Molding of hollow molded fibrous articles

Abstract

A mold for further forming a hollow molded fibrous article, said mold comprising: one or more inner surfaces collectively defining a cavity within which further forming is performed, the one or more inner surfaces comprising one or more porous regions extending to cover at least a majority of the total internal area of the cavity; a plurality of pores; and a delivery system configured to operatively engage the hollow molded fibrous article with the mold for further molding. The pores are distributed over the porous region to provide a continuous porosity over the porous region, and the pores have an average pore size of less than or equal to 90 [mu] m. A molding system comprising such a mold, a method of making such a mold, and a method of providing a processed hollow molded fibrous article using such a mold are also provided.

Description

Technical Field

[0001] This invention relates to methods and systems for manufacturing containers using fiber suspensions, such as fiber suspensions comprising pulp. The containers can be consumer packaging for containing liquids, powders, other flowable substances, one or more solid objects, or combinations thereof, such as bottles, jars, or certain types of vases. Background Technology

[0002] The aim is to reduce the use of glass and plastic in consumer goods, especially packaging. Neckless containers, such as trays, bowls, and other simple-shaped containers, are typically made of pulp. However, more complex necked containers, such as bottles, jars, or certain types of vases, are more difficult to design due to the narrowing of the interior between the container body and the opening.

[0003] Various methods for manufacturing containers using fiber suspensions are known. Many of these methods involve molding hollow molded fiber articles, which can be further processed to provide finished containers. In particular, such further processing may include additional molding processes on the hollow molded fiber articles to further shape them. For example, such further molding can be used to achieve desired necks and surface finishes, such as embossed and / or dented surface features. Further molding can also (or conversely) increase the rigidity and / or strength of the hollow molded fiber articles, for example, by compressing the hollow molded fiber articles and / or by removing liquid / water from them. However, such further molding processes still present some challenges, such as in achieving an appropriate level of quality for the hollow molded fiber articles and / or achieving an appropriate yield level for the further molding processes. Summary of the Invention

[0004] To alleviate the aforementioned problems related to achieving appropriate quality levels and / or appropriate yield levels for further molding processes of hollow molded fiber articles, and / or to alleviating other problems related to further molding of hollow molded fiber articles, the inventors propose using a mold for such further molding that comprises a plurality of pores with an average pore size less than or equal to 90 μm, distributed over one or more porous regions of the mold cavity to provide continuous porosity over these porous regions. The inventors believe that a mold with pores having an average pore size less than or equal to 90 μm can provide a suitable quality level for the further molded hollow molded fiber article, for example, including a relatively smooth surface on the hollow molded fiber article. Furthermore, when these pores are distributed over one or more porous regions of the mold cavity to provide continuous porosity over these porous regions, these porous regions extend to cover at least a majority of the total internal area of ​​the mold cavity, and these pores appropriately drain moisture and / or vapor from the mold cavity during the further molding of the hollow molded fiber article. This discharge reduces (or eliminates) the need for additional drying of hollow molded fiber articles, thereby increasing yield in further molding processes. The inventors further believe that the continuous porosity provided by the pores helps the hollow molded fiber articles achieve a suitable quality level. For example, this is because it avoids significant discontinuities in drying rates between different regions of the hollow molded fiber article. The inventors believe that such discontinuities in drying rates could cause different regions to shrink at significantly different rates, thereby increasing the risk of warping during further molding.

[0005] Therefore, according to a first aspect of the invention, a molding system for providing a finished hollow molded fiber article is provided, the system comprising: a mold for further molding the hollow molded fiber article to provide a finished hollow molded fiber article, the mold comprising: one or more inner surfaces that collectively define a cavity within which the further molding of the hollow molded fiber article is performed during system use, the cavity having a total internal area, and the one or more inner surfaces comprising one or more porous regions extending to cover at least a majority of the total internal area; a plurality of pores distributed over the one or more porous regions to provide a continuous porosity over the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; and a conveying system configured to operatively engage the hollow molded fiber article with the mold for further molding.

[0006] It has been found that molds with an average pore size of less than or equal to 90 μm can provide a relatively smooth surface for hollow molded fiber products after further molding, while also allowing sufficient drainage of fluids, such as steam or liquids (e.g., steam or water), from the cavity of the mold during the further molding process of the hollow molded fiber products.

[0007] Optionally, the system further includes: a master mold comprising a cavity; and a fiber suspension supply system configured to deposit a quantity of fiber suspension into the cavity of the master mold, such that the quantity of fiber suspension can be formed into a hollow molded fiber article through the cavity of the master mold. In the example, the master mold is positioned upstream of a mold for further forming the hollow molded fiber article. Alternatively or additionally, a conveying system may be configured to convey the hollow molded fiber article from the master mold to an operatively engaged mold for further forming of the hollow molded fiber article.

[0008] Optionally, the system also includes a heating system for heating the hollow molded fiber article during further molding of the article through a mold. In an example, the heating system includes a heater operable to heat the mold, which in turn heats the hollow molded fiber article (e.g., by heat conduction). In such an example, the mold can be described as a thermoforming mold. Alternatively (or additionally), the heating system can be configured to supply heated fluid to the interior of the hollow molded fiber article.

[0009] Optionally, the system also includes a pressurizing system for applying pressure to the interior of the hollow molded fiber article during further molding of the article through a mold, so as to press the exterior of the hollow molded fiber article against one or more inner surfaces of the mold. In an example, the pressurizing system includes an expandable element, such as an inflatable element, configured to expand during further molding of the hollow molded fiber article using a mold, such that the exterior of the expandable element presses against the interior of the hollow molded fiber article, thereby applying pressure to the interior of the hollow molded fiber article.

[0010] According to a second aspect of the invention, a method for providing a processed hollow molded fiber article is provided, the method comprising: placing the hollow molded fiber article into a mold, the mold comprising: one or more inner surfaces that collectively define a cavity having a total internal area, the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; a plurality of pores distributed over the one or more porous regions to provide continuous porosity over the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; and further forming the hollow molded fiber article within the cavity of the mold to provide the processed hollow molded fiber article.

[0011] It has been found that using a mold with an average pore size of less than or equal to 90 μm to further mold hollow molded fiber articles can provide a relatively smooth surface for the hollow molded fiber articles, while also allowing sufficient drainage of fluids, such as steam or liquids (e.g., steam or water), from the cavity of the mold during the further molding process of the hollow molded fiber articles.

[0012] In the example, during the further molding process of the hollow molded fiber article, a fluid (such as steam or liquid, like water vapor or water) exits the cavity of the mold through multiple pores. Subsequently, the fluid can flow through the outer surface of the mold and exit the mold.

[0013] Optionally, further shaping the hollow molded fiber article in the cavity of the mold to provide the finished hollow molded fiber article includes at least one of the following: moving the mold to a closed position so that the hollow molded fiber article is located in the cavity of the mold; and pressing the exterior of the hollow molded fiber article against one or more inner surfaces of the mold.

[0014] Optionally, further shaping the hollow molded fiber article within the cavity of the mold to provide a finished hollow molded fiber article includes heating the hollow molded fiber article. In an example, heating the hollow molded fiber article includes heating the mold. In such an example, the mold may, in turn, heat the hollow molded fiber article (e.g., by heat conduction). Alternatively (or additionally), heating the hollow molded fiber article may include introducing heated fluid into the interior of the hollow molded fiber article. In an example where further shaping the hollow molded fiber article includes pressing the exterior of the hollow molded fiber article against one or more inner surfaces of the mold, heating the hollow molded fiber article may be performed during pressing the exterior of the hollow molded fiber article against one or more inner surfaces of the mold.

[0015] In an example where further molding of the hollow molded fiber article includes pressing the exterior of the hollow molded fiber article against one or more inner surfaces of a mold, pressing the exterior of the hollow molded fiber article against one or more inner surfaces of the mold includes applying pressure to the interior of the hollow molded fiber article. In a particular example, applying pressure to the interior of the hollow molded fiber article includes inflating an inflatable element such that the exterior of the inflatable element presses against the interior of the hollow molded fiber article.

[0016] According to a third aspect of the invention, a mold is provided for further shaping a hollow molded fiber article to provide a finished hollow molded fiber article, the hollow molded fiber article being operatively engaged with the mold via a conveying system, the mold comprising: one or more inner surfaces that collectively define a cavity within which the hollow molded fiber article is further shaped during mold use, the cavity having a total internal area; the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and a plurality of pores distributed over the one or more porous regions to provide continuous porosity over the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm.

