Mold part and molding station

Abstract

Disclosed is a mold part for forming a hollow formed fibrous article, the mold part being capable of cooperating with another mold part in use to collectively define a cavity in which the hollow formed fibrous article is formed, the mold portion has a base portion corresponding to a portion of a base of the hollow shaped fibrous article to be shaped by the mold portion in use, wherein the base portion has a positive draft angle. A forming station and a forming system are also disclosed.

Description

TECHNICAL FIELD

[0001] The present invention relates to a mould part, a mould, a forming station, a forming system and a method for manufacturing a container from a fibrous suspension, such as a fibrous suspension comprising paper pulp. The container can be a consumer package, such as a bottle, a jar or a certain type of vase, for containing a liquid, a powder, other flowable substance, one or more solid objects or a combination thereof. BACKGROUND

[0002] It is desirable to reduce the use of glass and plastic in consumer products, especially in packaging. Neckless containers, such as trays, bowls and other simple shapes, are often made of paper pulp. However, more complex containers with a neck, like bottles, jars or certain types of vases, are more difficult to design due to the internal narrowing of the container between the main body part of the container and the opening of the container.

[0003] At certain stages, in particular early stages, during the forming of the hollow formed fibre product, the hollow formed fibre product can be relatively fragile. Thus, the hollow formed fibre product can be susceptible to damage from impact, for example, during handling of the hollow formed fibre product. SUMMARY

[0004] According to a first aspect of the present invention, there is provided a mould part for forming a hollow formed fibre product, the mould part, when in use, being co-operable with a further mould part to collectively define a cavity in which the hollow formed fibre product is formed, the mould part having a base portion corresponding to a portion of a base of the hollow formed fibre product to be formed by the mould part in use, wherein the base portion has a positive draft angle.

[0005] At certain stages, in particular early stages, during the forming of the hollow formed fibre product, the hollow formed fibre product can be relatively fragile. Thus, the hollow formed fibre product can be susceptible to damage from impact, for example, during handling of the hollow formed fibre product. The base portion being non-parallel to the direction of ejection from the mould part, as compared to the base portion being parallel to the direction of ejection or the base portion having a negative draft angle, can reduce the force required to remove the hollow formed fibre product from the mould part. In turn, this provides the advantage of helping to reduce the chance of damaging the hollow formed fibre product when removing or ejecting the hollow formed fibre product from the mould part after the hollow formed fibre product has been formed in the mould part. The positive draft angle can also assist with subsequently inserting the hollow formed fibre product into another mould.

[0006] During molding of the hollow molded fiber article and subsequent ejection of the hollow molded fiber article from the mold, stray fibers can be caused to extend from the outer surface of the hollow molded fiber article. Such stray fibers can become trapped between the mold portions of a subsequent mold (e.g., a thermoforming mold) and can damage the contact surfaces of the mold portions of the subsequent mold. Providing a mold portion having a positive draft angle of the base portion provides a hollow molded fiber article having a generally convex base. Thus, when the hollow molded fiber article is inserted into the mold portions of a subsequent mold, a smaller portion of the base of the hollow molded fiber article can be in contact with the mold portions of the subsequent mold than a hollow molded fiber article molded in a mold portion having a flat base portion. This can reduce the number of stray fibers that can become trapped between the mold portions of the subsequent mold.

[0007] In some examples, the entire base portion has a positive draft angle, or a combination of a positive draft angle and a neutral draft angle. That is, there is no negative draft angle of any portion of the base portion.

[0008] The mold portion includes an aperture through which the hollow molded fiber article passes during ejection of the hollow molded fiber article from the mold portion. The aperture extends along the parting plane of the mold portion. The ejection direction of the mold portion is orthogonal to the parting plane. The base portion is not orthogonal to the parting plane of the mold portion and is at an acute angle relative to the parting plane. Thus, the base portion is at a positive draft angle relative to the ejection direction.

[0009] In some examples, the positive draft angle is no more than 5 degrees. At greater angles, the hollow molded fiber article is more likely to be damaged during subsequent processing that alters the shape of the base of the hollow molded fiber article (e.g., processing that forms a punt in the base of the hollow molded fiber article or flattens the base of the hollow molded fiber article). At a positive draft angle of no more than 5 degrees, the benefit of easier ejection from the mold portion is provided without forming a sharp apex (i.e., less than 170 degrees) along the parting line of the base of the hollow molded fiber article when using a mold that includes the mold portion. A sharp apex along the parting line of the base of the hollow molded fiber article can represent an area that is more likely to be damaged during processing of the hollow molded fiber article.

[0010] In some examples, the positive draft angle is no more than 4.5 degrees, 4 degrees, 3.5 degrees, or 3 degrees.

[0011] In some examples, the positive draft angle is uniform across the base portion. That is, the base portion is planar. This can further facilitate ejection of the hollow molded fiber article from the mold portion compared to ejection from a mold portion that includes a non-planar base portion.

[0012] In some examples, the free edge of the base portion extends linearly along the parting plane of the mold portion in a direction perpendicular to a longitudinal axis of the mold portion. The longitudinal axis of the mold portion extends along the parting plane from a center of the base portion toward an upper portion of the mold portion.

[0013] In some examples, the free edge of the base portion is a lowest edge of an interior molding cavity defined in part by the mold portion.

[0014] In some examples, the base portion includes one or more dewatering holes extending therethrough. Water (optionally containing additives) in the fibrous slurry is drawn through the one or more dewatering holes when the mold portion is in use. Such a process can be referred to as dewatering.

[0015] In some examples, each of the one or more dewatering holes defines a respective conduit fluidically connecting the interior molding cavity defined in part by the mold portion to an exterior of the mold portion, the conduit being angularly inclined with respect to an ejection direction of the mold portion. During dewatering, fibers in the fibrous slurry can be at least partially drawn into the one or more dewatering holes and can subsequently inhibit ejection of the hollow molded fibrous article from the interior molding cavity defined in part by the mold portion as additional force is required to release stray fibers from the dewatering holes. Where the conduit is angularly inclined with respect to the ejection direction of the mold portion, the force required to remove the hollow molded fibrous article from the mold portion can be less than a mold portion in which the dewatering holes extend in a direction perpendicular to the ejection direction.

[0016] In some examples, the ejection direction is perpendicular to the parting plane.

[0017] In some examples, the conduit extends in a direction perpendicular to the base portion. As the base portion has a positive draft angle, the dewatering hole extends in a direction that is not parallel to the parting plane of the mold portion and that is not perpendicular to the ejection direction of the mold portion. Thus, the force required to remove the hollow molded fibrous article from the mold portion can be less than a mold portion in which the dewatering hole extends in a direction parallel to the parting plane of the mold portion. This is because stray fibers are less likely to extend into the conduit at an angle perpendicular to the direction in which the hollow molded fibrous article is ejected from the mold portion.

[0018] In some examples, the mold portion includes one or more side walls upstanding from the base portion, wherein a height of the one or more side walls at the parting plane of the mold portion is greater than a height of the one or more side walls at a back portion of the mold portion opposite the parting plane. This can achieve a positive draft angle on the base portion. This can also cause the hollow molded fibrous article to have a height differential, which can reduce the chance that a portion of the base of the hollow molded fibrous article gets stuck on an edge of a mold portion of a subsequent mold (e.g., a thermoforming mold).

