Methods of processing moulded fibre products

Abstract

Provided herein is a method of processing a hollow moulded fibre product, the method comprising depositing a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product. Also described is a system for processing a hollow moulded fibre product, the system including a vapour deposition apparatus which can deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

Description

[0001] P24-001

[0002] 1

[0003] METHODS OF PROCESSING MOULDED FIBRE PRODUCTS

[0004] TECHNICAL FIELD

[0005] Hollow moulded fibre products may be manufactured from a fibre suspension, such as a fibre suspension comprising paper pulp. The present invention relates to methods and systems for processing hollow moulded fibre products. The product also included coated hollow moulded fibre products.

[0006] The present invention also includes receptacles, such as those obtainable or obtained by the disclosed methods. The receptacles may be consumer packaging, such as bottles, jars or certain types of vases, useful for holding liquids, powders, other flowable materials, one or more solid objects, or a combination thereof.

[0007] BACKGROUND

[0008] It is desirable to reduce glass and plastics use in consumable items, particularly packaging. Non-necked receptacles, such as trays, bowls and other simple shapes, are commonly made from paper pulp. However, a more complex necked receptacle, like a bottle, jar or certain types of vase, is more difficult to engineer due to an internal narrowing of the receptacle between a main body portion of the receptacle and an opening of the receptacle.

[0009] As part of the manufacture of a moulded fibre receptacle, a coating may be applied to a surface, such as an internal surface, of the moulded fibre receptacle. For example, such a coating can provide a barrier between the fibrous material from which the moulded fibre receptacle is formed and the contents to be held in the receptacle, such as a liquid. It is known to apply coatings to moulded fibre receptacles using liquid coating formulation, for example, using spray coating.

[0010] SUMMARY

[0011] According to a first aspect of the present invention, there is provided a system for processing a hollow moulded fibre product, the system comprising: P24-001

[0012] 2 a manufacturing apparatus configured to manufacture the hollow moulded fibre product; and a vapour deposition apparatus downstream of the manufacturing apparatus, wherein the vapour deposition apparatus is configured to receive the hollow moulded fibre product from the manufacturing apparatus and to deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

[0013] Optionally, the surface of the hollow moulded fibre product is an internal surface.

[0014] Optionally, the manufacturing apparatus comprises a moulding apparatus configured to manufacture the hollow moulded fibre product by a moulding process. Optionally, the moulding apparatus comprises a reservoir for storing a fibre suspension and a mould fluidically connected to the reservoir and configured to mould a hollow moulded fibre product precursor from the fibre suspension. Optionally, the hollow moulded fibre product precursor is the hollow moulded fibre product. Optionally, the moulding apparatus comprises a thermoforming apparatus configured to receive the hollow moulded fibre product precursor from the mould and to apply heat and pressure to the hollow moulded fibre product precursor to form the hollow moulded fibre product.

[0015] In other examples, the manufacturing apparatus comprises alternative apparatus, other than moulding apparatus, configured to manufacture the hollow moulded fibre product. For example, such alternative apparatus may comprise an additive manufacturing apparatus configured to manufacture the hollow moulded fibre product by an additive manufacturing process.

[0016] Optionally, the system comprises a drying apparatus downstream of the vapour deposition apparatus, wherein the drying apparatus is configured to receive the coated hollow moulded fibre product and to reduce a moisture content of the coated hollow moulded fibre product. P24-001

[0017] 3

[0018] Optionally, the system comprises a coating apparatus downstream of the vapour deposition apparatus, wherein the coating apparatus is configured to receive the coated hollow moulded fibre product and to apply at least one coating to the coated hollow moulded fibre product to form a further-coated hollow moulded fibre product.

[0019] Optionally, the system comprises a drying station downstream of the coating apparatus, wherein the drying station is configured to receive the further-coated hollow moulded fibre product and to reduce a moisture content of the further-coated hollow moulded fibre product.

[0020] In some examples, the hollow moulded fibre product is a necked hollow moulded fibre product, such as a bottle, jar or a type of vase, and the manufacturing apparatus is a necked-hollow moulded fibre product manufacturing apparatus. In some examples, the hollow moulded fibre product is a bottle.

[0021] Optionally, the vapour deposition apparatus comprises a vapour deposition chamber that is configured to receive the hollow moulded fibre product from the manufacturing apparatus, a vacuum generator that is configured to generate a vacuum in the vapour deposition chamber, and a gas supply configured to supply a gas to the hollow moulded fibre product while the hollow moulded fibre product is in the vapour deposition chamber and the vacuum generator is generating the vacuum in the vapour deposition chamber.

[0022] Optionally, the gas supply is configured to supply gas to the vapour deposition chamber, such that the material may be deposited on to at least a portion of both the external and the internal surface of the hollow moulded fibre product.

[0023] Optionally, the vapour deposition chamber has a retainer for retaining the hollow moulded fibre product so that an opening of the hollow moulded fibre product is retained in a predetermined position relative to the vapour deposition chamber, and the vacuum generator is configured to engage with the opening of the hollow moulded fibre product. P24-001

[0024] 4

[0025] Optionally, the vacuum generator is configured to generate a vacuum in an internal cavity of the hollow moulded fibre product.

[0026] Optionally, the retainer is configured to form a seal with the opening of the hollow moulded fibre product, such that the internal cavity of the hollow moulded fibre product is physically separated from a remaining portion of the vapour deposition chamber (i.e. the volume of the vapour deposition chamber external to the hollow moulded fibre product). In some such embodiments, the gas supply is configured to supply gas to the internal cavity of the hollow moulded fibre product and not the remaining portion of the vapour deposition chamber, such that the material may be deposited on to at least a portion of the internal surface, and not the external surface, of the hollow moulded fibre product; or the gas supply is configured to supply gas to the the remaining portion of the vapour deposition chamber and not internal cavity of the hollow moulded fibre product, such that the material may be deposited on to at least a portion of the external surface, and not the internal surface, of the hollow moulded fibre product.

[0027] Optionally, the vapour deposition apparatus comprises a plasma discharge element that is configured to generate a plasma from the gas supplied by the gas supply.

[0028] Optionally, the vapour deposition apparatus comprises a microwave source that is configured to generate a plasma from the gas supplied by the gas supply.

[0029] Optionally, the vapour deposition chamber has a retainer for retaining the hollow moulded fibre product so that an opening of the hollow moulded fibre product is retained in a predetermined position relative to the plasma discharge element, and the plasma discharge element is configured to be inserted into the opening of the hollow moulded fibre product.

[0030] Optionally, the vapour deposition apparatus comprises a permeability reduction apparatus that is configured to reduce a permeability of at least a portion of the hollow moulded fibre product, prior to generating the vacuum in the vapour deposition chamber. P24-001

[0031] 5

[0032] Optionally, the permeability reduction apparatus comprises a primer layer applicator configured to apply a primer layer to the at least a portion of the hollow moulded fibre product to reduce the permeability of at least the portion of the hollow moulded fibre product.

[0033] Optionally, the permeability reduction apparatus comprises a device that abuts the at least a portion of the hollow moulded fibre product to temporarily reduce the permeability during the vapour deposition.

[0034] Optionally, the vapour deposition apparatus comprises a functional layer applicator, configured to apply a functional layer to the at least a portion of the hollow moulded fibre product, prior to generating the vacuum in the vapour deposition chamber. The functional layer may be, in some cases, a layer which reduces water transmission through the hollow moulded fibre product, and the applicator may be referred to as a water transmission reduction layer applicator.

[0035] Optionally, in some cases, the vapour deposition apparatus may include a primer layer applicator and a functional layer applicator, configured to apply a primer layer to the at least a portion of the hollow moulded fibre product, and then apply a functional layer to the at least a portion of the hollow moulded fibre product on top of the primer layer, all prior to generating the vacuum in the vapour deposition chamber.

[0036] Optionally, the vapour deposition apparatus comprises a permeability sensor that is configured to sense the permeability of the at least a portion of the hollow moulded fibre product.

[0037] Optionally, the vapour deposition apparatus is configured to carry out vapour deposition only when the permeability of at least the portion of the hollow moulded fibre product sensed by the permeability sensor is lower than a threshold permeability. In some examples, the vapour deposition apparatus is configured to deposit the material only when the permeability of at least the portion of the hollow moulded fibre product sensed by the permeability sensor is within a predetermined range. P24-001

[0038] 6

[0039] According to a second aspect of the present invention, there is provided a method comprising depositing a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

[0040] Optionally, the vapour deposition comprises physical vapour deposition or plasma-enhanced chemical vapour deposition.

[0041] Optionally, the vapour deposition comprises plasma-enhanced chemical vapour deposition, wherein the plasma-enhanced chemical vapour deposition comprises: providing a gas; and generating a plasma from the gas. In some embodiments, the generating a plasma comprises applying microwave radiation to the gas. In some embodiments, the method comprises providing a plasma discharge element; and generating a plasma from the gas using the plasma discharge element.

[0042] Optionally, the material deposited by the vapour deposition comprises one or more components selected from the group consisting of SiOx, carbon (suitably diamondlike carbon) and aluminium. In some cases, the material may have a water contact angle of at least about 50°, suitably at least about 55° or at least about 60°.

[0043] In some cases, the material deposited by vapour deposition comprises carbon. In some cases, the carbon material may be deposited from an acetylene gas phase. In some cases, the carbon to hydrogen molar ratio in the deposited material is >1, suitably >1.25 or >1.5. In some cases, the material may comprise less than lwt% oxygen (relative to the total weight of the deposited material).

[0044] The presence of one or more components selected from the group consisting of SiOx, carbon (suitably diamond-like carbon), aluminium and aluminium oxide may lead to improved oxygen transmission rate (OTR) properties compared with an uncoated hollow moulded fibre product or hollow moulded fibre products comprising conventional coatings, such as polymer coatings. Additionally, aluminium may allow detection of coating failures, for example, by conductivity measurements. P24-001

[0045] 7

[0046] Optionally, the depositing forms a layer of the material on at least one surface of the hollow moulded fibre product. Forming a layer of the material may lead to further improvement in the properties provided by the material.

[0047] Optionally, the depositing forms a layer of the material, and the layer of the material has a mean thickness of between about 10 nm and about 100 nm.

[0048] Optionally, the layer of the material has a mean thickness of about 20 to 80 nm, or about 30 to 70 nm, or about 40 to 60 nm.

[0049] Optionally, the depositing deposits the material onto an internal surface and / or an external surface of the hollow moulded fibre product. In some embodiments, the depositing deposits the material onto an internal surface of the hollow moulded fibre product and, optionally, not onto an external surface. In some embodiments, the depositing deposits the material onto an external surface of the hollow moulded fibre product and, optionally, not onto an internal surface.

[0050] The presence of the material on an internal surface of the hollow moulded fibre product may reduce or prevent the leaching of liquids through the hollow moulded fibre product. For example, when the hollow moulded fibre product contains contents, components of the contents may be prevented from leaching into the hollow moulded fibre product. Such leaching can cause damage to the hollow moulded fibre product and / or result in leaking of the contents through the hollow moulded fibre product. Advantageously, the presence of the material on the hollow moulded fibre product may lead to increased product life.

[0051] Optionally, a primer layer is disposed on at least one surface of the hollow moulded fibre product.

[0052] Optionally, the primer layer is disposed on at least one surface of the hollow moulded fibre product, and the depositing deposits the material onto the same at least one P24-001

[0053] 8 surface of the hollow moulded fibre product, such that the primer layer is disposed between the hollow moulded fibre product and the material deposited by the vapour deposition.

[0054] Optionally, the primer layer is disposed on at least one surface of the hollow moulded fibre product, and the depositing deposits the material onto a different at least one surface of the hollow moulded fibre product.

[0055] Optionally, the at least one surface on which the primer layer is disposed comprises an internal surface.

[0056] Optionally, the primer layer is disposed on at least one surface of the hollow moulded fibre product prior to the depositing. In some embodiments, the depositing deposits the material onto an exposed surface of the primer layer. The exposed surface of the primer layer may have an increased smoothness compared with a surface of the hollow moulded fibre product without the primer layer. When the material is deposited by the vapour deposition onto the exposed surface of the primer layer, the penetration of the material into the fibre wall may be reduced compared with depositing the material onto an uncoated surface of the hollow moulded fibre product. This may facilitate a more cohesive and / or continuous layer of the material deposited by vapour deposition on the at least one surface of the moulded fibre product. A cohesive and / or continuous layer of the material deposited by vapour deposition may be required to achieve desired barrier properties.

[0057] Optionally, the primer layer is disposed between the at least one surface of the hollow moulded fibre product and the material (or the layer of the material) deposited by the vapour deposition.

[0058] Optionally, the coating weight of the primer layer is from about 10 to about 100 grams per square metre (gsm, g / m2or g.m'2), where the coating weight is expressed as a mass relative to the surface area of the at least one surface of the hollow moulded fibre product on which the primer layer is disposed. In other words, the coating weight is a P24-001

[0059] 9 mean mass of the primer layer measured across a given portion of the at least one surface. In some embodiments, the amount of the primer layer disposed on the at least one surface is from about 40 to about 80 g.m'2or about 40 - 60 g.m'2, and suitably is around 60 g.m'2.

[0060] Optionally, the method comprises applying the primer layer onto at least one surface of the hollow moulded fibre product.

[0061] Optionally, the primer layer is applied onto at least one surface of the hollow moulded fibre product prior to the vapour deposition.

[0062] Optionally, prior to the depositing, the primer layer is applied onto at least one surface of the hollow moulded fibre product as an aqueous emulsion and then the primer layer is dried.

