of the mandrel can be moved relative to the assembly to change the length of the expandable member, and thereby change the width of the expandable member. The expandable member can be considered as an inflatable member or a bladder. As a result, the width of the expandable member can 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 travel through the opening of the mold, which may occur when the mandrel system is inserted into the mold and then withdrawn from the mold. Reducing the width can enable the expandable member to travel through the opening without contacting the mold and thereby 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 the molding operation to the container, reducing the width can reduce the possibility of the expandable member contacting and damaging the container during insertion and / or extraction. It may be advantageous to increase the width of the expandable member during the expansion of the expandable member because the expandable member may be able to expand relatively uninhibited by the mandrel. The uninhibited expansion of the expandable member can improve the amplitude and uniformity of the pressure applied to the container by the expandable member during the molding operation. In addition, the uninhibited expansion can reduce the stress concentration in the expandable member that can damage or fatigue the expandable member and thus extend the life of the expandable member. In addition, increasing the length of the expandable member can put the expandable member under tension, which can reduce the amount of relaxation of the expandable member. Thus, the expandable member is less likely to contact and damage the container during insertion and / or extraction. Optionally, the assembly includes a connector for connecting the mandrel system to the mold. Optionally, the assembly is part of the mandrel. In some examples, the container is a bottle, such as a fiber bottle. Optionally, the fluid can flow from the outside of the mandrel to the inside of the mandrel through the hole when in use.

[0004] The expandable member may be attached or attachable to the end of the mandrel. As a result, improved control of the width of the expandable member may be achieved. Specifically, the end of the mandrel may be moved away from the assembly to increase the length of the expandable member, which results in a corresponding decrease in the width of the expandable member. The end of the mandrel may then be moved toward the assembly to decrease the length of the expandable member, which results in a corresponding increase in the width of the expandable member. Optionally, the end of the mandrel may move relative to the assembly in response to expansion of the expandable member.

[0005] The expandable member may be removably attached to or removably attachable to the end of the mandrel. As a result, the end of the mandrel may be attached to or detached from the expandable member during different stages of the manufacturing process. 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 or extraction of the mandrel system into or from the mold. When removed 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 amplitude and uniformity of the pressure applied by the expandable member to the container within the mold. Thus, the quality of the container may be improved due to the improved amplitude and uniformity of the applied pressure, which may lead to improved compactability. In addition, the uninhibited expansion may reduce stress concentrations in the expandable member that may cause damage or fatigue to the expandable member. Thus, the life of the expandable member may be extended.

[0006] The expandable member can be arranged to be detached from the end of the mandrel in response to the expansion of the expandable member. As a result, 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 amplitude and uniformity of the pressure applied by the expandable member to the container in the mold. In addition, the uninhibited expansion can reduce stress concentrations in the expandable member that can cause damage or fatigue to the expandable member. As a result, the life of the expandable member can be extended.

[0007] The end of the mandrel can be rotated relative to the assembly to twist the expandable member around the mandrel. By twisting the expandable member around the mandrel, a greater variation in the width of the expandable member can be achieved than would otherwise be possible without twisting the expandable member. This can enable the mandrel system to be used in conjunction with a wider range of mold geometries. Specifically, some molds may have relatively small openings, but relatively wide mold cavities. In these cases, relatively wide expandable members are required to fully fill these mold cavities. However, the expandable member also needs to be small enough to be inserted into and extracted from the mold via a relatively small opening. By twisting the expandable member around the mandrel, the mandrel system can include a relatively wide expandable member, and the width of the expandable member can still be reduced so that the expandable member can be inserted and extracted through the relatively small opening of the mold. In addition, the inventors have found that twisting and stretching the expandable member can cause the twisting to be more evenly distributed along the length of the expandable member, which can result in a greater width variation than the width variation provided by twisting or stretching alone.

[0008] The mandrel may have a cylindrical shape. By having a cylindrical shape, sharp edges along the length of the mandrel are omitted, which can reduce the possibility of the mandrel damaging the expandable member (e.g., by drilling holes in the expandable member). Alternatively, the ends of the mandrel may be rounded. Thereby, sharp edges at the ends of the mandrel can be omitted.

[0009] The spindle system may include a controller configured to move the end of the spindle relative to the assembly. As a result, the amount of operator input required to operate the spindle system may be reduced compared to, for example, a spindle system in which the operator manually moves the end of the spindle relative to the assembly. This, in turn, may improve overall product quality and consistency. Additionally, this may result in reduced processing time and increased production output.

[0010] The end of the mandrel may be movable relative to the assembly along the longitudinal axis; the end of the mandrel may be rotatable relative to the assembly about the longitudinal axis; and the controller may be configured to rotate the end of the mandrel relative to the assembly about the longitudinal axis while moving the end of the mandrel relative to the assembly along the longitudinal axis. As a result, the expandable member may be elongated when twisted. This may reduce the likelihood of damage to the expandable member during twisting and / or cause the expandable member to collapse or expand more quickly, thereby resulting in reduced processing time and increased production.