[0019] In some examples, at the parting plane, the side wall extends perpendicularly away from the parting plane. This can help to shape the hollow shaped fibrous article with a smooth wall at the parting plane and to release the hollow shaped fibrous article from the mould portion.

[0020] In some examples, the mould portion comprises a single side wall having a semi-circular cross-sectional profile, as viewed from an end (i.e. a top or a bottom) of the mould portion. This can further help to release the hollow shaped fibrous article from the mould portion.

[0021] According to a second aspect of the present application, there is provided a shaping station for shaping a hollow shaped fibrous article, the shaping station comprising a mould having a first mould portion and a second mould portion, each of the first mould portion and the second mould portion being according to the first aspect, wherein the first mould portion and the second mould portion are mutually co-operable when the mould is in use to collectively define a mould cavity in which the hollow shaped fibrous article is shaped. Such a shaping station can provide the advantages described above with reference to the first aspect.

[0022] In some examples, the base portion of the first mould portion and the base portion of the second mould portion have the same positive draft angle. This can help to ensure that the mould cavity has a substantially symmetrical base formed by the base portions of the first mould portion and the second mould portion. Thus, the base of the hollow shaped fibrous article can be substantially symmetrical about the parting plane of the mould.

[0023] In some examples, the cavity defined by the first mould portion and the second mould portion is symmetrical about the parting plane.

[0024] According to a third aspect of the present application, there is provided a shaping system for providing a thermoformed hollow shaped fibrous article, the shaping system comprising: a shaping station of the second aspect; and a thermoforming mould, wherein the thermoforming mould comprises a third mould portion and a fourth mould portion, the third mould portion and the fourth mould portion being co-operable when the thermoforming mould is in use to collectively define a thermoforming cavity in which the hollow shaped fibrous article is shaped to form the thermoformed hollow shaped fibrous article, each of the third mould portion and the fourth mould portion comprising a respective base portion having a draft angle that is less than the positive draft angle of the base portion of the first mould portion and the base portion of the second mould portion.

[0025] During use of the thermoforming mold, the third mold portion and the fourth mold portion of the thermoforming mold can be held or clamped closed with a relatively large pressure compared to the mold used to form the thermoformed non-hollow formed fibrous article, such that the fibers trapped between the third mold portion and the fourth mold portion can damage the contact surfaces of the mold portions.

[0026] By using a mold to form the hollow formed fibrous article, the hollow formed fibrous article is formed to have a base that is more convex than the corresponding base portion of the thermoforming mold. Thus, when the hollow formed fibrous article is inserted into the thermoforming mold, only a small portion of the base of the hollow formed fibrous article can be in contact with the respective base portions of the third mold portion and the fourth mold portion. In turn, this can reduce the chance of damage to the base of the hollow formed fibrous article during insertion into the thermoforming mold, and / or reduce the accumulation of fibers at the edges of the third mold portion or the fourth mold portion during insertion of the hollow formed fibrous article into the third mold portion or the fourth mold portion of the thermoforming mold.

[0027] In some examples, each of the base portions of the third mold portion and the fourth mold portion has a draft angle of zero degrees, which provides a thermoformed hollow formed fibrous article having a flat base. In some examples, each of the base portions of the third mold portion and the fourth mold portion has a negative draft angle, and can provide a dished bottom in the base of the thermoformed hollow formed fibrous article.

[0028] In some examples, the bottom edge of the sidewall of the third mold portion and the fourth mold portion defines the lowest edge of the respective interior forming cavity defined by the third mold portion and the fourth mold portion.

[0029] In some examples, the third mold portion and the fourth mold portion are configured to be held together with a pressure of at least 15 bar. During use of the thermoforming mold, this can help overcome the pressure exerted on the interior surfaces of the thermoforming mold by such a bladder inserted within the hollow formed fibrous article when a bladder is used.

[0030] In some examples, the third mold portion and the fourth mold portion are configured to be held together with a pressure of at least 20 bar.

[0031] In some examples, the forming system includes a transfer mechanism for transferring the hollow formed fibrous article from the forming station to the thermoforming mold.

[0032] According to a fourth aspect of the application, there is provided a method of using a mould to provide a hollow formed fibrous article, the mould comprising a first mould part and a second mould part, the first mould part and the second mould part being mutually co-operable to collectively define a mould cavity when the mould is in use and each having a base portion, the base portion having a positive draft angle, the method comprising: supplying a fibrous slurry to the mould cavity; and using the mould to form the fibrous slurry in the mould cavity to provide a hollow formed fibrous article, the hollow formed fibrous article having a convex base due to the draft angle of the base portions of the first mould part and the second mould part.

[0033] Such a method can provide the advantages described above with reference to the first aspect. Each of the first mould part and the second mould part can be as described according to the first aspect. The mould can be comprised in the forming station of the second aspect or the forming system of the third aspect.

[0034] In some examples, the method comprises demoulding the hollow formed fibrous article from the mould. The positive draft angle in the base portion of each of the first mould part and the second mould part can facilitate such demoulding.

[0035] According to a fifth aspect of the application, there is provided a method of providing a thermoformed hollow formed fibrous article, the method comprising: performing the method of the fourth aspect; subsequently transferring the hollow formed fibrous article to a thermoforming mould, the thermoforming mould comprising a third mould part and a fourth mould part, the third mould part and the fourth mould part being co-operable to collectively define a thermoforming cavity when the thermoforming mould is in use, each of the third mould part and the fourth mould part comprising a respective base portion, the respective base portion having a draft angle that is less than the positive draft angle of the base portion of the first mould part and the positive draft angle of the base portion of the second mould part; enclosing the third mould part and the fourth mould part when the hollow formed fibrous article is located in the thermoforming cavity; and using the thermoforming mould to form the hollow formed fibrous article in the thermoforming cavity to provide a thermoformed hollow formed fibrous article.

[0036] Such a method can provide the advantages described above with reference to the third aspect. The thermoforming mould can be as described according to the third aspect. The method can be performed by the forming system of the third aspect.

[0037] In some examples, the thermoformed hollow formed fibrous article has a flat base. In some examples, the thermoformed hollow formed fibrous article has a concave base, for example, with a concave bottom.

[0038] In some examples, the thermoformed hollow formed fibrous article has a less convex base than the hollow formed fibrous article.

[0039] According to a sixth aspect of the application, there is provided a forming system controller configured to cause a forming station for forming a hollow formed fibre article to perform the method of the fourth aspect, or to cause a forming system for providing a hot-formed hollow formed fibre article to perform the method of the fifth aspect.

[0040] According to a seventh aspect of the application, there is provided a non-transitory storage medium storing machine-readable instructions which, when executed by a processor of a forming system controller, cause the processor to cause a forming station to perform the method of the fourth aspect, or to cause a forming system to perform the method of the fifth aspect.

[0041] In some examples of any of the above aspects, the hollow formed fibre article is a necked hollow formed fibre article, such as a bottle, a jar or a vase. In some examples of any of the above aspects, the hollow formed fibre article is a bottle.

[0042] According to an eighth aspect of the application, there is provided a container manufacturing line comprising a forming system for providing a hot-formed hollow formed fibre article of the third aspect, and apparatus for performing at least one additional process on the hot-formed hollow formed fibre article to provide a container.

