GB2618540A

GB2618540A - A receptacle forming system

Info

Publication number: GB2618540A
Application number: GB2206728.4A
Authority: GB
Inventors: Edward Hammond Bruce
Original assignee: Pulpex Ltd
Current assignee: Pulpex Ltd
Priority date: 2022-05-09
Filing date: 2022-05-09
Publication date: 2023-11-15

Abstract

Forming a receptacle, such as a bottle, from fibre suspension, particularly paper pulp, comprises a support surface 202 and a depositing element 204 in fluid communication with a container 206 storing the suspension, the depositing element is moveable along one or more predetermined paths relative to the support surface and deposits the fibre suspension along the paths, to form the receptacle. The depositing element may deposit the fibre suspension against a surface of a receptacle mould 222 to form the receptacle in a three-dimensional shape defined by the receptacle mould. A second depositing element may deposit a coating onto the surface of the receptacle mould, when the receptacle is separated from the receptacle mould, the coating may adhere to the fibre suspension to form a coating layer of the receptacle. Each layer may comprise protrusions and the opening of the depositing element may be shaped to encourage the fibres to protrude from the surface of the fibre suspension. First and second receptacle walls (246, 248, figure 11) may be formed, and a wall compression element (256a, 256b, figure 11) may compress the walls together. A method and receptacle are also provided. The receptacle may be considered to be “3D printed.”

Description

A RECEPTACLE FORMING SYSTEM

TECHNICAL FIELD

The present invention relates to receptacle forming systems and methods of forming receptacles. The receptacle forming systems are useable to form receptacles from a fibre suspension, such as a fibre suspension comprising paper pulp The receptacles may form consumer packaging, such as bottles, useful for holding liquids, powders, other flowable materials or solid objects.

BACKGROUND

Bottles made from a fibre suspension are known and may be used in place of plastic bottles. These -pulp-moulded" bottles can therefore reduce the amount of plastic used in disposable consumer goods.

Published patent document W02018/020219A1 describes forming a bottle from paper pulp in a mould. A fibre suspension is introduced into a porous mould, and liquid (such as water), is removed from the fibre suspension under vacuum. This causes a layer of fibre suspension to be deposited on the inside of the mould. From here, a deflated "bladder" is introduced into the mould and is expanded. The expansion of the bladder presses the fibre suspension against the mould to force further water out of the fibre suspension, resulting in a bottle being formed. This process of removing water is commonly known as "dewatering".

SUMMARY

As mentioned, the use of moulds and inflatable bladders in forming pulp-moulded receptacles is known. However, using such conventional methods of forming receptacles can limit the complexity of the receptacle designs. Furthermore, to ensure that the fibre suspension can coat the inside of the receptacle moulds, the fibre suspension must have a relatively high liquid content, which increases the length of time and/or number of processing steps required to dry the receptacle after being formed in the mould. Further still, because the inflatable bladder is inserted into the mould after the fibre suspension has been applied to the inside of the mould, and is removed again later, the delicate layer of fibre suspension spread across the inside of the mould can be damaged. In addition, the process of introducing the fibre suspension under vacuum can result in an uneven thickness of fibre suspension, which can result in the moulded receptacle being unevenly formed.

To mitigate the problems caused by the use of such conventional systems and processes, the inventors have developed an alternative method of forming a receptacle from a fibre suspension by depositing the fibre suspension along one or more predetermined paths. The receptacle may therefore be considered to be "3D printed" on a support surface. As such, according to a first aspect of the present invention, there is provided a receptacle forming system for forming a receptacle from a fibre suspension, the system comprising: (i) a support surface and (ii) a depositing element, for fluid communication with a container storing the fibre suspension therein, wherein the depositing element is: (a) moveable along one or more predetermined paths relative to the support surface, and (b) operable to deposit the fibre suspension along the one or more predetermined paths, to form the receptacle from the fibre suspension on the support surface.

In some examples, the system further comprises: (iii) a controller, communicatively coupled to the depositing element, configured to control operation of the depositing element. hi a particular example, the controller is housed within the depositing element.