[0011] According to a second aspect of the present invention, there is provided a mold system for molding a container, the mold system comprising: a mold, the mold comprising a mold cavity and an opening; a mandrel system of the first aspect, wherein the mandrel system can be inserted into the mold cavity through the opening and can be used in conjunction with the mold to mold a container in the mold cavity. As described above, the width of the expandable member can be thereby changed to facilitate the expansion member to travel through the opening of the mold. In some examples, the container is a bottle, such as a fiber bottle.

[0012] The mandrel system may include a reference point; the mandrel system may 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 the base of the mold cavity opposite to the opening; and the end of the mandrel and the expandable member may be moved relative to the reference point to change the gap. As a result, 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 fills 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. The inhibited expansion may result in the expandable member not being able 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). As a result, this portion of the container may be insufficiently compacted, resulting in the container being fragile and / or the container being of poor quality. Alternatively, the inhibited expansion may cause the expandable member to overstretch to completely fill the lower portion of the container. Overstretching can reduce the uniformity of the pressure applied to the container by the expandable member. This reduction in uniformity can adversely affect the quality of the container, such as causing the container to become brittle or have variable thickness. In addition, overstretching can fatigue the expandable member, thereby shortening the life of the expandable member, or cause the expandable member to rupture. Having a movable mandrel enables the expandable member to be properly positioned within the mold cavity. As a result, the quality of the container manufactured in the mold system can be improved and / or the life of the expandable member can be extended.

[0013] The assembly of the spindle system may include a connector for connecting the spindle system to the mold, and the reference point is included by 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.

[0014] The end of the mandrel can be moved between a first position and a second position relative to the assembly; and when the end of the mandrel is in the second position, the width of the expandable member can be no greater than the width of the opening. Thus, the possibility of the expandable member damaging the container or the expandable member being damaged when being withdrawn from or inserted into the mold cavity is further reduced.

[0015] According to a third aspect of the present invention, a method for molding a container is provided, the method comprising: providing a mold, the mold comprising a mold cavity and an opening; providing a mandrel system of the first aspect; when an expandable member is attached to the assembly and the mandrel is at least partially located inside the expandable member, moving the end of the mandrel relative to the assembly to change the length of the expandable member, and thereby changing the width of the expandable member; and inserting the mandrel system into the mold cavity via the opening or withdrawing the mandrel system from the mold cavity via the opening. As a result, the width of the expandable member can 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 travel through the opening of the mold, which may occur when the expandable member is inserted into the mold cavity and then withdrawn from the mold cavity. Reducing the width can enable the expandable member to travel through the opening without contacting the mold and thereby damaging the expandable member. In addition, in the case where the container is located in the mold cavity and the expandable member is inserted into the container to apply the molding operation to the container, reducing the width can reduce the possibility of the expandable member contacting and damaging the container during insertion and / or withdrawal. Increasing the width of the expandable member during expansion of the expandable member may be advantageous because the expandable member may be able to expand relatively uninhibited by the mandrel. Uninhibited expansion of the expandable member may improve the amplitude and uniformity of the pressure applied by the expandable member to the container during the molding operation. In addition, uninhibited expansion may reduce stress concentration in the expandable member that may cause damage or fatigue to the expandable member and thereby extend the life of the expandable member. In addition, increasing the length of the expandable member may place the expandable member under tension, which may reduce the amount of slack in the expandable member. As a result, the expandable member is less likely to contact and damage the container during insertion and / or withdrawal. Optionally, the method may include expanding the expandable member to apply the molding operation to the container located within the mold cavity. In some examples, the container is a bottle, such as a fiber bottle.

[0016] The method may include at least one of the following: after inserting the mandrel system into the mold cavity via the opening, detaching the end of the mandrel from the expandable member; and before withdrawing the mandrel system from the mold cavity via the opening, attaching the end of the mandrel to the expandable member. As a result, the end of the mandrel can be attached to or detached from the expandable member during different stages of the manufacturing process. For example, when attached to the mandrel, the expandable member can be more easily positioned and moved. This may be beneficial for positioning the expandable member within the mold before expansion and / or during insertion or withdrawal of the expandable member into the mold cavity. When detached 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 can improve the amplitude and uniformity of the pressure applied by the expandable member to the container in the mold cavity. Thus, the quality of the container can be improved due to the improved amplitude and uniformity of the applied pressure, which can lead to improved compactability. In addition, the uninhibited expansion can reduce stress concentrations in the expandable member that can damage or fatigue the expandable member. Thereby, the life of the expandable member can be extended.

[0017] The method may include: expanding an expandable member; and during the expansion of the expandable member, detaching the end of the mandrel from the expandable member. Thereby, the expandable member can move freely relative to the end of the mandrel during expansion, and thereby expand without being inhibited by the end of the mandrel. As discussed above, the uninhibited expansion of the expandable member can improve the amplitude and uniformity of the pressure applied by the expandable member to the container within the mold cavity. In addition, the uninhibited expansion can reduce stress concentrations in the expandable member that can cause damage or fatigue to the expandable member. Thereby, the life of the expandable member can be extended. Alternatively, the method may include expanding the expandable member to apply a molding operation to the container located within the mold cavity; and during the expansion of the expandable member, moving the end of the mandrel relative to the assembly.