[0017] It has been found that using a mold with an average pore size of less than or equal to 90 μm to further mold hollow molded fiber articles can provide a relatively smooth surface for the hollow molded fiber articles, while also allowing sufficient drainage of fluids, such as steam or liquids (e.g., steam or water), from the cavity of the mold during the further molding process of the hollow molded fiber articles.

[0018] In the example, the mold is a thermoforming mold. Therefore (or otherwise), the mold may include or be connected to a heater.

[0019] According to a fourth aspect of the invention, a method for manufacturing a mold is provided for further shaping a hollow molded fiber article that has been operatively engaged with the mold by a conveying system, the mold comprising: one or more inner surfaces that collectively define a cavity in which further shaping of a container is performed during use of the mold, the cavity having a total internal area; the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and a plurality of pores distributed on the one or more porous regions to provide continuous porosity on the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; the method comprising: forming the mold into one or more parts.

[0020] Optionally, forming one or more parts from a mold includes additive manufacturing of the one or more parts. In an example, additive manufacturing of the one or more parts includes receiving data defining the three-dimensional shape of each of the one or more parts. Alternatively, additive manufacturing of the one or more parts includes sintering particles. In an example, the particles are made of metal.

[0021] Optionally, manufacturing the mold into one or more parts includes machining at least one piece of porous material. As used herein, "machining" refers to the use of a subtractive manufacturing process. In examples, the porous material is metallic, such as porous aluminum or a porous aluminum alloy, or porous stainless steel. In some examples, machining may be performed under computer control and may include, for example, receiving data on a computer defining the three-dimensional shape of each of the one or more parts.

[0022] In some examples of the systems, methods, and molds disclosed herein, the average pore size is less than or equal to 80 μm, while in other examples, the average pore size is less than or equal to 70 μm, and in still other examples, the average pore size is less than or equal to 60 μm. In further examples, the average pore size is less than or equal to 50 μm, and in yet another example, the average pore size is less than or equal to 40 μm. In still more advanced examples, the average pore size is less than or equal to 30 μm, and in yet another example, the average pore size is less than or equal to 20 μm.

[0023] In some examples of the systems, methods, and molds disclosed herein, the average pore size is greater than or equal to 10 μm. This allows for a relatively high level of venting of moisture and / or vapor from the cavity to the outside of the mold 125 during further molding of the hollow molded fiber article. However, in some examples, the average pore size may be less than or equal to 10 μm.

[0024] In the examples of the systems, methods, and molds disclosed herein, the mold for further molding hollow molded fiber articles comprises aluminum, comprising at least Y% by weight of the total weight of the mold, wherein Y is 50%. In some examples, Y is 60%, in others it is 70%, in still others it is 80%, and in yet another example it is 90%.

[0025] In other examples of the systems, methods, and molds disclosed herein, the molds used for further molding hollow molded fiber articles comprise stainless steel, comprising at least Y% by weight of the total weight of the mold, where Y is 50%. In some examples, Y is 60%, in others 70%, in still others 80%, and in yet another 90%.

[0026] In some examples of the systems, methods, and molds disclosed herein, each hole has a circular cross-sectional shape in a plane orthogonal to the central axis of the hole. Therefore, each hole can be considered circular.

[0027] According to a fifth aspect of the invention, a control system is provided, which is configured to cause a molding system to perform the method for providing processed hollow molded fiber articles as described in any of the examples disclosed herein.

[0028] A non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a molding system controller, cause the molding system to perform any of the methods for providing processed hollow molded fiber articles as described in the examples disclosed herein.

[0029] In some examples of the above aspects, one or more porous regions extend to cover at least 60% of the total interior area. In other examples, they extend to cover at least 70% of the total interior area.

[0030] In some examples of any of the foregoing aspects, the finished hollow molded fiber article is a hollow molded fiber article with a neck, such as a bottle, jar, or a type of vase. In some examples of any of the foregoing aspects, the finished hollow molded fiber article is a bottle.

[0031] According to a sixth aspect of the invention, a container production line is provided, comprising a molding system for providing a processed hollow molded fiber article according to any of the examples disclosed herein, and means for performing at least one additional processing on the processed hollow molded fiber article to provide a container.

[0032] The apparatus may include an internal coating machine, and at least one additional processing may include the internal coating machine coating at least a portion of the interior of an article to produce an internally coated article. The apparatus may include a sealing portion applicator, and at least one additional processing may include the sealing portion applicator applying a sealing portion to the article or an internally coated article to produce a closable or enclosed article. The apparatus may include an external coating machine, and at least one additional processing may include the external coating machine coating at least a portion of the exterior of the article, the internally coated article, or the closable or enclosed article to produce an externally coated article. The apparatus may include a decorator, and at least one additional processing may include the decorator decorating the article, the internally coated article, the closable or enclosed article, or the externally coated article to produce a decorated article. The apparatus may include a dryer, and at least one additional processing may include the dryer drying the article, the internally coated article, the closable or enclosed article, the externally coated article, or the decorated article to produce a dried article. The apparatus may include an evaluator, and at least one additional processing may include the evaluator evaluating the article, internally coated article, closable or enclosed article, externally coated article, decorative article, or dried article to produce an evaluated article. In some examples, the container is an article, an internally coated article, a closable or enclosed article, an externally coated article, a decorative article, a dried article, or an evaluated article.

[0033] In some examples, the container is a necked container, such as a bottle, jar, or a type of vase, and the container production line is a necked container production line. In some examples, the container is a bottle.

[0034] According to a seventh aspect of the invention, a method for manufacturing a container is provided, the method comprising performing a method for providing a processed hollow molded fiber article according to any of the examples disclosed herein to provide the processed hollow molded fiber article, and subsequently performing at least one additional processing on the processed hollow molded fiber article to provide a container.

[0035] The at least one additional processing may include coating at least a portion of the interior of the article to produce an internally coated article. The at least one additional processing may include applying a closure to the article or an internally coated article to produce a closable or enclosed article. The at least one additional processing may include coating at least a portion of the exterior of the article, the internally coated article, or the closable or enclosed article to produce an externally coated article. The at least one additional processing may include decorating the article, the internally coated article, the closable or enclosed article, or the externally coated article to produce a decorated article. The at least one additional processing may include drying the article, the internally coated article, the closable or enclosed article, the externally coated article, or the decorated article to produce a dried article. The at least one additional processing may include evaluating the article, the internally coated article, the closable or enclosed article, the externally coated article, the decorated article, or the dried article to produce an evaluated article. In some examples, the container is an article, an internally coated article, a closable or enclosed article, an externally coated article, a decorated article, a dried article, or an evaluated article.

[0036] In some examples, the container is a necked container, such as a bottle, jar, or a type of vase. In other examples, the container is a bottle.

[0037] According to an eighth aspect of the invention, a method for providing a container for containing contents is provided, the method comprising: providing a container obtained by the method described in any of the examples of the eighth aspect of the invention; and providing contents into the container to provide the container for containing the contents.

[0038] In some examples, providing contents into a container includes placing the contents into the container. Conversely, in some examples, providing the container includes providing the container with contents that are already present in the container, thereby providing the contents of the container.

[0039] The contents may be in the form of, for example, liquids, powders, other flowable substances, one or more solid objects, or combinations thereof. For example, the contents may be food (e.g., condiments), beverages (e.g., alcoholic beverages), household care products (e.g., detergents or other cleaning products), personal care products (e.g., hair care products, personal hygiene products, health products, pharmaceuticals, or cosmetics), fragrance products (e.g., perfumes), vehicle products (e.g., engine oil), or industrial products. Other suitable contents will be apparent to those skilled in the art, given the content of this application and common general knowledge.

[0040] In some examples, the container is a necked container, such as a bottle, jar, or a type of vase. In other examples, the container is a bottle.

[0041] Optionally, the method includes: closing the opening of the container after the contents are provided into the container, and / or affixing a label or marker to the container. In some examples, closing includes affixing a closure (e.g., a lid or cap or heat seal) to the container to close the opening. In some examples, closing includes affixing a heat seal to the container and (e.g., subsequently) applying a lid or cap to the container. In some examples, affixing a label or marker to the container is performed after the contents are provided into the container (i.e., affixing a label or marker to the container containing the contents). In other examples, affixing a label or marker to the container is performed before or during the provision of the contents into the container. In some examples, the affixing occurs before closing. In some examples, the affixing occurs after closing. In some examples, the affixing occurs during closing.