[0043] The apparatus can comprise an internal coating device, and the at least one additional process can comprise the internal coating device coating at least a portion of an interior of the article to produce an internally coated article. The apparatus can comprise a closure portion applicator, and the at least one additional process can comprise the closure portion applicator applying a closure portion to the article or the internally coated article to produce a closable or closed article. The apparatus can comprise an external coating device, and the at least one additional process can comprise the external coating device coating at least a portion of an exterior of the article or the internally coated article or the closable or closed article to produce an externally coated article. The apparatus can comprise a decorator, and the at least one additional process can comprise the decorator decorating the article or the internally coated article or the closable or closed article or the externally coated article to produce a decorated article. The apparatus can comprise a dryer, and the at least one additional process can comprise the dryer drying the article or the internally coated article or the closable or closed article or the externally coated article or the decorated article to produce a dried article. The apparatus can comprise an evaluator, and the at least one additional process can comprise the evaluator evaluating the article or the internally coated article or the closable or closed article or the externally coated article or the decorated article or the dried article to produce an evaluated article. In some examples, the container is the article or the internally coated article or the closable or closed article or the externally coated article or the decorated article or the dried article or the evaluated article.

[0044] In some examples, the container is a necked container, such as a bottle, jar or a type of vase, and the container manufacturing line is a necked container manufacturing line. In some examples, the container is a bottle.

[0045] According to a ninth aspect of the application, there is provided a method of manufacturing a container, the method comprising: performing the method of the fifth aspect to provide a hot-formed hollow formed fibrous article; and then performing at least one additional process on the hot-formed hollow formed fibrous article to provide the container.

[0046] The at least one additional process can comprise coating at least a portion of the interior of the article to produce an interior-coated article. The at least one additional process can comprise applying a closure portion to the article or the interior-coated article to produce a closable or closed article. The at least one additional process can comprise coating at least a portion of the exterior of the article or the interior-coated article or the closable or closed article to produce an exterior-coated article. The at least one additional process can comprise decorating the article or the interior-coated article or the closable or closed article or the exterior-coated article to produce a decorated article. The at least one additional process can comprise drying the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article to produce a dried article. The at least one additional process can comprise evaluating the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article or the dried article to produce an evaluated article. In some examples, the container is the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article or the dried article or the evaluated article.

[0047] 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.

[0048] According to a tenth aspect of the application, there is provided a method of providing a container containing content, the method comprising: providing a container obtained by the method of the ninth aspect; and providing content into the container to provide the container containing content.

[0049] In some examples, providing content into the container comprises filling the container with the content. Conversely, in some examples, providing the container comprises providing the container with content that is already present in the container, thereby providing content into the container.

[0050] The contents can be in the form of, for example, a liquid, a powder, other flowable material, one or more solid objects, or a combination thereof. For example, the contents can be a foodstuff (such as a condiment), a beverage (such as an alcoholic beverage), a home care product (such as a detergent or other cleaning product), a personal care product (such as a hair care product or personal cleansing product or health care product or pharmaceutical product or cosmetic product), a fragrance product (such as a perfume), a vehicle product (such as motor oil), or an industrial product. Other suitable contents will be apparent to those skilled in the art in view of the content of the present application and their general knowledge.

[0051] In some examples, the container is a necked container, such as a bottle, a jar, or a vase of the sort. In some examples, the container is a bottle.

[0052] In some examples, the method includes, after providing the contents into the container, closing the opening of the container, and / or applying a marking or indicium to the container.

[0053] In some examples, the closing includes applying a closure (such as a lid or the cap or heat seal) to the container to close the opening. In some examples, the closing includes applying a heat seal to the container and (e.g. thereafter) applying a lid or cap to the container.

[0054] In some examples, applying the marking or indicium to the container occurs after providing the contents into the container (i.e. to the container containing the contents). In other examples, applying the marking or indicium to the container occurs before or during providing the contents into the container.

[0055] In some examples, the applying occurs before the closing. In some examples, the applying occurs after the closing. In some examples, the applying occurs during the closing.

[0056] According to an eleventh aspect of the present application, there is provided use of a container obtained by the method of the ninth aspect for containing contents. The use can be, for example, by a person (such as a natural person or a company) who fills the container with the contents; or a person who transports the contents; or a person who wishes to deliver the contents (e.g. to a consumer or end user), tender the contents (e.g. to a consumer or end user), import the contents, or hold the contents, whether for the purpose of delivery or for other purposes.

[0057] For example, the contents can be in the form of any of those discussed above.

[0058] In some examples, the container is a necked container, such as a bottle, a jar, or a vase of the sort. In some examples, the container is a bottle.

[0059] According to a twelfth aspect of the application, there is provided a container obtainable or obtained by a manufacturing method comprising the method of any one of the fifth, ninth or tenth aspects.

[0060] For example, the container can be obtainable or obtained by the method of the second aspect of the application. The manufacturing method can comprise at least one additional process. The at least one additional process can comprise coating at least a portion of the interior of the article to produce an interior-coated article. The at least one additional process can comprise applying a closure portion to the article or the interior-coated article to produce a closable or closed article. The at least one additional process can comprise coating at least a portion of the exterior of the article or the interior-coated article or the closable or closed article to produce an exterior-coated article. The at least one additional process can comprise decorating the article or the interior-coated article or the closable or closed article or the exterior-coated article to produce a decorated article. The at least one additional process can comprise drying the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article to produce a dried article. The at least one additional process can comprise evaluating the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article or the dried article to produce an evaluated article. In some examples, the container is the article or the interior-coated article or the closable or closed article or the exterior-coated article or the decorated article or the dried article or the evaluated article.

[0061] In some examples, the container is a necked container, such as a bottle, a jar or a vase of the sort. In some examples, the container is a bottle.

[0062] The container obtainable or obtained by such a manufacturing method can be distinguished from containers manufactured by other methods; such containers can comprise a feature indicative of a shape change of the base portion of the hollow-forming fibrous article precursor, said shape change having occurred whereby the hollow-forming fibrous article is provided from the hollow-forming fibrous article precursor. For example, the indicative feature can comprise fibres aligned in the direction in which the base portion of the hollow-forming fibrous article precursor is re-shaped, and / or fibres separated from one another in the direction in which the base portion of the hollow-forming fibrous article precursor is re-shaped, but to an extent that is acceptable in view of the intended function of the final article.

[0063] It will be appreciated that optional features of aspects of the application can equally apply to other aspects of the application, where appropriate. BRIEF DESCRIPTION OF DRAWINGS

[0064] Embodiments of the application will now be described, by way of example only, with reference to the accompanying drawings in which:

[0065] Figure 1 is a schematic illustration of an example container manufacturing line for carrying out a method of manufacturing a container from pulp;

[0066] Figure 2 is a schematic view of a forming system according to an example;

[0067] Figure 3 is a cross-sectional view of a mould according to an example;

[0068] Figure 4a and Figure 4b is a view of a mould portion of the mould of Figure 3

[0069] Figure 5 is a cross-sectional view of a portion of a mould portion of the mould of Figure 3

[0070] Figure 6 is a cross-sectional view of a portion of a hot forming mould in use according to an example;

[0071] Figures 7a and Figure 7b illustrate a container in various stages of manufacture according to an example;

[0072] Figure 8 illustrate a method according to an example;

[0073] Figure 9 illustrate a method according to an example;

[0074] Figure 10 illustrate a non-transitory computer readable storage medium according to an example;

[0075] Figure 11 illustrate a schematic cross-sectional view of a container containing contents according to an example; and

[0076] Figure 12 illustrate a method of providing a container containing contents. DETAILED DESCRIPTION

[0077] The following description presents exemplary embodiments and is provided to explain principles of embodiments of the application.

