Mold System and Method

Abstract

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

Description

Technical Field

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

Background Art

[0002] A mandrel system may be inserted into a mold of a mold system such that an expandable member of the mandrel system expands to apply a molding operation to a container, such as a bottle, disposed within the mold. In some examples, after the molding operation is applied, the mandrel system may be withdrawn from the mold.

Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a mold system for forming a container, the mold system including a mold including a mold cavity and an opening, and a mandrel system including a reference point, a mandrel, and an expandable member. The mandrel is at least partially disposed within or at least partially disposably within the expandable member and includes one or more holes through which fluid can flow from the interior of the mandrel to the exterior of the mandrel during use to expand the expandable member. When the mandrel is at least partially located within the expandable member, the reference point is in a fixed position relative to the mold, and the mandrel system is positionable relative to the mold such that the mandrel and the expandable member extend into the mold cavity through the opening with a gap between the expandable member and the base of the mold cavity on the opposite side of the opening. At least a portion of the expandable member and the mandrel are movable relative to the reference point to vary the gap. The expandable member may be regarded as an expansion member or a bladder. As a result, the expandable member can be properly positioned relative to the base. If the expandable member is improperly positioned (e.g., positioned too far from the base), during expansion, the expandable member may contact the upper part of the container within the mold cavity before the expandable member fills the lower part of the container. In that case, further downward expansion of the expandable member may be inhibited by the friction between the expandable member and the upper part of the container. When the expansion is inhibited, the expandable member may not completely fill the lower part of the container. As a result, incorrect pressure may be applied to the lower part of the container (e.g., the bottom of the container). Thus, the compression of this part of the container may be insufficient, which may lead to a decrease in the strength and / or quality of the container. Alternatively, when the expansion is inhibited, the expandable member may extend excessively to completely fill the lower part of the container. Excessive elongation may reduce the uniformity of the pressure applied to the container by the expandable member. This reduction in uniformity may adversely affect the quality of the container, for example, resulting in variations in the fragility or thickness of the container. Furthermore, excessive elongation may fatigue the expandable member, thereby shortening the life of the expandable member or leading to rupture of the expandable member.At least a part of the mandrel is movable, enabling proper positioning of the expandable member within the mold cavity. As a result, the quality of the container produced by the mold system may be improved, and / or the lifespan of the expandable member may be improved. Optionally, the entire expandable member and mandrel are movable relative to a reference point to vary the gap. The mandrel may be of an integral type. It can be particularly advantageous in examples where the mandrel is one of a plurality of molds having cavities of different shapes, especially different heights, and at least a part of the mandrel is movable. In these examples, the gap may be varied based on the specific shape of each mold cavity to properly position the expandable member within each mold. Advantageously, this can eliminate the need for each mold to have a custom mandrel system. In some embodiments, the container is a bottle, such as a bottle made of a fibrous material. Optionally, during use, the fluid is flowable through a hole from outside the mandrel to inside the mandrel.

[0004] The mandrel system may include a connector for connecting the mandrel system to the mold, and the reference point may be included by the connector. The connector can provide a convenient way to position the mandrel system relative to the mold and fix the reference point relative to the mold.

[0005] The mandrel system may include a controller configured to cause movement of at least a part of the expandable member and the mandrel relative to the reference point. Thereby, the amount of operator input required to operate the mold system may be reduced, for example, compared to a mold system where the operator manually moves the mandrel and the expandable member. This can improve the overall product quality and consistency. Additionally, this can shorten the processing time and potentially improve throughput.

[0006] The controller can be configured to cause movement of at least a portion of the expandable member and the mandrel relative to a reference point such that the gap has a predetermined value. Advantageously, the predetermined value can enable specification of a desired gap. Specifically, as described above, if the gap is too large, downward expansion of the expandable member may be inhibited. Conversely, if the gap is too small (i.e., if the expandable member is too close to the base), non-optimal expansion of the expandable member can occur. Specifically, the expandable member may contact the base of the container prematurely, thereby potentially inhibiting subsequent expansion of the expandable member outwardly at the corners of the container. This can result in a degradation of the quality of the container and / or, as described above, a shortening of the lifespan of the expandable member. The mold can be one of a plurality of molds having cavities of different shapes, particularly different heights. Regardless of the shape of the mold cavity, the controller moves the mandrel and the expandable member such that the gap between the expandable member and the base of the mold reaches the same predetermined value. As a result, the expandable member can be appropriately positioned for each mold without the need for a custom mandrel and expandable member for each mold. This can reduce the cost of the system and, by eliminating the need to switch the mandrel and the expandable member when changing molds, can shorten the processing time.

[0007] The predetermined value can be 2 mm or more. As a result, the expandable member can be appropriately positioned to reduce the possibility of non-optimal expansion of the expandable member, as described above.

[0008] The predetermined value can be 11 mm or less. Thereby, the expandable member can be appropriately positioned to reduce the possibility that downward expansion of the expandable member is inhibited, as described above.

[0009] The controller may be configured to determine a predetermined value based on the characteristics of the mold. Thereby, the expandable member can be appropriately arranged for a specific mold. Further, since it is not necessary for the operator to determine and input the predetermined value, the amount of operator input required to operate the mold system can be further reduced. Optionally, the characteristics of the mold may be one of: the height of the mold, the width of the mold, and the shape of the mold. Optionally, the controller may be configured to determine a predetermined value based on the characteristics of the expandable member. The characteristics of the expandable member may be, for example, one of the height of the expandable member, the width of the expandable member, the geometric shape of the expandable member, and the material of the expandable member.

[0010] The controller may store a look-up table of different predetermined values associated with each different mold characteristic, and the controller may be configured to use the characteristics of the mold to select a predetermined value from the look-up table. Thereby, when the mold is replaced with another mold of a different shape, the operator can be eliminated from the need to calculate the gap. Therefore, the downtime that occurs when switching between molds can be reduced. Optionally, the predetermined value may be associated with each different mold characteristic and each different expandable member characteristic. The controller may be configured to use the characteristics of the mold and the characteristics of the expandable member to select a predetermined value from the look-up table.

[0011] The end of the mandrel may be attachable to, or may be attached to, an expandable member. For example, the end of the mandrel may be removably attachable to, or may be removably attached to, an expandable member. As a result, the end of the mandrel can be attached to, or separated from, the expandable member during different stages of the manufacturing process. For example, the expandable member can be more easily positioned and moved when attached to the mandrel. This can be beneficial for positioning the expandable member within the mold before expansion and / or during insertion or withdrawal of the mandrel system from the mold. When separated from the mandrel, the expandable member can expand without being restrained by the end of the mandrel, which might otherwise restrain expansion. The unrestrained expansion of the expandable member can potentially improve the magnitude and uniformity of the pressure applied by the expandable member to the container within the mold. Thereby, the quality of the container can be improved by the improved compression that can result from the improved magnitude and uniformity of the applied pressure. Further, the unrestrained expansion can potentially reduce stress concentration in the expandable member, which might damage or fatigue the expandable member. Thereby, the lifespan of the expandable member can be improved.

[0012] When the end of the mandrel is attached to an expandable member, the end of the mandrel can be movable relative to a reference point in response to expansion of the expandable member. Thus, the expandable member can expand while attached to the mandrel with relatively little interference from the mandrel. By being attached to the mandrel, it becomes beneficially possible for the mandrel to manipulate the expandable member, thereby improving the functionality of the mandrel system. For example, the mandrel can be used to properly position the expandable member within a mold, twist the expandable member around the mandrel, and / or change the length of the expandable member, thereby changing the width of the expandable member. Optionally, the mandrel includes a first portion and a second portion, the second portion includes the end of the mandrel, and the second portion is movable relative to the first portion, such as telescopically, in response to expansion of the expandable member. Optionally, the mandrel system includes an actuator operable in a first mode, the actuator moving the end of the mandrel relative to a reference point to change the length of the expandable member, thereby changing the width of the expandable member, and having a second mode in which the actuator enables movement of the end of the mandrel relative to the reference point in response to expansion of the expandable member or moves the end of the mandrel. The actuator can comprise one of a rack and pinion system, a pneumatic system, and a hydraulic system.

[0013] The expandable member can be arranged to separate from the end of the mandrel in response to expansion of the expandable member. Thus, the expandable member can move freely relative to the end of the mandrel during expansion and can expand without being inhibited by the end of the mandrel. As described above, the uninhibited expansion of the expandable member can improve the magnitude and uniformity of the pressure applied by the expandable member to a container within a mold. Further, the uninhibited expansion can reduce stress concentration in the expandable member, which can otherwise damage or fatigue the expandable member. As a result, the lifespan of the expandable member can be improved.