[0018] The method may include at least one of the following: rotating the end of the mandrel relative to the assembly to twist the expandable member around the mandrel; and rotating the end of the mandrel relative to the assembly to untie the expandable member from around the mandrel. By twisting the expandable member around the mandrel, a greater variation in the width of the expandable member can be achieved than may otherwise be achieved without twisting the expandable member. This may enable the mandrel system to be used in conjunction with a wider range of mold geometries. Specifically, some molds may have relatively small openings but relatively wide mold cavities. In these cases, relatively wide expandable members are required to fully fill these mold cavities. However, the expandable member also needs to be small enough to be inserted into and extracted from the mold via the relatively small opening. By twisting the expandable member around the mandrel, the mandrel system can include a relatively wide expandable member, and the width of the expandable member can still be reduced so that the expandable member can be inserted and extracted through the relatively small opening of the mold. By untying the expandable member, the expandable member is free to expand uninhibitedly by twisting around the mandrel. Additionally, the inventors have discovered that twisting and elongating the expandable member can cause the twisting to be more evenly distributed along the length of the expandable member, which can result in a greater change in width than provided by twisting or elongating alone.

[0019] Rotating the end of the mandrel relative to the assembly can occur simultaneously with moving the end of the mandrel relative to the assembly to change the length of the expandable member. As a result, the expandable member may be elongated when twisted. This can reduce the likelihood of damage to the expandable member during twisting and / or cause the expandable member to collapse or expand more quickly.

[0020] The mandrel may have a cylindrical shape. By having a cylindrical shape, sharp edges along the length of the mandrel are omitted, which can reduce the possibility of the mandrel damaging the expandable member (e.g., by drilling holes in the expandable member). Alternatively, the ends of the mandrel may be rounded. Thereby, sharp edges at the ends of the mandrel can be omitted.

[0021] Moving the end of the mandrel relative to the assembly may include moving the assembly relative to the mold while maintaining the end of the mandrel stationary relative to the mold. As a result, in preparation for withdrawing the expandable member from the mold cavity, the width of the expandable member can be reduced without requiring the end of the mandrel to move relative to the mold. This may be beneficial because it may enable the end of the mandrel to be located proximate to the base of the mold cavity, which may be desirable for properly positioning the expandable member within the mold cavity.

[0022] The mandrel system may include a reference point; and 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 the base of the mold cavity opposite to the opening of the mold; 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. As a result, 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 fills 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. The inhibited 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). As a result, this portion of the container may be insufficiently compacted, resulting in a fragile container. Alternatively, the inhibited expansion may cause the expandable member to overstretch to completely fill the lower portion of the container. Overstretching can reduce the uniformity of the pressure applied to the container by the expandable member. This reduction in uniformity can adversely affect the quality of the container, such as causing the container to become brittle or have variable thickness. In addition, overstretching can fatigue the expandable member, thereby shortening the life of the expandable member, or cause the expandable member to rupture. Optionally, a component of the mandrel system includes a connector, the connector including a reference point, and positioning the mandrel system includes connecting the connector to the mold. The connector can provide a convenient way to position the mandrel system relative to the mold and to fix the reference point relative to the mold.

[0023] Moving the end of the mandrel relative to the assembly may include moving the end of the mandrel relative to the assembly between a first position and a second position; and when the end of the mandrel is in the second position, the width of the expandable member may be no greater than the width of the opening. Thus, the possibility of the expandable member damaging the container or the expandable member being damaged when being withdrawn from the mold cavity is further reduced.

[0024] The method may include providing a container within a mold cavity, the container being at least partially formed from paper pulp; inserting a mandrel system into the container; and expanding an expandable member as part of a forming operation of the container. From an ecological perspective, paper is a more environmentally friendly choice than plastic. However, because the container is formed from paper pulp, the container is particularly susceptible to damage by the expandable member when the expandable member is inserted into or withdrawn from the container. By varying the width of the expandable component, the width of the expandable component can be reduced to reduce the likelihood that the expandable component will contact and damage the container during insertion and / or withdrawal. Optionally, the forming operation includes thermoforming. In some examples, the container is a bottle, such as a fiber bottle.

[0025] According to a fourth aspect of the invention, there is provided a container obtainable by or by a manufacturing method comprising the method of the third aspect of the invention. The container may be a bottle, such as a fiber bottle. The manufacturing method may include at least one additional process. The at least one additional process may include coating the container to produce a coated container. The at least one additional process may include drying the container or the coated container to produce a dry container. The at least one additional process may include applying a closure to the container, the coated container or the dry container. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0027] Figure 1 A schematic diagram showing an example process for making bottles from pulp;

[0028] Figure 2 A simplified cross-sectional view of an example mold system is shown;

[0029] Figure 3 The various stages of inserting a mandrel system into and withdrawing it 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 moves 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 extends into the mold; (e) the expandable member expands to apply a molding operation to a container located within the mold; (f) the expandable member collapses; (g) the connector and mandrel move to reduce the width of the expandable member; and (h) the mandrel system is withdrawn from the mold;