The system therefore allows a receptacle to be formed by "printing" the receptacle using a fibre suspension. Due to the precise deposition method provided by the depositing element, the receptacle can have more intricate designs, and allows bespoke bottles and other receptacles to be created. In some examples, this can also allow a receptacle to be formed without needing to create specific moulds or tools, thereby enabling rapid prototyping of different receptacles and reducing manufacturing costs. As mentioned, in some examples, the fibre suspension may have a lower liquid (such as water) content than that of fibre suspensions used in known techniques for moulding receptacles where the fibre suspension is drawn onto a mould surface under a vacuum. This can advantageously reduce a required drying time of the receptacle, once formed.

In some examples, the support surface is a substantially flat, horizontal surface on which the receptacle is formed. The support surface may therefore be planar. In some examples, the support surface comprises contours which are imparted onto the receptacle as it is being formed. In a particular example, the receptacle has a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension. The support surface may form a plane in the first and second dimensions.

In some cases, the depositing element is operable to extrude the fibre suspension.

The depositing element may be coupled to the container via a tube or line through which the fibre suspension flows.

The one or more predetermined paths may be adjoined or spaced apart, in some examples. Each of the one or more predetermined paths represents a movement of the depositing element relative to the support surface.

In some examples, the receptacle forming system is a bottle forming system for forming a bottle from the fibre suspension.

In some examples, the depositing element is or comprises one or more nozzles for depositing the fibre suspension along the one or more predetermined paths. In some examples, the one or more predetermined paths are coiled paths, such as spiral, helical or partially helical.

In some examples, the fibre suspension comprises paper pulp fibres, a liquid (such as water) and optionally one or more additives (such as A10). In some examples, the fibre suspension has a solids content of 60-80wr4 based on a dry weight of fibres in the fibre suspension.

In certain examples, the receptacle may be known as an article, a bottle, a container, a receptacle for containing fluid (such as a liquid) or solids (such as pharmaceutical or other tablets/capsules), an article for containing fluid, a bottle for containing fluid, a container for containing fluid, etc. The receptacle may be a partially formed receptacle, and may therefore undergo further processing steps (such as drying or coating steps) before being considered fully formed.

The receptacle may have a longitudinal axis along its length. The length/height of the receptacle may be greater than a width and/or depth of the receptacle. In some examples, the receptacle may have a generally circular footprint owing to a generally cylindrical form of the receptacle (at least along a portion of its length). In some examples, the receptacle may have a footprint that is square or squircular.

In some examples, the fibre suspension being deposited is self-supporting. That is, the receptacle may be formed without being supported by a supporting structure. However, in other examples, the fibre suspension is deposited against a surface/wall of a receptacle mould, rather than being self-supporting. Accordingly, in an example, the depositing element is operable to deposit the fibre suspension against a surface of a receptacle mould to form the receptacle in a three-dimensional shape defined by the receptacle mould, where the receptacle mould is a three-dimensional object having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension. The one or more predetermined paths extend in IS the first, second and third dimensions.

The use of a receptacle mould provides a support against which the receptacle can be formed. This may be useful when a wall of the receptacle is particularly thin, and is thus unable to be self-supporting. The surface of the receptacle mould can also provide a particular surface finish to the receptacle (such as a smooth finish, or impart a logo or other indicia onto the surface of the receptacle).

The first, second and third dimensions are perpendicular to each other. The first dimension may be a first axis, such as an x-axis. The second dimension may be a second axis, such as a z-axis. The third dimension may be a third axis, such as a y-axis.

In some examples, the one or more predetermined paths extend around the receptacle mould in the first, second and third dimensions. In a specific example, the receptacle (or at least a receptacle wall) is formed by one continuous path.

In some examples, the receptacle mould is arranged on the support surface or comprises the support surface. For example, the support surface may be the surface of the receptacle mould.

"Deposit the fibre suspension against a surface" may mean that the fibre suspension is deposited in direct contact with the surface, in some examples. However, in other examples, "deposit the fibre suspension against a surface" may mean that the fibre suspension is deposited in indirect contact with the surface. For example, there may be one or more intermediate layers (such as one or more coating layers) between the fibre suspension and the surface when the fibre suspension is deposited.