[0042] According to a ninth aspect of the invention, there is provided a use of a container obtained by a method for manufacturing a container according to any of the examples disclosed herein in containing contents. For example, this use may be by a person (such as a natural person or company) filling the container with contents; or by a person conveying the contents; or by a person (whether for disposal purposes or not) disposing of the contents (such as disposing of them to a consumer or end user), removing the contents for disposal (such as disposing of them to a consumer or end user), importing the contents, or storing the contents. For example, the contents may take any of the forms described above. In some examples, the container is a necked container, such as a bottle, jar, or a type of vase. In some examples, the container is a bottle.

[0043] It should be understood that, where appropriate, optional features of one aspect of the invention may also be applied to other aspects of the invention. Attached Figure Description

[0044] Embodiments of the invention will now be described by way of example with reference only to the accompanying drawings, wherein:

[0045] Figure 1 This is a schematic diagram of an exemplary container production line for performing a method of manufacturing containers from pulp;

[0046] Figure 2 This is a schematic diagram of an example of a molding system according to one aspect of the present invention;

[0047] Figures 3A to 3D yes Figure 2 The side view of the molding system was taken at various points in time as the hollow molded fiber product was operatively joined to the mold by the conveying system to further mold the hollow molded fiber product.

[0048] Figures 4A to 4C These are cross-sectional views of an exemplary molding system, taken at various time points before further molding of the hollow molded fiber product;

[0049] Figure 5 This is a schematic diagram illustrating another example of a molding system, which includes a main mold for forming a hollow molded fiber article from a fiber suspension, and a mold for further molding such a hollow molded fiber article.

[0050] Figure 6 This is a flowchart illustrating an example of a mold manufacturing method according to another aspect of the present invention;

[0051] Figure 7 This is a flowchart illustrating an example of a method for providing a processed hollow molded fiber article according to another aspect of the present invention;

[0052] Figure 8 A non-transitory computer-readable storage medium is shown according to one example;

[0053] Figure 9 A schematic cross-sectional view of a container for holding contents, according to an example, is shown; and

[0054] Figure 10 A method for providing a container to hold contents is shown. Detailed Implementation

[0055] The following description presents exemplary embodiments and, together with the accompanying drawings, explains the principles of embodiments of the present invention.

[0056] Figure 1 A container production line is shown for performing a method of manufacturing a container from pulp (i.e., the basis for which an exemplary fiber suspension can be formed), in this example a container with a neck, and more specifically, in this example, in the form of a bottle. A “necked container” refers to a container having an internal narrow portion or “neck” between the body portion and the opening, wherein most or all of the container’s contents are stored in the body portion when in use, and the contents can enter or exit the container through the opening. The internal width of the container neck may be the same as or different from the internal width of the opening. However, the internal width of the neck is less than the internal width of the body portion, thus defining a shoulder between the neck and the body portion. This shoulder complicates the manufacture of the container because it hinders (and in some cases, hinders the insertion of) any mold tools subsequently inserted into the container to form the internal shape of the container. Examples of necked containers include bottles, jars, and certain types of vases. The process described is merely exemplary and is provided to give context for examples of the invention. It should be understood that in other examples, the container production line can be used to manufacture neckless containers (i.e., containers without such a neck), such as bowls or trays.

[0057] In a broad sense, this exemplary process includes providing a fiber suspension; introducing the fiber suspension into the cavity of a porous first mold and draining liquid (e.g., water) from the fiber suspension to produce a hollow molded fiber article (which may be referred to as a wet precursor or embryo) in the mold cavity; further molding the hollow molded fiber article to produce a hollow, further molded fiber article; drying and then internally coating the hollow, further molded fiber article to produce an internally coated article; drying the internally coated article to produce a dried article; applying a closure portion to the dried article to produce a closable or enclosed article; externally coating and / or decorating the closable or enclosed article to produce an externally coated and / or decorated article; and subsequently drying the externally coated or decorated article to produce another dried article. It will be apparent at least from the following description that modifications can be made to the exemplary process to provide variations thereof, in which other examples of the invention may be embodied. For example, in some cases, the internal coating or external coating and / or decoration may be omitted. Furthermore, in this case and as... Figure 1 As indicated by the asterisks Ins.1 to Ins.5, the process includes inspecting or evaluating hollow molded fiber articles, internally coated articles, closable or enclosed articles, externally coated or decorated articles, and dried articles to produce the corresponding evaluated articles. In some examples, the container is one of the following: a hollow molded fiber article, a hollow molded fiber article, an internally coated article, a closable or enclosed article, an externally coated or decorated article, a dried article, or one of the corresponding evaluated articles.

[0058] In this example, providing a fiber suspension includes preparing a fiber suspension from its components. More specifically, preparation includes providing pulp fibers, such as paper pulp fibers, and mixing the pulp fibers with a liquid to provide hydrated pulp fibers. In this example, the pulp fibers are provided by a supplier in sheet form, and the liquid includes water and one or more additives. In this example, the liquid is mixed with the pulp fibers to provide hydrated pulp fibers with a solid fiber content of 1 wt% to 5 wt% (based on fiber dry weight). In this example, one or more additives include sizing agents, such as alkyl ketene dimers (AKD). Hydrated pulp fibers typically contain AKD in an amount of 0.4 wt% of the total dry weight of solid fibers in the hydrated pulp fibers. In some examples, one or more additives are present in the liquid when the pulp fibers are mixed with the liquid. In some examples, after the pulp fibers are mixed with the liquid, the hydrated pulp fibers contain one or more additives (e.g., the pulp fibers are hydrated for a period of time, such as from 2 hours to 16 hours, and then one or more additives are supplied to the hydrated pulp fibers). Hydrated pulp fibers pass between the plates of a Walley beater 11 or refiner that move relative to each other. This causes partial or complete fibrillation of the fibers, meaning that the cell walls of these fibers partially delaminate, resulting in the wetted surfaces of these fibers comprising protruding hairs or fibrils. These fibrillated structures contribute to increased bonding strength between fibers in the dried final product. In other examples, the Walley beater 11 or refiner may be omitted.

[0059] The resulting treated pulp is stored in drum 12 in a relatively concentrated form (e.g., with a solid fiber content of 1 wt% to 5 wt%) to reduce the required storage space. At appropriate times, the treated pulp is transferred to mixing station 13, where it is diluted with more water and optionally mixed with one or more additives (and / or in lieu of one or more additives provided with the hydrated pulp fibers) to provide a fiber suspension ready for molding. In this example, solid fibers comprise 0.7 wt% (based on fiber dry weight) of the resulting fiber suspension; however, in other examples, the proportion of solid fibers in the fiber suspension may vary, such as another value in the range of 0.5 wt% to 5 wt% or 0.1 wt% to 1 wt% (based on fiber dry weight). In some examples, one or more additives mixed with the treated pulp and water include dehydrating agents, such as modified and / or unmodified polyethyleneimine (PEI), for example, under trade names... SK sells modified PEI. In some examples, one or more additives are mixed with water, and then the water and one or more additives are mixed with the treated pulp; in other examples, the treated pulp and water are mixed, and then one or more additives are mixed with the treated pulp and water. The fiber suspension typically comprises an amount of 0.3 wt% of the total dry weight of the solid fibers.

[0060] SK. Mixing the fiber suspension at mixing station 13 helps to homogenize the fiber suspension. In other examples, the treated slurry or fiber suspension may be provided in other ways, such as being supplied off-the-shelf.

[0061] Downstream of barrel 12 and mixing station 13 is a first molding station, which includes a porous first mold 15. In this example, the porous first mold 15 includes two half-molds 14 that are movable toward and away from each other, in this example utilizing hydraulic cylinders. In this example, each of the half-molds 14 is an integral or single tooling that defines a mold profile by additive manufacturing (e.g., 3D printing), and when the half-molds 14 contact each other, their respective mold profiles engage to define a cavity in which a hollow molded fiber article is to be formed. Each half-mold 14 itself defines a smaller molding cavity, and when engaged with a second half-mold 14, the smaller molding cavities combine to provide an integral mold cavity. The two half-molds 14 can be considered individually as “split” or “molds,” and the integral porous first mold 15 can be considered as a “split mold” or again as a “mold.” In other examples, the porous first mold 15 may include more than two splits 14, such as three, four, or six splits, which cooperate to define molding cavities.