[0014] The mandrel and the expandable member can be movable relative to a reference point in order to vary the width of the expandable member. As a result, the width of the expandable member can be varied to best suit the requirements of the manufacturing process employing the mandrel system. For example, reducing the width of the expandable member can be beneficial in facilitating the passage of the expandable member through an opening in a mold that can occur when the mandrel system is inserted into the mold and then withdrawn from the mandrel system. By reducing the width, the expandable member can pass through the opening without contacting the mold, thereby preventing damage to the expandable member. Further, when a container is placed within the mold and the expandable member is inserted into the container to apply a forming operation to the container, reducing the width can potentially reduce the likelihood that the expandable member contacts and damages the container during insertion, and / or leads to detachment. Increasing the width of the expandable member can be beneficial during expansion of the expandable member since the expandable member can expand without being relatively restrained by the mandrel. The unrestrained expansion of the expandable member can potentially improve the magnitude and uniformity of the pressure applied to the container during a forming operation by the expandable member. Further, the unrestrained expansion can potentially reduce stress concentration in the expandable member that can be a potential for damage or fatigue of the expandable member, thereby potentially improving the lifespan of the expandable member. Optionally, the mandrel system can include a connector for connecting the mandrel system to a mold, the expandable member can be attached to the connector, and the mandrel can be movable relative to the connector. Optionally, the base of the mold is at a fixed distance from the opening of the mold. As a result, the mold can be more robust and less costly to manufacture compared to a mold where the base of the mold can be movable relative to the opening to achieve mold cavities of different heights.

[0015] The mold system may include an additional mold. The additional mold may include an additional mold cavity and an additional opening. The additional mold cavity may have a geometry different from the geometry of the mold cavity, and when the mandrel is at least partially located inside the expandable member, the reference point is in a fixed position relative to the additional mold, and the mandrel system is arranged such that the mandrel and the expandable member extend into the expandable member and there is an additional gap between the expandable member and the base of the additional mold cavity on the opposite side of the additional opening. The additional opening may be positioned relative to the additional mold cavity through the additional opening. The mandrel and the expandable member may be movable relative to the reference point to change the additional gap. The mandrel system may include a controller configured to move the mandrel and the expandable member relative to the reference point such that the gap and the additional gap have the same value. As a result, different geometric shapes (e.g., different heights) of containers can be manufactured using the same mandrel system while ensuring proper positioning of the expandable member.

[0016] According to a second aspect of the present invention, a method of forming a container is provided, the method comprising providing the mold system of the first aspect of the present invention; moving at least a portion of the expandable member and the mandrel relative to a reference point when the mandrel is at least partially located inside the expandable member to change the gap; positioning the mandrel system relative to the mold such that the reference point is in a fixed position relative to the mold and the mandrel and the expandable member extend into the mold cavity through an opening. As a result, the expandable member can be properly positioned relative to the base. If the expandable member is improperly positioned (for example, if it is positioned too far from the base), during expansion, the expandable member may contact the upper part of the container in the mold cavity before filling the lower part of the receiver. In that case, further downward expansion of the expandable member can be inhibited by the friction between the expandable member and the upper part of the container. If the expansion is inhibited, the expandable member may not completely fill the lower part of the container. As a result, incorrect pressure may be applied to the lower part of the container (for example, the bottom of the container). Thus, the compression of this part of the container may be insufficient, which may lead to a decrease in the strength and / or quality of the container. Alternatively, if the expansion is inhibited, the expandable member may extend excessively to completely fill the lower part of the container. Excessive elongation may reduce the uniformity of the pressure applied to the container by the expandable member. This reduction in uniformity can adversely affect the quality of the container, for example, resulting in variations in the fragility or thickness of the container. Furthermore, excessive elongation may fatigue the expandable member, which may shorten the life of the expandable member or lead to rupture of the expandable member. The ability of at least a portion of the mandrel to move allows for proper positioning of the expandable member within the mold cavity. As a result, the quality of the container produced by the mold system may be improved and / or the life of the expandable member may be improved. Optionally, the movement includes moving the entire expandable member and mandrel relative to the reference point to change the gap. The mandrel may be integral.If at least a part of the mandrel is movable, it can be particularly advantageous in the example where the mold is one of a plurality of molds having cavities of different shapes, especially different heights. In these examples, the gap may be varied based on the specific shape of each mold cavity in order to appropriately arrange the expandable member within each mold. As a result, advantageously, the need for each mold to have a custom mandrel system can be eliminated. Optionally, the method may include expanding the expandable member and applying a forming operation to a container disposed within the mold cavity. In some embodiments, the container is a bottle such as a bottle made of a fibrous material.

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

[0018] The movement may include moving at least a part of the expandable member and the mandrel relative to a reference point such that the gap has a predetermined value. Advantageously, the predetermined value may enable specifying a desired gap. Specifically, as described above, if the gap is too large, downward expansion of the expandable member may be inhibited. Conversely, if the gap is too small (i.e., if the expandable member is too close to the base), non-optimal expansion of the expandable member may occur. Specifically, the expandable member may contact the base of the container prematurely, which may inhibit subsequent expansion of the expandable member outwardly at the corners of the container. As a result, as described above, there may be a possibility of a decrease in the quality of the container and / or a shortening of the lifespan of the expandable member. The mold may be one of a plurality of molds having different shapes, particularly cavities of different heights. Regardless of the geometry of the mold cavity, the controller moves the mandrel and the expandable member such that the gap between the expandable member and the base of the mold reaches the same predetermined value. As a result, the expandable member can be appropriately arranged for each mold without the need for a custom mandrel and expandable member for each mold. Thereby, the cost of the system can be reduced, and the processing time can be shortened by eliminating the need to switch the mandrel and the expandable member when changing the mold. Optionally, the predetermined value may be 2 mm or more. The predetermined value may be 11 mm or less.

[0019] The method may include determining a predetermined value based on the characteristics of the mold. Thereby, the expandable member can be appropriately arranged for a specific mold. Optionally, the characteristics of the mold may be one of the height of the mold, the width of the mold, and the geometry of the mold. Optionally, the method includes determining a predetermined value based on the characteristics of the expandable member. The characteristics of the expandable member may be, for example, one of the height of the expandable member, the width of the expandable member, the geometry of the expandable member, and the material of the expandable member. Optionally, the mandrel system includes a controller, and determining includes the controller determining a predetermined value based on the characteristics of the mold.

[0020] Determining the predetermined value may include selecting the predetermined value from a look-up table of different predetermined values associated with respective different mold characteristics using the characteristics of the mold. This can eliminate the need for an operator to calculate the gap when the mold is replaced with another mold of a different geometry. As a result, the downtime occurring during mold switching can be reduced. Optionally, selecting the predetermined value may include selecting the predetermined value from a look-up table of different predetermined values associated with respective different mold characteristics and respective different characteristics of the expandable member using the characteristics of the mold and the characteristics of the expandable member.

[0021] The method can include at least one of separating the end of the mandrel from the expandable member and attaching the end of the mandrel to the expandable member. As a result, the end of the mandrel can be attached to or separated from the expandable member during different stages of the manufacturing process. For example, the expandable member can be more easily positioned and moved when attached to the mandrel. This can be beneficial for placing the expandable member within the mold before expansion and / or during insertion or withdrawal of the expandable member from the mold. When separated from the mandrel, the expandable member can expand without being restrained by the end of the mandrel, which might otherwise restrain expansion. The unrestrained expansion of the expandable member can improve the magnitude and uniformity of the pressure applied by the expandable member to the container within the mold. Thereby, the quality of the container can be improved by the improvement in compression that can result from the improvement in the magnitude and uniformity of the applied pressure. Additionally, the unrestrained expansion can reduce stress concentration in the expandable member, which might damage or fatigue the expandable member. Thereby, the lifespan of the expandable member can be improved. Alternatively, the method can include expanding the expandable member to apply a forming operation to a container disposed within the mold cavity and moving the end of the mandrel relative to a reference point while the expandable member is expanding. Optionally, the method includes attaching the end of the mandrel to the expandable member or the method includes moving the end of the mandrel relative to a reference point in response to expansion of the expandable member.