The receptacle mould is configured to support the fibre suspension as the receptacle is being formed In some examples, the system comprises the receptacle mould.

In a particular example, the receptacle mould comprises an outer surface, and the depositing element is operable to deposit the fibre suspension against the outer surface of the receptacle mould. Depositing around the outside of the receptacle mould can avoid having to insert the depositing element inside a receptacle mould, such as into a cavity of the mould, which may be difficult due to space constraints The mould is therefore a "male" mould. In some examples, the mould further comprises an inner surface.

Since the receptacle is formed around the receptacle mould, the mould is therefore "inside" the receptacle, and it must be removed from within the receptacle after the receptacle has been formed. In a particular example, the receptacle mould is collapsible/deformable, and is configured to be collapsible before being removed from the receptacle. In one example, the receptacle defines an opening through which the receptacle mould is removed after the receptacle has been formed. A cross-sectional width of the receptacle mould is therefore reduced as the receptacle mould is collapsed/deformed. In a specific example, the receptacle mould is an expandable/inflatable member (such as a "bladder"). The expandable member may therefore be deflated (and therefore collapsed/deformed) and removed from within the receptacle via the opening.

In certain examples, the system is operable to separate the receptacle mould from the receptacle after the receptacle has been formed.

In alternate arrangements, the receptacle mould comprises an Inner surface, and the depositing element is operable to deposit the fibre suspension against the inner surface of the receptacle mould. Depositing around the inside of the receptacle mould can provide a controlled environment in which the receptacle is formed (such as free from contaminants, or maintainable at an appropriate humidity and/or temperature). Furthermore, depositing inside a receptacle mould can make it easier to separate the mould from the receptacle since the mould surrounds the receptacle.

The mould is therefore a "female" mould. In some examples, the mould further comprises an outer surface.

In some examples, the receptacle mould (also referred to as a mould) defines a cavity (also known as a "mould cavity") therein, and the mould comprises a mould opening into the cavity, and the cavity comprises the inner surface (the inner surface also being known as a "mould cavity wall"). In some examples, the depositing element is configured to be introducible into the cavity via the mould opening. In some examples, the receptacle mould is a split mould, and is configured to separate after the receptacle has been formed, such that the receptacle can be removed from within the receptacle mould.

In some examples, the cavity has a main body portion (also known as a first portion) and a neck portion (also known as a second portion). Both portions of the cavity together form the cavity. The neck portion may be used to form the neck of the receptacle. A lid/cap may be applied to an end of the neck of the receptacle, for example. In some examples, the main body portion has a cross-sectional width that is larger than the cross-sectional width of the neck portion (the cross-section being taken in a plane parallel to a longitudinal axis of the receptacle mould).

In some examples, the formed receptacle comprises a protective coating on the inside and/or outside of the receptacle. In some examples of the present invention, rather than spraying or dipping the formed receptacle into a coating material, the coating material may instead be applied onto the surface of the receptacle mould and the fibre suspension is then deposited against this coating. As the fibre suspension contacts the coating on the mould, the coating sticks to the fibre suspension.

Accordingly, in some examples, the receptacle forming system comprises a second depositing element operable to deposit a coating onto the surface of the receptacle mould and wherein the depositing element is operable to deposit the fibre suspension along the one or more predetermined paths after the second depositing element has deposited the coating onto the surface, such that the fibre suspension is deposited onto the coating, so that the coating is between the surface of the receptacle mould arid the fibre suspension deposited and when the receptacle is separated from the receptacle mould, the coating adheres to the fibre suspension to form a coating layer of the receptacle.

Coating layers are useful, for example, to provide "waterproof' membranes or to provide a surface to allow printing ink to be deposited thereon. Applying the coating onto the surface of the mould can provide a more even coating layer onto the receptacle than can be achievable by conventional spray or dip coating techniques. Furthermore, spraying the receptacle with a coating can in some cases damage the delicate receptacle, and this can be avoided by depositing the coating onto the mould surface. Further still, the smooth surface of the mould can mean that a thinner coating layer could be provided than is possible when providing the coating directly onto the receptacle by other means, thereby reducing the weight of the coating.