[0063] Optionally, the primer layer comprises fibre material and / or a polymer.

[0064] Optionally, the polymer is not a polyester.

[0065] Optionally, the primer layer further comprises at least one selected from the group consisting of: a natural wax, a plasticiser, a rheology modifier and silica. In some embodiments, the fibre material comprises cellulose microfibres, such as a microfibrillated cellulose (MFC). In some embodiments, the polymer is an acrylic polymer. For example, the polymer may be a styrene acrylate copolymer.

[0066] Optionally, the primer layer may have a water contact angle of at least about 60°, 65°, 70°, 75° or 80°.

[0067] Optionally, one or more further layers are disposed on the primer layer prior to the depositing by vapour deposition.

[0068] Optionally, the method comprises applying the one or more further layers on to the primer layer. P24-001

[0069] 10

[0070] The one or more further layers may be included to provide performance benefits such as (but not limited to) reduced water transmission, reduced oxygen transmission, or improved compatibility with the intended contents of the hollow article. In some cases, the further layer is a water transmission reduction layer, which provides a coated hollow moulded fibre product with reduced water transmission through the moulded fibre as compared to a corresponding product without the water transmission reduction layer. In some cases, the water transmission reduction layer may result in a coated hollow moulded fibre product with a moisture vapour transmission rate of less than about 0.5 or 0.3 g.m'2 / day (at ambient conditions). In some cases, the moisture vapour transmission rate at 37°C and 50% relative humidity is less than about 3 g.m'2 / day.

[0071] Optionally, the coating weight of the water transmission reduction layer is from about 10 to about 35 grams per square metre (gsm, g / m2or g.m'2), where the coating weight is expressed as a mass relative to the surface area of the at least one surface of the hollow moulded fibre product on which the layer is disposed. In other words, the coating weight is a mean mass of the water transmission reduction layer measured across a given portion of the at least one surface. In some embodiments, the amount of the water transmission reduction layer disposed on the at least one surface is from about 20 to about 30 g.m'2, optionally 23 to 27 g.m'2.

[0072] Optionally, the one or more further layers, such as the water transmission reduction layer, may each comprise one or more components selected from: a polymer; a natural wax, a rheology modifier and silica. In some embodiments, the polymer may be an acrylic polymer. For example, the polymer may be a styrene acrylate copolymer. Layers comprising natural wax may have water barrier properties. In some embodiments, at least one of the one or more further layers such as the water transmission reduction layer comprises a styrene acrylate copolymer and a natural wax. In some cases, the water transmission reduction layer may be hydrophobic, and in some particular cases, may have a water contact angle of at least 65°, 70°, 75° or 80°. P24-001

[0073] 11

[0074] Optionally, the depositing deposits material onto an exposed surface of the one or more further layers, such that the one or more further layers is / are disposed between the hollow moulded fibre product and the material deposited by vapour deposition. In some embodiments, the one or more further layers is / are configured to have water barrier properties. In some such embodiments, the one or more further layers comprises a natural wax. In some embodiments, when the depositing deposits material onto an exposed surface of the one or more further layers and the one or more further layers is configured to have water barrier properties, the method further comprises plasma treatment of the exposed surface of the one or more further layers prior to the depositing. It may be difficult to deposit a material by vapour deposition on to an exposed surface of a layer configured for water barrier properties. Plasma treatment of the exposed surface prior to vapour deposition may improve adhesion of the material to the exposed surface of the one or more further layers.

[0075] Optionally, the amount of each of the one or more further layers disposed on the primer layer is from about 5 to about 50 grams per square metre (gsm, g / m2or g.m'2), where the amount is expressed as a mass relative to the surface area of the at least one surface of the hollow moulded fibre product on to which the one or more further layers are disposed. In other words, it is a mean mass of the coating measured across a given portion of the at least one surface. In some embodiments, the coating weight is from about 15 to about 30 g.m'2.

[0076] In some embodiments, the one or more further layers may be disposed between the primer layer and the material (or between the primer layer and the layer of the material) deposited by vapour deposition. In some embodiments, the one or more further layers may be disposed on top of the material (or the layer of the material) deposited by vapour deposition.

[0077] Optionally, the method further comprises applying one or more coating layers onto the material deposited by vapour deposition. P24-001

[0078] 12

[0079] Optionally, the one or more coating layers are configured to have water barrier properties. As described above, it may be difficult to deposit the material onto a layer configured to have water barrier properties. When the depositing deposits material onto an exposed surface of a primer layer, applying the one or more coatings on top of the material may allow for a product having water barrier properties, without the difficulty of depositing the material on to the exposed surface of a coating configured to have barrier properties. For example, this may obviate the need for plasma coating of the exposed surface of the layer configured to have water barrier properties if the material were to be deposited onto an exposed surface of the layer having water barrier properties.

[0080] According to a third aspect of the present invention, there is provided a method of processing a hollow moulded fibre product, the method comprising: reducing a permeability of at least a portion of the hollow moulded fibre product to a reduced permeability; and optionally applying a water transmission reduction layer to the at least a portion of the hollow moulded fibre product; and depositing a material by vapour deposition onto at least one surface of the at least a portion of the hollow moulded fibre product having the reduced permeability to form a coated hollow moulded fibre product.

[0081] By reducing the permeability of the hollow moulded fibre product to a reduced permeability, a stable and sufficiently low vacuum suitable for vapour deposition can be achieved. Vapour deposition may allow for coating of different types of materials onto the hollow moulded fibre product than would not be possible by other coating methods.

[0082] The reducing may result in a reduced permeability within a predetermined range. In such cases, a permeability in excess of the range may mean that the vacuum conditions required for vapour deposition are difficult to achieve and / or maintain. In such cases, a permeability below the range may mean that the hollow moulded fibre product fails under the vacuum conditions required for vapour deposition. P24-001

[0083] 13

[0084] Optionally, the reducing comprises providing a device that abuts the at least a portion of the hollow moulded fibre product to temporarily reduce the permeability during the depositing.

[0085] Optionally, the reducing comprises applying a primer layer onto at least one surface of the at least a portion of the hollow moulded fibre product. When a primer layer is applied onto at least one surface of a hollow moulded fibre product, the product obtained after the applying may have the reduced permeability. Hollow moulded fibre products comprising a primer layer disposed on at least one surface may have the reduced permeability. The presence of a primer layer may reduce the permeability of the product sufficiently for vapour deposition to be carried out on the product. As a result, hollow moulded fibre products comprising a primer layer on at least one surface may have a permeability between a maximum (above which a suitable vacuum for vapour deposition cannot be formed in the internal volume of the container) and a minimum (below which application of the vacuum would result in delamination of the coating from the fibre wall). It should be noted that this effect can be achieved regardless as to whether the primer layer is coated on an external and / or an internal surface of the hollow moulded fibre product.

[0086] Optionally, the depositing deposits the material onto an internal surface of the hollow moulded fibre product. Advantageously, as discussed above, the presence of the material on the hollow moulded fibre product may lead to increased product life.

[0087] In some examples of the above methods of processing a hollow moulded fibre product, the hollow moulded fibre product is a necked hollow moulded fibre product, such as a bottle, jar or a type of vase, and the method is a method of processing a necked- hollow moulded fibre product. In some examples, the hollow moulded fibre product is a bottle.

[0088] In some examples of the above methods of processing a hollow moulded fibre product, the hollow moulded fibre product is a hollow moulded fibre product closure, such as a lid for a bottle ar or a type of vase, and the method is a method of processing P24-001

[0089] 14 a hollow moulded fibre closure. In some examples, the hollow moulded fibre closure is a lid for a bottle.

[0090] Optionally, after the depositing by any of the above methods, the portion of the hollow moulded fibre product on to which the material was deposited by vapour deposition has an oxygen transmission rate (OTR) of less than 0.8 cc / package / day, or less than 0.7 cc / package / day, or less than 0.6 cc / package / day, or less than 0.5 cc / package / day, or less than 0.4 cc / package / day, or less than 0.3 cc / package / day, or less than 0.2 cc / package / day, or less than 0.1 cc / package / day, or less than 0.08 cc / package / day. OTR may be measured by a standard method such as ASTM D3985 or ASTM F1927-07. One day is equivalent to 86,400 seconds (s). The OTR may be expressed relative to the surface area of the portion hollow moulded fibre product over which the measurement is made. In some embodiments, the portion of the hollow moulded fibre product on to which the material was deposited by vapour deposition has an oxygen transmission rate (OTR) of less than 100 cc / m2 / day, or less than 50 cc / m2 / day, or less than 40 cc / m2 / day, or less than 30 cc / m2 / day, or less than 25 cc / m2 / day, or less than 20 cc / m2 / day, or less than 15 cc / m2 / day, or less than 10 cc / m2 / day, or less than 5 cc / m2 / day, or less than 1 cc / m2 / day.

[0091] According to a fourth aspect of the present invention, there is provided a receptacle obtainable or obtained by the method according to the second or the third aspect.

[0092] According to a fifth aspect of the present invention, there is provided a coated hollow moulded fibre product comprising at least one surface and a layer of material disposed on the at least one surface, wherein the layer of material (a) has a thickness of between about lOnm and lOOnm and (b) comprises one or more components selected from the group consisting of SiOx, carbon (suitably diamond-like carbon) and aluminium.

[0093] Optionally, the layer is a vapour-deposited layer.

[0094] Optionally, the layer is disposed on an internal surface and / or an external surface.

[0095] In some embodiments, the layer is disposed on an internal surface and, optionally, not on P24-001

[0096] 15 an external surface. In some embodiments, the layer is disposed on an external surface and, optionally, not on an internal surface.

[0097] Optionally, the layer has a mean thickness of about 20 to 80 nm, or about 30 to 70 nm, or about 40 to 60 nm, or about 50 nm.

[0098] Optionally, the layer of material comprises carbon (suitably diamond-like carbon).

[0099] In some embodiments of the methods of fourth or the fifth aspect, in a pressure decay test of the hollow moulded fibre product prior to vapour deposition, wherein the external pressure, pi, is 10 mbar, and the initial internal pressure, p2, is 300 pbar, the observed decay rate of the internal pressure, p2, is less than 0.90 mbar.s'1, or less than 0.85 mbar.s'1, or less than 0.80 mbar.s'1, or less that 0.75 mbar.s'1or less that 0.70 mbar.s' or less than 0.50 mbar.s'1, or less than 0.40 mbar.s'1, or less than 0.30 mbar.s'1, 0.20 mbar.s'1, or less than 0.15 mbar.s'1, or less than 0.14 mbar.s'1, or less than 0.13 mbar.s'1, or less than 0.12 mbar.s'1, or less than 0.11 mbar.s'1, or less than 0.10 mbar.s'1.

[0100] In some embodiments of the methods of fourth or the fifth aspect, in a pressure decay test of the hollow moulded fibre product prior to vapour deposition, wherein the external pressure, pi, is 10 mbar, and the initial internal pressure, p2, is 300 pbar, the observed normalised decay rate of the internal pressure, p2, is less than 0.110 s'1, or less than 0.100 s'1, or less than 0.090 s'1, or less than 0.080 s'1, or less than 0.070 s'1, or less than 0.06 s'1, or less than 0.05 s'1, or less than 0.045 s-1or less than 0.040 s'1, or less than 0.035 s'1, or less than 0.030 s'1, or less than 0.025 s'1, or less than 0.020 s'1, or less than 0.015 s'1, or less than 0.010 s'1.

[0101] In some embodiments of the methods of fourth or the fifth aspect, in a pressure decay test of the hollow moulded fibre product prior to vapour deposition, wherein the external pressure, pi, is from about 2 mbar to about 15 mbar, and the initial internal pressure, p2, is from about 200 to 400 pbar, the observed normalised decay rate of the internal pressure, p2, is less than 0.110 s'1, or less than 0.100 s'1, or less than 0.090 s'1, or less than 0.080 s'1, or less than 0.070 s'1, or less than 0.06 s'1, or less than 0.05 s'1, or less P24-001

[0102] 16 than 0.045 s-1or less than 0.040 s’1, or less than 0.035 s’1, or less than 0.030 s’1, or less than 0.025 s’1, or less than 0.020 s’1, or less than 0.015 s’1, or less than 0.010 s’1.

[0103] According to a sixth aspect of the present invention, there is provided a coated hollow moulded fibre product comprising at least one surface and a vapour-deposited layer of material disposed on the at least one surface.

[0104] Optionally, the vapour-deposited layer is disposed on an internal surface and / or an external surface. In some embodiments, the vapour-deposited layer is disposed on an internal surface and, optionally, not on an external surface. In some embodiments, the vapour-deposited layer is disposed on an external surface and, optionally, not on an internal surface.

[0105] Optionally, in the fifth or sixth aspect, a primer layer is disposed between the at least one surface and the layer of material.

[0106] Optionally, the primer layer has a coating weight of about 40 to 60 g.m’2.

[0107] Optionally, the primer layer comprises fibre material and / or a polymer.

[0108] Optionally, the primer layer further comprises at least one selected from the group consisting of: a natural wax, a plasticiser, a rheology modifier and silica. In some embodiments, the primer layer comprises a polymer and a natural wax. Optionally, the polymer is an acrylic copolymer, for example a styrene acrylate copolymer.

[0109] Optionally, the hollow moulded fibre product comprises two or more layers disposed between the at least one surface and the layer of the material. The two or more layers may include the primer layer described above and one or more further layers. The one or more further layers may include a layer configured to have water barrier properties.