[0030] 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;

[0031] Figure 5 A simplified cross-sectional view of an alternative example spindle system is shown;

[0032] Figure 6 The various stages of inserting and withdrawing an alternative example mandrel system from a mold are illustrated by simplified cross-sections, wherein (a) the alternative example mandrel system is located outside the mold; (b) the mandrel moves 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 extends into the mold; (e) the expandable member expands to apply a molding operation to a container located within the mold; (f) the expandable member collapses; (g) the connector and mandrel move to reduce the width of the expandable member; and (h) the alternative example mandrel system is withdrawn from the mold;

[0033] Figure 7 shows a simplified cross-sectional view of another example spindle system; and

[0034] Figure 8 Simplified cross-sections are used to illustrate different stages of inserting and withdrawing another example mandrel system from a mold, wherein (a) another example mandrel system is located outside the mold; (b) the mandrel moves relative to the connector to reduce the width of the expandable member of the other example mandrel system; (c) another example mandrel system is inserted into the mold; (d) another example mandrel system extends into the mold; (e) the expandable member expands to apply a molding operation to a container located within the mold; (f) the expandable member collapses; (g) the connector and mandrel move to reduce the width of the expandable member; and (h) another example mandrel system is withdrawn from the mold. DETAILED DESCRIPTION

[0035] The following description presents exemplary embodiments and, together with the accompanying drawings, serves to explain principles of embodiments of the present invention.

[0036] Figure 1 A process for making a bottle from pulp (i.e., pulp that may form the basis of an example fiber suspension) is shown. The process is merely exemplary and is provided to provide context for examples of the invention. Broadly speaking, the exemplary method 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.

[0037] 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 the 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.

[0038] 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.

[0039] 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 are in contact with 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 combined 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 "splits" or "molds", and the overall porous first mold 15 can be considered a "split mold" or again considered 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.

[0040] 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 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 that is sucked together with the fiber suspension in the line 16 is water, or mainly water (because additives may also be present). The liquid sucked in under vacuum via the line 18 and into the tank 17 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.

[0041] 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 expansion 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 inflation 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 inflation element 19 so that the inflation 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).

[0042] 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.

[0043] 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 are 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.

[0044] 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.

[0045] The molded container 22 then enters 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 undergoes 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, the curing process 34 can be omitted, such as when the further drying phase 30 occurs after the coating phase.

[0046] 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.

[0047] Figure 2 A mold system 101 is shown that can 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.

[0048] The mold 103 includes a first part 111 and a second part 113. In other examples, the mold 103 may include more than two parts. The two parts 111, 113 can be separated to open the mold 103. Each part includes a cavity. When the two parts 111, 113 are put together to close the mold 103, a mold cavity 115 is formed in the mold 103, which includes the cavities of the first part 111 and the second part 113. In this particular example, the mold cavity 115 has the shape of a bottle and includes a body portion and a neck. The neck has a diameter smaller than 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 distance between the base 119 and the opening 117 is fixed, 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.

[0049] The mandrel system 105 includes a connector 121, a mandrel 123, an expandable member 125, a first actuator 127, a second actuator 129, a controller 131, and a control panel (not shown).

[0050] The connector 121 includes an orifice 122 that extends through the connector 121 from the top of the connector 121 to the bottom of the connector. An annular seal is located within the orifice 122 and provides a seal between the connector 121 and the mandrel 123 extending through the orifice 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 withdrawn from the mold 102, the mandrel 123 moves relative to the reference point 133. In other examples, the reference point 133 may be included by other components of the mandrel system 105.

[0051] The mandrel 123 includes a cylindrical tube 134 and a first part 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 at a position 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 part 137 of the attachment mechanism includes a magnet located at the lower end of the mandrel 123, i.e., at the end of the mandrel 123 located within the expandable member 125. The mandrel 123 extends through the orifice 122 in the connector 121 and into the expandable member 125 so that the lower portion of the mandrel 123 is located within the expandable member 125. In some examples, the mandrel 123 can be located entirely within the expandable member 125 and a different connector 121 can be used. The upper portion of the mandrel 123 is connected to the pipeline 109. The spindle 123 is free to move relative to the connector 121, and therefore free to move relative to the reference point 133. Specifically, the spindle 123 is free to move up and down within the aperture 122, and rotate within the aperture 122 in the connector 121.

[0052] The expandable member 125 includes an inflatable member in the form of an elastic bladder 138. The bladder 138 includes a neck and a body portion. The neck is sealingly connected to the bottom of the connector 121. The neck has a diameter smaller than the body portion. In other examples, the bladder 138 may include a single portion having a constant diameter. The second part 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 mandrel 123 to removably connect the expandable member 125 to the mandrel 123.

[0053] 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 an electric motor and a transmission (e.g., a gear, a friction wheel, and / or a rack and pinion) for transmitting the torque generated by the electric 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.

[0054] The second actuator 129 is located at the top end of the spindle 123 and is coupled to the spindle 123. 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 an electric motor and a transmission (e.g., a gear, a friction wheel, and / or a rack and pinion) for transmitting the torque generated by the electric 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.