In examples where the receptacle mould is a male mould, the coating layer is formed on an inner surface of the receptacle, and therefore forms an inner coating layer.

In examples where the receptacle mould is a female mould, the coating layer is formed on an outer surface of the receptacle, and therefore forms an outer coating layer.

The coating may be a liquid when it is deposited onto the surface. The coating may dry, cure or harden after it has adhered to the fibre suspension or the rest of the receptacle. The coating may also partially dry before the fibre suspension is deposited onto the coating.

In some examples, the second depositing element is the depositing element. For example, the depositing element may comprise a first nozzle to deposit the fibre suspension and a second nozzle to deposit the coating. In other examples, the second depositing element and the depositing element are two separate elements. The controller of the system is communicatively coupled to the second depositing element, and is therefore configured to control operation of the second depositing element.

In certain examples, the depositing element deposits the fibre suspension to form a plurality of vertically stacked layers. Accordingly, in some examples, the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension, and the depositing element is operable to deposit the fibre suspension to form a plurality of layers, each layer extending in the first and second dimensions, and the plurality of layers being stacked in the third dimension.

Depositing the receptacle in multiple layers can allow each layer to sufficiently settle, solidify, cure, and/or dry before the subsequent layer is deposited. This can improve the structural integrity of the receptacle.

In an example, the depositing element is operable to deposit the fibre suspension along only a single predetermined path, such that the path extends in the first, second and third dimensions over its course. In another example, the depositing element is operable to deposit the fibre suspension along a plurality of predetermined paths, and each path exists in a single layer (and therefore in the first and second dimensions) and may not extend in the third dimension.

In some examples, the receptacle has a wall extending in the third dimension, the wall formed from the plurality of layers. In some examples, the system further comprises a wall compression element to compress the wall. This can improve binding between layers.

In an example, the third dimension is a vertical dimension.

In certain configurations, as the layers are deposited, certain parts of each layer are configured to extend in a particular direction, such that when a subsequent/adjacent layer is deposited on top, the layer extends into the adjacent layer. By having adjacent layers extend into each other, the cohesion of the layers can be improved, thereby increasing the structural integrity of the receptacle. This can also reduce leakage from the receptacle, in examples where the receptacle is configured to hold a liquid therein.

Accordingly, in some examples, the depositing element is operable to deposit: (i) a first layer of fibre suspension comprising a plurality of layer protrusions that extend in a first direction along the third dimension, and (ii) a second layer of fibre suspension comprising a plurality of layer protmsions that extend in a second direction along the third dimension, the first and second directions being opposite to each other. The plurality of layer protrusions of the first layer extend into the second layer, and the plurality of layer protrusions of the second layer extend into the first layer.

In one example, the layer protrusions are fibres comprised in the fibre suspension. In another example, alternatively or additionally, the layer protrusions are portions of the fibre suspension, each of the portions comprising a plurality of fibres In an example, the first direction is an upwards direction, and the third dimension is a vertical dimension. In an example, the second direction is a downwards direction.

In an example, the plurality of layer protrusions within each layer are spaced apart, and the layer protrusions from one layer extend into spaces between the plurality of layer protrusions of the other layer.

The second layer may be deposited on top of the first layer. The layers are adjacent.

In some examples, the depositing element is operable to deposit a plurality of alternating first and second layers.

To form the layer protrusions, the depositing element may have an opening through which the fibre suspension flows, and the opening may have a specific shape to IS impart the layer protrusions as the fibre suspension is deposited. For example, when the layer protrusions are fibres of the fibre suspension, the depositing element may have a surface property, or be shaped, or may otherwise be configured, to encourage the fibres of the fibre suspension to protrude from the surface of the fibre suspension. In another example, when the layer protrusions are portions of the fibre suspension, the opening has a first opening portion and a second opening portion, the second opening portion being wider than the first opening portion, where the second opening portion deposits the fibre suspension to form the layer protrusions.