[0022] This method may include expanding an expandable member to apply a forming operation to a container disposed within a mold cavity and separating an end of a mandrel from the expandable member during expansion of the expandable member. Thereby, the expandable member can move freely relative to the end of the mandrel during expansion and thus expand without being restrained by the end of the mandrel. As described above, the unrestrained expansion of the expandable member may improve the magnitude and uniformity of the pressure applied to the container within the mold by the expandable member. Further, the unrestrained expansion may reduce stress concentration in the expandable member, which may damage or fatigue the expandable member. As a result, the life of the expandable member may be improved.

[0023] By moving at least a portion of the expandable member and the mandrel relative to a reference point, the width of the expandable member can be varied. As a result, the width of the expandable member can be varied to best suit the requirements of the manufacturing process employing the mandrel system. For example, reducing the width of the expandable member can be beneficial in facilitating the passage of the expandable member through the opening of the mold that can occur when the mandrel system is inserted into the mold and then withdrawn from the mandrel system. By reducing the width, the expandable member can pass through the opening without contacting the mold, thereby preventing damage to the expandable member. Further, when the container is placed within the mold and the expandable member is inserted into the container to apply a forming operation to the container, reducing the width can reduce the likelihood that the expandable member contacts and damages the container during insertion and / or withdrawal. Increasing the width of the expandable member can be beneficial during expansion of the expandable member as the expandable member can expand relatively unconstrained by the mandrel. The unconstrained expansion of the expandable member can improve the magnitude and uniformity of the pressure applied to the container during the forming operation by the expandable member. Further, unconstrained expansion can reduce stress concentrations in the expandable member that can cause damage or fatigue to the expandable member, thereby improving the lifespan of the expandable member.

[0024] This method can include placing a container within a mold, where the container is at least partially formed of paper pulp, and expanding an expandable member to apply a forming operation to the container. The choice of paper is more environmentally friendly than plastic. However, when formed of paper, the quality of the container is particularly susceptible to the effects of poor compression. For example, insufficient compression can result in increased permeability to liquids and / or excessive weakening of the container. By varying the gap between the expandable member and the base of the mold to enable proper positioning of the expandable member, the effects of such quality degradation can be reduced. In some embodiments, the container is a bottle, such as a bottle made of a fibrous material.

[0025] The method may include expanding an expandable member as part of a thermoforming operation on a container disposed within a mold cavity. The thermoforming may improve mechanical properties of the container, such as rigidity, as well as the surface finish of the container. Optionally, moving the mandrel and the expandable member relative to a reference point may include moving the mandrel and the expandable member relative to the reference point such that a gap has a predetermined value. The method may include providing a further mold, the further mold including a further mold cavity and a further opening, the further mold cavity having a geometry different from the geometry of the mold cavity. The method may include moving the mandrel and the expandable member relative to a reference point to vary a gap between the expandable member and a further base of the further mold cavity on an opposite side of the further opening such that a further gap has a predetermined value. The method may include positioning the mandrel system relative to the further mold such that the reference point is in a fixed position relative to the further mold and the mandrel and the expandable member extend into the further mold cavity through the further opening. Thereby, different geometries (e.g., different heights) of containers can be manufactured using the same mandrel system while ensuring proper positioning of the expandable member. In some embodiments, the container is a bottle, such as a bottle made of a fibrous material.

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

[0027] The container can be a bottle such as a bottle made of a fibrous material. For example, the container may be obtainable or acquirable from the method of the third aspect of the present invention. This manufacturing method may include at least one additional process. The at least one additional process may include coating the container to produce a coated container. The at least one additional process may include drying the container or the coated container to produce a dried container. The at least one additional process may include attaching a closure to the container, the coated container or the dried container.

[0028] According to a fourth aspect of the present invention, there is provided a mandrel system for use with a mold for forming a container, the mandrel system including a reference point and a mandrel, the mandrel including a plurality of holes, fluid being flowable from the inside of the mandrel to the outside of the mandrel during use, and at least a part of the mandrel being movable relative to the reference point to vary the distance between the reference point and the end of the mandrel.

[0029] Optionally, the mandrel system includes a connector for connecting the mandrel system to the mold, the reference point being included by the connector.

[0030] Optionally, the mandrel system includes a controller configured to cause at least a part of the mandrel to move relative to the reference point.

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

[0032] Optionally, the controller may be configured to determine the predetermined value based on the characteristics of the mold.

[0033] Optionally, the controller stores look-up tables of different predetermined values associated with respective different mold characteristics, and the controller is configured to use the characteristics of the mold to select a predetermined value from the look-up table.

[0034] Optionally, the mandrel system includes an expandable member, and the end of the mandrel is attachable to or attached to the expandable member.

[0035] Optionally, when the end of the mandrel is attached to the expandable member, the end of the mandrel can be movable relative to a reference point in response to expansion of the expandable member.

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

[0037] Optionally, the mandrel and the expandable member can be movable relative to a reference point to vary the width of the expandable member.

[0038] The optional features of the aspects of the present invention can, where appropriate, be applied equally to other aspects of the present invention.

[0039] Embodiments of the present invention will be described by way of example only with reference to the accompanying drawings.

Brief Description of the Drawings

[0040]

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DETAILED DESCRIPTION OF THE INVENTION

[0041] The following description presents exemplary embodiments and, together with the drawings, serves to explain the principles of the embodiments of the present invention.

[0042] Figure 1 shows a process for making a bottle from paper pulp (i.e., capable of forming the basis of an exemplary fiber suspension). This process is merely exemplary and is provided to give context to embodiments of the present invention. Broadly speaking, the exemplary process includes providing a fiber suspension, introducing the fiber suspension into the mold cavity of a porous first mold, using the porous first mold to drain liquid (such as water) from the fiber suspension to produce a wet precursor or embryo (which may itself be considered a formed container), further shaping the wet precursor with a mold to produce a further shaped container, further coating the further shaped container to produce a coated shaped container, drying the coated shaped container to produce a dried container, and applying a closure to the dried container. As will be apparent at least from the following description, modifications can be made to the exemplary process to provide variants that can embody other examples of the present invention.

[0043] In this example, providing a fiber suspension includes preparing the fiber suspension from its components. More specifically, the preparation includes providing pulp fibers such as paper pulp fibers and mixing the pulp fibers with a liquid to provide a hydrated pulp fiber. In this example, the pulp fibers are provided in sheet form from a supplier, and the liquid includes water and one or more additives. In this example, the liquid is mixed with the pulp fibers to provide a hydrated pulp fiber having a solid fiber content of 1 wt% to 5 wt% (based on the dry mass of the fibers). In an example, the one or more additives include sizing agents such as alkyl ketene dimer (AKD). The hydrated pulp fiber typically includes AKD in an amount of 0.4 wt% based on the total dry mass of the solid fibers in the hydrated pulp fiber. In some examples, the one or more additives are present in the liquid at the time of mixing the pulp fibers with the liquid. In some examples, the one or more additives are included in the hydrated pulp fiber after mixing the pulp fibers with the liquid. (For example, the pulp fibers are hydrated for a period of time, such as 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fiber.) The hydrated pulp fibers pass between the plates of a valley beater 11 or a refiner that are moving relative to each other. This fibrillates some or all of the fibers, which means that the cell walls of those fibers are partially delaminated and the wet surfaces of the fibers include protruding hairs or fibrillations. These fibrillations help increase the strength of the bonds between the fibers in the dried final product. In other examples, the valley beater 11 or the refiner may be omitted.

[0044] The resulting treated pulp is stored in a tank 12 in a relatively concentrated form (e.g., a solid fiber content of 1 wt% to 5 wt%) to reduce the required storage space. At an appropriate time, the treated pulp is transferred to a mixing station 13 where the treated pulp is diluted with additional water and optionally mixed with one or more additives (with or instead of one or more additives provided with the hydrated pulp fiber) to provide a fiber suspension ready for forming.

[0045] In this example, the porous first mold 15 includes two half - molds, which in this case are movable towards and away from each other using hydraulic rams. In this example, each of the half - molds is a monolithic or unitary tool formed by additive manufacturing (e.g., 3D printing) that defines a mold profile, and when the half - molds contact each other, their respective mold profiles cooperate to define a mold cavity in which a wet precursor or a formed container is formed. Each half - mold can itself define a smaller molding cavity, and when cooperating with the second half - mold, the smaller molding cavities can combine to provide the cavity of the entire mold. The two half - molds may themselves be regarded as “split parts” or “molds”, and the overall porous first mold 15 may be regarded as a “split mold” or in this case also a “mold”. In other examples, the porous first mold 15 may include more than two split parts, such as three, four, or six split parts that cooperate to define a molding cavity.