[0055] 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 then improves the control of the linear and rotational movement of the spindle 123, and can independently control 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 electric motor, and one or more of the transmissions may be clutched. In this way, the advantages of independent control of the linear and rotational movement of the spindle can be achieved using a single electric motor. The controller 131 controls the operation of the actuators 127, 129, and thereby controls 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.

[0056] 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.

[0057] The pump 107 includes a cylinder that can discharge 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, the discharge of 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 tube 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, and thereby collapse and shrink the expandable member 125.

[0058] Now it will pass Figure 3 The use of the mold system 101 is provided. Figure 3(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.

[0059] Now turn to Figure 3 (b), the controller 131 controls the first actuator 127 to move the mandrel 123 downward relative to the reference point 133. When the mandrel 123 moves downward, the end of the mandrel 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 a corresponding decrease in the width of the expandable member 125. At the same time, the controller 131 operates the second actuator 129 to rotate the mandrel 123 relative to the reference point 133. Since the expandable member 125 is attached to the end of the mandrel 123 by an attachment mechanism (i.e., the magnet 137 and the metal plate 139), the rotation causes the expandable member 125 to twist around the mandrel 123. By twisting and stretching the expandable member 125, a greater reduction in the width of the expandable member 125 can be achieved compared to twisting or stretching alone.

[0060] 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. Thus, the mandrel 123 and the expandable member 125 can travel through the opening 117 of the mold 103 without the expandable member 125 contacting the mold 103 or the container 22. Beneficially, this can reduce the possibility of the container 22 being damaged by the expandable member 125 and the expandable member 125 being damaged by the mold 103.

[0061] Now turn to Figure 3 (c), the controller 131 then controls the robot arm to move the connector 121 downward and toward the mold 103 until the connector 121 contacts and connects to the top of the mold 103 (eg, 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. Since the mandrel 123 previously moved downward relative to the connector 121 (refer to Figure 3(b) Discussion), the length of the mandrel 123 is too large to fit into the mold cavity 115. Therefore, once the mandrel 123 of a predetermined length is 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 and at the same rate of travel as the connector 121 moves downward toward the mold 103. As a result, 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.

[0062] 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 As shown in (d), 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. The gap is the minimum separation distance between the base 119 of the mold cavity and the expandable member 125 when the reference point 133 is in a fixed position relative to the mold 103. 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 will be discussed in more detail below.

[0063] The controller 131 then operates the second actuator 129 to rotate the mandrel 123 relative to the reference point 133 to unwind the expandable member 125 from around the mandrel 123. This then causes the width of the expandable member 125 to further increase.

[0064] When the expandable member 125 is now located within the mold cavity 115, the molding 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 causing the expandable member 125 to be removed from the end of the mandrel 123. The expandable member 125 continues to expand in the container. When expanded to a sufficient size, the expansion member 125 contacts the container 22 and presses it against the mold 103 to form the container 22.

[0065] Now turn to Figure 3 (f), once the forming operation is complete, the controller 131 controls the pump 107 to withdraw 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.

[0066] 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 connector 121 moves upward, so that the end of the mandrel 123 is stationary relative to the mold 103. As a result, 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. When the expandable member 125 is elongated 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.

[0067] Now turn to Figure 3 (h), the controller 131 controls the robot arm to move the connector 121 upward relative to the mold 103 to extract 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 extracted from the mold 103, the mold 103 is opened by separating the two parts 111, 113, and the container 22 is removed 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.

[0068] 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 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 fills the lower portion of the container 22. Then, further expansion of the expandable member 125 in the downward direction may be inhibited by friction between the expandable member 125 and the upper portion of the container 22. The inhibited 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). As a result, this portion of the container 22 may not be sufficiently compacted, resulting in the container 22 being fragile. Alternatively, the inhibited expansion may cause the expandable member 125 to overstretch to completely fill the lower portion of the container 22. Overstretching can reduce the uniformity of the pressure applied to the container 22 by the expandable member 125. This reduction in uniformity can adversely affect the quality of the container 22, such as causing the container 22 to become brittle or have variable thickness. In addition, overstretching can fatigue the expandable member 125, thereby shortening the life of the expandable member 125, or causing the expandable member 125 to rupture. Having a movable mandrel 123 enables the expandable member 125 to be properly positioned within the mold cavity 115. As a result, 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 extended.

[0069] By moving the mandrel 123 relative to the connector 121 to change the length of the expandable member 125, and thereby change 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 expansion of the expandable member 125 through the opening 117 of the mold 103, which may occur when the expandable member 125 is inserted into the mold 103 and then withdrawn from the mold. Reducing the width may enable the expandable member 125 to travel 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 withdrawal. Increasing the width of the expandable member 125 during expansion of the expandable member 125 may be advantageous because the expandable member 125 may be able to expand relatively uninhibited by the mandrel 123. 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 during the molding operation. In addition, uninhibited expansion can reduce stress concentrations in the expandable member 125 that can damage or fatigue the expandable member 125 and thereby extend the life of the expandable member 125.