[0062] exist Figure 1 In this process, a fiber suspension (also called slurry) is filled from the top into a porous first mold 15, unlike a molding process where the mold is immersed in slurry. The fiber suspension is drawn into the porous first mold 15 under vacuum conditions via line 16, with excess suspension drawn through the porous first mold 15 into a tank 17 under vacuum conditions via line 18. Injection quality can be controlled by measuring (e.g., weighing) the amount of liquid drawn into tank 17. Figure 1 The weighing platform supporting tank 17 is visible. Once the required amount (e.g., a predetermined volume, such as 10 liters, or a predetermined mass, such as 10 kg) of liquid has been collected in tank 17, the intake of the suspension through the porous first mold 15 is stopped, and the first mold 15 is opened to the surrounding air. In this example, the suspension drawn along with the fiber suspension in line 16 is water, or primarily water (as additives may also be present). The liquid drawn into tank 17 via line 18 under vacuum conditions is substantially fiber-free, as these fibers remain on the walls of the porous first mold 15 to form a hollow molded fiber article.

[0063] In one example, to further remove suspended liquid (e.g., water) from a hollow molded fiber article and to form or solidify the three-dimensional shape of the article, a high-pressure fluid (e.g., compressed air) is introduced into a first mold 15 to compress the fiber suspension against the cavity walls of the first mold 15. This process can enhance the strength of the article, making it easier to process and allowing water to drain between the fibers, thereby improving the efficiency of subsequent drying processes. A hydraulic pump 20 is used to regulate the fluid. The pump 20 has a cylinder that discharges fluid from line 21 into the first mold 15. In an alternative example, a waterproof, inflatable element in the form of a collapsible bladder is inserted into the first mold 15 and inflated by introducing fluid from line 21 into the bladder to act as an internal high-pressure core structure of the first mold 15. In this alternative, the fluid within line 21 is preferably incompressible, such as water or oil, although in other examples it can be a compressible fluid, such as air. The advantage of water over other incompressible liquids is that any leakage or rupture of the bladder will not introduce new substances into the system (since the suspension is already water or predominantly water).

[0064] Demolding occurs when the first mold 15 is opened to remove the self-supporting hollow molded fiber article 22. Preferably, mold cleaning 23 is then performed to remove any remaining small fibers and / or other debris and to maintain the porosity of the porous first mold 15. In this example, a radially emitted high-pressure jet is inserted into the mold cavity when the first mold 15 is opened. This causes debris to detach from the cavity walls. Alternatively or additionally, water from tank 17 is pressurized and passed through the back of the porous first mold 15 to dislodge trapped fibers and / or other debris. The water is then drained to circulate back to the upstream portion of the system. It is noteworthy that cleaning is important for conditioning the first mold 15 for reuse. The first mold 15 may appear clean after container removal, but its performance may be compromised if it is not cleaned.

[0065] according to Figure 1The hollow molded fiber article 22 is then conveyed to a second molding station, where pressure and heat are applied in, for example, an aluminum mold 25 to thermoform the desired neck and surface finish, optionally including embossed and / or concave surface features. Once the two halves of the mold 25 are closed around the article 22, a pressurizer is engaged. For example, a bladder 26 (e.g., a thermoformed bladder 26) is inserted into the article 22. The bladder 26 is inflated by a pump 28 via a line 27 with pressurized fluid. The pressurized fluid is preferably an incompressible fluid, such as water or oil, although in other examples it can be a compressible fluid, such as air. In other examples, the pressurized fluid is heated during supply, for example, with a heater, or alternatively cooled, for example, with a heat exchanger. In some examples, the outer mold block 24 of the mold 25 and / or the mold 25 itself are also or alternatively heated. Compared to the state of the article 22 when it was demolded from the first mold 15, the state of the thermoformed article 22 (which can now be considered as a hollow, further-shaped fiber article) is considered to be more rigid and the sidewalls are subjected to more compression.

[0066] As shown, a drying stage 30 (e.g., microwave drying or other drying process) of the article 22 is performed downstream of thermoforming to provide a dried article. In one example, drying stage 30 is performed before thermoforming to provide a dried article. However, some moisture is needed during molding in mold 25 to aid in bonding during the compression process. Drying can be performed using a dryer, such as a machine for drying articles or simply a rack or other support on which the article 22 is placed while drying.

[0067] Then, article 22 enters the internal coating stage. In this example, an internal coating machine in the form of a spray gun 31 is inserted into article 22 and one or more surface coatings are applied to the inner wall of article 22 to produce an internally coated article. In another example, article 22 is replaced with liquid that coats the inner wall of article 22, and then the liquid is drained. In effect, this coating provides a protective layer to prevent contents from seeping into the bottle wall, thereby preventing its penetration and / or weakening of the bottle wall. The choice of coating depends on the intended contents of the finished container, such as beverages, food, detergents, lubricants, pharmaceuticals, etc. In this example, the internally coated article 22 then undergoes a curing or drying process 32, which can be configured or optimized according to the internal coating, such as drying under ambient conditions for twenty-four hours or by a rapid drying method. Drying can be performed again using a dryer, such as a machine for drying articles or simply a rack or other support on which article 22 is placed while drying. After drying, the coated article 22 is considered as another dried article.

[0068] Then, a closure or opening forming process is performed on article 22 using a closure applicator to produce a closable or closed article. For example, such as Figure 1As shown, the neck fitting 33 is secured to the dried article. This allows the article to be subsequently closed by positioning a cap, lid, or other closure relative to the neck fitting. An external coating and / or decoration are then applied to the article 22 using an external coating machine and / or decorator, as shown in a further stage 34, to produce an externally coated and / or decorated article. In one example, the article 22 is immersed in a liquid to coat its outer surface, as... Figure 1 As shown. In another example, the outer surface receives an external coating in a different manner. The coating and / or decoration may cover all or part of the outer surface of the article. The article 22 is then dried in warm air to produce another dried article. In other examples, drying may be performed using one of the dryers discussed above.

[0069] Therefore, article 22 (considered the final "container") can be fully formed and ready to receive contents therein. In other examples, the container can be fully formed immediately after one of the drying processes or one of the inspection and / or evaluation processes, without securing the neck fitting 35 and / or without applying the inner coating and / or the outer coating and / or the decoration, without applying any embellishment. For example, in some cases, a closure is provided to the article by forming the closure portion during the molding of the article at the first molding station and / or the second molding station.

[0070] Now for reference Figure 2 This is a schematic diagram of a molding system 100 for providing processed hollow molded fiber articles according to an exemplary embodiment of the present invention.

[0071] As shown in the figure, the molding system 100 includes a mold 125 for further molding the hollow molded fiber article 22. Further molding can, for example, achieve the desired neck and surface finish of the hollow molded fiber article 22; for example, further molding can form embossed and / or recessed surface features on the hollow molded fiber article 22. Further molding can also (or conversely) increase the rigidity and / or strength of the hollow molded fiber article, for example, by compressing the hollow molded fiber article 22 and / or by removing liquid / moisture therefrom. Therefore, it can be understood that the molding system 100 can form the above-referenced... Figure 1 The described container production line, in which mold 125 replaces Figure 1 The mold shown is 25.

[0072] like Figure 2 As shown, mold 125 includes a cavity 136 within which the hollow molded fiber article 22 is further formed during use of system 100. Also as shown, the mold includes several inner surfaces 140 that collectively define the cavity 136.

[0073] like Figure 2As shown, the inner surface 140 of the mold 125 includes one or more porous regions 141. In the specific example shown, the porous regions 141 are provided by one or more pieces of porous material 126a, 126b (although this is not necessary, and in other examples, the porous regions 141 can be provided, for example, by machining pores in a non-porous material (e.g., by laser drilling)). In the example shown, each porous region 141 is provided by a corresponding piece of porous material 126a, 126b (e.g., Figure 2 (As shown); however, in other examples, each porous region may be provided by multiple sheets of porous material. Also as shown, there is no mesh or grid in cavity 136 (again, this is not required). Therefore (or otherwise), the inner surface defining the cavity is typically smooth, except for the presence of multiple pores.

[0074] It is understandable that porous materials 126a and 126b contain a large number of pores, each of which has a circular cross-sectional shape in a plane orthogonal to the central axis of the pore, such as... Figure 2 The dotted patterns on the porous materials 126a and 126b are shown. Specifically, the porous materials 126a and 126b provide a plurality of pores, each having a circular cross-sectional shape in a plane orthogonal to the pore's central axis. These pores are distributed on the porous region 141 of the inner surface 140 to provide continuous porosity on the porous region 141. It is envisioned that these pores should have an average pore diameter of less than or equal to 90 μm (e.g., measured at the inner surface 140). The inventors believe that pores with an average pore diameter of less than or equal to 90 μm can provide a suitable level of quality for the further molded hollow molded fiber article 22, for example, including a relatively smooth surface on the hollow molded fiber article 22. Furthermore, when these pores are distributed on one or more porous regions 141 of the mold cavity 136 to provide a continuous porosity on these porous regions 141, these porous regions 141 extend to cover at least a majority of the total internal area of ​​the mold cavity 136, and these pores properly discharge moisture and / or steam from the mold cavity 136 to the outside of the mold 125 during further molding of the hollow molded fiber article 22.