[0046] In FIG. 1, unlike the molding process of immersing the mold in a suspension, the fiber suspension (also known as a slurry) is filled into the porous mold 15 from above. The fiber suspension is drawn into the porous mold 15 via line 16 under vacuum, and the excess suspension is drawn into tank 17 via line 18 through the porous mold 15 under vacuum. The shot mass may be controlled by measuring (e.g., metering) the amount of liquid drawn into tank 17. A weight scale platform supporting tank 17 is shown in FIG. 1. When the required amount (e.g., a predetermined volume such as 10 liters, or a predetermined mass such as 10 kilograms) of liquid is collected in tank 17, the suction of the suspension through the porous mold 15 is stopped and the porous mold 15 is opened to the ambient air. In this example, the suspension drawn in with the fiber suspension in line 16 is water, or mainly water (additives may also be present). The liquid drawn into tank 17 via line 18 under vacuum is substantially fiber - free because the fibers remain on the walls of the porous mold 15 to form the embryo of the formed container.

[0047] In one form, an impermeable expansion element 19, such as a foldable bladder, is inserted into the porous mold 15 to further remove the suspension (e.g., water) from the embryo body and to form or integrate the three-dimensional shape of the container. The expansion element 19 is expanded and functions as an internal high-pressure core structure of the porous mold 15. This process strengthens the wet embryo body so that it can be processed, moving water from between the fibers, thereby improving the efficiency of the subsequent drying process. The expansion element 19 is actuated and adjusted using a hydraulic pump 20. The pump 20 has a cylinder that moves the fluid in line 21 into the expansion element 19, expanding the expansion element 19 radially to conform to the mold cavity. The fluid in line 21 is preferably incompressible, such as water. Also, water has the advantage that a leak or rupture of the bladder 19 does not introduce new substances into the system (since the suspension is already water, or mainly water).

[0048] Demolding is performed when the porous mold 15 opens to remove the self-supporting molded container 22. It is preferably followed by mold cleaning 23 to remove small fibers and maintain the porosity of the porous mold 15. In this example, while the mold 15 is open, a high-pressure jet fired radially is inserted into the mold cavity. This removes the fibers from the walls of the mold cavity. Alternatively or additionally, water from the tank 17 is pressurized through the back of the porous mold 15 to remove the trapped fibers. The water is discharged for recirculation to the upstream part of the system. Note that cleaning is important to condition the porous mold 15 for reuse. The porous mold 15 may appear clean after removing the container, but its performance may be impaired if not cleaned.

[0049] According to FIG. 1, the formed but unfinished container 22 is then transferred to a second forming station where pressure and heat are applied, for example, with an aluminum mold 25, for thermoforming the desired neck and for a surface finish including optionally embossing and / or debossing surface features. After the two halves of the mold 25 are closed around the container 22, a press is engaged. For example, a bladder 26 (e.g., a thermoforming bladder 26) is inserted into the container 22. The bladder 26 is expanded via line 27 by a pump 28 to supply a pressurized fluid such as air, water, or oil. Optionally, during supply, the pressurized fluid is heated, for example, with a heater, or alternatively, cooled, for example, with a heat exchanger. The outer mold block 24 of the mold 25, and / or the mold 25 itself may also be heated or alternatively heated. The state of the formed container 22 after thermoforming is considerably more rigid and the side walls are more compressed compared to the state at demolding from the porous mold 15.

[0050] As shown, a drying stage 29 (e.g., a microwave drying process or other drying process) is performed downstream of the thermoforming. In one example, the drying stage 29 is performed prior to thermoforming. However, forming with the mold 25 requires some water content to assist in bonding during the compression process. FIG. 1 shows a further drying stage 30 after the drying stage 29, which can utilize hot air circulated, for example, within a “hot box” over the formed container 22. In some examples, microwave or other drying processes may be performed at multiple stages of the overall manufacturing process.

[0051] The formed container 22 is then subjected to a coating stage, during which, in this example, a spray lance 31 is inserted into the formed container 22 to apply one or more surface coatings to the inner wall of the formed container 22. In another example, the formed container 22 is filled with a liquid that coats the inner wall of the formed container 22 instead. In practice, such coatings provide a protective layer to prevent the release of contents that may penetrate the bottle wall and / or weaken the bottle wall. The coating is selected according to the intended contents of the container 22, such as beverages, detergents, pharmaceuticals, etc. In some examples, an additional drying stage 30 is performed after (or both before and after) the coating stage. In this example, the formed container 22 is then provided to a curing process 34, which can be configured or optimized according to the coating, for example, dried for 24 hours under ambient conditions or dried by a flash drying method. In some examples, for example, if an additional drying stage 30 is performed after the coating stage, the curing process 34 may be omitted.

[0052] A process for forming a closure or mouth may be performed on the formed container 22 at an appropriate production stage (e.g., during thermoforming, or before or after coating). For example, as shown in FIG. 1, a neck fitting 35 may be attached. In some examples, an external coating is applied to the formed container 22 as shown in an additional coating stage 32. In one example, the formed container 22 is immersed in a liquid that coats its outer surface as shown in FIG. 1. Next, one or more additional drying or curing processes may be performed. For example, the formed container 22 may be dried in warm air. Thus, the formed container 22 is fully formed and ready to receive contents therein.

[0053] FIG. 2 shows a mold system 101 that can be used to thermoform the above-described self-standing forming container 22. The mold system 101 includes a mold 103, a mandrel system 105, a pump 107, and a line 109.

[0054] The mold 103 includes a first part 111 and a second part 113. In other examples, the mold 103 may include three or more parts. The two parts 111, 113 are separable to open the mold 103. Each part includes a cavity. When the two parts 111, 113 are joined to close the mold 103, a mold cavity 115 including the cavities of the first part 111 and the second part 113 is created within the mold 103. In this particular example, the mold cavity 115 has the shape of a bottle and includes a body portion and a neck portion. The neck portion has a smaller diameter than the body portion and extends up to the upper part of the mold 103. The mold 103 includes an opening 117 to the mold cavity 115. Further, the mold cavity 115 includes a base 119 on the opposite side of the opening 117. The base 119 is at a fixed distance from the opening 117. That is, the base 119 does not move relative to the opening 117. Thereby, a relatively robust and inexpensive mold can be provided as compared with a mold having a base movable relative to the opening.

[0055] The mandrel system 105 includes a connector 121, a mandrel 123, an expandable member 125, a first actuator 127, a second actuator 129, a controller 131, and a control panel (not shown).

[0056] The connector 121 includes a bore 122 that extends through the connector 121 from the upper part to the bottom part of the connector 121. An annular seal is disposed within the bore 122 to provide a seal between the connector 121 and the mandrel 123, which extends through the bore 122. The seal is a low-friction seal that allows movement of the mandrel 123 relative to the connector 121. In this embodiment, the connector 121 has a reference point 133. As will be described in more detail below, when inserting and removing the mandrel 123 and the expandable member 125 into and from the mold 102, the mandrel 123 moves relative to the reference point 133. In other examples, the reference point 133 may be included by other components of the mandrel system 105.

[0057] The mandrel 123 includes a cylindrical tube 134 and a first portion 137 of the mounting mechanism of the mandrel system 105. A plurality of holes 135 are formed along the length of the tube 134. The holes 135 are located along the lower portion of the tube 134 and extend radially through the tube 134 to allow fluid to flow from the inside of the mandrel 123 to the outside of the mandrel 123. The first portion 137 of the mounting mechanism includes a magnet located at the lower end of the mandrel 123, i.e., at the end of the mandrel 123 located inside the expandable member 125. The mandrel 123 extends into the expandable member 125 through the bore 122 of the connector 121 such that the lower portion of the mandrel 123 is located inside the expandable member 125. In some embodiments, the mandrel 123 may be fully disposed inside the expandable member 125 and different connectors 121 may be used. The upper portion of the mandrel 123 is connected to the line 109. The mandrel 123 is free to move with respect to the connector 121 and thus with respect to the reference point 133. In particular, the mandrel 123 is free to move up and down within the bore 122 and can rotate within the bore 122 of the connector 121.