[0110] In some cases, the hollow moulded fibre product comprises a primer layer on at least a portion of an internal surface of the product, a water transmission reduction layer P24-001

[0111] 17 disposed on the primer layer and a vapour-deposited layer disposed on the water transmission reduction layer. In some cases, the primer layer comprises a styrene acrylate copolymer and / or is applied at between 40 and 80 g.m'2. In some cases, the water transmission reduction layer comprises a styrene acrylate copolymer and / or is applied at between 20 and 30 g.m'2. In some cases, the vapour-deposited layer comprises carbon (suitably diamond-like carbon). In some cases, the hollow moulded fibre product may comprise an additional layer applied to at least a portion of an external surface, and this additional layer may be an anti-scuff layer (providing a physical protective barrier to the fibre) and in some cases this may be applied at around 15-20g.m'2.

[0112] Optionally, the hollow moulded fibre product comprises one or more coating layers disposed on top of the layer of the material. The one or more coating layers may include a layer configured to have water barrier properties.

[0113] Optionally, the product comprises a primer layer as described above disposed between the at least one surface and the layer of material, and one or more coating layers disposed on top of the material, wherein the one or more coating layers includes a layer configured to have water barrier properties.

[0114] In any of the embodiments described above, the layer configured to have water barrier properties may comprise a polymer and a natural wax.

[0115] Optionally, the product comprises cellulose fibres.

[0116] According to a seventh aspect of the present invention, there is provided a control system configured to cause a coating system to perform the method according to the second or third aspect.

[0117] According to an eighth aspect of the present invention, there is provided a non- transitory storage medium storing machine-readable instructions that, when executed by a processor of a control system, cause a coating system to perform the method according to the second or third aspect. P24-001

[0118] 18

[0119] In some examples of any of the above aspects, the hollow moulded fibre product is a necked hollow moulded fibre product, such as a bottle, a jar or a type of vase. In some examples of any of the above aspects, the hollow moulded fibre product is a bottle.

[0120] According to a ninth aspect of the present invention, there is provided a receptacle manufacturing line comprising the system according to the first aspect for forming the coated hollow moulded fibre product and apparatus for performing at least one additional process on the coated hollow moulded fibre product to provide the receptacle.

[0121] The apparatus may comprise an interior coater and the at least one additional process may comprise the interior coater coating at least a portion of an interior of the product to produce an internally coated product. The apparatus may comprise a closurepart applicator and the at least one additional process may comprise the closure-part applicator applying a closure part to the product or the internally coated product to produce a closable or closed product. The apparatus may comprise an exterior coater and the at least one additional process may comprise the exterior coater coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product. The apparatus may comprise a decorator and the at least one additional process may comprise the decorator decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The apparatus may comprise a dryer and the at least one additional process may comprise the dryer drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The apparatus may comprise an evaluator and the at least one additional process may comprise the evaluator evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product. P24-001

[0122] 19

[0123] In some examples, the receptacle is a necked receptacle, such as a bottle, jar or a type of vase, and the receptacle manufacturing line is a necked-receptacle manufacturing line. In some examples, the receptacle is a bottle.

[0124] According to a tenth aspect of the present invention, there is provided method of manufacturing a receptacle, the method comprising performing the method according to the first or second aspect to form the coated hollow moulded fibre product, and then performing at least one additional process on the coated hollow moulded fibre product to provide the receptacle.

[0125] The at least one additional process may comprise coating at least a portion of an interior of the product to produce an internally coated product. The at least one additional process may comprise applying a closure part to the product or the internally coated product to produce a closable or closed product. The at least one additional process may comprise coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product. The at least one additional process may comprise decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The at least one additional process may comprise drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The at least one additional process may comprise evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product.

[0126] In some examples, the receptacle is a necked receptacle, such as a bottle ar or a type of vase. In some examples, the receptacle is a bottle.

[0127] According to an eleventh aspect of the present invention, there is provided method of providing a content-containing receptacle, the method comprising providing a P24-001

[0128] 20 receptacle obtained by the method according to the tenth aspect and providing the contents in the receptacle to provide the content-containing receptacle.

[0129] In some examples, the providing the contents in the receptacle comprises putting the contents into the receptacle. In contrast, in some examples, the providing the receptacle comprises providing the receptacle with the contents already present in the receptacle, thereby providing the contents in the receptacle.

[0130] The contents may be in the form of, for example, a liquid, a powder, other flowable materials, one or more solid objects, or a combination thereof. For example, the contents may be a foodstuff such as a condiment, a beverage such as an alcoholic beverage, a household care product such as a detergent or other cleaning product, a personal care product such as a hair care product or a personal cleansing product or a healthcare product or a pharmaceutical product or a cosmetics product, a fragrance product such as a perfume, a vehicle product such as motor oil, or an industrial product. Other suitable contents will be apparent to the skilled reader in view of the content of this application and their common general knowledge.

[0131] In some examples, the receptacle is a necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

[0132] Optionally, the method comprises: closing an opening of the receptacle after the providing contents in the receptacle, and / or applying a label or indicia to the receptacle.

[0133] In some examples, the closing comprises applying a closure (such as a lid or a cap or a heat seal) to the receptacle to close the opening. In some examples, the closing comprises applying a heat seal to the receptacle and (e.g., thereafter) applying a lid or a cap to the receptacle. P24-001

[0134] 21

[0135] In some examples, the applying the label or indicia to the receptacle occurs after the providing the contents in the receptacle (that is, the label or indicia is applied to the content-containing receptacle). In other examples, the applying the label or indicia to the receptacle occurs before or during the providing the contents in the receptacle.

[0136] In some examples, the applying occurs before the closing. In some examples, the applying occurs after the closing. In some examples, the applying occurs during the closing.

[0137] In another aspect, there is provided a use of a receptacle obtained by the method of manufacturing a receptacle to contain contents.

[0138] The use could be, for example, by a person (such as a natural person or a company) who puts the contents into the receptacle, or by a person who transports the contents, or by a person who wishes to dispose of (e.g., to a consumer or end user), offer to dispose of (e.g., to a consumer or end user), import, or keep the contents whether for disposal or otherwise.

[0139] The contents may, for example, be in the form of any of those discussed above.

[0140] In some examples, the receptacle is a necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

[0141] It will be appreciated that optional features of aspects of the present invention may be equally applied to other aspects of the present invention, where appropriate.

[0142] BRIEF DESCRIPTION OF DRAWINGS

[0143] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: P24-001

[0144] 22

[0145] Figure 1 is a schematic view of an example receptacle manufacturing line for performing a method of manufacturing receptacles from paper pulp;

[0146] Figure 2 is a schematic side view of a vapour deposition apparatus according to an example.

[0147] Figure 3 shows a method of processing a hollow moulded fibre product comprising vapour deposition according to an example.

[0148] Figure 4 shows a method of processing a hollow moulded fibre product comprising application of one or more coating layers according to an example.

[0149] Figure 5 shows a method of vapour deposition according to an example.

[0150] Figure 6 shows a method of processing a hollow moulded fibre product comprising plasma treatment according to an example.

[0151] Figure 7 shows schematic cross-sectional views of hollow moulded fibre products according to examples.

[0152] Figure 8 shows a non-transitory computer-readable storage medium according to an example;

[0153] Figure 9 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and

[0154] Figure 10 shows a method of providing a content-containing receptacle.

[0155] DETAILED DESCRIPTION

[0156] The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of embodiments of the invention. P24-001

[0157] 23

[0158] Figure 1 shows a receptacle manufacturing line for performing a method of manufacturing receptacles, in this case necked receptacles, and more specifically in this case in the form of bottles, from paper pulp (i.e., which can form the basis of an example fibre suspension). By “necked receptacle” it is meant that the receptacle has an internal narrowing, or “neck”, between a main body portion, in which most of or all the contents of the receptacle are stored in use, and an opening through which the contents can enter or leave the receptacle in use. The internal width of the receptacle at the neck may be the same as or different to the internal width of the opening. However, the internal width of the neck is smaller than that of the main body portion, so that a shoulder is defined by and between the neck and the main body portion. This shoulder complicates manufacture of the receptacle, since it interferes with subsequent removal (and, in some cases, insertion) of whatever mould tool is inserted into the receptacle to form the internal shape of the receptacle. Examples of necked receptacles are bottles, jars, and certain types of vases. The process is merely exemplary and is provided to give context to examples of the present invention. It will be appreciated that, in other examples, the receptacle manufacturing line could be for making non-necked receptacles (i.e., receptacles without such a neck), such as bowls or trays.

[0159] Broadly speaking, the exemplary process comprises providing a fibre suspension, introducing the fibre suspension into a mould cavity of a porous first mould and expelling a liquid (such as water) from the fibre suspension to produce a hollow moulded fibre product (which may be called a wet precursor or embryo) in the mould cavity, further moulding the hollow moulded fibre product to produce a hollow further-moulded fibre product, drying and then internally-coating the hollow further-moulded fibre product to produce an internally coated product, drying the internally coated product to produce a dried product, applying a closure part to the dried product to produce a closable or closed product, externally-coating and / or decorating the closable or closed product to produce an externally coated and / or decorated product, and then drying the externally coated or decorated product to produce another dried product. As will be apparent at least from the following description, modifications may be made to the exemplary process to provide variants thereof in which other examples of the present invention may be embodied. For example, in some cases, either the internal coating or the external coating and / or decorating may be omitted. Moreover, in the present case and as indicated by the stars labelled Ins. 1 to Ins. 5 in Figure 1, the process comprises inspecting or evaluating the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, and the dried product to produce respective evaluated products. In some examples, the receptacle is the hollow moulded fibre product, the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, one of the dried products, or one of the respective evaluated products.

[0160] In this example, providing the fibre suspension comprises preparing the fibre suspension from ingredients thereof. More specifically, the preparing comprises providing pulp fibres, such as paper pulp fibres, and mixing the pulp fibres with a liquid to provide hydrated pulp fibres. In this example, the pulp fibres are provided in sheet form from a supplier and the liquid comprises water and one or more additives. In this example, the liquid is mixed with the pulp fibres to provide hydrated pulp fibres having a solid fibres content of lwt% to 5wt% (by dry mass of fibres). In examples, the one or more additives includes a sizing agent, such as alkylketene dimer (AKD). The hydrated pulp fibres typically comprise AKD in an amount of 0.4wt% with respect to the total dry mass of the solid fibres in the hydrated pulp fibres. In some examples, one or more additives are present in the liquid at the point of mixing the pulp fibres with the liquid. In some examples, one or more additives are included in the hydrated pulp fibres after mixing the pulp fibres with the liquid (for example, the pulp fibres are hydrated for a period of time, such as from 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fibres). The hydrated pulp fibres are passed between plates of a valley beater 11 or refiner that are in motion relative to each other. This fibrillates some, or all, of the fibres, meaning that cell walls of those fibres are caused to become partially delaminated so that wetted surfaces of those fibres comprise protruding hairs or fibrillations. These fibrillations will help to increase a strength of bonds between the fibres in the dried end product. In other examples, the valley beater 11 or refiner may be omitted.

[0161] The resultant processed pulp is stored in a vat 12 in a relatively concentrated form (for example, a solid fibres content of lwt% to 5wt%) to reduce a required storage space. 25

[0162] At an appropriate time, the processed pulp is transferred to a mixing station 13 at which the processed pulp is diluted in further water and, optionally, mixed with one or more additives (as well as, or in place of, the one or more additives provided with the hydrated pulp fibres) to provide the fibre suspension ready for moulding. In this example, the solid fibres account for 0.7wt% of the resultant fibre suspension (by dry weight of fibres), but in other examples the proportion of solid fibres in the fibre suspension may be different, such as another value in the range of 0.5wt% to 5wt%, or 0.1 wt% to lwt%, of the fibre suspension (by dry weight of fibres). In some examples, the one or more additives mixed with the processed pulp and water includes a dewatering agent, such as modified and / or unmodified polyethylene imine (PEI), for example modified PEI sold under the trade name Polymin® SK. In some examples, the one or more additives are mixed with the water, and the water and one or more additives subsequently mixed with the processed pulp; in other examples, the processed pulp and water are mixed, and the one or more additives subsequently mixed with the processed pulp and water. The fibre suspension typically comprises Polymin® SK in an amount of 0.3wt% with respect to the total dry mass of the solid fibres. Mixing of the fibre suspension at the mixing station 13 helps to homogenise the fibre suspension. In other examples, the processed pulp or the fibre suspension may be provided in other ways, such as being supplied ready-made.

[0163] Downstream of the vat 12 and the mixing station 13 is a first moulding station that comprises a porous first mould 15. In this example, the porous first mould 15 comprises two half-moulds 14 that are movable towards and away from each other, in this case using a hydraulic ram. In this example, each of the half-moulds 14 is a monolithic or unitary tool formed by additive manufacturing (for example, 3D-printing) that defines a mould profile, and, when the half-moulds 14 are brought into contact with each other, their respective mould profiles cooperate to define the mould cavity in which the hollow moulded fibre product is to be formed. Each half-mould 14 itself defines a smaller moulding cavity and, when brought into cooperation with a second half-mould 14, the smaller moulding cavities combine to provide the overall mould cavity. The two halfmoulds 14 may themselves be considered “splits” or “moulds” and the overall porous first mould 15 may be considered a “split-mould” or, again, a “mould”. In other examples, P24-001

[0164] 26 the porous first mould 15 may comprise more than two splits 14, such as three, four or six splits, that cooperate to define the moulding cavity.