[0078] Figure 1 ​​A container manufacturing line for performing a method of manufacturing a container from pulp (i.e., which can form the basis of an example fibrous suspension) is shown, the container in this case being in the form of a necked container, and more particularly in this case a bottle. By "necked container" it is meant that the container has an internal narrowing or "neck" between a body portion, in which most or all of the contents of the container are stored when in use, and an opening through which the contents can enter or exit the container when in use. The internal width of the container at the neck can 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, such that a shoulder is defined by the neck and body portion and between the neck and body portion. This shoulder complicates the manufacture of the container, as it impedes the subsequent removal of any mould tool inserted into the container to form the internal shape of the container (and in some cases, its insertion). Examples of necked containers are bottles, jars and certain types of vases. The process is merely exemplary and is provided to give context to the examples of the present invention. It will be appreciated that in other examples, the container manufacturing line can be used to make a non-necked container (i.e., a container without such a neck), such as a bowl or tray.

[0079] Broadly, the exemplary process comprises providing a fibrous suspension; introducing the fibrous suspension into a mould cavity of a porous first mould, and draining liquid (such as water) from the fibrous suspension to produce a hollow shaped fibrous article (which can be referred to as a wet precursor or embryo) in the mould cavity; further shaping the hollow shaped fibrous article to produce a hollow further shaped fibrous article; drying, and then internally coating the hollow further shaped fibrous 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 closed article; externally coating and / or decorating the closable or closed article to produce an externally coated and / or decorated article; and then drying the externally coated or decorated article to produce a further dried article. As will be apparent from at least the following description, the exemplary process can be modified to provide variants thereof in which other examples of the present invention can be embodied. For example, in some cases, the internal coating or the external coating and / or decoration can be omitted. Furthermore, in the present case and as will be apparent from the following description, the process comprises inspecting or assessing the hollow shaped fibrous article, the hollow further shaped fibrous article, the internally coated article, the closable or closed article, the externally coated or decorated article, and the dried article to produce respective assessed articles. In some examples, the container is one of the hollow shaped fibrous article, the hollow further shaped fibrous article, the internally coated article, the closable or closed article, the externally coated or decorated article, the dried article, or one of the respective assessed articles. Figure 1 As indicated by the asterisks labelled Ins. 1 to Ins. 5 in the middle, the process comprises inspecting or assessing the hollow shaped fibrous article, the hollow further shaped fibrous article, the internally coated article, the closable or closed article, the externally coated or decorated article, and the dried article to produce respective assessed articles. In some examples, the container is one of the hollow shaped fibrous article, the hollow further shaped fibrous article, the internally coated article, the closable or closed article, the externally coated or decorated article, the dried article, or one of the respective assessed articles.

[0080] In this example, providing the fibrous suspension includes preparing the fibrous suspension from its components. More specifically, preparing 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 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 fibers to provide hydrated pulp fibers having a solids fiber content of 1% to 5% by weight (dry mass of fibers). In examples, the one or more additives include a sizing agent, such as alkyl ketene dimer (AKD). The hydrated pulp fibers typically include AKD in an amount of 0.4% by weight relative to the total dry mass of solids fibers in the hydrated pulp fibers. In some examples, the one or more additives are present in the liquid when the pulp fibers are mixed with the liquid. In some examples, the one or more additives are included in the hydrated pulp fibers after the pulp fibers are mixed with the liquid (e.g., the pulp fibers are hydrated for a period of time, such as from 2 hours to 16 hours, and then the one or more additives are supplied to the hydrated pulp fibers). The hydrated pulp fibers are passed between the plates of a Valley beater 11 or refiner that are moving relative to each other. This causes some or all of the fibers to fibrillate, meaning to partially delaminate the cell walls of these fibers so that the wetted surfaces of these fibers include protruding hairs or fibrils. These fibrils will help to increase the bond strength between the fibers in the dried final product. In other examples, the Valley beater 11 or refiner can be omitted.

[0081] The resulting treated slurry is stored in a relatively concentrated form (e.g. 1-5% by weight solids content) in a vat 12 to reduce the storage space required. At an appropriate time, the treated slurry is transferred to a mixing station 13 where it is diluted in further water and optionally mixed with one or more additives (and / or instead of one or more additives provided with the hydrated slurry fibres) to provide a fibrous suspension ready for forming. In this example, the solids content of the fibres is 0.7% by weight (by dry weight of fibres) of the resulting fibrous suspension, but in other examples the proportion of solids fibres in the fibrous suspension can be different, such as 0.5-5% by weight of the fibrous suspension, or another value in the range 0.1-1% by weight (by dry weight of fibres). In some examples, the one or more additives mixed with the treated slurry and water include a dehydrating agent such as a modified and / or unmodified polyethyleneimine (PEI), for example a modified PEI sold under the trade name Polymin® SK. In some examples, the one or more additives are mixed with the water and the water and one or more additives are subsequently mixed with the treated slurry; in other examples, the treated slurry and water are mixed and the one or more additives are subsequently mixed with the treated slurry and water. The fibrous suspension typically includes 0.3% by weight of Polymin® SK relative to the total dry mass of solids fibres. Mixing the fibrous suspension at the mixing station 13 helps to homogenise the fibrous suspension. In other examples, the treated slurry or fibrous suspension can be provided in other ways, such as supplied ready-made.

[0082] Downstream of the vat 12 and mixing station 13 is a first forming station comprising a porous first mould 15. In this example, the porous first mould 15 comprises two half-moulds 14 which are movable towards and away from each other, in this example using hydraulic cylinders. In this example, each of the half-moulds 14 is a unitary or single tool defining a mould profile, formed by additive manufacturing (e.g. 3D printing), and when the half-moulds 14 are in contact with each other, their respective mould profiles cooperate to define a mould cavity in which a hollow formed fibrous article is to be formed. Each half-mould 14 defines a smaller forming cavity in itself, and when cooperating with the second half-mould 14, the smaller forming cavities combine to provide the overall mould cavity. The two half-moulds 14 can be considered as “parts”, “halves” or “moulds” in themselves, and the overall porous first mould 15 can be considered as a “split mould” or again as a “mould”. In other examples, the porous first mould 15 can comprise more than two halves 14, such as three, four or six halves which cooperate to define the forming cavity.