[0058] The expandable member 125 includes an expansion member in the form of an elastomeric bladder 138. The bladder 138 includes a neck portion and a body portion. The neck portion is sealingly connected to the bottom of the connector 121. The neck portion has a smaller diameter than the body portion. In other examples, the bladder 138 may include a single portion of a constant diameter. The second component 139 of the mounting mechanism comprises a metal plate 139 formed from a ferromagnetic metal such as iron. The metal plate 139 is attached to the bottom of the bladder 138. The metal plate 139 cooperates with the magnet 137 of the mandrel 123 to removably attach the expandable member 125 to the mandrel 123.

[0059] The first actuator 127 is disposed on the connector 121 and coupled to the mandrel 123. By the operation of the first actuator 127, the mandrel 123 moves linearly with respect to the reference point 133 along the longitudinal axis of the mandrel 123. In this example, the first actuator 127 includes an electric motor and a transmission (e.g., gears, friction wheels, and / or a rack and pinion) for transmitting the torque generated by the electric motor to the mandrel 123. In other examples, the first actuator 127 may include a hydraulic or pneumatic system for moving the mandrel 123 with respect to the reference point 133.

[0060] The second actuator 129 is located at the upper end of the mandrel 123 and coupled to the mandrel 123. By the operation of the second actuator 129, the mandrel 123 rotates with respect to the reference point 133 about the longitudinal axis of the mandrel 123. In this embodiment, the second actuator 129 includes an electric motor and a transmission (e.g., gears, friction wheels, and / or a rack and pinion) for transmitting the torque generated by the electric motor to the mandrel 123. In other embodiments, the second actuator 129 may include a hydraulic or pneumatic system for rotating the mandrel 123 with respect to the reference point 133.

[0061] In this example, the mandrel system 105 includes separate actuators 127, 129 for linearly moving the mandrel 123 and for rotating the mandrel 123. Accordingly, this improves the control over the linear and rotational movement of the mandrel 123 and enables independent control over the rotational and linear movement. In other embodiments, the mandrel system 105 may comprise a single actuator operable to linearly move and rotate the mandrel 123. In further embodiments, the actuator may comprise a single electric motor and one or more of the transmissions may be clutch-type. In this way, the advantages of independent control over the linear and rotational movement of the mandrel can be achieved using a single electric motor. The controller 131 controls the operation of the actuators 127, 129 and thereby controls the movement of the mandrel 123 relative to the reference point 133. The controller 131 also controls a robot arm (not shown) that moves the connector 121 relative to the mold 103 and the pump 107.

[0062] A control panel (not shown) is connected to the controller 131 and is for receiving instructions and data related to the mold 103 and the expandable member 125.

[0063] The pump 107 comprises a cylinder for moving the fluid within the line 109. In some embodiments, the fluid is one of air, water, or oil. Since the line 109 is connected to the top of the mandrel 123, displacing the fluid causes the pump 107 to supply pressurized fluid inside the mandrel 123. The pressurized fluid then flows into the expandable member 125 through the holes 135 in the tube 134. Thereby, the pump 107 is used to expand the expandable member 125. The pump 107 can also operate in the opposite direction to discharge the fluid from the expandable member 125 and thereby fold and contract the expandable member 125.

[0064] Next, the use of the mold system 101 is provided by FIG. 3. As shown in FIG. 3(a), the two parts 111, 113 of the mold 103 are closed around the container 22 such that the container 22 is located inside the mold cavity. At this stage, the mandrel system 105 is disposed outside the mold cavity 115. The magnet 137 is attached to a magnetic plate 139 that attaches the expandable member 125 to the end of the mandrel 123.

[0065] Referring now to FIG. 3(b), the controller 131 controls the first actuator 127 to move the mandrel 123 downward with respect to the reference point 133. As the mandrel 123 moves downward, the end of the mandrel 123 pushes the bottom of the expandable member 125 downward, thereby expanding the length of the expandable member 125. The increase in the length of the expandable member 125 results in a corresponding decrease in the width of the expandable member 125. At the same time, the controller 131 operates the second actuator 129 to rotate the mandrel 123 with respect to the reference point 133. Since the expandable member 125 is attached to the end of the mandrel 123 by an attachment mechanism (i.e., the magnet 137 and the metal plate 139), rotation causes the expandable member 125 to twist around the mandrel 123. By twisting and elongating the expandable member 125, a greater reduction in the width of the expandable member 125 can be achieved than if the expandable member 125 were twisted or elongated alone.

[0066] Next, the controller 131 controls the actuators 127, 129 to stop the downward movement and rotation of the mandrel 123. At this stage, the width of the expandable member 125 is less than or equal to the width of the opening 117 of the mold 103. Thereby, the mandrel 123 and the expandable member 125 can pass through the opening 117 of the mold 103 without the expandable member 125 contacting the mold 103 or the container 22. Advantageously, this can reduce the possibility that the container 22 is damaged by the expandable member 125 and the possibility that the expandable member 125 is damaged by the mold 103.

[0067] Referring now to FIG. 3(c), the controller 131 controls the robot arm to move the connector 121 downward toward the mold 103 until the connector 121 contacts and connects to the upper part of the mold 103 (as shown in FIG. 3(d)). As the connector 121 descends, the mandrel 123 and the expandable member 125 are inserted into the mold cavity 115 through the opening 117. Due to the previous downward movement of the mandrel 123 with respect to the connector 121 (described with reference to FIG. 3(b)), the length of the mandrel 123 is too long to fit within the mold cavity 115. Therefore, when a mandrel 123 of a predetermined length is inserted into the mold cavity 115, the controller 131 operates the first actuator 127 to move the mandrel 123 upward with respect to the connector 121. This upward movement of the mandrel 123 occurs simultaneously with and at the same movement speed as the connector 121 moves downward toward the mold 103. As a result, the position of the mandrel 123 within the mold appears to remain stationary. The upward movement of the mandrel 123 with respect to the connector 121 reduces the length of the expandable member 125 and increases the width of the expandable member 125.

[0068] When the connector 121 contacts and connects to the upper part of the mold 103, the controller 131 controls the robot arm to stop the downward movement of the connector 121. Further, the controller 131 controls the first actuator 127 to stop the upward movement of the mandrel 123 with respect to the connector 121. As shown in FIG. 3(d), in the state where the connector 121 is connected to the upper part of the mold 103, the reference point 133 is in a fixed position with respect to the mold 103. At this stage, the gap between the base 119 of the mold cavity 115 and the bottom of the expandable member 125 is indicated by the length of the mandrel 123 extending directly below the connector 121. This gap is the minimum separation distance between the base 119 of the mold cavity and the expandable member 125 when the reference point 133 is in a fixed position with respect to the mold 103. By changing the length of the mandrel 123 extending below the connector 121, the controller 131 can change the gap. The controller 131 controls the first actuator 127 (and thus the length of the mandrel 123 extending below the connector 121) so that the gap has a predetermined value. Accordingly, the bottom of the expandable member 125 can be properly positioned with respect to the base 119. This will be described in more detail below.

[0069] Next, the controller 131 operates the second actuator 129 to rotate the mandrel 123 with respect to the reference point 133 to straighten the expandable member 125 around the mandrel 123. Thereby, the width of the expandable member 125 further increases.

[0070] With the expandable member 125 disposed within the mold cavity 115, the molding operation is performed with the container 22 (FIG. 3(e)). The controller 131 controls the pump 107 such that pressurized fluid is supplied to the mandrel 123, and the pressurized fluid flows through the holes 135 of the mandrel 123 into the expandable member 125, expanding the expandable member 125. The expansion of the expandable member 125 applies a force to the bottom of the expandable member 125, which overcomes the magnetic attraction between the magnet 137 and the metal plate 139, separating the expandable member 125 from the end of the mandrel 123. The expandable member 125 continues to expand within the container. At sufficient expansion, the expandable member 125 contacts the container 22 relative to the mold 103, compressing it to form the container 22.

[0071] Referring now to FIG. 3(f), upon completion of the forming operation, the controller 131 controls the pump 107 to draw pressurized fluid from the expandable member 125, thereby folding and contracting the expandable member 125. When the expandable member 125 contracts, the attraction between the magnet 137 and the metal plate 139 is sufficient to reattach the expandable member 125 to the end of the mandrel 123.