In another example, the opening has a wider central portion and tapered side portions, and the portions of the fibre composition which is extruded through the narrow portions form the layer protrusions.

Accordingly, in an example, the depositing element comprises an opening through which the fibre suspension is extruded, the opening being shaped to form the layer protrusions.

In some examples, the receptacle has multiple walls/wall layers that surround each other. In effect, the receptacle is formed two or more times (each "receptacle" being slightly different in size). By having multiple receptacle walls, the rigidity of the receptacle can be improved. Depositing separate receptacle walls instead of a thicker single receptacle wall can allow the fibre suspension within each receptacle wall to settle and/or dry before the subsequent receptacle wall is formed. Separate receptacle walls can also improve insulation within the receptacle because air pockets can be formed between the receptacle walls.

Accordingly, in some examples, the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension, and the depositing element is operable to deposit the fibre suspension to form: (i) a first receptacle wall, the first receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension, and (ii) a second receptacle wall against the first receptacle wall, the second receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension.

In some examples, the first receptacle wall is formed by depositing the fibre suspension in one or more first predetermined paths, and the second receptacle wall is formed by depositing the fibre suspension in one or more second predetermined paths.

The receptacle walls may have a wall thickness, measured in a first dimension, of between about 1mm and about 6mm.

In examples where the receptacle mould is a "male' mould, the first receptacle wall may be an inner receptacle wall and the second receptacle wall may be an outer receptacle wall. The second receptacle wall may therefore have a larger perimeter or overall extent than the first receptacle wall. The second receptacle wall may therefore be positioned further away from the centre of the receptacle than the first receptacle wall.

In examples where the receptacle mould is a "female" mould, the first receptacle wall may be an outer receptacle wall and the second receptacle wall may be an inner receptacle wall. The first receptacle wall may therefore have a larger perimeter or overall extent than the second receptacle wall The first receptacle wall may therefore be positioned further away from the centre of the receptacle than the second receptacle wall.

In some examples, the first receptacle wall is fully formed before the second receptacle wall has started to be formed. Thus, the depositing element is operable to deposit the fibre suspension to fully form the first receptacle wall before depositing the fibre suspension of the second receptacle wall In examples where the depositing element is operable to deposit the fibre suspension to form a plurality of layers stacked in the third dimension, the first receptacle wall comprises the plurality of layers, and the second receptacle wall comprises a plurality of layers.

In the same way that the layers of the receptacle can be formed with layer protrusions to better bind adjacent layers together, the walls may also be formed with wall protrusions that extend into an adjacent wall to improve binding between adjacent walls.

Accordingly, in some examples the depositing element is operable to deposit the fibre suspension to form: (i) the first receptacle wall having a plurality of receptacle wall protrusions that extend in a first direction along the first dimension, and (ii) the second receptacle wall having a plurality of receptacle wall protrusions that extend in a second IS direction along the first dimension, the first and second directions being opposite to each other. The plurality of receptacle wall protrusions in the first receptacle wall extend into the second receptacle wall, and the plurality of receptacle wall protrusions in the second receptacle wall extend into the first receptacle wall.

In one example, the depositing element comprises an opening through which the fibre suspension is extruded, the opening being shaped to form the receptacle wall protrusions.

In certain arrangements, the first receptacle wall is formed by moving/tracing the depositing element in a clockwise direction, and the second receptacle wall is formed around the outside (or on the inside) of the first receptacle wall by moving/tracing the depositing element around in an anticlockwise direction. These opposing directions improve the structural integrity of the bottle. Accordingly, in some examples, the depositing element is operable to deposit: (i) fibre suspension forming the first receptacle wall along one or more predetermined paths in a first azimuthal direction around an axis extending in the third dimension; and (ii) fibre suspension forming the second receptacle wall along one or more predetermined paths in a second azimuthal direction around the axis, the first and second azimuthal directions being opposite to each other.

The axis extending in the third direction may be a vertical or y-axis, for example. The axis may be a longitudinal axis of the receptacle.

In an example, the first azimuthal direction is a clockwise direction, and the second azimuthal direction is an anti cl ocicwi se direction.