[0083] In Figure 1In this case, a fibrous suspension (also known as a slurry) is filled into the porous first mould 15 from the top, in contrast to a moulding process where the mould is dipped into the slurry. The fibrous suspension is drawn under vacuum via line 16 and into the porous first mould 15, where excess suspension liquid is drawn under vacuum via line 18 through the porous first mould 15 into a tank 17. The injection mass can be controlled by measuring (e.g. weighing) the amount of liquid drawn into the tank 17. A weigh platform supporting the tank 17 is visible in Figure 1 In this case, a fibrous suspension (also known as a slurry) is filled into the porous first mould 15 from the top, in contrast to a moulding process where the mould is dipped into the slurry. The fibrous suspension is drawn under vacuum via line 16 and into the porous first mould 15, where excess suspension liquid is drawn under vacuum via line 18 through the porous first mould 15 into a tank 17. The injection mass can be controlled by measuring (e.g. weighing) the amount of liquid drawn into the tank 17. A weigh platform supporting the tank 17 is visible in

[0084] In one example, to remove further suspension liquid (e.g. water) from the hollow formed fibrous article, and to form or consolidate the three-dimensional shape of the article, a high pressure fluid such as compressed air is introduced into the first mould 15 to compress the fibrous suspension against the cavity walls of the first mould 15. This process strengthens the article so that it can be handled and drained of water from between the fibres, improving the efficiency of the subsequent drying process. A hydraulic pump 20 is used to regulate the fluid. The pump 20 has a cylinder which expels fluid in line 21 into the first mould 15. In an alternative example, an impermeable inflation element in the form of a collapsible bladder is inserted into the first mould 15 and inflated by introducing fluid from line 21 into the bladder to act as an internal high pressure core structure for the first mould 15. In this alternative, the fluid within line 21 is preferably incompressible such as water or oil, but 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 does not introduce a new substance into the system (as the suspension liquid is already water or predominantly water).

[0085] De-moulding occurs when the first mould 15 opens to remove the self- supporting hollow formed fibre product 22. Mould cleaning 23 is preferably subsequently performed to remove any remaining small fibres and / or other debris and to maintain the porosity of the porous first mould 15. In this example, a high pressure jet is injected into the mould cavity when the first mould 15 opens, which is fired radially. This will cause debris to fall off the walls of the mould cavity. Alternatively or additionally, water from the tank 17 is pressurised through the back of the porous first mould 15 to cause trapped fibres and / or other debris to fall off. The water is drained to be recycled back to an upstream part of the system. It is worth noting that cleaning is important for handling the first mould 15 for re-use. After removal of the container, the first mould 15 can appear clean, but without cleaning, its performance can be compromised.

[0086] According to Figure 1 , the hollow formed fibre product 22 is subsequently transported to a second forming station in which pressure and heat are applied in, for example, an aluminium mould 25 to thermoform the desired neck and surface finish, optionally including embossed and / or debossed surface features. After the two halves of the mould 25 are closed around the product 22, a pressuriser is activated. For example, a bladder 26 (e.g. a thermoforming bladder 26) is inserted into the product 22. The bladder 26 is inflated by a pump 28 with pressurised fluid supplied via a line 27. The pressurised fluid is preferably an incompressible fluid such as water or oil, but in other examples it can be a compressible fluid such as air. In other examples, the pressurised fluid is heated with, for example, a heater, or alternatively cooled with, for example, a heat exchanger, during the supply. In some examples, the outer mould block 24 of the mould 25 and / or the mould 25 itself is also heated or alternatively heated. After thermoforming, the state of the product 22 (now arguably a further formed hollow fibre product) becomes quite rigid and the sidewall is more compressed compared to the state of the product 22 when de-moulding from the first mould 15.

[0087] As shown, a drying stage 30 (e.g. a microwave drying process or other drying process) is performed on the product 22 downstream of the thermoforming to provide a dried product. In one example, the drying stage 30 is performed before the thermoforming to provide a dried product. However, some moisture is required in the mould 25 to assist with the bonding during the compression process. Drying can be performed using a dryer such as a machine for causing drying of the product or simply a shelf or other support on which the product 22 is placed while drying.

[0088] The article 22 then enters an interior coating stage, during which, in this example, an interior coating device in the form of a spray gun 31 is inserted into the article 22 and one or more surface coatings are applied to the interior walls of the article 22 to produce an interior coated article. In another example, the article 22 is instead filled with a liquid that coats the interior walls of the article 22, and the liquid is subsequently drained. In effect, such a coating provides a protective layer to prevent contents from seeping into the bottle walls, which the contents can penetrate and / or weaken. The choice of coating depends on the intended contents of the finished container, e.g., beverages, foodstuffs, detergents, lubricants, pharmaceuticals, etc. In this example, the interior coated article 22 then undergoes a curing or drying process 32, which can be configured or optimized according to the interior coating, e.g., drying for twenty-four hours under ambient conditions or by a flash-drying method. Drying can again be performed using a dryer, such as a machine for causing drying of the article or simply a shelf or other support on which the article 22 is placed while drying. After drying, the coated article 22 is considered another dried article.

[0089] The article 22 is then subjected to a closure or mouth-forming process by a closure portion applicator to produce a closable or closed article. For example, as shown in Figure 1 the neck finish 33 is secured to the dried article. This enables the article to be subsequently closed by positioning a cap, closure, or other closure relative to the neck finish. The article 22 is then subjected to an exterior coating and / or decoration by an exterior coating device and / or decorator, respectively, to produce an exterior coated and / or decorated article, as shown in further stage 34. In one example, the article 22 is immersed in a liquid to coat its exterior surface, as shown in Figure 1 In another example, the exterior surface receives an exterior coating in a different manner. The coating and / or decoration can cover all or only a portion of the exterior surface of the article. The article 22 is then allowed to dry in warm air to produce another dried article. In other examples, drying can be performed using a dryer, such as one of those discussed above.

[0090] The article 22 can thus be fully formed (considered a final "container") and ready to accept contents therein. In other examples, in other examples, the container can be fully formed without the neck finish 35 being secured and / or without the interior coating being applied and / or without the exterior coating being applied and / or without the decoration being applied and / or immediately after one or more of the drying processes and / or one or more of the inspection and / or evaluation processes. For example, in some cases, the article is provided with a closure portion by having the closure portion formed during forming of the article at the first forming station and / or the second forming station.

[0091] Figure 2A forming system 100 for providing a thermoformed, hollow formed fiber bottle 22b is shown in accordance with an example. The forming system 100 includes a forming station 110, a thermoforming mold 120, and a transfer mechanism 130. The forming station 110 includes a mold 111 having a pair of mold portions 112 that are mutually engageable along a parting plane 113 to define a mold cavity 114. In some examples, the mold 111 is the mold 15 described with reference to Figure 1 The thermoforming mold 120 includes a pair of thermoforming mold portions 122 that are mutually engageable along a parting plane 123 to define a mold cavity 124. In some examples, the thermoforming mold 120 is the mold 25 described with reference to Figure 1

[0092] The mold cavity 114 of the mold 111 is shaped differently than the mold cavity 124 of the thermoforming mold 120, as will be described in greater detail herein.

[0093] Figure 3 is a cross-sectional side view of the mold 111 with the mold portions 112 mutually engaged to define the mold cavity 114. Figure 4a and Figure 4b respectively show an isometric view and a front view of one of the mold portions 112 of the mold 111. Each mold portion 112 has an inner wall 142 that defines the shape of the mold cavity 114 and an outer wall 144 that is separated from the inner wall 142 by a gap 146. In this example, the inner wall 142 and the outer wall 144 have a geometry such that the gap 146 has a substantially uniform thickness.