[0165] In Figure 1, the fibre suspension (also known as slurry) is top-filled into the porous first mould 15, in contrast to moulding processes that dip a mould in slurry. The fibre suspension is drawn under vacuum via a line 16 and into the porous first mould 15, with excess suspending liquid being drawn through the porous first mould 15 under vacuum via a line 18 into a tank 17. Shot mass may be controlled by measuring (for example, weighing) the amount of liquid drawn into the tank 17. A weight scale platform supporting the tank 17 is visible in Figure 1. Once a required amount (for example, a predetermined volume, such as 10 litres, or a predetermined mass, such as 10 kilograms) of liquid has been collected in the tank 17, suction of the suspending liquid through the porous first mould 15 is stopped and the first mould 15 is opened to ambient air. In this example, the suspending liquid drawn with the fibre suspension in line 16 is water, or predominantly water (as additives may also be present). The liquid drawn under vacuum via the line 18 and into the tank 17 is substantially free of fibres, since these are left behind against the walls of the porous first mould 15 to form the hollow moulded fibre product.

[0166] In one example, in order to remove further suspending liquid (for example, water) from the hollow moulded fibre product, and form or consolidate the three-dimensional shape of the product, high pressure fluid (such as compressed air) is introduced into the first mould 15 to compress the fibre suspension against the cavity wall of the first mould 15. This process strengthens the product so that it can be handled, and displaces water from in between the fibres, thereby increasing the efficiency of a subsequent drying process. The fluid is regulated using a hydraulic pump 20. The pump 20 has a cylinder that displaces the fluid in a line 21 into the first mould 15. In an alternative example, an impermeable inflation element in the form of a collapsible bladder is inserted into the first mould 15 and expanded, by introduction of a fluid into the bladder from the line 21, to act as an internal high-pressure core structure for the first mould 15. In such an alternative, the fluid within the line 21 is preferably non-compressible, such as water or oil, although in other examples it could be a compressible fluid, such as air. Water has the advantage over other non-compressible liquids that any leaking or bursting of the P24-001

[0167] 27 bladder will not introduce a new substance to the system (since the suspending liquid is already water, or predominantly water).

[0168] Demoulding occurs when the first mould 15 opens for removal of the self- supporting hollow moulded fibre product 22. Mould cleaning 23 is preferably performed subsequently, to remove any remaining small fibres and / or other debris and maintain a porosity of the porous first mould 15. In this example, a radially firing high-pressure jet is inserted into the mould cavity while the first mould 15 is open. This dislodges debris from the wall of the mould cavity. Alternatively, or in addition, water from the tank 17 is pressurised through the back of the porous first mould 15 to dislodge entrapped fibres and / or other debris. Water is drained for recycling back to an upstream part of the system. It is noteworthy that cleaning is important for conditioning the first mould 15 for re-use. The first mould 15 may appear visibly clean after removal of the receptacle, but its performance could be compromised without cleaning.

[0169] According to Figure 1, the hollow moulded fibre product 22 is subsequently transported to a second moulding station where, in a, for example, aluminium, mould 25, pressure and heat are applied for thermoforming a desired neck and surface finish, optionally including embossed and / or debossed surface features. After two halves of the mould 25 have closed around the product 22, a pressuriser is engaged. For example, a bladder 26 (for example, a thermoforming bladder 26) is inserted into the product 22. The bladder 26 is inflated with a pressurised fluid supplied via a line 27 by a pump 28 . The pressurised fluid is preferably a non-compressible fluid such as water or oil, although in other examples it could be a compressible fluid such as air. In other examples, during supply, the pressurised fluid is heated with, for example, a heater or, alternatively, is cooled with, for example, a heat exchanger. An external mould block 24 of the mould 25, and / or the mould 25 itself, is also, or alternatively, heated in some examples. After thermoforming, a state of the product 22, which may now be considered a hollow further- moulded fibre product, is considerably more rigid, with more compressed side walls, as compared with the state of the product 22 at demoulding from the first mould 15.

[0170] A drying stage 30 (for example, a microwave drying process or other drying process) is performed on the product 22 downstream of the thermoforming, as shown, to P24-001

[0171] 28 provide a dried product. In one example, the drying stage 30 is performed before thermoforming to provide a dried product. However, moulding in the mould 25 requires some water content to assist with bonding during the compression process. The drying may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying.

[0172] The product 22 is then subjected to an internal-coating stage during which, in this example, an interior coater in the form of a spray lance 31 is inserted into the product 22 and applies one or more surface coatings to internal walls of the product 22 to produce an internally coated product. In another example, the product 22 is instead filled with and subsequently drained of a liquid that coats the internal walls of the product 22. In practice, such coatings provide a protective layer to prevent egress of contents into the bottle wall, which may permeate and / or weaken it. Coatings will be selected dependent on the intended contents of finished receptacle, for example, a beverage, foodstuff, detergent, lubricant, pharmaceutical product, etc. In this example, the internally coated product 22 is then subjected to a curing or drying process 32, which can be configured or optimised dependent on the internal coating, for example, drying for twenty-four hours at ambient conditions or by a flash drying method. The drying again may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying. Following the drying, the coated product 22 is considered another dried product.

[0173] A closure or mouth forming process is then performed on the product 22 by a closure-part applicator to produce a closable or closed product. For example, as shown in Figure 1, a neck fitment 33 is affixed to the dried product. This results in the product being closable subsequently by positioning of a cap, lid or other closure relative to the neck fitment. An exterior coating and / or decoration is then applied to the product 22 by an exterior coater and / or a decorator, respectively, as shown in the further stage 34, to produce an externally coated and / or decorated product. In one example, the product 22 is dipped into a liquid to coat its outer surface, as shown in Figure 1. In another example, the outer surface receives the external coating in a different manner. The coating and / or decoration may cover all or only part of an external surface of the product. The product P24-001

[0174] 29

[0175] 22 is then allowed to dry in warm air to produce another dried product. In other examples, the drying may be performed using a dryer such as one of those discussed above.

[0176] The product 22 may therefore be fully formed, considered the end “receptacle”, and ready to accept contents therein. In other examples, the receptacle may be fully formed without the neck fitment 35 being affixed and / or without the interior coating being applied and / or without the exterior coating being applied and / or without the decoration being applied and / or immediately after one of the drying processes or one of the inspecting and / or evaluating processes. For example, in some cases, the product is provided with the closure part by moulding the closure part during moulding of the product at the first moulding station and / or the second moulding station.

[0177] Referring now to Figure 2, there is illustrated a vapour deposition apparatus 200 for depositing a material onto at least one surface of a moulded fibre product, such as the moulded fibre product 22 described above with reference to Figure 1. The vapour deposition apparatus 200 comprises a vapour deposition chamber 202. The vapour deposition chamber 202 is configured to receive the hollow moulded fibre product 22 from a manufacturing apparatus. For example, the apparatus 200 is configured to receive the product 22 from one of the manufacturing apparatuses described with reference to Figure 1, from which the output is a hollow moulded fibre product 22.

[0178] The vapour deposition apparatus 200 further comprises a vacuum generator 204 that is configured to generate a vacuum in the vapour deposition chamber 202. The vapour deposition chamber 202 has a retainer 206 for retaining the hollow moulded fibre product 22 so that an opening of the hollow moulded fibre product 22 is retained in a predetermined position relative to the vapour deposition chamber 202, and the vacuum generator 204 is configured to engage with the opening of the hollow moulded fibre product 22. The retainer is configured to secure the product 22 around a necked region of the product 22. The product 22 is provided inside the vapour deposition chamber 202, and the retainer 206 connects the product 22 with the vacuum generator 204 and a gas supply 208 of the vapour deposition apparatus 200, the vacuum generator 204 and the gas supply 208 being situated outside the vapour deposition chamber 202. P24-001

[0179] 30

[0180] The gas supply 208 is configured to supply a gas to the hollow moulded fibre product 22 while the hollow moulded fibre product 22 is in the vapour deposition chamber 202 and the vacuum generator 204 is generating the vacuum in the vapour deposition chamber 202. The gas is suitable for depositing a material onto a surface of the hollow moulded fibre product by physical or chemical vapour deposition. In physical vapour deposition, the gas comprises the material, wherein the material is in a gaseous state. In physical vapour deposition, in the depositing, the material condenses on the surface. In chemical vapour deposition, the gas can undergo one or more chemical reactions to form the material. In the depositing, the material is formed by the one or more chemical reactions. The gas may be a plasma, and the reactions occur between ions of the plasma. The gas may be a mixture of two or more gases, the two or more gases capable of reacting with one another to form the material. In the illustrated example, a plasma discharge element 210 is configured to generate a plasma from the gas supplied by the gas supply. The plasma discharge element comprises an electrode. The retaining member 206 retains the hollow moulded fibre product 22 in a predetermined position relative to the plasma discharge element 210, such that the plasma discharge element 210 can be inserted into the opening of the hollow moulded fibre product. Once inserted, the plasma discharge element 210 can generate a plasma inside the internal cavity of the hollow moulded fibre product 22.

[0181] In other examples, the vapour deposition apparatus may not include a plasma discharge element 210. In some such cases, the deposition process may comprise physical vapour deposition or a chemical vapour deposition that is not plasma-enhanced.

[0182] In some embodiments, the vacuum generator 204 is configured to generate a first vacuum pressure, pi, in the portion of the vapour deposition chamber 202 surrounding the product 22 (i.e., excluding the internal volume of the product 22), and a second vacuum pressure, p2, in the internal cavity of the hollow moulded fibre product 22.

[0183] In some embodiments, the vapour deposition apparatus 200 comprises a permeability reduction apparatus (not shown) that is configured to reduce a permeability of at least a portion of the hollow moulded fibre product 22, prior to the vacuum generator 204 generating the vacuum in the vapour deposition chamber 202. Optionally, the P24-001

[0184] 31 permeability reduction apparatus may comprise a primer layer applicator configured to apply a primer layer to the at least a portion of the hollow moulded fibre product 22 to reduce the permeability of at least the portion of the hollow moulded fibre product 22. In some embodiments, the permeability reduction apparatus may comprise a device that abuts the at least a portion of the hollow moulded fibre product 22 to temporarily reduce the permeability during vapour deposition. Controlling the permeability of the hollow moulded fibre product 22 may be useful in achieving a first vacuum pressure, pi, in the vapour deposition chamber 202, and a second vacuum pressure, p2, in the internal cavity of the hollow moulded fibre product 22. For example, if the permeability is too low, the hollow moulded fibre product 22 may collapse. For example, if the permeability is too high, and the pressure p2 is lower than the pressure pi, the vacuum generator may not be able to establish the pressure p2 in the internal cavity of the hollow moulded fibre product 22 due to leaking from the vapour deposition chamber 202 into the internal cavity of the hollow moulded fibre product 22, via the permeable moulded fibre walls of the hollow moulded fibre product 22.

[0185] In some embodiments, the vapour deposition apparatus 200 comprises a water transmission reduction layer applicator (not shown), configured to apply a water transmission reduction layer to the at least a portion of the hollow moulded fibre product 22.

[0186] In some embodiments, the vapour deposition apparatus 200 comprises a permeability sensor (not shown) that is configured to sense the permeability of at least the portion of the hollow moulded fibre product 22. The vapour deposition apparatus 200 may be configured to carry out vapour deposition only when the permeability of at least the portion of the hollow moulded fibre product 22 sensed by the permeability sensor is within a predetermined range. This may prevent the aforementioned problems associated with a permeability that is too high or too low. For example, this may prevent damage to the hollow moulded fibre product and / or poor deposition of a material by vapour deposition.

[0187] Referring now to Figure 3, there is illustrated a method 300 of processing a hollow moulded fibre product, the method 300 comprising: in block 302, providing a hollow P24-001

[0188] 32 moulded fibre product comprising at least one surface; in block 304, reducing the permeability of at least a portion of the hollow moulded fibre product to a reduced permeability; and in block 306, depositing a material by vapour deposition onto at least one surface of the at least a portion of the hollow moulded fibre product having the reduced permeability. For example, this method may be carried out after, for example immediately after, the internal coating stage or the external coating stage described above. In some examples, this method may be carried out after, for example immediately after, the plasma surface treatment described herein. In some examples, this method may be carried out as part of the coating stage described above. In some examples, the method described with reference to Figure 3 may be performed after the thermoforming and / or drying stage, or after the closure or mouth forming process, described above with reference to Figure 1. As such, the method 300 may be part of the fabrication process described above with reference to Figure 1. The reducing 304 and / or the depositing 306 may be performed by a vapour deposition apparatus, for example the vapour deposition apparatus 200 described above with reference to Figure 2.

[0189] In examples, the hollow moulded fibre product is a hollow moulded fibre receptacle and the at least one surface is a moulded fibre surface of a hollow moulded fibre receptacle. In these examples, the method comprises in block 302, providing a hollow moulded fibre receptacle comprising at least one moulded fibre surface; in block 304, reducing the permeability of the hollow moulded fibre receptacle; and, in block 306, applying a material onto the at least one surface of the hollow moulded fibre receptacle by vapour deposition. In some examples, the receptacle is a necked receptacle. In some such examples, the receptacle is a bottle.

[0190] In some examples, in block 304, the reducing comprises providing a device that abuts the at least a portion of the hollow moulded fibre product to temporarily reduce the permeability during vapour deposition. That is, the reducing the permeability need not relate to a modification of the hollow moulded fibre product. Additionally, the reduced permeability is only required during the depositing 306, and therefore the device need only be provided during the depositing 306 and then the product may be removed or otherwise separated from the device; in other words, the reducing the permeability may comprise a temporary reduction in the permeability. P24-001

[0191] 33

[0192] In some examples, the hollow moulded fibre product provided in block 302 is uncoated. In some examples, a primer layer is disposed on at least one surface of the hollow moulded fibre product and, optionally, one or more further layers are disposed on the primer layer. In some examples, a coating is disposed on an external surface of the hollow moulded fibre product, such as an anti-scuff coating. The anti-scuff coating may comprise an acrylate copolymer.