[0075] In some examples, in order to allow moisture and / or steam to be discharged from the cavity 136 to the outside of the mold 125 at a relatively high level during the further molding process of the hollow molded fiber article 22, the average pore size may be at least 10 μm.

[0076] To facilitate providing continuous porosity across one or more porous regions, the average spacing between adjacent pores 38 can, for example, be on the same order of magnitude as the average pore width (as defined at the corresponding inner surface 40 of each pore 38). Thus, in some examples, the average pore spacing may be less than or equal to 10 times the average pore width.

[0077] It is understood that, since the size of the pores in the porous region 141 is small compared to the typical size of the mold cavity 136 (e.g., the width and height may be several centimeters), in many examples, a very large number of pores (e.g., more than 1,000 or more than 10,000) are distributed on the porous region 141 to help provide a continuous porosity on one or more porous regions 141.

[0078] It is also understood that when the porous region 141 is provided by one or more porous materials 126a, 126b, the pores of the porous region 141 provided on the inner surface 140 of the cavity 136 may only account for a portion of the pores contained in the porous materials 126a, 126b, since all the pores contained in a single porous material 126a, 126b are usually distributed over the entire volume of the porous material 126a, 126b in question.

[0079] In many cases, the pores of each piece of porous material 126a, 126b not located on one of the inner surfaces 140 (and therefore not belonging to the porous region 141) will have substantially the same average size as the pores located on one of the inner surfaces 140. In other words, the pore size of each piece of porous material may be uniform. However, while such porous material may be easier to manufacture, this is by no means necessary, and in other examples, some or all of the porous material may, for example, have pores whose size gradually increases (or decreases) from one side (or one end) of the porous material to the other.

[0080] It should also be understood that each piece of porous material may be uniform in porosity, or have uniform porosity among other properties. However, to reiterate, while such porous materials may be easier to manufacture, this is by no means necessary.

[0081] Back Figure 2 The figure also shows a conveying system 170, which constitutes another part of the molding system 100. The conveying system 170 is configured to operatively engage the hollow molded fiber article 22 with the mold 125 for further molding of the hollow molded fiber article 22. For example, the conveying system 170 may convey the hollow molded fiber article 22 to a position where the mold 125 can be closed around the hollow molded fiber article 22, as shown below. Figures 3A to 3D The subject of discussion.

[0082] When the molding system 100 constitutes the above reference Figure 1 When the container production line is part of the aforementioned production line, mold 125 replaces... Figure 1The mold 25 shown, and the conveying system 170, can be configured to collect the hollow molded fiber article 22 from the main mold 15, and then operatively engage the hollow molded fiber article 22 with the mold 125 for further shaping. However, this is by no means necessary, and in other examples, the conveying system 170 can be configured differently to collect the hollow molded fiber article 22, for example, from a conveying system or storage container.

[0083] like Figure 2 As shown, the conveying system 170 includes a robotic arm, specifically a robot arm 175. However, this is by no means necessary, and in other examples, the conveying system 170 may include, for example, a transfer system with suitable grippers to receive the hollow molded fiber article 22.

[0084] When the conveying system 170 includes a robotic arm (e.g., a robotic arm 175), one end of the robotic arm may include a gripper 176 for grasping the hollow molded fiber article 22, such as... Figure 2 As shown. However, this is not necessary; the robotic arm 175 may include various other suitable grippers that enable it to grasp or hold the hollow molded fiber article 22. For example, such grippers may be enlarged or extended within the neck or body portion of the hollow molded fiber article 22, for example, by inflating an inflatable member within the neck or body portion of the hollow molded fiber article 22.

[0085] Refer again Figure 2 It can be noted that in the specific example shown, mold 125 is formed by two separate mold parts (or “splits”) 124a, 124b, similar to Figure 1 The mold 25 is shown. However, this is by no means necessary, and in other examples, the mold 125 may consist of three, four, or other parts.

[0086] It should also be noted that, Figure 2 In the specific example shown, each mold portion 124a, 124b includes a corresponding shell portion 127a, 127b and a corresponding porous material 126a, 126b mounted on the corresponding shell portion 127a, 127b. However, as can be understood from the above discussion, in other examples, each shell portion 127a, 127b may have multiple pieces of porous material 126a, 126b mounted thereon. In the example, each shell portion 127a, 127b may include a channel (not shown) providing fluid communication between the one or more pieces of porous material mounted thereon and the exterior of the mold portion 124a, 124b. Such channels can help remove fluid generated during further molding of the hollow molded fiber article 22 due to the drainage of moisture and / or steam from the cavity 136.

[0087] In the example shown, the finished hollow molded fiber article 22 (i.e., the further shaped hollow molded fiber article 22) is or will be (after further processing) a bottle. However, by making appropriate modifications to the system (e.g., the shape of the cavity 136), the hollow molded fiber article 22 can be or can be used to manufacture (through further processing) other types of containers, such as jars or a type of vase.

[0088] Refer again Figure 2 The figure also shows a control system 180, which in some examples constitutes another part of the molding system 100. The control system 180 controls the operation of the molding system 100, particularly the mold 125 and the conveying system 170, to provide the processed hollow molded fiber article 22.

[0089] To facilitate this control, the control system 180 communicates with the mold 125 and the conveying system 170 via data or signals, such as... Figure 2 As shown, through the wiring extending from the control system 180. Similarly, as... Figure 2 As shown, the control system 180 includes at least one processor 182, which is appropriately programmed to control the operation of the molding system 100, for example based on signals and / or data received from the mold 125 and the conveying system 170.

[0090] Next reference Figures 3A to 3D They are Figure 2 The side view of the molding system 100 was taken at various points in time during which the hollow molded fiber article 22 is operatively engaged with the mold 125 via the conveying system 170 for further molding of the hollow molded fiber article 22. It should be noted that this description is merely exemplary and pertains to... Figure 2 The function of a particular example of the molding system 100 shown; the functions of other examples may be quite different, depending on the construction and arrangement of their mold 125 and conveying system 170.

[0091] First go to Figure 3A The image shows a robotic arm 175 using a gripper 176 to hold a hollow molded fiber article 22 and lower the hollow molded fiber article 22 to a position within a mold 125.

[0092] Figure 3B The system 100 is shown later, at which point the hollow molded fiber article 22 is positioned as desired within the mold 125. The clamp 176 then releases the hollow molded fiber article 22, and as... Figure 3C As shown, the robot arm 175 moves away from the mold 125, and the mold portions 124a and 124b begin to move toward the closed position. Figure 3DA mold in a closed arrangement is shown, wherein the hollow molded fiber article 22 is located within the cavity 136 of the mold 125.

[0093] As mentioned above, in Figures 3A to 3D In the specific example shown, the conveying system 170 is configured to operatively engage the hollow molded fiber article 22 with the mold 125 by moving it to a position inside the mold 125. Specifically, the hollow molded fiber article 22 is moved to a position between mold portions 124a and 124b of the mold 125. However, this is by no means necessary, and other types of operative engagement with the mold 125 may be suitable for molds with different constructions. Therefore, in other examples, the conveying system 170 may be configured to move the hollow molded fiber article 22 to a position on or inside one of the mold portions 124a and 125b, or to a position near (but not inside) the mold 125.

[0094] Next reference Figures 4A to 4C They are Figures 2 to 3D The figure shows a cross-sectional view of the molding system 100, in which other components of the molding system 100 can be seen. Figures 4A to 4C The views were taken at various points in time before the further molding of the hollow molded fiber product 22.

[0095] First refer to Figure 4A The diagram shows a view of the molding system 100 at a certain point in time before further molding of the hollow molded fiber article 22. (See diagram for reference.) Figure 4A As shown, the molding system 100 also includes a pressurization system 190, which is not shown in the diagram for clarity. Figures 2 to 3D As shown in the diagram, the pressurization system 190 is configured to apply pressure to the interior of the hollow molded fiber article 22 during further molding of the article 22 through the mold 125, so as to press the exterior of the article 22 against the inner surface 140 of the mold 125. In this example, the pressurization system 190 is controllable to apply a specified amount of pressure to the interior of the hollow molded fiber article 22.