[0094] Each mold portion 112 has a parting face 150 that seals the gap 146 at the parting plane 113. When the mold portions 112 are mutually engaged to form the mold cavity 114, as shown in Figure 3 the parting face 150 of one of the mold portions 112 is in contact with the parting face 150 of the other mold portion 112. The shape of each mold portion 112 is substantially identical to one another. Thus, the mold cavity 114 is bisected by the parting plane 113.

[0095] The inner wall 142 of each mold portion 112 has a body portion 152, a base portion 154, a shoulder portion 156, and a neck portion 158. The body portion 152, the shoulder portion 156, and the neck portion 158 collectively define a sidewall that upstands from the base portion 154. The base portion 154 of each mold portion 112 is not orthogonal to the parting plane 113 and is at an acute angle A2 with respect to the parting plane 113. Thus, the base portion 154 of each mold portion 112 has a positive draft angle Al with respect to a demolding direction B of the mold portion 112, which in this example is about 2.5 degrees, as shown in Figure 5 ​As shown, this figure illustrates a cross-sectional side view of the lower portion of the base portion 154 and the body portion 152 of one of the mold portions 112 of mold 111. Therefore, the distance from the upper edge 160 of the mold portion to the base portion 154 along the dividing plane 113 is greater than the distance from the edge 153 furthest from the dividing plane 113 towards the base portion 154. The base portion 154 is substantially planar, such that the draft angle A1 is uniform along the base portion 154 from the edge 153 to the dividing plane 113.

[0096] The body portion 152 stands upright from the base portion 154, and thus forms a wall standing upright from the base portion 154 of each mold portion 112. At the dividing plane 113, the wall extends vertically away from the dividing plane 113. Along the dividing plane 113, the mold portion 112 has a first height D1. Away from but parallel to the dividing plane 113, the mold portion 112 has a second height D2 that is less than the first height D1.

[0097] like Figure 4a As shown, a plurality of dewatering holes 155 extend through the base portion 154 of each mold portion 112. Each hole 155 defines a corresponding channel 155a that fluidly connects the mold cavity 114 to the gap 146 between the inner wall 142 and the outer wall 144 of the mold portion 112. This is in Figure 5 This is shown more clearly in the text.

[0098] In this example, the channel extends in a direction orthogonal to the surface of the wall forming the cavity 114 of the base portion 154. Due to the positive draft angle of the base portion 154, the channel is angled relative to the demolding direction B of the mold portion 112. The demolding direction B is perpendicular to the dividing plane 113.

[0099] Each thermoforming die portion 122 has an inner wall 162 defining the shape of a cavity 114 and an outer wall 164 separated from the inner wall 162 by a gap 166. In this example, the inner wall 162 and the outer wall 164 have a geometry such that the gap 166 has a substantially uniform thickness. Each thermoforming die portion 122 of the thermoforming die 120 also has a dividing surface 170 that contacts a dividing surface 170 of another die portion 122. The inner wall 162 of each thermoforming die portion 122 also includes a body portion 172, a base portion 174, a shoulder portion, and a neck portion. The body portion 172, the shoulder portion 176, and the neck portion 178 together define a sidewall erected from the base portion 174.

[0100] Unlike the mold portion 112 of mold 111, the base portion 174 of each thermoforming mold portion 122 has a substantially zero draft angle. This is in Figure 6The figure best illustrates a cross-sectional side view of the base portion 174 and the lower portion of the body portion 172 of the thermoforming mold portion 122, which collectively form a mold cavity 124 along with the mold portion 123, in which the hollow formed fiber bottle 22a is located. Thus, the distance from the upper edge of the thermoforming mold portion 122 to the base portion 172 in a direction parallel to the parting plane 123 is equal when measured along the parting plane 123 and when measured from the edge 173 of the base portion 174 that is furthest from the parting plane 123.

[0101] The mold 111 and the thermoforming mold 120 are configured for use in a manufacturing line configured to form a necked container, in this example a bottle. The manufacturing line can be the container manufacturing line described with reference to Figure 1 The mold 111 is configured to form a hollow formed fiber bottle 22a and the thermoforming mold 120 is configured to form a thermoformed hollow formed fiber bottle 22b, as best illustrated in Figures 7a and Figure 7b and described in more detail below.

[0102] In use of the forming system 100, a fiber slurry is supplied to the mold cavity 114 of the mold 111 with the pair of mold portions 112 of the mold mated to one another to define the mold cavity 114. In use of the mold 111, water (optionally containing additives) in the fiber slurry is drawn from the mold cavity 114 via the aperture 155. The fiber slurry is formed by the mold 111 into the shape of the mold cavity 114 of the mold 111 to provide a hollow formed fiber bottle 22a (shown in Figure 7a).

[0103] The hollow formed fiber bottle 22a is shaped in correspondence with the mold cavity 114 of the mold 111. Thus, the hollow formed fiber bottle 22a is generally cylindrical and has a body portion 132, a base portion 134 sealing a lower end of the body portion 132, a shoulder portion 136 at an end of the body portion 132 opposite the base portion 134, and a neck portion 138. The shoulder portion 136 is between the body portion 132 and the neck portion 138. A length L of the hollow formed fiber bottle 22a extends along a longitudinal central axis 140 of the hollow formed fiber bottle 22a. A maximum outer diameter D3 of the hollow formed fiber bottle 22a is in the body portion 132. The neck portion 138 has a constant outer diameter D4 along its length, which is less than the maximum outer diameter D3 of the body portion 132. The diameter of the bottle 22a, 22b changes along the shoulder portion 136. When formed in the mold 111, the central longitudinal axis 140 of the bottle 22a is on the parting plane 113.

[0104] Due to the positive draft angle of the base portion 154 of the mold portions 112, the base portion 134 of the hollow molded fiber bottle 22a is convex. That is, the base portion 134 protrudes from the body portion 132 in a direction along the longitudinal central axis 140 and away from the body portion 132.

[0105] Returning to the use of the molding system 100, the mold portions 112 of the mold 111 are separated from one another to permit the hollow molded fiber bottle 22a to be ejected from the mold 111. The hollow molded fiber bottle 22a is ejected from the mold portions 112 in a direction perpendicular to the parting plane 113, as indicated by arrow A in FIG. 7a.

[0106] The transfer mechanism 130 is configured to transfer the hollow molded fiber bottle 22a from the mold 111 to one of the thermoforming mold portions 122. The thermoforming mold portions 122 are then moved together such that the hollow molded fiber bottle 22a is positioned in the mold cavity 124 of the thermoforming mold 120. Due to the difference in shape between the mold cavity 114 of the mold 111 and the mold cavity 124 of the thermoforming mold 120, an annular gap 176 is formed between the outer surface of the hollow molded fiber bottle 22a and the inner surface of the inner wall 162 when the transfer mechanism 130 inserts the hollow molded fiber bottle 22a into the thermoforming mold 120. This gap between the outer surface of the hollow molded fiber bottle 22a and the inner surface of the inner wall 162 can help prevent fibers extending outward from the outer surface of the base portion 134 of the hollow molded fiber bottle 22a from catching on the thermoforming mold portions 122 when the hollow molded fiber bottle 22a is inserted into the thermoforming mold 120.