[0072] Next, the controller 131 controls the robotic arm to move the connector 121 upward with respect to the mold 103 (FIG. 3(g)). At the same time, the controller 131 controls the first actuator 127 to move the mandrel 123 downward with respect to the reference point 133 at the same speed as the connector 121 moves upward so that the end of the mandrel 123 remains stationary with respect to the mold 103. Thereby, the length of the expandable member 125 increases, and as a result, the width of the expandable member 125 decreases. The controller 131 also controls the second actuator 129 to rotate the mandrel 123 with respect to the reference point 133 so that the expandable member 125 is twisted around the mandrel 123 to further reduce the width of the expandable member 125. With the expandable member 125 being elongated and twisted around the mandrel 123, the controller 131 controls the actuators 127, 129 to stop the movement of the mandrel 123 with respect to the reference point 133.

[0073] Referring now to FIG. 3(h), the controller 131 controls the robotic arm to move the connector 121 upward with respect to the mold 103 to withdraw the mandrel 123 and the expandable member 125 from the mold 103 through the opening 117. When the mandrel 123 and the expandable member 125 are withdrawn from the mold 103, the mold 103 is opened by separating the two parts 111, 113, and the container 22 is removed for further processing. For example, the container 22 can be dried at the drying stage 29 as described above with reference to FIG. 1.

[0074] By moving the mandrel 123 and the expandable member 125 relative to the reference point 133, the bottom of the expandable member 125 can be properly positioned relative to the base 119. If the bottom of the expandable member 125 is improperly positioned (e.g., if the bottom is too far from the base 119 of the mold), during expansion, the expandable member 125 may contact the upper part of the container 22 before the expandable member 125 fills the lower part of the container 22. In that case, further downward expansion of the expandable member can be inhibited by the friction between the expandable member 125 and the upper part of the container 22. When the expansion is inhibited, the expandable member 125 may not completely fill the lower part of the container 22. This can result in an incorrect pressure being applied to the lower part of the container 22 (e.g., the base of the container 22). Thus, this part of the container 22 may be insufficiently compressed, leading to weakening of the container 22. Alternatively, when the expansion is inhibited, the expandable member 125 may extend excessively to completely fill the lower part of the container 22. Excessive elongation may reduce the uniformity of the pressure applied to the container 22 by the expandable member 125. This reduction in uniformity can have an adverse effect on the quality of the container 22, for example, resulting in variations in the vulnerability or thickness of the container 22. Furthermore, excessive elongation can fatigue the expandable member 125, thereby shortening the life of the expandable member 125 or leading to rupture of the expandable member 125. Having a movable mandrel 123 enables proper positioning of the expandable member 125 within the mold cavity 115. As a result, the quality of the containers manufactured by the mold system 101 may be improved and / or the life of the expandable member 125 may be improved.

[0075] Moving the mandrel 123 relative to the connector 121 to vary the length of the expandable member 125, and thereby vary the width of the expandable member 125, the width of the expandable member 125 can be varied to best fit the requirements of the manufacturing process. This process uses the mandrel system 105. For example, reducing the width of the expandable member 125 can be beneficial in facilitating the passage of the expandable member 125 through the opening 117 of the mold 103 that can occur when the mandrel system 105 is inserted into the mold and then withdrawn from the mandrel system 103. By reducing the width, the expandable member 125 can pass through the opening 117 without contacting the mold 103, thereby preventing damage to the expandable member 125. Further, by reducing the width, the possibility that the expandable member 125 contacts the container 22 and damages the container 22 during insertion and / or removal can be reduced. Increasing the width of the expandable member 125 can be beneficial during the expansion of the expandable member 125 because the expandable member 125 can be expanded without being relatively restrained by the mandrel 123. The unrestrained expansion of the expandable member 125 may improve the magnitude and uniformity of the pressure applied to the container 22 during the forming operation by the expandable member 125. Further, the unrestrained expansion may reduce stress concentration in the expandable member 125 where there is a possibility of damage or fatigue of the expandable member 125, thereby improving the lifespan of the expandable member 125. Additionally, increasing the length of the expandable member 125 may place the expandable member 125 under tension, thereby reducing the amount of slack in the expandable member 125. Thereby, the expandable member 125 can be less likely to contact and damage the container 22 during insertion and / or retraction.

[0076] In the above embodiment, the end of the mandrel 123 is removably attached to the expandable member 125. As a result, the end of the mandrel 123 can be attached to or separated from the expandable member 125 during different stages of the manufacturing process. For example, the expandable member 125 can be more easily positioned and moved when attached to the mandrel 123. This can be beneficial for positioning the expandable member 125 within the mold 103 before expansion and / or during insertion or withdrawal of the expandable member 125 from the mold 103. When separated from the mandrel 123, the expandable member 125 can expand without being restrained by the mandrel 123. The unrestrained expansion of the expandable member 125 may improve the magnitude and uniformity of the pressure applied to the container 22 within the mold 103 by the expandable member 125. Thereby, the quality of the container 22 can be improved by the improvement in compression that may result from the improvement in the magnitude and uniformity of the applied pressure. Further, the unrestrained expansion may reduce stress concentration in the expandable member 125, which may damage or fatigue the expandable member 125. As a result, the lifespan of the expandable member 125 can be improved.

[0077] In the above-described embodiment, after insertion but before expansion, the gap between the bottom of the expandable member and the base of the mold has a predetermined value of 8 mm. However, other values may be used for the gap. As described above, as the gap between the bottom of the expandable member and the base of the mold decreases, the possibility of inhibiting the downward expansion of the expandable member 125 decreases. Thereby, the possibility of insufficient compression leading to the weakening of the container 22 and / or the possibility of excessive stretching of the expandable member 125 leading to fatigue of the expandable member 125 can be reduced. However, as the gap decreases, the possibility of non-optimal expansion of the expandable member 125 that occurs increases. Specifically, the expandable member 125 may come into early contact with the base of the container 22, whereby subsequent expansion of the expandable member 125 to the outside of the corner of the container 22 may be inhibited. As a result, as described above, there is a possibility that the quality of the container 22 may deteriorate and / or the lifespan of the expandable member 125 may be shortened. A good balance of competing needs of reducing the possibility of inhibited downward expansion and reducing the possibility of non-optimal expansion can be provided by a gap of 11 mm or less and 2 mm or less.

[0078] The user may manually input the required gap (e.g., via a control panel), but in this embodiment, the controller 131 is configured to select or determine a predetermined gap based on the characteristics of the mold 103 and the characteristics of the expandable member 125. In an embodiment, the controller 131 receives the characteristics of the mold 103 and the characteristics of the expandable member 125 via a control panel. Next, the controller 131 selects a predetermined gap from an indexed look-up table using the received characteristics of the mold 103 and the received characteristics of the expandable member 125. Thereby, when different molds or different expandable members are used, the operator does not need to calculate a new gap. Thus, the downtime occurring when switching between molds can be reduced. The look-up table may have been previously generated through experiments and process modeling to determine predetermined values optimal for different characteristics. The characteristics of the mold 103 may be one of the height, width, and geometry of the mold 103. The characteristics of the expandable member 125 may also be one of the height, width, geometry, and elasticity of the expandable member 125.

[0079] Referring now to FIG. 4, the mold system 101 further includes an additional mold 201. The additional mold 201 includes an additional mold cavity 203 having a geometry different from that of the mold cavity 115. Specifically, the height of the additional mold cavity 203 is lower than the height of the mold cavity 115. As a result, using the mold system 101, various container sizes can be formed. Regardless of the geometry of the mold cavities 115, 203, the controller 131 moves the mandrel 123 and the expandable member 125 so that the gap between the bottom of the expandable member 125 and the bases 119, 205 of the mold cavities 115, 203 is the same predetermined value. As a result, the expandable member 125 can be properly positioned with respect to each mold 103, 201 without the need for a custom mandrel and expandable member for each mold 103, 201. Thereby, the cost of the mold system 101 can be reduced, and the processing time can be shortened by eliminating the need to switch the mandrel 123 and the expandable member 125 when switching the molds 103, 201.

[0080] In the above embodiment, the first portion 137 of the attachment mechanism includes a magnet 137, and the second portion 139 of the attachment mechanism includes a magnetically attractable element in the form of a metal plate 139. Similarly, in other embodiments, the first portion 137 and the second portion 139 may include a plug and socket, or a clamp and a clampable structure. In fact, it is also conceivable that the attachment mechanism is a single part disposed on either the mandrel 123 or the expandable member 125, for example, a clamp on the mandrel 123 that clamps a part of the expandable member 125.