[0070] In the above example, the end of the mandrel 123 is removably attached to the expandable member 125. As a result, the end of the mandrel 123 can be attached to or detached from the expandable member 125 during different stages of the manufacturing process. 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 insertion or extraction of the expandable member 125 into or from the mold. When detached 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 amplitude and uniformity of the pressure applied by the expandable member 125 to the container 22 within the mold 103. Thus, the quality of the container 22 can be improved due to the improved amplitude and uniformity of the applied pressure, which can lead to improved compactability. In addition, the uninhibited expansion can reduce stress concentrations in the expandable member 125 that can damage or fatigue the expandable member 125. Thus, the life of the expandable member 125 can be extended.

[0071] In the above example, 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 may be used. As discussed above, as the gap between the bottom of the expandable member and the base of the mold decreases, the likelihood of the expandable member 125 being inhibited from expanding downward decreases. This can reduce the likelihood of the container 22 being fragile due to insufficient compaction and / or the expandable member 125 being fatigued due to excessive stretching of the expandable member 125. However, as the gap decreases, the likelihood of the expandable member 125 undergoing suboptimal expansion increases. Specifically, the expandable member 125 may contact the bottom of the container 22 prematurely, which may inhibit the expandable member 125 from subsequently expanding outward to the corners of the container 22. This may reduce the quality of the container 22 and / or shorten the life of the expandable member 125, as also described above. By having a gap of no more than 11mm and no less than 2mm, a good balance between the competing demands of reducing the likelihood of inhibited downward expansion and reducing the likelihood of suboptimal expansion can be provided.

[0072] 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 that is indexed using the received characteristics of the mold 103 and the received characteristics of the expandable member 125. Thus, if a different mold or a different expandable member is used, the operator does not need to calculate a new gap. Thus, 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 ​​for different characteristics. The characteristic of the mold 103 may be one of the height, width, and geometry of the mold 103. The characteristic of the expandable member 125 may be one of the height, width, geometry, and elasticity of the expandable member 125.

[0073] Now turn to Figure 4 , the mold system 101 also 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. As a result, 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. As a result, the expandable member 125 can be appropriately positioned for each mold 103, 201 without the need to customize the mandrel and expandable member for each mold 103, 201. By eliminating the 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.

[0074] In the above example, the first part 137 of the attachment mechanism includes a magnet 137, and the second part 139 of the attachment mechanism includes a magnetically attractive element in the form of a metal plate 139. Likewise, in other examples, the first part 137 and the second part 139 can include a plug and a socket, or a clamp and a clampable structure. In fact, it is conceivable that the attachment mechanism is a single component located on the mandrel 123 or the expandable member 125, for example, a clamp on the mandrel 123 that can clamp a portion of the expandable member 125.

[0075] In the above example, connector 121 contacts and connects to the top of mold 103. However, in other examples, connector 121 cannot contact and connect to the top of mold 103. Instead, connector 121 can move downward until connector 121 is located at a specified position above the top of mold 103, with mandrel 123 and expandable member 125 extending into mold 103. In this example, when connector 121 is located at the specified position, reference point 133 is located at a fixed position relative to mold 103.

[0076] In the above example, the movement of the connector 121 and the spindle 123 is controlled by the controller 131. However, it is contemplated that the operator may manually control the movement. However, the use of a controller may improve overall product quality and may result in reduced processing time and increased production.

[0077] In the above example, mandrel 123 and expandable member 125 of mandrel system 105 are inserted into and withdrawn from mold cavity 115 through opening 117. It should be understood that the entire mandrel system 105 need not be inserted. Thus, inserting means that at least a portion of mandrel system 105 is inserted.

[0078] In the above examples, the mandrel system 123 includes attachment mechanisms 137, 139 for removably attaching the expandable member 125 to the mandrel 123. However, in other examples, the attachment mechanism may be omitted. For example, Figure 5 An example of a mandrel system 301 is shown in which the expandable member 125 is fixedly attached to the mandrel 123. The mandrel system 301 and Figure 2 The spindle system is the same as that of the , but with the following differences.

[0079] 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 mandrel 123 .

[0080] The first actuator 303 is operable in a first mode and a second mode. In the first mode, the first actuator 303 moves the spindle 123 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 separated 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 connected to the spindle 123, but provides little or no resistance to the movement of the spindle 123. In an example in which the first actuator 303 includes a hydraulic system, the hydraulic system can be exhausted to the atmosphere in the idle mode.

[0081] Now turn to Figure 6 , the spindle system 301 is with Figure 2 The spindle system operates in the same manner, but with the following differences.

[0082] The expandable member 123 remains attached to the mandrel 125 during all stages of operation. The controller 131 operates the first actuator 127 in a first mode to move the mandrel 123 up and down relative to the reference point 133.

[0083] In order to perform the 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. As a result, 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 expanded sufficiently, the expansion member 125 contacts the container 22 and presses it against the mold 103 to form the container 22.

[0084] Now turn to Figure 6 (f), once the molding operation is completed, the controller 131 controls the pump 107 to withdraw 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.

[0085] 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. As a result, 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.