[0107] With the thermoforming mold portions 122 held together with a pressure of about 19.5 bar, a bladder, such as the thermoformed bladder 26 described with reference to Figure 1 is inserted into the hollow molded fiber bottle 22a and inflated to a pressure of about 17 bar. The hollow molded fiber bottle 22a is pressed by the bladder against the inner surface of the inner wall 162 of the thermoforming mold 120 to substantially eliminate the annular gap 176 between the outer surface of the bottle 22a and the inner surface of the inner wall 162 and thus form the thermoformed hollow molded fiber article 22b.

[0108] Figure 7b The bottle 22b is shown after being molded by the thermoforming mold 120, with the base portion 134 being substantially flat and not protruding from the body portion 132 in a direction along the central longitudinal axis 140. Since the hollow molded fiber bottle 22a and the thermoformed hollow molded fiber bottle 22b are each a precursor to the final bottle and thus the same bottle at different stages of manufacture, corresponding portions of the bottles 22a, 22b are shown with the same reference numerals in FIGS. 7a and Figure 7b 7b.

[0109] In other examples, at least a portion of the base portion 174 of each thermoforming mold portion 122 has a positive draft angle. For example, each base portion 174 is shaped to form a portion of the concave bottom in the base portion 134 of the thermoformed hollow formed fiber bottle 22b. In such examples, the distance from the upper edge of the thermoforming mold portion 122 to the base portion 174 in a direction parallel to the parting plane 123, as measured along the parting plane 123, is less than the distance as measured from the edge 173 of the base portion 174 that is farthest from the parting plane 123.

[0110] It will be appreciated that a control system 102 is provided that is configured to cause a forming station 110 to supply a fiber slurry to a mold cavity 114 of a mold 111 of the forming station 110 and use the mold 111 to form the fiber slurry in the mold cavity 114 to provide a hollow formed fiber bottle 22a that has a convex base due to the positive draft angle of the base portion 154 of the first and second mold portions 112 of the mold 111. A control system 104 is also provided that is configured to cause the forming system 100 to: cause the forming station 110 of the forming system 100 to form a fiber slurry in a mold cavity 114 defined by a mold portion 112 having a respective base portion that includes a positive draft angle to form a hollow formed fiber bottle 22a; cause a transfer mechanism 130 of the forming system 100 to transfer the hollow formed fiber bottle 22a to a mold cavity 124 of a thermoforming mold 120 of the forming system 100, the mold cavity 124 being defined by a thermoforming mold portion 122 having a respective base portion that includes a draft angle that is less than the mold portion 112; and cause the thermoforming mold 120 to form the hollow formed hollow formed fiber bottle 22a in the mold cavity 124 to provide a thermoformed hollow formed fiber bottle 22b.

[0111] Figure 8 A method 200 of using a mold to provide a hollow formed fiber article is shown, the mold including a first mold portion and a second mold portion that can cooperate with one another to collectively define a mold cavity when the mold is in use and each having a base portion with a positive draft angle. The mold can be the mold 111 described above with reference to Figure 2 to Figure 5 The method 200 includes supplying a fiber slurry to the mold cavity, as shown in block 210, and using the mold to form the fiber slurry in the mold cavity to provide a hollow formed fiber article, as shown in block 220. The resulting hollow formed fiber article has a convex base due to the draft angle of the base portions of the first and second mold portions. The method 200 also includes de-molding the hollow formed fiber article from the mold, as shown in block 230, although this step can be omitted in other examples.

[0112] Figure 9 A method 300 of providing a hot-formed, hollow-formed fibrous article is shown. In some examples, the method 300 can be referred to as a manufacturing method. The method 300 includes performing the method 200 described above with reference to Figure 8 The method 300 includes, after the hollow-formed fibrous article is ejected from the mold, subsequently transferring the hollow-formed fibrous article to a hot-forming mold, as indicated by block 310. The hot-forming mold includes a third mold portion and a fourth mold portion that, when the hot-forming mold is in use, can cooperate to collectively define a hot-forming cavity, each of the third and fourth mold portions including a respective base portion having a draft angle that is less than the draft angle of the base portion of the first mold portion and the draft angle of the base portion of the second mold portion. The hot-forming mold can be the hot-forming mold 120 described above with reference to at least Figure 2 and Figure 6 The method 300 further includes enclosing the third and fourth mold portions when the hollow-formed fibrous article is located in the hot-forming cavity, as indicated by block 320. In this example, the third and fourth mold portions are kept enclosed with a pressure of about 19.5 bar. The method 300 further includes using the hot-forming mold to hot-form the hollow-formed fibrous article in the hot-forming cavity to provide a hot-formed, hollow-formed fibrous article, as indicated by block 330. The hot-forming presses the hollow-formed fibrous article against the walls defining the hot-forming cavity such that the hot-formed, hollow-formed fibrous article takes the shape of the hot-forming cavity, which is different from the shape of the mold cavity of the mold. Thus, the shape of the hot-formed, hollow-formed fibrous article is different from the shape of the hollow-formed fibrous article.

[0113] Accordingly, the method 300 forms a container. For example, Figure 11 A container 900 obtained by the manufacturing method is depicted.

[0114] Figure 10A 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 of the molding system, cause the molding system to perform the method according to the example. In some examples, the control system 810 is or includes a control system 102 of the molding station 110 as described above. Instructions 830 include: causing the molding station to supply 831 fiber slurry to the mold cavity of a mold of the molding station, and using the mold to mold 832 the fiber slurry in the mold cavity to provide a hollow molded fiber article 22a having a convex base due to a positive draft angle of the base portions of the first and second mold portions of the mold. In other examples, control system 810 is or includes control system 104 of molding system 100 as described above, and instruction 830 includes: causing a molding station to mold fiber slurry in a cavity defined by a mold portion having a corresponding base portion including a positive draft angle to form a hollow molded fiber article; causing a transfer mechanism to transfer the article to a cavity of a thermoforming mold defined by a thermoforming mold portion having a corresponding base portion including a smaller draft angle than the mold portion; and causing the thermoforming mold to mold the article in the cavity to provide a thermoformed hollow molded fiber article. In other examples, instruction 830 includes instructions for performing any other example methods described herein.

[0115] It should also be understood that a container manufacturing line (such as...) is also provided. Figure 1 The container manufacturing line shown includes a forming system for providing thermoformed hollow fiber articles and equipment for performing at least one additional process on the thermoformed hollow fiber articles to provide a container. Similarly, a method of manufacturing a container is also provided, the method comprising: forming fiber slurry in a mold cavity defined by a mold portion having a corresponding base portion including a positive draft angle to form a hollow fiber article; causing a transfer mechanism to transfer the article to a mold cavity of a thermoforming mold, the mold cavity being defined by a thermoforming mold portion having a corresponding base portion including a smaller draft angle than the mold portion; and causing the thermoforming mold to form the article in the mold cavity to provide a thermoformed hollow fiber article, and then performing at least one additional process on the thermoformed hollow fiber article to provide a container. (See above reference) Figure 1 An example describing "at least one additional process" is given.