In one example, the depositing element is operable to deposit: (i) fibre suspension forming the first receptacle wall along one or more predetermined paths in a first helix, and (ii) fibre suspension forming the second receptacle wall along one or more predetermined paths in a second helix. In an example, the second helix is of the opposite sense/direction to the first helix. For example, the first helix may be a right-handed helix and the second helix may be a left-handed helix.

To improve binding between the two or more receptacle walls, the receptacle walls may be compressed together. Fibres from each wall may therefore intertwine.

Accordingly, in one example, the receptacle forming system further comprises a wall compression element operable to compress the first and second receptacle walls together. For example, the wall compression element is operable to apply a force to at least one of the first and second receptacle walls such that they are compressed together. In a specific example, the receptacle walls are formed in the opposing azimuthal directions and are then compressed together. Having both walls formed in opposite directions and being compressed can dramatically enhance the structural integrity of the receptacle.

In one example, the depositing element is operable to form a base of the receptacle by depositing the fibre suspension in a spiral shape. Forming the base in a spiral shape can encourage the fibre suspension to adhere, thereby reducing the likelihood of leakage from the receptacle.

The receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, arid a height extending in a third dimension, and the base extends in substantially the first and second dimensions. The base may be substantially flat (so extends in only the first and second dimensions), or may be curved, such that the base also extends in the third dimension (for example the base of the receptacle may comprise an indent).

According to a second aspect of the present invention there is provided a method of forming a receptacle, the method comprising depositing a fibre suspension in one or more predetermined paths to form the receptacle from the fibre suspension. In some examples, the method is a method of forming a bottle, the method comprising depositing the fibre suspension in one or more predetermined paths to form the bottle from the fibre suspension, In some examples, the depositing the fibre suspension in one or more predetermined paths comprises flowing the fibre suspension from a container and through a depositing element.

In some examples, the method comprises depositing the fibre suspension on a support surface.

In some examples, the depositing the fibre suspension is extruding the fibre suspension.

In some examples, the depositing the fibre suspension forms a wall of the receptacle, and the method further comprises: compressing the wall together. For example, the wall may be compressed between two plates or between one plate and a surface of a receptacle mould.

In certain examples, the method further comprises providing a receptacle mould, the receptacle mould being a three-dimensional object haying a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension, wherein: (i) the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against a surface of the receptacle mould to form the receptacle in a three-dimensional shape defined by the receptacle mould, and (ii) the one or more predetermined paths extend in the first, second and third dimensions.

In some examples, the receptacle mould comprises an outer surface, the receptacle mould is collapsible, and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against the outer surface of the receptacle mould. The method further comprises: (i) collapsing the receptacle mould after the receptacle is formed, and (ii) removing the receptacle mould from within the receptacle. As mentioned, the receptacle mould may be removed from an opening formed in the receptacle In a particular example, the receptacle mould comprises an inner surface, the receptacle mould is separable into two or more mould parts, and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against the inner surface of the receptacle mould. The method further comprises separating the receptacle mould into the two or more mould parts after the receptacle is formed. For example, two halves of the mould may be separated from each other so that the receptacle can be removed from within a cavity of the mould.

In one example, the method further comprises depositing a coating onto the surface of the receptacle mould, wherein the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension after depositing the coating onto the surface, such that the fibre suspension is deposited onto the coating, the coating then being between the surface of the receptacle mould and the fibre suspension IS deposited The method further comprises separating the receptacle from the receptacle mould such that the coating adheres to the fibre suspension to form a coating layer of the receptacle.

In a particular example, the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension to form a plurality of layers, each layer extending in the first and second dimensions, the plurality of layers being stacked in the third dimension.

In one example, the depositing the fibre suspension to form the plurality of layers comprises after depositing a first layer of fibre suspension, depositing a second layer of fibre suspension such that the first and second layers extend into each other. As previously mentioned, the layers may extend into each other by forming a plurality of layer protrusions.

In some examples, the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension, and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension to form: (i) a first receptacle wall, the first receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension (ii) and a second receptacle wall against the first receptacle wall, the second receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension.