[0193] Coating layers disposed on the hollow moulded fibre product such as a primer layer, and optionally one or more further layers such as a water transmission reduction layer, may reduce the permeability of the hollow moulded fibre product. Thus, in some cases, the reducing 304 may not be required if the hollow moulded fibre product already has the reduced permeability (because, for example, the coating layers are already in place). In some cases, the reducing 304 comprises applying the coating layers to the moulded fibre product to reduce its permeability. In some examples, the presence of such coating layers reduces the permeability of the hollow moulded fibre product sufficiently to allow for a stable and low vacuum pressure to be generated on the side of the hollow moulded fibre product comprising the at least one surface. This may be an internal surface of the hollow moulded fibre product.

[0194] In some examples, the reduced permeability of the hollow moulded fibre product may be in a range defined by a first and a second permeability, the first permeability being a minimum permeability, below which application of the vacuum would result in delamination of the coating from the fibre wall and / or would result in the hollow moulded fibre product collapsing or otherwise failing, and the second permeability being a maximum permeability, above which a suitable vacuum for vapour deposition cannot be formed in the internal volume of the hollow moulded fibre product.

[0195] In some embodiments, a primer layer is disposed on at least one surface of the hollow moulded fibre product and the depositing 306 deposits the material onto a different at least one surface, for example, an uncoated moulded fibre surface. In some embodiments, a primer layer is disposed on at least one surface of the hollow moulded fibre product and the depositing 306 deposits the material onto the exposed surface of the primer layer. In some embodiments, a primer layer is disposed on at least one surface of P24-001

[0196] 34 the hollow moulded fibre product, one or more further layers (such as a water transmission reduction layer) are disposed on the primer layer, and the depositing 306 deposits the material onto the exposed surface of the one or more further layers. In other words, the material is deposited onto at least one surface of the hollow moulded fibre product, and the at least one surface may be an uncoated moulded fibre surface, or an exposed surface of a coating layer disposed on a moulded fibre surface. When two or more coating layers are disposed on the moulded fibre surface, the depositing 306 may deposit the material onto the exposed surface of the outermost coating layer that is in place during the vapour deposition stage (i.e., the coating layer which is furthest away from the moulded fibre surface).

[0197] In some embodiments, the primer layer comprises fibre material and / or a polymer. In some embodiments, the primer layer further comprises at least one selected from the group consisting of natural waxes, plasticisers, rheology modifiers and silica. In some embodiments, the fibre material comprises cellulose microfibres, such as a microfibrillated cellulose (MFC). In some embodiments, the polymer is an acrylic polymer. For example, a styrene acrylate copolymer. In some such embodiments, the primer layer may comprise a styrene acrylate copolymer and a plasticiser. The presence of a plasticiser may improve the resistance and flexibility of the primer layer.

[0198] In some embodiments, the one or more further layers may each comprise a polymer. In some embodiments, the one or more further layers may each comprise a polymer and one or more components selected from: a natural wax, rheology modifiers and silica. In some embodiments, the polymer may be an acrylic polymer. For example, the polymer may be a styrene acrylate copolymer. In some such embodiments, the one or more further layers comprises a styrene acrylate copolymer and a natural wax. The presence of the natural wax may impart water barrier properties.

[0199] The amount of the primer layer or the amount of the one or more further layers disposed on a moulded fibre surface may be expressed as a mass of coating relative to the surface area of the at least one surface of the hollow moulded fibre product onto which they are disposed. In other words, the amount of coating may be expressed as a mean coating weight measured across a given portion of the surface. In some embodiments, the P24-001

[0200] 35 coating weight of the primer layer is from about 10 to about 100 grams per square metre (gsm, g / m2or g.m'2), In some embodiments, the coating weight is from about 40 to about 80 g.m'2, from about 40 to about 60 g.m'2, or is suitably about 60 g.m'2. In some embodiments, the coating weight of each of the one or more further layers, such as a water transmission reduction layer is from about 5 to about 50 g.m'2, or about 10 to about 30 g.m'2, about 20 to about 30 g.m'2, about 23 to 27 g.m'2, or about 15 to about 20 g.m'2.

[0201] In some examples, the vapour deposition in block 306 comprises physical vapour deposition or plasma-enhanced chemical vapour deposition. Vapour deposition methods for forming thin films of a material on a product are known in the art. Typically, a gas is provided. In physical vapour deposition, the gas condenses on the surface of product to deposit the material. In some examples of physical vapour deposition, the deposition does not involve any chemical transformations of the gas. That is, the gas and the material deposited on the surface have the same chemical composition. In chemical vapour deposition, the gas is first converted to one or more reactive species. These reactive species react on the surface of the product to deposit the material. In chemical vapour deposition, the chemical composition of the gas and the material may be different. For example, the gas may comprise two gases that react to form the material on the at least one surface.

[0202] In some embodiments, the vapour deposition is plasma-enhanced chemical vapour deposition and the reactive species is or comprises a plasma (that is, an ionised gas formed of positive ions and free electrons). In some embodiments, the material deposited by vapour deposition comprises at least one selected from: SiOx, carbon (suitably diamondlike carbon - DLC) and aluminium. In some such embodiments, the material to be deposited comprises carbon (suitably diamond-like carbon), and the gas comprises at least one of: acetylene and methane; and / or the plasma comprises carbon ions. In some such embodiments, the material to be deposited comprises SiOx, and the gas comprises a silicon source. In some such embodiments, the gas further comprises oxygen and / or the silicon source is hexamethyldisiloxane (HMDSO). The reaction of a silicon source with oxygen during chemical vapour deposition may deposit a material comprising SiOxon the at least one surface. In some embodiments, the material to be deposited comprises aluminium, and the gas comprises aluminium. In some such embodiments, the vapour P24-001

[0203] 36 deposition is physical vapour deposition. In some embodiments, the material to be deposited comprises aluminium oxide (AI2O3). In some such embodiments, the vapour deposition is chemical vapour deposition and the gas comprises oxygen-containing gas and an aluminium-containing gas. In some embodiments, the oxygen-containing gas comprises at least one of: H2O, O2 and O3. In some embodiments, the aluminium- containing gas comprises at least one of: an aluminium halide, a metal alkyl and a metal alkoxide. In some embodiments, the aluminium-containing gas comprises at least one of: aluminium chloride (AICI3), trimethylaluminium (A1(CH3)3), aluminium tri-isopropoxide (Al(O1Pr)3) and aluminium acetyl acetonate (Al(acac)3).

[0204] In some embodiments, the vapour deposition forms a layer of the material on the at least one surface of the hollow moulded fibre product. The layer may be a substantially continuous layer across a portion of, the at least one surface. In some cases, the layer may cover more than 50%, 60%, 70, 80%, 90%, or 95% of the at least one surface, or substantially all of the at least one surface. In some embodiments, the layer of the material has a mean thickness of between about 10 nm and about 100 nm. In some embodiments, the layer of the material has a mean thickness of about 20 to 80 nm, or about 30 to 70 nm, or about 40 to 60 nm.

[0205] Referring now to Figure 4, there is illustrated a method 400 of processing a hollow moulded fibre product, the method 400 comprising vapour deposition of a material onto at least one surface of the hollow moulded fibre product. Blocks 402 and 408 correspond to blocks 302 and 306, respectively, of Figure 3 described above. In examples, the method 400 comprises, in block 402, providing a hollow moulded fibre product comprising at least one surface; in block 404, applying a primer layer onto at least one surface of the hollow moulded fibre product; in block 406, applying one or more further layers onto the primer layer; in block 408, depositing a material onto at least one surface by vapour deposition; and in block 410, applying one or more coating layers onto the material deposited by vapour deposition. In some examples, the method 400 consists of blocks 402, 404 and 408. In other words, block 406 and 410 are optional. In some examples, block 404 of applying the primer layer reduces the permeability of the hollow moulded fibre product such that vapour deposition block 408 is possible. P24-001

[0206] 37

[0207] The at least one surface of the hollow moulded fibre product onto which the primer layer is applied in block 404 may be the same or different at least one surface onto which the material is deposited by vapour deposition in block 408. In some examples, the at least one surface referred to in block 404 comprises the at least one surface referred to in block 308. In other words, the material may be deposited onto a portion of, or all of, the primer layer, or the material may be deposited onto an uncoated moulded fibre surface or a surface on which a primer layer is not disposed.

[0208] In some embodiments, the primer layer may be applied onto an external and an internal surface of the hollow moulded fibre product in block 404, and the material may be deposited onto the primer layer on the internal surface in block 408. In such embodiments, a primer layer is disposed on the external surface and the internal surface of the hollow moulded fibre product obtained after the method 400, and the material deposited by vapour deposition is disposed on the internal surface, with the primer layer that is disposed on the internal surface being disposed between the internal surface and the material. In some such embodiments, block 406 is included in the method 400 and, in block 408, the material is deposited onto the one or more further layers applied in block 406. In such embodiments, the primer layer, the one or more further layers and the material deposited by vapour deposition are disposed on the internal surface, and the one or more further layers are disposed between the primer layer that is disposed on the internal surface and the material.

[0209] In some embodiments, the block 410 is included in the method 400 and the hollow moulded fibre product obtained by the method 400 comprises one or more coating layers disposed on the material deposited by vapour deposition. In some examples, at least one of the one or more coating layers applied in the block 410 is configured for water barrier properties. For example, the one or more coating layers comprises a natural wax, or a polymer and a natural wax. In some examples, the polymer is an acrylic polymer such as a styrene acrylate copolymer.

[0210] It should be noted that the primer layer and / or each of the one or more further layers and / or the one or more coating layers need not be applied in a single application. For example, the desired coating thickness may be achieved by applying the same coating P24-001

[0211] 38 formulation two or more times in a series of coating steps. That is, the applying 404, 406 and / or 410 may each comprise one or more applications of a given coating formulation. For example, a primer coating formulation may be applied twice to achieve double the thickness compared with a single application, or three times to achieve three times the thickness. In some examples, a primer coating of about 40 g.m'2is achieved through two applications of a coating formulation, or a primer coating of about 60 g.m'2is achieved through three applications of a coating, formulation where each application increases the thickness of the primer layer by about 20 g.m'2. Coating formulations may comprise about 20-40 wt% solid components with respect to the weight of the total coating formulation (i.e. including both solid and liquid components), or about 25-35 wt%, or about 30 wt%.

[0212] In some embodiments, the method 400 comprises applying a coating onto an external surface. The coating applied onto the external surface may be an anti-scuff coating. It will be understood that this may be applied at any suitable point during the method 400 such that the anti-scuff coating is the outermost coating layer on the external surface of the hollow moulded fibre product. For example, the anti-scuff coating may be applied as the final layer of one or more coating layers applied onto the external surface, or it may be the only coating layer applied onto the external surface.

[0213] Referring now to Figure 5, there is illustrated a method 500 of processing a hollow moulded fibre product. The method 500 is an example of a method of depositing a material onto at least one surface of a hollow moulded fibre product by vapour deposition, such as blocks 306 and 408 of the methods 300 and 400, respectively, described above. In examples, the method 500 comprises, in block 502, providing a hollow moulded fibre product to a vapour deposition chamber of a vapour deposition apparatus, the hollow moulded fibre product comprising at least one internal surface; in block 504, reducing the pressure inside the vapour deposition chamber to a first pressure; in block 506, sealing the hollow moulded fibre product; in block 508, reducing the pressure of an internal cavity of the hollow moulded fibre product to a second pressure; in block 510, providing a gas to the internal cavity; in block 512, depositing a material onto at least one internal surface of the hollow moulded fibre product by vapour deposition. P24-001

[0214] 39

[0215] In some embodiments, the hollow moulded fibre product provided in block 502 may be: an uncoated hollow moulded fibre product; a hollow moulded fibre product with a primer layer disposed on at least one surface; or a hollow moulded fibre product with a primer layer disposed on at least one surface and one or more further layers disposed on the primer layer. In some embodiments, the method 500 is the vapour deposition of block 306 of the method 300 described above with reference to Figure 3, and the hollow moulded fibre product provided at block 502 is the product obtained from block 304 in the method 300. In some embodiments, the method 500 is the vapour deposition of block 408 of the method 400 described above with reference to Figure 4, and the hollow moulded fibre product provided at block 502 is the product obtained from the block 404 or the block 406 in the method 400.

[0216] In some embodiments, in block 502, the hollow moulded fibre product is provided to a vapour deposition chamber and, in block 504, the pressure inside the chamber is reduced to a first pressure. In block 506, the hollow moulded fibre product is sealed and connected to the vapour deposition apparatus, for example, by providing a closure fitment which provides a tight seal with the opening of the hollow moulded fibre product, the closure fitment being connectable to the vapour deposition apparatus and providing fluid connection between the internal cavity of the hollow moulded fibre product and a vacuum generator of the vapour deposition apparatus. Once connected, the internal cavity of the hollow moulded fibre product is physically separated from a remaining portion of the vapour deposition chamber external to the hollow moulded fibre product. In block 508, the pressure of the internal cavity is reduced to a second pressure. The second pressure is a pressure which is suitable for vapour deposition and is lower than the first pressure in block 504. In some examples of the method 500, the first pressure in block 504 is about 10 to 30 mbar, or about 20 mbar and / or the second pressure in block 508 is about 1 to 5 mbar, or about 2 mbar.