[0086] 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 cause the mandrel 123 to move in a manner that is consistent with the reference point 133. Figure 3(e) matches the expansion speed of the disassembled expandable member 125 moving downward toward the base 119 of the mold 103. During the subsequent collapse of the expandable member 125, the first actuator 303 can move the mandrel 123 upward away from the base 119 of the mold 103, thereby causing the expandable member 125 to collapse.

[0087] 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 7 An example of a spindle system 401 is shown, which includes a two-part spindle 403. The spindle system 401 and Figure 5 The spindle system 105 is the same as that of FIG. 1 , but has the following differences.

[0088] The mandrel 403 includes a first member 405 and a second member 407. The first member 405 has the form of a cylindrical tube and includes a plurality of holes 135 formed along the length of the first member 405. The holes 135 are located along a lower portion of the first member 405 and extend radially through the first member 405 to allow fluid to flow from the interior of the mandrel 403 to the exterior of the mandrel 403.

[0089] The second component 405 has a cylindrical shape and has an outer diameter that is smaller than the inner diameter of the first component 409. The second component 407 is located inside the first component 405 at the lower end of the first component 405. One end of the second component 407 is attached to the main body of the expandable member 125. The second component 407 is keyed to the first component 405 so that the second component 407 moves linearly relative to the first component 405, but is prevented from rotating relative to the first component 405. For example, the first component 405 may include a channel extending parallel to the longitudinal axis of the first component 405, and the second component 407 may include a protrusion received in the channel. The second component 407 moves between a retracted position and an extended position along the longitudinal axis of the first component 405. The length of the mandrel 403 is greater in the extended position than in the retracted position.

[0090] The first actuator 409 and the second actuator 411 are similar to Figure 5129, except that the first actuator 409 operates only in the first mode. The actuators 409, 411 are each coupled to a first member 405 of the spindle. The first actuator 409 is operable to cause the first member 405 of the spindle 403 to move linearly 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 cause the first member 405 of the spindle 403 to rotate relative to the connector 121 and the reference point 133. Since the first member 405 is keyed to the second member 407 of the spindle 403, the rotation of the first member 405 causes the second member 407 to also rotate.

[0091] Now turn to Figure 8 , the spindle system 401 is with Figure 5 The spindle system operates in the same manner, but with the following differences.

[0092] like Figure 8 As 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. Thus, when the expandable member 125 is in the collapsed state, the second part 407 of the mandrel 403 is biased toward the retracted position by the expandable member 125. Specifically, the elasticity of the expandable member 125 biases the second part 407 toward the retracted position.

[0093] In order to perform the 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 part 407 of the mandrel 403 to move from a retracted position to an extended position. The expandable member 125 continues to expand within the container 22. When expanded sufficiently, the expansion member 125 then contacts the container 22 and applies pressure to press the container 22 against the mold 103 to form the container 22.

[0094] Now turn to Figure 8(f), once the molding operation is complete, the controller 131 controls the pump 107 to pump 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 part 407 of the mandrel 403 to move from the extended position to the contracted position.

[0095] exist Figure 7 In the example of FIG. 4 , the expandable member 125 is attached to the second component 407 of the mandrel 403, and the second component 407 moves relative to the first component 405 in response to the expansion of the expandable member 125. As a result, the above-mentioned benefits of relatively uninhibited expansion of the expandable member 125 while still attached to the mandrel 403 can be achieved. In addition, providing a two-component mandrel 403 can provide a convenient way to enable the end of the mandrel 403 to move relative to the connector 121 in response to the expansion of the expandable member.

[0096] exist Figure 7 In the example of FIG. 1 , the first part 405 of the mandrel 403 is movable relative to the connector 121. However, it is contemplated that in other examples, the first part 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 part 405 move together during insertion and withdrawal of the mandrel 403 and the expandable member 125. During expansion and collapse of the expandable member 125, the second part 407 of the mandrel 403 is still able to move relative to the first part 405 of the mandrel 403, and thus the expansion and collapse of the expandable member 125 continues to be uninhibited by the mandrel 403.

[0097] In the above example, the movement of the mandrel 123 relative to the reference point 133 is controlled so that the gap between the bottom of the expandable member 125 and the base 119 of the mold 103 can be changed. However, it is conceivable that in other examples, the movement of the mandrel 123 relative to the reference point 133 may not cause the gap to change. For example, the lower end of the mandrel 123 may not be attached to the bottom of the expandable member 125. The gap between the bottom of the expandable member 125 and the base 119 of the mold 103 is then determined by the natural (unstretched) length of the expandable member 125. If the connector 121 is moved upward relative to the mandrel 123, the end of the mandrel 123 will contact the bottom of the expandable member 125 and apply a force to increase the length, and thereby reduce the width of the expandable member 125. Then, moving the connector 121 downward relative to the mandrel 123 will eliminate the force, causing the expandable member 125 to return to its natural length and width. This arrangement can achieve the above-mentioned benefit of varying the width of expandable member 125 to suit the requirements of the manufacturing process, but may not achieve the above-mentioned benefit of properly positioning expandable member 123. However, because the gap is determined by the natural length of expandable member 125, expandable member 125 can be optimized for the specific geometry of mold 103.