[0096] like Figures 4A to 4C As shown, the pressurization system 190 includes an expandable element 191, which is configured to expand during further molding of the hollow molded fiber article 22 through the mold 125. Figures 4A to 4CIn the specific example shown, the expandable element 191 is an inflatable element 191. The expansion of the expandable element 191 causes the exterior of the inflatable element 191 to be pressed against the interior of the hollow molded fiber article, thereby applying pressure to the interior of the hollow molded fiber article 22 by the pressurization system 190. As a result, the exterior of the hollow molded fiber article 22 is pressed against one or more inner surfaces 140 of the mold 125. Thus, the pressurization system 190 facilitates further molding of the hollow molded fiber article 22.

[0097] like Figure 4A As indicated by the arrows, in some examples, the pressurization system 190 is operable to move the expandable element 191 relative to the mold 125, such that the expandable element 191 is inserted into the hollow molded fiber article 22. However, in other examples, the mold 125 is operable to move relative to the expandable element 191.

[0098] Next reference Figure 4B The diagram illustrates the molding system 100 at a later point in time, when the expandable element 191 of the pressurizing system 190 has been fully inserted into the hollow mold fiber article 22. In the specific example shown, when the expandable element 191 is fully inserted into the mold 125, the connector 195 of the pressurizing system 190 abuts against the top of the mold 125, thus acting as a front stop. However, including such a connector is by no means necessary, and in other examples, the pressurizing system 190 may be connected or engaged with the mold 125 in any suitable manner.

[0099] Once the expandable element 191 is fully inserted into the hollow molded fiber article 22 and the mold 125, the expandable element 191 expands. In the specific example shown, the expandable element 191 is an inflatable element 191. For example, such an inflatable element 191 can be inflated by introducing fluid into its interior. In the specific example shown, this is achieved by allowing fluid to flow along the interior of a tubular member 193 (or “mandrel”) extending within the inflatable element 191. The fluid exits the tubular member 193 through a series of holes 194 formed within it, thus entering the lumen 192 of the inflatable element 191. The inflatable element 191 thus expands as follows: Figure 4C As shown. In some examples, the fluid is one of air, water, or oil. For example, a pump 196 can be used to force the fluid to flow along the interior of a tubular member 193, displacing the fluid in a pump line 197 that is fluidly connected to the tubular member 193, such as... Figures 4A to 4C As shown.

[0100] Although Figures 4A to 4C In the specific example shown, the expandable element 191 is an inflatable element 191, but it should be understood that this is not necessary. It should be understood that in other examples, the expandable element 191 may be inflated using a variety of other methods.

[0101] More generally, it should be understood that it is not necessary to use the expandable element 191 to apply pressure to the interior of the hollow molded fiber article 22, thereby pressing the exterior of the hollow molded fiber article 22 against one or more inner surfaces 140 of the mold 125. In other examples, the pressurization system 190 may apply pressure to the interior of the hollow molded fiber article 22 in a variety of other ways.

[0102] Back Figures 4A to 4C The diagram further illustrates a heating system comprising multiple heaters 129a, 129b for heating the mold 125, particularly during further molding of the hollow molded fiber article 22 through the mold 125. It is understood that this heating of the mold 125, in turn, heats the hollow molded fiber article 22 (e.g., through heat conduction). Heating the hollow molded fiber article 22 during further molding through the mold 125 can help remove fluids (e.g., steam or liquids, such as vapor or water) from the hollow molded fiber article 22, which can enhance the strength and / or hardness of the hollow molded fiber article 22, and / or can smooth or otherwise improve its surface finish.

[0103] although Figures 4A to 4C Two heaters 129a and 129b are shown (one for each of the two mold parts 124a and 124b), but it should be understood that the heating system may include only one heater, or may include three, four or more heaters, as appropriate.

[0104] More generally, although in Figures 4A to 4C In the example shown, the heating system heats the mold, thereby heating the hollow molded fiber article 22. However, in other examples, the heating system may use different methods to heat the hollow molded fiber article 22. For example, the heating system may be configured to supply heated fluid to the interior of the hollow molded fiber article 22. In some examples, the heated fluid may, for example, contact the interior of the hollow molded fiber article 22, while in other examples, the heated fluid may be contained within an inflatable element (e.g., inflatable element 191) that contacts the interior of the hollow molded fiber article 22, thereby transferring heat to the hollow molded fiber article 22.

[0105] More generally, although Figures 4A to 4C A molding system comprising both a heating system and a pressurizing system is shown, but these systems can be implemented independently. Therefore, it should be understood that the heating system according to any of the above examples can be implemented independently of the pressurizing system 190 according to any of the above examples.

[0106] Regarding materials, the inventors believe that mold 125 can be suitably formed from metallic materials, such as aluminum, stainless steel, or titanium. For example, the mold can be made at least partially of aluminum, aluminum alloys, or stainless steel, or of aluminum or stainless steel particles fused with an adhesive (e.g., resin). In specific examples, mold 125 may comprise at least 50% by weight of aluminum, or possibly at least 60%, 70%, 80%, or 90% by weight of the total weight of the mold, or may comprise at least 50% by weight of stainless steel, or possibly at least 60%, 70%, 80%, or 90% by weight of the total weight of the mold.

[0107] In addition, in such Figure 2 In the example shown, the porous region 141 is provided by one or more pieces of porous material 126a, 126b, which may include aluminum or stainless steel. For example, the porous material may be porous aluminum or a porous aluminum alloy, or porous stainless steel. In the example, the porosity of the porous material may be between about 10% (inclusive) and about 70% (inclusive).

[0108] Now for reference Figure 5 This is a schematic diagram illustrating a further, more detailed example of the molding system 100'. As shown, the molding system 100' includes the components referenced above. Figures 2 to 4C The mold 125 described above for further molding the hollow molded fiber article 22 and the reference above. Figures 4A to 4C The pressurization system 190 is described.

[0109] Similarly, Figure 5 As shown, the molding system 100 also includes a master mold 15 configured to form a hollow molded fiber article 22 using a fiber suspension; and a fiber suspension supply system 50 configured to deposit a certain amount of fiber suspension into a cavity 36 of the master mold 15, such that a certain amount of fiber suspension can be formed into a hollow molded fiber article 22 through the cavity 36 of the master mold 15. In some examples, the master mold 15 is the one referenced above. Figure 1 Mold 15 as described.

[0110] Figure 5 A conveying system 175 is also shown, which constitutes another part of the forming system 100. The conveying system 175 may include the components referenced above. Figures 2 to 3D Any features of the described conveyor system 175. Figure 5In the example shown, the conveying system 175 is configured to convey the hollow molded fiber article 22 from the master mold 15 to an operatively engaged mold 125 for further molding of the hollow molded fiber article 22. Thus (or otherwise), the master mold 15 can be described as being arranged “upstream” of the mold 125 for further molding of the hollow molded fiber article 22. Therefore, it can be understood that the molding system 100' can form the above-referenced... Figure 1 Part of the container production line, wherein the main mold 15 replaces Figure 1 The mold 15 and mold 125 shown are used instead of Figure 1 The mold 25 is shown. Alternatively, a fiber suspension supply system 50 can be used in place of mixing station 13 and pipeline 16 to supply fiber suspension to the cavity of main mold 15.

[0111] Refer again Figure 5 The figure also shows a control system 180, which in some examples constitutes another part of the molding system 100. The control system 180 controls the operation of the molding system 100, and in particular controls the main mold 15, the fiber suspension supply system 50, the mold 125 for further molding the hollow molded fiber article 22, and the conveying system 170, thereby providing the processed hollow molded fiber article 22.

[0112] To facilitate this control, the control system 180 communicates with the main mold 15, the fiber suspension supply system 50, the mold 125 for further molding the hollow molded fiber product 22, the conveying system 170, and the pressurizing system 190 via data or signals, such as... Figure 5 As shown, through the wiring extending from the control system 180. Similarly, as... Figure 5 As shown, the control system 180 includes at least one processor 182, which is appropriately programmed to control the operation of the molding system 100, for example based on signals and / or data received from the master mold 15, the fiber suspension supply system 50, the mold 125 for further molding the hollow molded fiber article 22, the conveying system 170, and the pressurization system 190.