[0217] In some embodiments, the vapour deposition is physical vapour deposition. In some embodiments, the vapour deposition is plasma-enhanced chemical vapour deposition and the method 500 further comprises, after the block 510 and before the block 512, generating a plasma from the gas. In some embodiments, the plasma is generated by applying microwave radiation. In some embodiments, a plasma discharge element comprising an electrode is provided and located in the internal cavity of the hollow moulded fibre product prior to the block 506, such that the electrode of the plasma discharge element is sealed inside the internal cavity of the hollow moulded fibre product in the block 506. In some such embodiments, the plasma may be generated by applying a high voltage (e.g., 1 to 10s of kV) to the electrode of the plasma discharge element so as to cause an electrical discharge into the surrounding gas, creating plasma.

[0218] Whilst the method 500 relates to depositing a material on the internal surface of a hollow moulded fibre product, it will be understood that vapour deposition may be carried out in order to deposit the material onto an external and / or an internal surface of a hollow moulded fibre product.

[0219] Referring now to Figure 6, there is illustrated a method 600 of processing a hollow moulded fibre product, the method 600 comprising plasma treatment of at least one surface of the product. For example, the method 600 may be carried out prior to, for example immediately prior to, the internal coating stage or the external coating stage in Figure 1 described above. In some examples, this method may be carried out as part of the coating stage. In some examples, the method 600 may be carried out prior to, for example immediately prior to, the deposition of a material by vapour deposition in Figure 3, 4 or 5 described above. In some examples, the method 600 may be performed after the thermoforming and / or drying stage described above with reference to Figure 1. As such, the method 600 may be part of the fabrication process described above with reference to Figure 1 and the product may be a product such as the product 22 described with reference to Figure 1. In broad overview, the method 600 comprises, in block 602, providing a hollow moulded fibre product, the hollow moulded fibre product comprising a surface having a surface energy; and, in block 604, treating at least a portion of the surface of the product with plasma, thereby increasing the surface energy of the portion of the surface. In examples, the treated surface is a moulded fibre surface of a hollow moulded fibre receptacle. In these examples, the method 600 comprises in block 602, providing a hollow moulded fibre receptacle comprising a moulded fibre surface having a surface energy; in block 604, treating at least a portion of the moulded fibre surface of the receptacle with plasma, thereby increasing the surface energy of the portion of the moulded fibre surface; and, in block 606, depositing a material onto the surface by vapour deposition. 41

[0220] Surface energy may be defined as excess energy at the surface of a material as compared to the energy of a bulk of the material and may quantify the disruption of intermolecular bonds at the surface. The surface energy of a surface can be increased by treating the surface with plasma (that is, an ionised gas formed of positive ions and free electrons). For example, the energy from the plasma can break molecular bonds on the surface of a relatively non-polar product, which broken bonds then recombine with free radicals to form polar groups on the surface, thereby increasing the surface energy. Increasing the surface energy of a surface increases the adhesiveness of the surface (e.g., the propensity of other materials to adhere to the surface). Increasing the surface energy of the portion of the moulded fibre surface may therefore allow for a reduction in an amount of coating that needs to be applied to the portion of the moulded fibre surface for in order to provide an effective coat. For example, this may allow for a reduction in an amount of coating that needs to be applied to the portion of the moulded fibre surface in order to coat the moulded fibre surface sufficiently to provide an effective barrier between a fibrous wall of the hollow moulded fibre product and the contents to be received in the hollow moulded fibre product. Additionally, improved adhesion of a coating or the material deposited by vapour deposition to the treated portion of the moulded fibre surface may improve the durability of the coating or the material and hence of the moulded fibre product. Additionally, treating the portion of the moulded fibre surface with plasma may help remove stray fibres or other surface imperfections from the moulded fibre surface. This may, in turn, provide for a flatter surface, which may allow for a reduction in the amount of the coating or the material deposited by vapour deposition that needs to be applied to the portion of the moulded fibre surface in order to provide an effective coat. This may also allow for the coating or the material to be more uniformly and consistently applied to the moulded fibre surface. Additionally, treating the portion of the moulded fibre surface with plasma may sterilise the portion of the moulded fibre surface. This may be useful, for example, where the moulded fibre product forms part of a receptacle for use in containing beverages or other consumables.

[0221] It should be noted that the plasma treatment and plasma-enhanced chemical vapour deposition described above are different processes. Plasma treatment refers to treatment of a surface to increase its surface energy and does not involve deposition of a P24-001

[0222] 42 material onto the surface. As such, plasma treatment may be referred to as a nondepository process, whereas plasma-enhanced chemical vapour deposition may be referred to as a depository process. Methods described may comprise both plasma treatment, to increase the surface energy of a surface, and plasma-enhanced chemical vapour deposition, to deposit a material onto at least one surface, such as a surface previously subjected to plasma treatment.

[0223] As described above with reference to Figure 6, plasma treatment in block 604 may be carried out prior to, such as immediately prior to, vapour deposition in block 606, and the material may be deposited onto the plasma-treated surface. That is, plasma treatment is carried out on the same at least one surface as vapour deposition. For example, plasma treatment is carried out on the at least one surface referred to in block 306 in the method 300, the at least one surface referred to in block 408 in the method 400 or the at least one surface referred to in block 512 in the method 500. When a material is deposited by vapour deposition onto a plasma treated portion of a surface, the material adheres to the plasma treated portion of the moulded fibre surface better than as compared with if the portion were untreated. By performing the vapour deposition immediately after plasma treatment, this may help ensure that the increased surface energy provided by the plasma treatment is present during the vapour deposition.

[0224] In addition to the method 500 described above, plasma treatment may also be carried out prior to, such as immediately prior to, another coating stage described herein. For example, plasma treatment may be carried out prior to, such as immediately prior to, a coating stage comprising applying a liquid coating formulation onto a surface of a hollow moulded fibre product, such that the surface is a plasma-treated surface. Examples of such coating stages described herein include the internal coating stage or the external coating stage described above with reference to Figure 1, or the applying a primer layer 404, the applying one or more further layers 406 and the applying one or more coating layers 410 described above with reference to Figure 4.

[0225] In some examples, the method may comprise treating at least a portion of an exposed surface of a coating with plasma, thereby increasing a surface energy of the portion of the exposed surface of the coating. For example, the plasma treatment of the P24-001

[0226] 43 exposed surface of the coating may be performed in substantially the same way as described herein for the moulded fibre surface. In examples, the coating may be a primer layer, or one or more further layers disposed on a primer layer. For example, plasma treatment may be carried out on the exposed surface of a primer layer prior to, or immediately prior to, the applying 406 described with reference to Figure 4. In another example, plasma treatment may be carried out on the exposed surface of the one or more further layers prior to, or immediately prior to, the depositing 408 described with reference to Figure 4. Treating the coating layer with plasma increases the wettability of the exposed surface, and hence may increase the degree to which any subsequent coating layers wets and adheres to the exposed surface. This may reduce the amount of subsequent coating that needs to be applied to provide an effective barrier as mentioned above. In some examples, the method may comprise applying (e.g., spraying) one or more further layers to the treated portion of the exposed surface of the primer layer.

[0227] In some examples, the method may comprise depositing a material by vapour deposition onto the treated portion of the exposed surface of the primer layer or the one or more further layers. This may improve adhesion of the material. For example, when the primer layer or one or more further layers is configured for water barrier properties, the exposed surface of the coating may require plasma treatment to achieve good adhesion of the material to the exposed surface of the primer layer or the one or more further layers. In such examples, plasma treatment of the exposed surface to increase its surface energy may lead to improved adhesion of the material deposited by vapour deposition, compared with the adhesion to an untreated exposed surface of the coating.

[0228] In some cases, when subject to the ASTM D3359 tape test, at least 80wt%, 85wt% or at least 90wt% of the layer of material is retained on the hollow moulded fibre product.

[0229] In some examples of plasma treatment, the plasma may be provided by a corona discharge. A corona discharge may refer to plasma created in air. A corona discharge may be provided by applying a high voltage (e.g., 1 to 10s of kV) to an electrode so as to cause an electrical discharge into the surrounding air, creating plasma. In some examples, only one electrode may be used with the current being dissipated into the surrounding air via the plasma. In other examples, two electrodes (separated by air) may be used, with current P24-001

[0230] 44 flowing between a first electrode and a second electrode via plasma created between the two. The use of two electrodes can help direct the plasma and / or help improve the extent over which plasma is generated. In some examples, the plasma may be provided by a plasma discharge. As used herein, a plasma discharge may refer to a plasma created in a gas or gasses additional to or instead of air. For example, such a gas may be Argon. For example, the plasma discharge may be provided using the same or similar equipment to that of a corona discharge (e.g., as described above), but with one or more gas sources to provide the gas or gases in addition to or instead of air, in the region in which plasma is to be generated. The additional gas or gasses may help reduce the operating voltage of the discharge, and hence improve efficiency. Alternatively or additionally, the additional gas or gasses (such as Argon) can help increase the extent over which plasma is generated, which may in turn help improve treatment coverage. This may, for example, help improve treatment efficiency, and / or allow for effective plasma treatment of receptacles with complex and / or intricate shapes. Alternatively, or additionally, the additional gas or gasses used to create the plasma may increase the amount by which the surface energy is increased, which may provide for further improved adhesiveness and wettability of the surface.

[0231] In some of the above examples, reference is made to the plasma treatment of an internal surface of a moulded fibre product. However, it will be appreciated that this need not necessarily be the case, and that in other examples the plasma treated surface may be an external surface of the moulded fibre product. This may allow for a reduction in the amount of coating that needs to be applied to an external surface of the receptacle in order for the coating to be effective. For example, an external coating may help prevent damage or external liquid or gas permeation into the moulded fibre product. An external coating to prevent damage to the external surface may be referred to as an anti-scuff coating. Other examples are possible.

[0232] In some examples, the methods disclosed herein comprise plasma treatment and plasma-enhanced chemical vapour deposition. In some such examples, the plasma treatment and the plasma-enhanced chemical vapour deposition comprise providing a plasma discharge element. It will be understood that the plasma discharge element used in each of the plasma treatment and the plasma-enhanced chemical vapour deposition P24-001

[0233] 45 may be the same or different. For example, the plasma discharge element may be the same, and the internal cavity of the hollow moulded fibre product may contain air or be provided with an inert gas such as argon and plasma treatment is carried out on at least one surface of the product; next the internal cavity may be evacuated (to remove the remaining air or inert gas) and subsequently provided with the gas for plasma-enhanced chemical vapour deposition. Plasma-enhanced chemical vapour deposition may then be carried out on the at least one surface, using the plasma discharge element to generate a plasma from the gas.

[0234] As described above in relation to the apparatus 200 and the method 300, the permeability of an uncoated hollow moulded fibre product may be too high for a suitable vacuum to be established during vapour deposition. This may render vapour deposition onto the surface of the product challenging or even impossible. Permeability may be measured, for example, by the gross leak test disclosed herein. The gross leak test may be suitable for determining whether a hollow moulded fibre product has the reduced permeability referred to in the block 304 in Figure 3. Commercial apparatuses for gross leak testing are available, such as those designed for leak testing plastic bottles and other containers. For example, a commercially available leak tester such as a QuickCheck Linear Leak Tester provided by ALPS Inspection may be used to carry out the gross leak test described herein.

[0235] The gross leak testing method can be carried out as follows. A hollow moulded fibre product is provided with a closure fitment in order to connect the hollow moulded fibre product to a gross leak apparatus. It is important to ensure a good seal between the closure fitment of the hollow moulded fibre product and the gross leak apparatus, such that leaks are minimised at the interface between the closure fitment and the gross leak apparatus. This ensures, as best as possible, that leaks measured by the gross leak test can be attributed to the permeability of the hollow moulded fibre walls of the hollow moulded fibre product rather than leaks occurring due to gaps at the interface between the hollow moulded fibre product and the closure fitment. For example, the closure fitment may be provided and subsequently adhered to the hollow moulded fibre product with the necessary quantity of hot melt glue to achieve a good seal. P24-001

[0236] 46

[0237] The hollow moulded fibre product is placed under the gross leak detector and a seal is clamped down onto the closure fitment. A force of around 67 N is used to achieve a secure clamping of the seal on the closure fitment. The bottle is then pressurised to 300 mbar. A flow sensor is built inline and measures an amount of air flowing into the bottle to maintain pressure inside the bottle. This equates to the amount of air being lost due to defects in the bottle. The maximum flow rate the sensor can measure is 2 L / min. The higher the flow rate detected by the flow rate sensor, the higher the permeability of the hollow moulded fibre product.

[0238] Gross leak tests were carried out on sixteen hollow moulded fibre bottles each coated with an external coating layer and a primer layer on the internal surface. Tests were carried out using a QuickCheck Linear Leak Tester provided by ALPS Inspection. All of the bottles were coated with the same primer layer and external layer. The primer layer comprised a styrene acrylate copolymer. The external coating was an anti-scuff coating and comprised an acrylate copolymer. The coating weight of the primer layer was about 60 g.m'2and the coating weight of the external coating layer was about 15 g.m'2.

[0239] Of the sixteen bottles comprising an external coating layer and a primer layer on the internal surface:

[0240] All of the bottles had a flow rate of less than 0.15 L / min in the gross leak test,

[0241] Five bottles had a flow rate of between 0.05 and 0.1 L / min, and the remaining ten bottles all had a flow rate less than 0.01 L / min.

[0242] All of the sixteen bottles had suitable permeability for vapour deposition, without the need to provide a device that abuts the bottle in order to achieve a suitable vacuum pressure in the internal cavity. For example, a suitable vacuum pressure of about 1 to 5 mbar could be achieved.