[0098] 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 mandrel system for use in conjunction with a mold to mold a container, the mandrel system comprising: Components; Mandrel; as well as an expandable member, in: the mandrel being or being locatable at least partially within the interior of 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 expandable member is attached or attachable to the assembly; and When the expandable member is attached to the assembly and the mandrel is at least partially located within the expandable member, the end of the mandrel is movable relative to the assembly to change the length, and thereby the width, of the expandable member.

2. The mandrel system of claim 1, wherein the expandable member is attached or attachable to the end of the mandrel.

3. The mandrel system of claim 2, wherein the expandable member is removably attached or removably attachable to the end of the mandrel.

4. The mandrel system of claim 3, wherein the expandable member is arranged to be detached from the end of the mandrel in response to expansion of the expandable member.

5. The mandrel system of any one of claims 1 to 4, wherein the end of the mandrel is rotatable relative to the assembly to twist the expandable member about the mandrel.

6. The mandrel system of any one of claims 1 to 5, wherein the mandrel has a cylindrical shape.

7. The spindle system of any one of claims 1 to 6, wherein the spindle system comprises a controller configured to move the end of the spindle relative to the assembly.

8. The spindle system of claim 7, wherein: The end of the mandrel is movable relative to the assembly along a longitudinal axis; The end of the spindle is rotatable relative to the assembly about the longitudinal axis; and The controller is configured to rotate the end of the mandrel relative to the assembly about the longitudinal axis while simultaneously moving the end of the mandrel relative to the assembly along the longitudinal axis.

9. 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 The spindle system according to any one of claims 1 to 8, Wherein the mandrel system is insertable into the mold cavity through the opening and can be used in conjunction with the mold to mold the container in the mold cavity.

10. The mold system of claim 9, wherein: The spindle system includes a reference point; The mandrel system is positionable 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 such that a gap exists between the expandable member and a seat of the mold cavity opposite the opening; and The end of the mandrel and the expandable member are movable relative to the reference point to change the gap.

11. The mold system of claim 10, wherein the component of the spindle system includes a connector for connecting the spindle system to the mold, and the reference point is included by the connector.

12. The mold system according to any one of claims 9 to 11, wherein: The end of the mandrel is movable relative to the assembly between a first position and a second position; and When the end of the mandrel is in the second position, the width of the expandable member is no greater than a width of the opening.

13. A method for molding a container, the method comprising: providing a mold, the mold comprising a mold cavity and an opening; Providing a spindle system as claimed in any one of claims 1 to 8; moving the end of the mandrel relative to the assembly to change the length, and thereby the width, of the expandable member when the expandable member is attached to the assembly and the mandrel is at least partially located within the expandable member; as well as The mandrel system is inserted into the mold cavity via the opening or the mandrel system is extracted from the mold cavity via the opening.

14. A method as claimed in claim 13, wherein the method includes at least one of the following: after inserting the mandrel system into the mold cavity through the opening, detaching the end of the mandrel from the expandable member; and before withdrawing the mandrel system from the mold cavity through the opening, attaching the end of the mandrel to the expandable member.

15. The method of claim 13 or 14, wherein the method comprises: expanding the expandable member; as well as During expansion of the expandable member, the end of the mandrel is detached from the expandable member.

16. A method as described in any one of claims 13 to 15, wherein the method includes at least one of: rotating the end of the mandrel relative to the assembly to twist the expandable member around the mandrel; and rotating the end of the mandrel relative to the assembly to untie the expandable member from around the mandrel.

17. The method of claim 16, wherein rotating the end of the mandrel relative to the assembly occurs simultaneously with moving the end of the mandrel relative to the assembly to change the length of the expandable member.

18. The method of any one of claims 13 to 17, wherein the mandrel has a cylindrical shape.

19. The method of any one of claims 13 to 18, wherein: Moving the end of the mandrel relative to the assembly includes moving the assembly relative to the mold while maintaining the end of the mandrel stationary relative to the mold.

20. The method of any one of claims 13 to 19, wherein: The spindle system includes a reference point; and The method comprises: moving the mandrel and the expandable member relative to the reference point to change a gap between the expandable member and a seat of the mold cavity opposite the opening of the mold; and The mandrel system is positioned relative to the mold such that the reference point is at a fixed position relative to the mold and the mandrel and the expandable member extend through the opening into the mold cavity.

21. The method of any one of claims 13 to 20, wherein: Moving the end of the mandrel relative to the assembly includes moving the end of the mandrel relative to the assembly between a first position and a second position; and When the end of the mandrel is in the second position, the width of the expandable member is no greater than a width of the opening.

22. The method of any one of claims 13 to 21, wherein the method comprises: providing a container within the mold cavity, the container being at least partially formed from paper pulp; inserting the mandrel system into the container; as well as As part of the forming operation of the container, the expandable member is expanded.

23. A container obtainable by or by a method of manufacturing comprising the method of any one of claims 14 to 22.

24. A container as claimed in claim 23, wherein the container is a bottle, such as a fibre bottle.

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