[0113] Figure 5 Various exemplary features of the fiber suspension supply system 50 are also shown. The description and illustration of these features are for illustrative purposes only and are not essential. References Figure 5 An exemplary fiber suspension supply system 50 includes a tank 56 that temporarily contains the fiber suspension 52 before it is introduced into the main mold 15. The fiber suspension supply system 50 can, for example, be connected to... Figure 1The fiber suspension supply system 50 can be used in conjunction with the mixing station 13, or the fiber suspension supply system 50 itself can perform the mixing function of the mixing station 13. The fiber suspension supply system 50 in this example also includes a conduit 54 along which the fiber suspension 52 flows from the tank 56 into the main mold 15. The fiber suspension supply system 50 also includes an arm 58 and a connector 60. The conduit 54 extends through the arm 58 and into the connector 60. The fiber suspension 52 exits the fiber suspension application system 50 and enters the mold 15 through the connector 60 and an opening 42 in the mold 15 that opens into the cavity 36. In some examples, the connector 60 is shaped to mate with the top of the mold 15 and / or the block 33 containing the mold.

[0114] As described above, these specific features of the fiber suspension supply system 50 are merely exemplary; the fiber suspension supply system 50 can be constructed in various ways to supply the fiber suspension to the cavity 36 of the mold 15. For example, the fiber suspension supply system 50 can deposit the fiber suspension into the cavity 36 of the mold 15 by spraying the fiber suspension into the cavity 36, by pouring the fiber suspension into the cavity 36, or by immersing the mold 15 in the fiber suspension. It should be understood that different configurations of the fiber suspension supply system 50 will be suitable for different configurations of the mold 15 (and vice versa).

[0115] Although for the sake of simplicity, Figure 2 and Figure 6 The control system 180 shown is illustrated as a single block, but it should be understood that this control system 180 need not be physically or functionally monolithic. In particular, the components of the control system 180 do not need to be located in the same location. Therefore, in some embodiments, some or all of the components of the control system 180 may be integrated within other (sub)systems within the entire molding system 100. Furthermore, the processing resources of the control system 180 need not be centralized; instead, processing may be distributed across multiple processors, for example, these processors may be integrated into various other (sub)systems within the entire molding system 100.

[0116] Now for reference Figure 6 This is a flowchart illustrating an example of a mold manufacturing method 600 according to another aspect of the present invention. The mold is used for further molding a hollow molded fiber article, which has been operatively engaged with the mold via a conveying system, and therefore may include the above references. Figures 2 to 5 The characteristics of mold 125 are described. For example... Figure 6As shown, method 600 includes fabricating one or more components at 602. The mold includes: one or more inner surfaces that collectively define a cavity, within which a container is further formed during mold use, the cavity having a total internal area; the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and a plurality of pores (each pore having, for example, a circular cross-sectional shape in a plane orthogonal to the pore's central axis), the pores being distributed over the one or more porous regions to provide continuous porosity over the one or more porous regions, the pores having an average pore diameter less than or equal to 90 μm. For example, the above reference can be formed in block 602. Figures 2 to 5 The mold 125. In a specific example, each piece of porous material 126a, 126b can be a corresponding piece formed in frame 602.

[0117] In the example, frame 602 includes at least some of the components of one or more parts formed in frame 602 by additive manufacturing. For example, additive manufacturing can suitably and precisely form mold features, such as features of its inner surface. Additive manufacturing performed as part of frame 602 can, for example, include sintering particles. In particular, the particles can be sintered to such an extent that pores are retained between the particles, which provide (at least partially) multiple pores distributed over a porous region of the mold. In the example, additive manufacturing can utilize powder bed melting techniques, such as direct metal laser sintering (DMLS), electron beam melting (EBM), or selective laser melting (SLM). The particulate material can suitably be metallic, for example, it can be a metal or a metal alloy. As an alternative to powder bed melting, powder adhesion techniques, such as using metal powder, can be used.

[0118] However, one or more mold components do not necessarily have to be formed by additive manufacturing. Therefore, frame 602 may alternatively (or additionally) include machining at least one piece of porous material, such as porous metal material, like porous aluminum. (As used herein, machining refers to the use of a subtractive manufacturing process, i.e., a process involving material removal.) Such machining can be performed under computer control; for example, a CNC machine can be used.

[0119] Now for reference Figure 7This is a flowchart illustrating an example of a method 700 for providing a processed hollow molded fiber article according to another aspect of the present invention. As shown, method 700 includes: at block 702, placing the hollow molded fiber article into a mold, the mold including: one or more inner surfaces that collectively define a cavity having a total internal area, the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; a plurality of pores (each pore having, for example, a circular cross-sectional shape in a plane orthogonal to the pore's central axis), the pores being distributed over the one or more porous regions to provide a continuous porosity over the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm. For example, the above reference can be used in block 702. Figures 2 to 5 The mold 125.

[0120] like Figure 7 As shown, method 700 further includes: in frame 704, further forming the hollow molded fiber article within the cavity of the mold to provide a finished hollow molded fiber article. In the example, the further forming of the hollow molded fiber article in frame 704 includes at least one of the following:

[0121] ●Move the 704a mold to a closed arrangement, so that the hollow molded fiber product is located within the cavity of the mold (e.g., as shown in the reference above). Figure 3C and Figure 3D (as stated); and

[0122] ● Press the outer surface of the hollow molded fiber article against one or more inner surfaces of the mold.

[0123] In an example where further molding of the hollow molded fiber article in frame 704 includes pressing the outer surface of the hollow molded fiber article 704b against one or more inner surfaces of the mold, during the pressing of the outer surface of the hollow molded fiber article 704b against one or more inner surfaces of the mold, a fluid (such as steam or liquid, e.g., vapor or water) exits the cavity of the mold through a plurality of pores. Thereafter, the fluid can flow through the outer surface of the mold and exit the mold.

[0124] In some examples of further molding of the hollow molded fiber article in frame 704, pressing the outer side of the hollow molded fiber article 704b against one or more inner surfaces of the mold, pressing the outer side of the hollow molded fiber article 704b against one or more inner surfaces of the mold includes applying pressure to the interior of the hollow molded fiber article. In a particular example, applying pressure to the interior of the hollow molded fiber article includes inflating an inflatable element such that the outer side of the inflatable element presses against the interior of the hollow molded fiber article.

[0125] In some examples, further molding of the hollow molded fiber article of frame 704 includes heating 704c of the hollow molded fiber article. For example, heating 704c of the hollow molded fiber article may include heating the mold (such that, for example, the mold further heats the hollow molded fiber article, for example, through heat conduction). Alternatively (or additionally), heating 704c of the hollow molded fiber article may include introducing heated fluid into the interior of the hollow molded fiber article. In some cases, the heated fluid will be in direct contact with the inner surface of the hollow molded fiber article. However, in other cases, the heated fluid may be introduced into a vessel located inside the hollow molded fiber article. For example, heated fluid may be introduced into an inflatable element located inside the hollow molded fiber article. The expansion of such an inflatable element may cause the exterior of the inflatable element to be pressed against the interior of the hollow molded fiber article, thereby helping to press the exterior of the hollow molded fiber article 704b against one or more inner surfaces of the mold. More generally, when further molding of the hollow molded fiber article of frame 704 includes pressing the outer side of the hollow molded fiber article 704b against one or more inner surfaces of the mold, heating 704c of the hollow molded fiber article according to any of the examples described above may be performed during pressing the outer side of the hollow molded fiber article 704b against one or more inner surfaces of the mold.

[0126] It should be understood that a control system 180 is provided, which is configured to make the mold (e.g., as shown in the above reference) Figures 2 to 5 The exemplary molds 125, 125' described herein provide finished hollow molded fiber articles. A control system 180 is also provided, which is configured to cause the molding system (e.g., as described above) to... Figures 2 to 5 The exemplary molding system 100, 100' described provides processed hollow molded fiber articles.

[0127] Figure 8 A schematic diagram of a non-transitory computer-readable storage medium 800 according to an example is shown. The non-transitory computer-readable storage medium 800 stores instructions 830, which, when executed by a processor 820 of a control system 810, cause the processor 820 to perform the method of the example described herein. In some examples, the control system 810 is or includes a control system 180 as described above. Instructions 830 include:

[0128] Directive 831 is used to place a hollow molded fiber article into a mold, the mold comprising: one or more inner surfaces that collectively define a cavity having a total internal area, the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and a plurality of pores (each pore having, for example, a circular cross-sectional shape in a plane orthogonal to the pore's central axis), the pores being distributed over the one or more porous regions to provide continuous porosity over the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; and

[0129] Directive 832 is used for further shaping of hollow molded fiber articles within the cavity of a mold to provide finished hollow molded fiber articles.