[0243] These results show that hollow moulded fibre products with a permeability corresponding to flow rate of less than 0.15 L / min in the gross leak test are suitable for vapour deposition, without the need to provide a device that abuts the bottle in order to achieve a suitable vacuum pressure in the internal cavity. Preferably, the permeability of P24-001

[0244] 47 a hollow moulded fibre product corresponds to a flow rate less than 0.1 L / min in the gross leak test, and more preferably a flow rate less than 0.01 L / min.

[0245] Further bottles without a primer layer were subject to gross leak testing and found to have a flow rate in excess of 0.5 L / min, or 1.0 L / min, or 1.5 L / min. Some examples of bottles without a primer layer were found to have a flow rate in excess of 2.0 L / min and could not be measured using the gross leak testing apparatus. With these bottles, it was not possible to maintain the required vacuum differential between the internal and external bottle volumes and vapour deposition could not be completed.

[0246] Permeability of a hollow moulded fibre product may also be measured by a pressure decay test wherein a difference in pressure is established between the internal cavity of the hollow moulded fibre product and the external environment, and the change in internal pressure is measured over time after the applied vacuum is removed. In this test, the external environment is pressurised to a first pressure, pi. The pressure in the internal cavity of the hollow moulded fibre product is pressurised to a second pressure, P2, which is lower than the first pressure, pi. The difference between pi and p2 may be referred to as the pressure difference, Ap. After establishing the pressure difference, Ap, the vacuum pump connected to the internal cavity of the bottle is switched off and the pressure difference of the hollow moulded fibre product is allowed to decay (the external vacuum pump remains on in order to maintain a constant external pressure, pi,). Assuming a leak-free seal between the opening of the hollow moulded fibre product and the testing apparatus, the decay of Ap can be attributed to the permeability of the walls of the hollow moulded fibre product. The increase in pressure p2 is measured over a period of time, t. The measurements may be used to calculate a decay rate (DR, equation 1 below) and a normalised decay rate (NDR, equation 2 below). The normalised rate allows for slight discrepancies in the external pressure, pl, between test runs to be accounted for.

[0247] Pl.t P24-001

[0248] 48

[0249] In an example, three hollow moulded fibre bottles were tested according to the above pressure decay test. Bottle 1 had an internal coating comprising a styrene acrylate copolymer. Bottle 2 was an uncoated bottle. Bottle 3 had an internal coating comprising microfibrillated cellulose (MFC).

[0250] The target for the first pressure, pl, was set to around 10 mbar and the target for the second pressure at the start of the test was set to around 0.3 mbar. The applied vacuum to the internal cavity was switched off and the internal pressure monitored for 60 seconds.

[0251] The actual pi pressures measured in the test device, the decay rate and the normalised decay rate are shown in Table 1 below. After 30 seconds, the internal pressure, P2, of bottle 2 had reached the external pressure, pi. The decay rates below are based on the first 10 seconds of pressure measurement.

[0252] Table 1 Results of pressure decay measurements on moulded fibre bottles.

[0253] Vapour deposition onto bottles 1, 2 and 3 was attempted using a DPM103 Plasma Coater from Delta Engineering. The pressure in the vapour deposition of the plasma coater was set to 20 mbar, and the internal pressure of the bottles was set to 20 pbar. If a pressure of less than 100 pbar is not achieved inside the bottle, vapour deposition cannot be carried out.

[0254] The data in Table 1 shows that bottle 1, having the styrene acrylate primer layer on the internal surface, had the lowest rate of pressure decay. When vapour deposition of DLC onto the internal surface of bottle 1 was attempted, a stable and suitably low vacuum pressure of around 30 pbar was generated in the internal cavity of the bottle. Bottle 1 was successfully coated by vapour deposition.

[0255] Bottle 2, the uncoated bottle, had the highest rate of pressure decay. When vapour deposition of DLC onto the internal surface of bottle 2 was attempted, a pressure of P24-001

[0256] 49 around 450 pbar was generated in the internal cavity of the bottle. The pressure inside the bottle could not be reduced further in order to achieve a suitably low vacuum pressure of less than 100 pbar. It was not possible to coat bottle 2 by vapour deposition.

[0257] Bottle 3, comprising the MFC primer layer had a higher rate of pressure decay than bottle 1, and a lower rate of pressure decay than bottle 2. When vapour deposition of DLC onto the internal surface of bottle 3 was attempted, a stable and suitably low vacuum pressure of around 40 pbar was generated in the internal cavity of the bottle. Establishing the required internal vacuum pressure took longer than for bottle 1. However, once the suitable vacuum pressure was established, bottle 3 was successfully coated by vapour deposition.

[0258] Also provided is a product obtainable by any of the methods disclosed herein. In some examples, there may be provided a product obtained from a method of manufacturing a hollow moulded fibre product (e.g., the method described above with reference to Figure 1), the method comprising the method of processing according to any one of the examples described above with reference to Figures 3 to 6. There may be provided a product 22 obtainable or obtained from a method of manufacturing comprising the method described above with reference to Figures 3 to 6. For example, the product may be obtainable or obtained from the method described above with reference to Figures 3 to 6. The method of manufacturing may comprise at least one additional process. The at least one additional process may comprise coating and drying the receptacle or the moulded receptacle to produce a coated product. The at least one additional process may comprise applying a closure to the product, the moulded product or the coated product. In some examples, the moulded fibre receptacle is a bottle.

[0259] In some of the above examples, the hollow moulded fibre product is a receptacle. In such examples, the method of manufacturing a hollow moulded fibre product (e.g., the method described above with reference to Figure 1) and the method of processing a hollow moulded fibre product (e.g., the method described above with reference to Figures 3 to 6) are methods of manufacturing and processing, respectively, a hollow moulded fibre receptacle. In some examples, the receptacle is a necked receptacle, such as a bottle, jar or a type of vase. In some examples, the receptacle is a bottle. There may be provided P24-001

[0260] 50 a receptacle obtained or obtainable from a method of manufacturing a hollow moulded fibre product (e.g., the method described above with reference to Figure 1) comprising the method of processing according to any one of the examples described above with reference to Figures 3 to 6. There may be provided a product 22 obtainable or obtained from a method of manufacturing comprising the method described above with reference to Figures 2 to 5. For example, the product may be obtainable or obtained from the method described above with reference to Figures 3 to 6. The method of manufacturing may comprise at least one additional process. The at least one additional process may comprise moulding a product to produce a moulded product. The at least one additional process may comprise coating and drying the receptacle or the moulded receptacle to produce a coated product. The at least one additional process may comprise applying a closure to the product, the moulded product or the coated product. In some examples, the moulded fibre receptacle is a bottle.

[0261] The present invention also provides a hollow moulded fibre product comprising at least one surface, wherein a layer of material is disposed on the at least one surface of the product, and the layer (a) has a thickness of between about lOnm and lOOnm and (b) comprises one or more components selected from the group consisting of SiOx, carbon (suitably diamond-like carbon) and aluminium. In some embodiments, the layer is a vapour-deposited layer. In some embodiments, the layer of the material has a mean thickness of about 20 to 80 nm, or about 30 to 70 nm, or about 40 to 60 nm, or about 50 nm.

[0262] In some embodiments, the product comprises cellulose fibres. In some embodiments, the product is a necked product. In some embodiments, the product is a bottle. In some embodiments, the product may be suitable for containing contents such as liquids. In some embodiments, the liquid is a beverage, for example a carbonated beverage.

[0263] In some embodiments, a primer layer may be disposed between the at least one surface of the hollow moulded fibre product and the layer of the material. For example, a primer layer as described above with reference to Figures 3 to 6. In some embodiments, the primer layer comprises fibre material and / or a polymer. In some embodiments, the P24-001

[0264] 51 primer layer further comprises at least one selected from the group consisting of: natural waxes, plasticisers, rheology modifiers and silica. In some embodiments, the fibre material comprises cellulose microfibres. For example, the primer layer may comprise microfibrillated cellulose (MFC). In some embodiments, the polymer is an acrylic polymer. For example, a styrene acrylate copolymer. In some such embodiments, the primer layer may comprise a styrene acrylate copolymer and a plasticiser. In some embodiments, the product comprises a primer layer having a coating weight of about 10 to 100 g.m'2, suitably 40 to 60 g.m'2

[0265] In some embodiments, two or more layers may be disposed between the at least one surface of the hollow moulded fibre product and the layer of the material. The two or more layers may include a primer layer as described above and one or more further layers, for example, the one or more further layers described above with reference to Figures 3 to 6. In some embodiments, the one or more further layers has a coating weight of from about 5 to about 50 g.m'2, or about 10 to about 30 g.m'2, or about 15 to about 30 or 20 g.m'2. In some embodiments, the one or more further layers may include a layer configured to have water barrier properties. The layer configured to have water barrier properties may comprise a polymer and a natural wax. In some such embodiments, the primer layer may have a coating weight of about 40 to 60 g.m'2and the layer configured to have water barrier properties may have a coating weight of about 15 to 30 or about 15 to 20 g.m'2.

[0266] In some embodiments, a primer layer and one or more further layers may be disposed between the at least one surface and the layer of the material, wherein the one or more further layers includes at least one layer configured to have water barrier properties, and the at least one layer configured to have water barrier properties comprises a polymer and a natural wax. In some such examples, the primer layer comprises a polymer. The polymer in the primer layer and / or the polymer in the one or more further layers may be an acrylic polymer, such as a styrene acrylate copolymer.

[0267] In some embodiments, one or more coating layers may be disposed on top of the layer of the material. The one or more coating layers may include a layer configured to have water barrier properties. The layer configured to have water barrier properties may P24-001

[0268] 52 comprise a polymer and a natural wax. In some such embodiments, a primer layer may be disposed between the at least one surface of the hollow moulded fibre product and the layer of the material. In some embodiments, the one or more coating layers, each of the one or more coating layers may have a coating weight of about 15 to 20 g.m'2.

[0269] In some embodiments, a primer layer may be disposed between the at least one surface and the layer of the material, and one or more coating layers may be disposed on top of the material, wherein the one or more coating layers includes a layer configured to have water barrier properties. In some such examples, the primer layer comprises a polymer and / or at least one of the one or more coating layers comprises a polymer and a natural wax. The polymer in the primer layer and / or the polymer in the one or more coating layers may be an acrylic polymer, such as a styrene acrylate copolymer. In some such embodiments, the primer layer may have a coating weight of about 40 to 60 g.m'2and each of the one or more coating layers may have a coating weight of about 15 to 20 -2 g.m2.

[0270] In some embodiments described above, the at least one surface is or comprises an internal surface of the hollow moulded fibre product. That is, a layer of the material may be disposed on an internal surface of the hollow moulded fibre product. In some such examples, a primer layer may be disposed between an internal surface and the layer of material. In other examples, a primer layer and one or more further layers may be disposed between an internal surface and the layer of material. In other examples, a primer layer may be disposed between an internal surface and the layer of material, and one or more coating layers may be disposed on top of the material.

[0271] As used herein, “disposed on” may refer to directly disposed on or indirectly disposed on. For example, when a layer is described as disposed on at least one surface of a hollow moulded fibre product, this will be understood as referring to directly disposed (i.e., no additional layers are disposed between the layer and the at least one surface) or indirectly disposed (i.e., one or more additional layers may be disposed between the layer and the at least one surface). In some examples, “disposed on” may refer to “directly disposed on”. P24-001

[0272] 53

[0273] Referring now to Figures 7a to 7g, there are provided cross-sectional views of portions of respective exemplary products according to examples of the present invention. For simplicity, the examples shown in Figures 7a to 7g are flat. However, it will be understood that the hollow moulded fibre products according to the present invention may take various shapes (e.g., they make include flat or curved moulded fibre surfaces), and the description with reference to Figures 7a to 7g applies equally to all such surfaces, irrespective of their shape or curvature.

[0274] Figure 7a shows a cross section of a portion of a hollow moulded fibre product 700a. The hollow moulded fibre product 700a comprises a moulded fibre wall 702. The moulded fibre wall may be any wall of a hollow moulded fibre product. For example, the product 700a may be a bottle and the wall 702 may be a portion of a side wall of the bottle, or a portion of a base wall, or a portion of a necked region. The moulded fibre wall 702 comprises a first surface 702a and a second surface 702b. A layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702. The layer of material 704 may comprise at least one of: SiOx, carbon (suitably diamond-like carbon) and aluminium. The layer of material 704 may be a vapour-deposited layer.

[0275] Figure 7b shows a cross section of a portion of another example of a hollow moulded fibre product 700b. The product 700b comprises a moulded fibre wall 702, the wall comprising a first surface 702a and a second surface 702b, and a layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702. In this example, a primer layer 706 is disposed between the first surface 702a of the moulded fibre wall 702 and the layer of material 704, such that the primer layer 706 is disposed directly on the first surface 702a of the moulded fibre wall 702. In this example, the layer of the material 704 is indirectly disposed on the first surface 702a of the moulded fibre wall 702, due to the presence of the primer layer 706 therebetween.

[0276] Figure 7c shows a cross section of a portion of another example of a hollow moulded fibre product 700c. The product 700c comprises a moulded fibre wall 702, the wall comprising a first surface 702a and a second surface 702b. In this example, a layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702 and a primer layer 706 is disposed on the second surface 702b of the moulded fibre wall 702. P24-001

[0277] 54

[0278] Figure 7d shows a cross section of a portion of another example of a hollow moulded fibre product 700d. The product 700d comprises a moulded fibre wall 702, the wall comprising a first surface 702a and a second surface 702b. In this example, a first primer layer 706a is disposed on the first surface 702a and a second primer layer 706b is disposed on the second surface 702b. The first primer layer 706a is disposed between the first surface 702a of the moulded fibre wall 702 and a layer of material 704.