[0081] In the above embodiments, the connector 121 contacts and connects to the upper part of the mold 103. However, in other examples, the connector 121 may not contact or connect to the upper part of the mold 103. Instead, the connector 121 may be moved downward until the connector 121 reaches a predetermined position above the uppermost part of the mold 103, and the mandrel 123 and the expandable member 125 extend into the mold 103. In this embodiment, when the connector 121 is in the predetermined position, the reference point 133 is in a fixed position relative to the mold 103.

[0082] In the above example, the movement of the connector 121 and the mandrel 123 is controlled by the controller 131. However, it is also conceivable that the operator can manually control the movement. However, by adopting a controller, the overall product quality can be improved, the processing time can be shortened, and the throughput can be improved.

[0083] In the above example, the mandrel 123 and the expandable member 125 of the mandrel system 105 are inserted into the mold cavity 115 through the opening 117 and withdrawn from the mold cavity 115. It will be understood that it is not necessary to insert the entire mandrel system 105. Therefore, being inserted means that at least a part of the mandrel system 105 is inserted.

[0084] In the above embodiment, the mandrel system 123 includes attachment mechanisms 137, 139 for removably attaching the expandable member 125 to the mandrel 123. However, in other examples, the attachment mechanism may be omitted. For example, FIG. 5 shows an embodiment of a mandrel system 301 in which the expandable member 125 is fixedly attached to the mandrel 123. The mandrel system 301 is the same as the mandrel system of FIG. 2, but different in the following points.

[0085] The attachment mechanisms 137, 139 are omitted, and the bottom of the main body portion of the expandable member 125 is fixedly attached to the lower end of the mandrel 123.

[0086] The first actuator 303 is operable in a first mode and a second mode. In the first mode, by the first actuator 303, the mandrel 123 moves linearly with respect to the reference point 133 along the longitudinal axis of the mandrel 123. In the second mode, the first actuator 303 enables the mandrel 123 to move freely with respect to the reference point 133. For example, the first actuator 303 may be disengaged from the mandrel 123 (e.g., using a clutch) in the second mode, allowing the mandrel 123 to move freely. In another embodiment, the first actuator 303 may be set to an idle mode, in which the first actuator 303 remains coupled to the mandrel 123 but provides little or no resistance to the movement of the mandrel 123. In an embodiment where the first actuator 303 includes a hydraulic system, the hydraulic system may be opened to the atmosphere in the idle mode.

[0087] Referring now to FIG. 6, the mandrel system 301 operates in the same manner as the mandrel system of FIG. 2, but is different in the following respects.

[0088] The expandable member 123 remains attached to the mandrel 125 during all operating stages. The controller 131 operates the first actuator 127 in the first mode to move the mandrel 123 up and down with respect to the reference point 133.

[0089] To perform a forming operation on the container 22 (FIG. 6(e)), the controller 131 controls the pump 107 so that the pressurized fluid is supplied to the mandrel 123. The pressurized fluid flows into the expandable member 125 through the holes 135 of the mandrel 123 and expands the expandable member 125. At the same time, the controller 131 operates the first actuator 303 in a second operating mode, whereby the mandrel 123 can move freely relative to the reference point 133. As a result, the mandrel 123 does not inhibit the expansion of the expandable member 125. Due to the expansion of the expandable member 125, the mandrel 123 moves downward toward the base 119 of the mold 103. The expandable member 125 continues to expand into the container 22. With sufficient expansion, the expandable member 125 contacts the container 22 against the mold 103 and compresses it to form the container 22.

[0090] Referring now to FIG. 6(f), when the forming operation is completed, the controller 131 controls the pump 107 to draw the pressurized fluid out of the expandable member 125, thereby folding and contracting the expandable member 125. The first actuator 303 continues to operate in the second mode. As a result, as the expandable member 125 contracts, the mandrel 123 moves upward with the bottom of the expandable member 125.

[0091] In the embodiment of FIG. 5, the mandrel 123 is movable relative to the connector 121 in response to the expansion of the expandable member 125. As a result, the expandable member 125 can expand relatively unconstrained by the mandrel 123 while still being attached to the mandrel 123. By being attached to the mandrel 123, it becomes beneficially possible for the mandrel 123 to manipulate the expandable member 125, whereby the function of the mandrel system 301 can be improved.

[0092] In the embodiment of FIG. 5, when the first actuator 303 operates in the second mode, it allows the mandrel 123 to move freely with respect to the reference point 133. However, in other embodiments, when the first actuator 303 operates in the second mode, instead, it may actively move the mandrel 125 in response to the expansion of the expandable member 125. Specifically, during the expansion of the expandable member 125, the first actuator 303 may move the mandrel 123 downward toward the base 119 of the mold 103 at a speed that perhaps corresponds to the expansion of the separated expandable member 125 of FIG. 3E. While the expandable member 125 subsequently collapses, the first actuator 303 can cause the expandable member 125 to collapse by moving the mandrel 123 away from the base 119 of the mold 103.

[0093] In the example of FIG. 5, the mandrel 125 is of one-piece construction, which can provide a relatively simple and robust mandrel. However, in other examples, the mandrel may be a mandrel composed of multiple parts. For example, FIG. 7 shows an example of a mandrel system 401 that includes a two-piece mandrel 403. The mandrel system 401 is the same as the mandrel system 105 of FIG. 5, but has the following differences.

[0094] The mandrel 403 includes a first part 405 and a second part 407. The first part 405 has the form of a cylindrical tube and includes a plurality of holes 135 formed along the length of the first part 405. The holes 135 are located along the lower part of the first part 405 and extend radially through the first part 405 to allow fluid to flow from the inside of the mandrel 403 to the outside of the mandrel 403.

[0095] The second portion 405 has a cylindrical shape and an outer diameter smaller than the inner diameter of the first portion 409. The second portion 407 is located inside the first portion 405 at the lower end of the first portion 405. The end of the second portion 407 is attached to the body portion of the expandable member 125. The second portion 407 is keyed to the first portion 405 such that the second portion 407 moves linearly with respect to the first portion 405 but is prevented from rotating with respect to the first portion 405. For example, the first portion 405 may include a channel extending parallel to the longitudinal axis of the first portion 405, and the second portion 407 may include a protrusion received within the channel. The second portion 407 moves along the longitudinal axis of the first portion 405 between a contracted position and an extended position. The length of the mandrel 403 is longer in the extended position than in the contracted position.

[0096] The first and second actuators 409, 411 are similar to the actuators 303, 129 of FIG. 5, except that the first actuator 409 operates only in the first mode. The actuators 409, 411 are each coupled to the first portion 405 of the mandrel. The first actuator 409 is operable to linearly move the first part 405 of the mandrel 403 along the longitudinal axis of the mandrel 403 with respect to the connector 121 and the reference point 133. The second actuator 411 is operable to rotate the first portion 405 of the mandrel 403 with respect to the connector 121 and the reference point 133. Since the first portion 405 is connected to the second portion 407 of the mandrel 403, rotation of the first portion 405 causes the second portion 407 to rotate as well.

[0097] Referring now to FIG. 8, the mandrel system 401 operates in the same state as the mandrel system 105 of FIG. 5, but has the following differences.

[0098] As shown in FIG. 8A, the operation of the mandrel system 401 begins with the two parts 111, 113 of the mold 103 being closed around the container 22 such that the container 22 is positioned inside the mold cavity 115. At this stage, the mandrel system 401 is located outside the mold cavity 115, and the expandable member 125 is in a folded state. In the folded state, the length of the mandrel 403 extending below the connector 121 is the same as the natural (unstretched) length of the expandable member 125. Thereby, when the expandable member 125 is in the folded state, the second portion 407 of the mandrel 403 is biased by the expandable member 125 toward the retracted position. Specifically, due to the elasticity of the expandable member 125, the second portion 407 is biased toward the retracted position.

[0099] To perform the forming operation on the container 22 (FIG. 8(e)), the controller 131 controls the pump 107 such that pressurized fluid is supplied to the mandrel 403. The pressurized fluid flows into the expandable member 125 through the holes 135 of the mandrel 403 and expands the expandable member 125. As the expandable member 125 expands, the bottom of the expandable member 125 moves downward toward the base 119 of the mold 103. The downward movement of the bottom of the expandable member 125 causes the second portion 407 of the mandrel 403 to move from the retracted position to the extended position. The expandable member 125 continues to expand within the container 22. When fully expanded, the expandable member 125 contacts the container 22, compresses it, presses the container 22 against the mold 103, and forms the container 22.