[0116] As a result of this application, the use of a container obtained by any of the methods described herein for containing contents is also provided. Figure 11An example such container 900 containing contents 910 is shown in FIG. 1. The container is in the form of a necked container and in particular a bottle. The use can be, for example, by a person who fills the container with the contents; a person who transports the contents; or a person who wishes to deliver the contents (e.g., to a consumer or end user), tender the contents (e.g., to a consumer or end user), import the contents, or hold the contents, whether for delivery purposes or for other purposes. The contents can be, for example, any one or more of the example contents described herein.

[0117] A method of providing a container containing contents is also provided. Figure 12 An example such method 1000 is shown in FIG. 10. The method 1000 includes providing 1010 a container, the container being in the form of a necked container and in particular a bottle, and then providing 1020 contents into the container. In this example, block 1020 follows block 1010, such that block 1020 includes filling the container provided at block 1010 with the contents. However, in some other examples, blocks 1010 and 1020 are performed simultaneously, such that providing 1010 the container includes providing the container with contents that are already present in the container. The contents can be, for example, any one or more of the example contents described herein. The method 1000 also includes closing 1030 an opening of the container after block 1020, and applying 1040 a marking or indicia to the container after block 1030. In this example, block 1030 involves applying a heat seal to the opening, and then screwing a cap or closure onto the container, and block 1040 includes sticking a label to the container.

[0118] In other respective examples, the order of blocks 1030 and 1040 is reversed, blocks 1030 and 1040 are performed simultaneously, block 1030 is omitted, and block 1040 is omitted. In some examples, block 1040 occurs before block 1020, or block 1040 occurs during block 1020. For example, in some cases, the marking or indicia is applied to the container, then the contents are provided into the container, and then the container is closed.

[0119] It will be appreciated that the method 1000 can be performed by the same party that manufactures the container, e.g., such that block 1010 includes the method discussed above with reference to the manufacturing line shown in FIG. 9. Figure 1 Alternatively, the method 1000 can be performed by a different party than the party that manufactures the container. In such an alternative, the different party performs block 1010 by obtaining the container from the party that manufactures the container (such as by the method discussed above with reference to FIG. 9) or from an intermediate party. Figure 1

[0120] ​Example embodiments of the application have been discussed with reference to the examples illustrated. However, it should be appreciated that variations and modifications are possible without departing from the scope of the present application as defined in the attached claims.

Claims

1. A mould portion for moulding a hollow formed fibrous article, the mould portion being co-operable with a further mould portion in use to collectively define a cavity in which the hollow formed fibrous article is moulded, the mould portion having a base portion corresponding to a portion of a base of the hollow formed fibrous article to be moulded by the mould portion in use, wherein the base portion has a positive draft angle.

2. The mould portion of claim 1, wherein the positive draft angle is no more than 5 degrees.

3. The mould portion of claim 1 or claim 2, wherein the positive draft angle is uniform across the base portion.

4. The mould portion of any preceding claim, wherein the base portion comprises one or more dewatering holes extending therethrough.

5. The mould portion of claim 4, wherein each of the one or more dewatering holes defines a respective channel, the respective channel fluidly connecting an interior moulding cavity defined by the mould portion to an exterior of the mould portion, the channel being angularly inclined with respect to an ejection direction of the mould portion.

6. The mould portion of any preceding claim, the mould portion comprising one or more side walls upstanding from the base portion, wherein a height of the one or more side walls at a parting plane of the mould portion is greater than a height of the one or more side walls at a rear portion of the mould portion opposite the parting plane.

7. The mould portion of claim 6, wherein at the parting plane, the side walls extend perpendicularly away from the parting plane.

8. A forming station for moulding a hollow formed fibrous article, the forming station comprising a mould having a first mould portion and a second mould portion, each of the first mould portion and the second mould portion being in accordance with any of claims 1 to 7, wherein the first mould portion and the second mould portion are co-operable with one another in use of the mould to collectively define a mould cavity in which the hollow formed fibrous article is moulded.

9. The forming station of claim 8, wherein the base portion of the first mould portion and the base portion of the second mould portion have the same positive draft angle.

10. A forming system for providing a thermoformed hollow formed fibrous article, the forming system comprising: a forming station as claimed in claim 8 or claim 9; and a thermoforming mould; wherein the thermoforming mould comprises a third mould portion and a fourth mould portion, the third mould portion and the fourth mould portion being co-operable in use of the thermoforming mould to collectively define a thermoforming cavity in which the hollow formed fibrous article is moulded to form the thermoformed hollow formed fibrous article, each of the third mould portion and the fourth mould portion comprising a respective base portion, the respective base portion having a draft angle that is less than the positive draft angle of the base portion of the first mould portion and the base portion of the second mould portion. ​ 11. The forming system of claim 10, wherein the third and fourth mold portions are configured to be held together with a pressure of at least 15 bar.

12. A method of using a mold to provide a hollow formed fibrous article, the mold comprising a first mold portion and a second mold portion, the first and second mold portions being mutually co-operable to collectively define a mold cavity when the mold is in use and each having a base portion with a positive draft angle, the method comprising: supplying a fibrous slurry to the mold cavity; and using the mold to form the fibrous slurry in the mold cavity to provide the hollow formed fibrous article, the hollow formed fibrous article having a convex base due to the draft angles of the base portions of the first and second mold portions.

13. The method of claim 12, wherein the method comprises demolding the hollow formed fibrous article from the mold.

14. A method of providing a thermoformed hollow formed fibrous article, the method comprising: performing the method of claim 13; subsequently transferring the hollow formed fibrous article to a thermoforming mold, the thermoforming mold comprising a third mold portion and a fourth mold portion, the third and fourth mold portions being co-operable to collectively define a thermoforming cavity when the thermoforming mold is in use, each of the third and fourth mold portions comprising a respective base portion, the respective base portion having a draft angle that is less than the positive draft angle of the base portion of the first mold portion and the positive draft angle of the base portion of the second mold portion; enclosing the third and fourth mold portions when the hollow formed fibrous article is located in the thermoforming cavity; and using the thermoforming mold to thermoform the hollow formed fibrous article in the thermoforming cavity to provide the thermoformed hollow formed fibrous article.

15. A forming system controller configured to cause a forming station for forming a hollow formed fibrous article to perform the method of claim 12 or claim 13, or to cause a forming system for providing a thermoformed hollow formed fibrous article to perform the method of claim 14.

16. A non-transitory storage medium storing machine readable instructions which, when executed by a processor of a forming system controller, cause the processor to cause a forming station to perform the method of claim 12 or claim 13, or to cause a forming system to perform the method of claim 14.

17. A container manufacturing line comprising a forming system for providing a thermoformed hollow formed fibrous article as claimed in claim 10 or claim 11, and apparatus for performing at least one additional process on the thermoformed hollow formed fibrous article to provide a container. ​ 18. A method of manufacturing a container, the method comprising performing the method of claim 14 to provide a thermoformed hollow formed fibre article, and subsequently performing at least one additional process on the thermoformed hollow formed fibre article to provide the container.

19. A method of providing a container containing contents, the method comprising providing a container obtained by the method of claim 18, and providing contents into the container to provide the container containing contents.

20. The method of claim 19, the method comprising: after the providing contents into the container, closing an opening of the container, and / or applying a label or a marking to the container.

21. Use of a container obtained by the method of claim 18 for containing contents.

22. A container obtainable or obtained by a manufacturing method comprising the method of any one of claims 14 or 18 to 20.

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