[0130] In other examples, instruction 830 includes instructions to perform any other example methods described herein. For example, instruction 830 may include instructions to move a mold into a closed arrangement with the hollow molded fiber article located within the cavity of the mold as part of further molding the hollow molded fiber article according to instruction 832. Additionally or alternatively, instruction 830 may include instructions to press the exterior of the hollow molded fiber article against one or more inner surfaces of the mold as part of further molding the hollow molded fiber article according to instruction 832.

[0131] It should also be understood that a container production line (e.g.) is also provided. Figure 1 The container production line shown includes a molding system for providing finished hollow molded fiber products (e.g., as referenced above). Figures 2 to 5 The molding system described above, and apparatus for performing at least one additional processing on the processed hollow molded fiber article to provide a container. Similarly, a method for manufacturing a container is also provided, the method comprising performing a method for providing a processed hollow molded fiber article (e.g., referred to above). Figure 7 The method described above, and the subsequent processing of the processed hollow molded fiber article by at least one additional processing to provide a container. (See above reference) Figure 1 An example of "at least one additional processing" is described.

[0132] As a result of this application, the use of containers obtained by any of the methods described herein to contain contents is also provided. Figure 9An example of such a container 900 containing contents 910 is shown, the container being in the form of a necked container, specifically a bottle. For example, the intended use could be for personnel to fill the container with contents; for personnel to transport the contents; or for personnel (whether for disposal purposes or not) to dispose of the contents (e.g., to a consumer or end user), to retrieve the contents for disposal (e.g., to a consumer or end user), to import the contents, or to store the contents. For example, the contents could be any one or more of the exemplary contents described herein.

[0133] It also provides a method for providing a container to hold the contents. Figure 10 An example of such a method 1000 is shown. Method 1000 includes providing a container 1010, which is in the form of a necked container, specifically a bottle, and then providing contents 1020 into the container. In this example, box 1020 follows box 1010, so box 1020 includes placing the contents into the container provided at box 1010. However, in some other examples, boxes 1010 and 1020 are performed simultaneously, such that providing the container 1010 includes providing the container with contents already present in the container. For example, the contents can be any or more of the exemplary contents described herein. Method 1000 also includes closing the opening of the container 1030 after box 1020, and affixing a label or tag 1040 to the container after box 1030. In this example, box 1030 involves applying a heat seal to the opening and then screwing a cap or lid onto the container, while box 1040 includes affixing a label to the container.

[0134] In other corresponding examples, the order of boxes 1030 and 1040 is reversed; boxes 1030 and 1040 are executed simultaneously; box 1030 is omitted; or box 1040 is omitted. In some examples, box 1040 occurs before box 1020, or box 1040 occurs during box 1020. For example, in some cases, a label or tag is affixed to a container, then the contents are served into the container, and then the container is closed.

[0135] It should be understood that method 1000 can be performed by the same party that manufactures the container, for example, such that box 1010 includes the reference above. Figure 1 The production line shown illustrates the method discussed. Alternatively, method 1000 can be performed by a party different from the party manufacturing the container. In this alternative, the different party performs the work from the party manufacturing the container (e.g., via a reference). Figure 1 (The method discussed) or obtain the container from the middle to execute box 1010.

[0136] Exemplary embodiments of the invention have been discussed with reference to the examples shown. However, it should be understood that variations and modifications may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. A molding system for providing pre-processed hollow molded fiber articles, the system comprising: A mold for further shaping the hollow molded fiber article to provide the processed hollow molded fiber article, the mold comprising: One or more inner surfaces collectively define a cavity within which the hollow molded fiber article is further formed during use of the system, the cavity having a total internal area, and the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; Multiple pores distributed across one or more porous regions to provide continuous porosity across the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; and A conveying system is configured to operatively engage the hollow molded fiber article with the mold for further shaping.

2. The molding system according to claim 1, further comprising: The main mold, which includes a cavity; and A fiber suspension supply system is configured to deposit a certain amount of fiber suspension into the cavity of the main mold, so that the certain amount of fiber suspension can be formed into the hollow molded fiber product through the cavity of the main mold.

3. The molding system according to claim 1 or claim 2 further includes a heating system for heating the hollow molded fiber article during further molding of the hollow molded fiber article through the mold.

4. The molding system according to any one of claims 1 to 3, further comprising a pressurizing system for applying pressure to the interior of the hollow molded fiber article during further molding of the hollow molded fiber article through the mold, so as to press the exterior of the hollow molded fiber article against the one or more inner surfaces of the mold.

5. A method for providing processed hollow molded fiber articles, the method comprising: A hollow molded fiber product is placed into a mold, the mold comprising: One or more inner surfaces collectively define a cavity having a total internal area, the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; Multiple pores distributed across one or more porous regions to provide continuous porosity across the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm; and The hollow molded fiber article is further formed within the cavity of the mold to provide the processed hollow molded fiber article.

6. The method according to claim 5, wherein, Further forming the hollow molded fiber article within the cavity of the mold includes pressing the exterior of the hollow molded fiber article against one or more inner surfaces of the mold; and heating the hollow molded fiber article.

7. A mold for further shaping a hollow molded fiber article to provide a finished hollow molded fiber article, the hollow molded fiber article having been operatively engaged with the mold via a conveying system, the mold comprising: One or more inner surfaces collectively define a cavity in which the hollow molded fiber article is further formed during the use of the mold, the cavity having a total internal area, and the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and Multiple pores distributed across one or more porous regions to provide a continuous porosity across the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm.

8. A method for manufacturing a mold for further shaping a hollow molded fiber article that has been operatively engaged with the mold via a conveying system, the mold comprising: One or more inner surfaces collectively define a cavity in which a container is further formed during the use of the mold, the cavity having a total internal area, and the one or more inner surfaces including one or more porous regions extending to cover at least a majority of the total internal area; and Multiple pores distributed across one or more porous regions to provide continuous porosity across the one or more porous regions, the pores having an average pore diameter of less than or equal to 90 μm. The method includes: The mold is used to make one or more parts.

9. The method according to claim 8, wherein, Making one or more parts from the mold includes additive manufacturing of the one or more parts.

10. The method according to claim 9, wherein, Additive manufacturing of one or more components includes sintered particulate matter.

11. The method according to claim 8, wherein, The mold is made into one or more parts, including machining at least one piece of porous material.

12. The molding system according to any one of claims 1 to 4, the method according to any one of claims 5 to 6 and 8 to 11, or the mold according to claim 7, wherein the average aperture is less than or equal to 50 μm.

13. The molding system according to any one of claims 1 to 4 and 12, the method according to any one of claims 5 to 6 and 8 to 12, or the mold according to claim 7 or claim 12, wherein the average aperture is greater than or equal to 10 μm.

14. The molding system according to any one of claims 1 to 4 and 12 to 13, the method according to any one of claims 5 to 6 and 8 to 13, or the mold according to any one of claims 7 and 12 to 13, wherein the mold for further molding the hollow molded fiber article comprises aluminum in a content of at least 50% by weight of the total weight of the mold.

15. The molding system according to any one of claims 1 to 4 and 12 to 13, the method according to any one of claims 5 to 6 and 8 to 13, or the mold according to any one of claims 7 and 12 to 13, wherein the mold for further molding the hollow molded fiber article comprises stainless steel, the content of which is at least 50% by weight of the total weight of the mold.

16. The molding system according to any one of claims 1 to 4 and 12 to 15, the method according to any one of claims 5 to 6 and 8 to 15, or the mold according to any one of claims 7 and 12 to 15, wherein each of the pores has a circular cross-sectional shape in a plane orthogonal to the central axis of the pore.

17. A control system configured to cause a molding system to perform a method for providing a processed hollow molded fiber article according to any one of claims 5 to 6 and 12 to 16.

18. A non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a controller of a molding system, cause the molding system to perform a method for providing a processed hollow molded fiber article according to any one of claims 5 to 6 and 12 to 16.

19. A container production line comprising a molding system for providing a processed hollow molded fiber article according to any one of claims 1 to 4 and 12 to 16, and means for performing at least one additional processing on the processed hollow molded fiber article to provide a container.

20. A method for manufacturing a container, the method comprising performing the method according to any one of claims 5 to 6 and 12 to 16 to provide a processed hollow molded fiber article, and subsequently performing at least one additional processing on the processed hollow molded fiber article to provide the container.

21. A method for providing a container for containing contents, the method comprising providing a container obtained by the method of claim 20, and providing contents into the container to provide the container for containing contents.

22. The method of claim 21, comprising: After the contents are fed into the container, the opening of the container is closed, and / or Affix a label or marker to the container.

23. Use of the container obtained by the method of claim 20 in containing contents.

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