[0100] Referring now to FIG. 8(f), when the forming operation is completed, the controller 131 controls the pump 107 to draw the pressurized fluid out of the expandable member 125, thereby folding and contracting the expandable member 125. As the expandable member 125 contracts, the bottom of the expandable member 125 moves upward away from the base 119 of the mold 103. The upward movement of the bottom of the expandable member 125 causes the second portion 407 of the mandrel 403 to move from the retracted position to the extended position.

[0101] In the embodiment of FIG. 7, the expandable member 125 is attached to the second portion 407 of the mandrel 403, and the second portion 407 moves relative to the first portion 405 in response to the expansion of the expandable member 125. As a result, the above-described advantage that the expandable member 125 can expand relatively unrestrained while being attached to the mandrel 403 can be achieved. Further, by providing a mandrel 403 composed of two parts, a convenient means can be provided that allows the end of the mandrel 403 to move relative to the connector 121 in response to the expansion of the expandable member.

[0102] In the embodiment of FIG. 7, the first part 405 of the mandrel 403 is movable relative to the connector 121. However, in other embodiments, it is conceivable that the first part 405 of the mandrel 403 is fixedly attached to the connector 121, such that it is immovable relative to the reference point 133. In this embodiment, the connector 121 and the first part 405 are moved together during the insertion and withdrawal of the mandrel 403 and the expandable member 125. During the expansion and folding of the expandable member 125, the second portion 407 of the mandrel 403 can still move relative to the first portion 405 of the mandrel 403, whereby the expansion and folding of the expandable member 125 continues without being inhibited by the mandrel 403.

[0103] In the above-described embodiment, the length of the expandable member 125 changes due to the movement of the mandrel 123 relative to the reference point 133, and thereby the width of the expandable member 125 changes. However, in other embodiments, it is also conceivable that the movement of the mandrel 123 relative to the reference point 133 may increase the length of the expandable member 125 without changing the width of the expandable member 125. Instead, the movement may only change the gap between the bottom of the expandable member 125 and the base 119 of the mold 103. For example, the upper part of the expandable member 125 may be sealingly connected to the mandrel 123 instead of the connector 121. Thereby, when the mandrel 123 moves up and down relative to the reference point 133, the expandable member 125 also moves up and down with the mandrel 123, and the length and thus the width of the expandable member 125 do not change. This arrangement can achieve the above-described advantage of properly positioning the expandable member 125, but may not realize the above-described advantage of changing the width of the expandable member 125 to meet the requirements of the manufacturing process. Further, this arrangement may have other advantages such as simplifying the sealing of the expandable member 125. Specifically, in this arrangement, the annular seal that allows movement of the mandrel 125 relative to the connector 121 can be omitted, and instead, a simpler seal that does not require significant movement can be used to sealingly connect the expandable member 125 to the mandrel 123.

[0104] It will be appreciated that changing the length of the mandrel 123 that extends below the connector 121 also changes the distance 200 (shown in FIG. 3a) between the lower end of the mandrel 123 (which is the first part 137 of the attachment mechanism in the example of FIG. 3a) and the reference point 133.

[0105] In the above embodiment, the controller 131 is configured to select or determine a predetermined gap based on the characteristics of the mold 103, and the controller 131 selects a predetermined gap from the indexed look-up table using the received characteristics of the mold 103. As described above, the gap is indicated by the distance 200. Therefore, in the above embodiment, the controller 131 is configured to select or determine a predetermined distance 200 based on the characteristics of the mold 103, and the controller 131 selects a predetermined distance 200 from the indexed look-up table using the received characteristics of the mold 103.

[0106] Exemplary embodiments of the present invention have been described with reference to the illustrated embodiments. However, it will be understood that changes and modifications can be made without departing from the scope of the present invention as defined by the appended claims.

Claims

1. A mold system for forming containers, A mold including a mold cavity and an opening, A mandrel system including a reference point, a mandrel, and an expandable member, The mandrel is at least partially located inside the expandable member, or at least partially locatable, and includes one or more holes through which fluid can flow from the inside of the mandrel to the outside of the mandrel in order to expand the expandable member during use. When the mandrel is at least partially located inside the expandable member, the reference point is in a fixed position relative to the mold, and the mandrel system is positionable relative to the mold such that the mandrel and the expandable member extend into the mold cavity through the opening such that there is a gap between the expandable member and the base of the mold cavity on the opposite side of the opening. A mold system in which at least a portion of the expandable member and the mandrel is movable relative to the reference point to change the gap.

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

3. The mold system according to claim 2, wherein the controller is configured to cause movement of at least a portion of the expandable member and the mandrel relative to the reference point such that the gap has a predetermined value.

4. The mold system according to claim 3, wherein the predetermined value is 4 mm or more.

5. The mold system according to claim 3, wherein the predetermined value is 11 mm or less.

6. The mold system according to claim 3, wherein the controller is configured to determine the predetermined value based on the characteristics of the mold.

7. The controller stores different lookup tables of predetermined values ​​associated with the characteristics of each different mold, and The mold system according to claim 6, wherein the controller is configured to select the predetermined value from the lookup table using the characteristics of the mold.

8. The end of the mandrel is attachable to, or attached to, the expandable member. The mold system according to claim 1, wherein when the end of the mandrel is attached to the expandable member, the end of the mandrel is movable relative to the reference point upon expansion of the expandable member.

9. The mold system according to claim 8, wherein the expandable member is positioned to separate from the end of the mandrel upon expansion of the expandable member.

10. The mold system according to claim 1, wherein the mandrel and the expandable member are movable relative to the reference point to change the width of the expandable member.

11. The mold system includes a further mold, The further mold includes further mold cavities and further openings, The aforementioned further mold cavity has a geometric shape different from the geometric shape of the mold cavity, When the mandrel is at least partially located inside the expandable member, the reference point is in a fixed position relative to the further mold, and the mandrel system is positionable relative to the further mold such that the mandrel and the expandable member extend into the further mold cavity through the further opening, where there is a further gap between the expandable member and the base of the further mold cavity on the opposite side of the further opening. The mandrel and the expandable member are movable relative to the reference point to change the further gap, and The mold system according to claim 1, wherein the mandrel system includes a controller configured to cause movement of the mandrel and the expandable member relative to the reference point such that the gap and the further gap have the same value.

12. A method for forming a container, To provide the mold system described in claim 1, When the mandrel is at least partially located inside the expandable member, the gap is changed by moving the expandable member and at least a portion of the mandrel relative to the reference point, and A method comprising positioning the mandrel system with respect to the mold such that the reference point is at the fixed position with respect to the mold and the mandrel and the expandable member extend through the opening into the mold cavity.

13. The method according to claim 12, wherein the movement includes moving the expandable member and at least a portion of the mandrel relative to the reference point such that the gap has a predetermined value.

14. The method according to claim 13, comprising determining the predetermined value based on the characteristics of the mold.

15. Determining the predetermined value means The method of claim 14, comprising using the characteristics of the mold to select the predetermined value from a lookup table of different predetermined values ​​associated with the characteristics of each different mold.

16. The method according to claim 12, comprising expanding the expandable member as part of a thermoforming operation into a container placed within the mold cavity.

17. A mandrel system for use with a mold to form a container, Including the reference point and the mandrel, The mandrel includes a plurality of holes, through which a fluid can flow from the inside of the mandrel to the outside of the mandrel during use, and A mandrel system in which at least a portion of the mandrel is movable relative to the reference point to change the distance between the reference point and the end of the mandrel.

18. The mandrel system according to claim 17, comprising a controller configured to cause the movement of at least a portion of the mandrel relative to the reference point.

19. The mandrel system according to claim 18, wherein the controller is configured to cause the movement of at least a portion of the mandrel relative to the reference point such that the distance has a predetermined value.

20. The mandrel system according to claim 19, wherein the controller is configured to determine the predetermined value based on the characteristics of the mold.

21. The controller stores different lookup tables of predetermined values ​​associated with the characteristics of each different mold, and The mandrel system according to claim 20, wherein the controller is configured to select the predetermined value from the lookup table using the characteristics of the mold.

22. The mandrel system includes an expandable member, and the end of the mandrel is attachable to or attached to the expandable member. The mandrel system according to claim 17, wherein when the end of the mandrel is attached to the expandable member, the end of the mandrel is movable relative to the reference point upon expansion of the expandable member.

23. The mandrel system according to claim 22, wherein the expandable member is arranged to separate from the end of the mandrel upon expansion of the expandable member.

24. The mandrel system according to claim 22, wherein the mandrel and the expandable member are movable relative to the reference point to change the width of the expandable member.

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