[0279] Figure 7e shows a cross section of a portion of another example of a hollow moulded fibre product 700e. The product 700e comprises a moulded fibre wall 702, the wall 702 comprising a first surface 702a and a second surface 702b, and a layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702. A primer layer 706 and a further layer 708 (such as a water transmission reduction layer) are disposed between the first surface 702a of the moulded fibre wall 702 and the layer of material 704, such that the primer layer 706 is disposed directly on the first surface 702a of the moulded fibre wall 702. In this example, the further layer 708 and the layer of the material 704 are indirectly disposed on the first surface 702a of the moulded fibre wall 702, due to the presence of the primer layer 706 therebetween. The further layer 708 is an example of the one or more further layers that may be disposed on a primer layer, as described above. For example, the further layer 708 may be a further layer as described above with reference to Figures 3 to 6. The further layer 708 may be configured to have water barrier properties.

[0280] Figure 7f shows a cross section of a portion of another example of a hollow moulded fibre product 700f. The product 700f comprises a moulded fibre wall 702, the wall 702 comprising a first surface 702a and a second surface 702b, and a layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702. A primer layer 706 is disposed between the first surface 702a of the moulded fibre wall 702 and the layer of material 704, such that the primer layer 706 is disposed directly on the first surface 702a of the moulded fibre wall 702. A further layer 710 is disposed on the layer of material 704. The further layer 710 may be configured to have water barrier properties. In this example, the further layer 710 and the layer of the material 704 are indirectly disposed on the first surface 702a of the moulded fibre wall 702, due to the presence of the primer layer 706 therebetween. The further layer 710 is an example of the one or more P24-001

[0281] 55 coating layers that may be disposed on the layer of the material, as described above, for example, as described above with reference to Figures 3 to 6.

[0282] Figure 7g shows a cross section of a portion of another example of a hollow moulded fibre product 700g. The product 700g comprises a moulded fibre wall 702, the wall 702 comprising a first surface 702a and a second surface 702b, and a layer of material 704 is disposed on the first surface 702a of the moulded fibre wall 702. A primer layer 706 and a further layer 708 (such as a water transmission reduction layer) are disposed between the first surface 702a of the moulded fibre wall 702 and the layer of material 704, such that the primer layer 706 is disposed directly on the first surface 702a of the moulded fibre wall 702. A further layer 710 is disposed on the layer of material 704. The further layer 710 may be configured to have water barrier properties. In this example, the further layers 708 and 710, and the layer of the material 704, are indirectly disposed on the first surface 702a of the moulded fibre wall 702, due to the presence of a primer layer 706 therebetween. The further layer 710 is an example of the one or more coating layers that may be disposed on the layer of the material, as described above, for example, as described above with reference to Figures 3 to 6.

[0283] Figure 7h shows a hollow moulded fibre product 700h. The hollow moulded fibre product 700h comprises a moulded fibre side wall 712 and a moulded fibre base wall 714. A coating layer 716 is disposed on the internal surface of the side wall 712. The coating layer 716 may be any of the coating layers described herein. For example, the coating layer 716 may include one or more of the layers 704, 706, 708, 710 described with the reference to Figures 7a to 7e. Products such as the product 700h may also comprise an external coating and the external coating may be the same as, or different to, the coating 716. Additionally or alternatively, the coating 716 and / or an external coating may be present on the base wall 714. Additionally or alternatively, the product may further comprise a necked region, and the coating 716 and / or an external coating may be present on the wall of the necked region.

[0284] Illustrated in Figure 1 is a control system 1130 that is configured to cause a manufacturing apparatus 1110 and a vapour deposition apparatus 1120 perform the methods outlined herein. P24-001

[0285] 56

[0286] In some examples, there is provided a system as illustrated in figure 1, for processing a hollow moulded fibre product, the system comprising; a manufacturing apparatus 1110 configured to manufacture the hollow moulded fibre product; and a vapour deposition apparatus 1120 downstream of the manufacturing apparatus, wherein the vapour deposition apparatus is configured to receive the hollow moulded fibre product from the manufacturing apparatus and to deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product. As shown in Figure 1, the vapour deposition apparatus 1120 may be configured to receive the hollow moulded fibre product 22 from the drying process 32 of the internal coating stage. Figure 8 shows a schematic diagram of a non-transitory computer-readable storage medium 800 according to an example. The non-transitory computer-readable storage medium 800 stores instructions 830 that, if executed by a processor 820 of a control system 810, cause the processor 820 to perform a method according to an example. In some examples, the control system 810 is or comprises the control system 1130 as described above. The instructions 830 comprise: causing the manufacturing apparatus 1110 to manufacture the hollow moulded fibre product and causing the vapour deposition apparatus 1120 which is downstream of the manufacturing apparatus 1110 and configured to receive the hollow moulded fibre product from the manufacturing apparatus, to deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

[0287] It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in Figure 11) comprising a manufacturing apparatus 1110 configured to manufacture the hollow moulded fibre product; and a vapour deposition apparatus 1120 downstream of the manufacturing apparatus, wherein the vapour deposition apparatus is configured to receive the hollow moulded fibre product from the manufacturing apparatus and to deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

[0288] It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in Figure 1) comprising a vapour deposition apparatus 200 for P24-001

[0289] 57 processing a hollow moulded fibre product 22 and apparatus for performing at least one additional process on the hollow moulded fibre product 22 to provide the receptacle. Similarly, also provided is a method of manufacturing a receptacle, the method comprising depositing (such as the depositing 306, 408, 512 and 606 shown in Figures 3 to 6) a material by vapour deposition to process a hollow moulded fibre product 22, and then performing at least one additional process on the hollow moulded fibre product 22 to provide the receptacle. Examples of the “at least one additional process” are described above with reference to Figure l.Also provided, as a result of the content of the present application, is use of a receptacle obtained by any of the methods described herein to contain contents. An example such receptacle 900, in the form of a necked receptacle and specifically a bottle, containing contents 910 is shown in Figure 9. The use could be, for example, by a person who puts the contents into the receptacle, by a person who transports the contents, or by a person who wishes to dispose of (for example, to a consumer or end user), offer to dispose of (for example, to a consumer or end user), import, or keep the contents whether for disposal or otherwise. The contents could, for example, be any one or more of the example contents described herein.

[0290] Also provided is a method of providing a content-containing receptacle. An example such method 1000 is shown in Figure 10. The method 1000 comprises providing 1010 the receptacle, in the form of a necked receptacle and specifically a bottle, and then providing 1020 the contents in the receptacle. In this example, block 1020 follows block 1010, so that block 1020 comprises putting the contents into the receptacle that has been provided at block 1010. However, in some other examples, blocks 1010 and 1020 are performed concurrently, so that the providing 1010 the receptacle comprises providing the receptacle with the contents already present in the receptacle. The contents could, for example, be any one or more of the example contents described herein. The method 1000 also comprises closing 1030 an opening of the receptacle after block 1020, and applying 1040 a label or indicia to the receptacle after block 1030. In this example, block 1030 involves applying a heat seal to the opening and then screwing a cap or lid onto the receptacle, and block 1040 comprises adhering a label onto the receptacle.

[0291] In respective other examples, the order of blocks 1030 and 1040 is reversed, blocks 1030 and 1040 are performed concurrently, block 1030 is omitted, and block 1040 P24-001

[0292] 58 is omitted. In some examples, block 1040 occurs before block 1020, orblock 1040 occurs during block 1020. For example, in some cases, the label or indicia is applied to the receptacle, then the contents are provided in the receptacle, and then the receptacle is closed. It will be appreciated that the method 1000 could be performed by the same party that manufactures the receptacle, for example so that block 1010 comprises the method discussed above with reference to the manufacturing line shown in Figure 1. Alternatively, the method 1000 could be performed by a different party to that which manufactures the receptacle. In such an alternative, the different party performs block 1010 by way of obtaining the receptacle from the party that manufactures the receptacle

[0293] (such as by way of the method discussed above with reference to Figure 1) or from an intermediary.

[0294] Example embodiments of the present invention have been discussed, with reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made without departing from the scope of the invention as defined by the appended claims.

Claims

P24-00159CLAIMS:

1. A system for processing a hollow moulded fibre product, the system comprising: a manufacturing apparatus configured to manufacture the hollow moulded fibre product; and a vapour deposition apparatus downstream of the manufacturing apparatus, wherein the vapour deposition apparatus is configured to receive the hollow moulded fibre product from the manufacturing apparatus and to deposit a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

2. The system according to claim 1, wherein the vapour deposition apparatus comprises a vapour deposition chamber that is configured to receive the hollow moulded fibre product from the manufacturing apparatus, a vacuum generator that is configured to generate a vacuum in the vapour deposition chamber, and a gas supply configured to supply a gas to the hollow moulded fibre product while the hollow moulded fibre product is in the vapour deposition chamber and the vacuum generator is generating the vacuum in the vapour deposition chamber.

3. The system according to claim 2, wherein the vapour deposition apparatus comprises a plasma discharge element that is configured to generate a plasma from the gas supplied by the gas supply.

4. The system according to claim 2 or claim 3, wherein the vapour deposition apparatus comprises a permeability reduction apparatus that is configured to reduce a permeability of at least a portion of the hollow moulded fibre product, prior to generating the vacuum in the vapour deposition chamber.

5. The system according to claim 4, wherein the vapour deposition apparatus comprises a primer layer applicator configured to apply a primer layer to the at least a portion of the hollow moulded fibre product to reduce the permeability of at least the portion of the hollow moulded fibre product, and a water transmissionP24-00160 reduction layer applicator configured to apply a functional layer to the at least a portion of the hollow moulded fibre product, prior to generating the vacuum in the vapour deposition chamber.

6. A method of processing a hollow moulded fibre product, the method comprising depositing a material onto at least one surface of the hollow moulded fibre product by vapour deposition to form a coated hollow moulded fibre product.

7. The method according to claim 6, wherein the vapour deposition comprises physical vapour deposition or plasma-enhanced chemical vapour deposition.

8. The method according to claim 6 or claim 7, wherein the material deposited by the vapour deposition comprises one or more components selected from the group consisting of SiOx, carbon (suitably diamond-like carbon) and aluminium.

9. The method according to any one of claims 6 to 8, wherein the depositing forms a layer of the material, and the layer of the material has a mean thickness of between about 10 nm and about 100 nm.

10. The method according to any one of claims 6 to 9, wherein the depositing deposits the material onto an internal surface of the hollow moulded fibre product.

11. The method according to any one of claims 6 to 10, wherein a primer layer is disposed on at least one surface of the hollow moulded fibre product.

12. The method according to claim 11, wherein the primer layer comprises fibre material and / or a polymer.

13. The method according to claim 11 or claim 12, wherein one or more further layers are disposed on the primer layer prior to the depositing by vapour deposition.P24-0016114. The method according to claim 13, wherein the one or more further layers include a water transmission reduction layer.

15. The method according to any one of claims 6 to 14, further comprising applying one or more coating layers onto the material deposited by vapour deposition.

16. A method of processing a hollow moulded fibre product, the method comprising: reducing a permeability of at least a portion of the hollow moulded fibre product to a reduced permeability; and optionally applying a water transmission reduction layer to the at least a portion of the hollow moulded fibre product; and depositing a material by vapour deposition onto at least one surface of the at least a portion of the hollow moulded fibre product having the reduced permeability to form a coated hollow moulded fibre product.

17. A receptacle obtainable or obtained by the method according to any one of claims 6 to 16.

18. A coated hollow moulded fibre product comprising at least one surface and a layer of material disposed on the at least one surface, wherein the layer of material (a) has a thickness of between about lOnm and lOOnm and (b) comprises one or more components selected from the group consisting of SiOx, carbon (suitably diamond-like carbon)and aluminium.

19. A coated hollow moulded fibre product comprising at least one surface and a vapour-deposited layer of material disposed on the at least one surface.

20. The coated hollow moulded fibre product according to claim 18 or claim 19, wherein a primer layer is disposed between the at least one surface and the layer of material.P24-0016221. The coated hollow moulded fibre product according to claim 20, wherein the primer layer comprises fibre material and / or a polymer.

22. The coated hollow moulded fibre product according to claim 20 or claim 21, wherein a water transmission reduction layer is disposed between the primer layer and the layer of material.

23. The coated hollow moulded fibre product according to claim 22, wherein the product comprises between about 40 and about 80 g.m'2of the primer layer, and / or between about 20 and about 30 g.m'2of the water transmission reduction layer, wherein these are expressed as a mass relative to the surface area of the hollow moulded fibre product on which the layer is disposed.

24. A control system configured to cause a coating system to perform the method according to any one of claims 6 to 16.

25. A non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a control system, cause a coating system to perform the method according to any one of claims 6 to 16.

26. A receptacle manufacturing line comprising the system according to any one of claims 1 to 5 for forming the coated hollow moulded fibre product and apparatus for performing at least one additional process on the coated hollow moulded fibre product to provide the receptacle.

27. A method of manufacturing a receptacle, the method comprising performing the method according to any one of claims 6 to 16 to form the coated hollow moulded fibre product, and then performing at least one additional process on the coated hollow moulded fibre product to provide the receptacle.P24-0016328. A method of providing a content-containing receptacle, the method comprising providing a receptacle obtained by the method according to claim 27 and providing the contents in the receptacle to provide the content-containing receptacle.

29. The method according to claim 28, comprising: closing an opening of the receptacle after the providing contents in the receptacle, and / or applying a label or indicia to the receptacle.

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