In one example, the depositing the fibre suspension to form the first receptacle wall comprises depositing fibre suspension in a first azimuthal direction around an axis extending in the third dimension, and the depositing the fibre suspension to form the second receptacle wall comprises depositing fibre suspension in a second azimuthal direction around the axis extending in the third dimension, the first and second azimuthal directions being opposite to each other.

In some examples, the method further comprises compressing the first and second receptacle walls together.

In some examples, the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension in a spiral shape to form a base of the receptacle.

According to a third aspect of the present invention there is provided a computer readable medium storing program instructions for causing a controller of a receptacle forming system to control the receptacle forming system to implement the method of the second aspect. In some examples, the computer readable medium is non-transient.

In some examples, the computer readable medium stores program instructions for causing a controller of a bottle forming system to control the bottle forming system to implement the method.

According to a fourth aspect of the present invention there is provided a receptacle obtainable or obtained from a fabrication method comprising the method of the second aspect. For example, the receptacle may be obtainable or obtained from the method of any one of the method steps discussed above.

The fabrication method may comprise at least one additional process. The at least one additional process may comprise moulding the receptacle to produce a moulded receptacle. The at least one additional process may comprise coating and drying the receptacle or the moulded receptacle to produce a coated receptacle. The at least one additional process may comprise applying a closure to the receptacle, the moulded receptacle or the coated receptacle In some examples, the receptacle is a bottle.

According to a fifth aspect of the present invention there is provided a receptacle comprising a base and a receptacle wall extending from the base, wherein the receptacle has a height, wherein the receptacle wall comprises layers of dried fibre suspension comprising fibres, and wherein the layers are stacked sequentially in a direction of the height of the receptacle.

In some examples, the receptacle is rotationally symmetrical about an axis in the direction of the height.

In some examples, the receptacle wall comprises a helix of the dried fibre suspension, the helix comprising the layers In some examples, the receptacle wall comprises plural closed loops of the dried fibre suspension, the closed loops comprising the layers.

IS In some examples, the base comprises a spiral of dried fibre suspension comprising fibres.

In a particular example, the receptacle has a width (such as a diameter) of between about 65mm and 70mm, a height of between about 190mm and about 200mm, and a volume of between about 500m1 and 600m1. In a further example, the receptacle has a diameter of about 68mm, a height of about 196mm and a volume of about 550m1.

Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows an example of a process for producing a receptacle at least partially moulded from a fibre suspension; Figures 2A-C show an example system for forming a receptacle using a depositing element; Figures 3A and 3B show top down views of the system of Figures 2A-C at different times; Figures 4A-C show another example system for forming a receptacle using a depositing element; Figure 5 shows a top-down view of the system of Figures 4A-C at a particular time Figure 6A shows an example expandable member in a deflated state; Figure 6B shows the expandable member of Figure 6A in an inflated state and acting as a mould on which a fibre suspension can be deposited; Figure 7 shows a cross section of an example mould as a coating and fibre suspension is applied to the outer surface of the mould, Figure 8 shows a cross section of an example mould as a coating and fibre IS suspension is applied to the inner surface of the mould; Figure 9A depicts two layers of a fibre suspension, where the two layers extend into each other, according to a first example; Figure 9B depicts two layers of a fibre suspension, where the two layers extend into each other, according to a second example; Figure 10 depicts a cross section of an example receptacle formed with two receptacle walls; Figure 11 depicts a cross section of an example receptacle formed with two receptacle walls being compressed together, and Figure 12 shows an example flow diagram of a method of forming a receptacle.

DETAILED DESCRIPTION

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

Figure 1 shows a comparative process for making bottles from paper pulp (i.e., which can form the basis of an example fibre suspension). The process is merely exemplary and is provided to give context to examples of the present invention. Broadly speaking, the process comprises providing a fibre suspension, introducing the fibre suspension into a mould cavity of a porous first mould and using the porous first mould to expel a liquid (such as water) from the fibre suspension to produce a wet precursor or embryo (which may itself be considered a moulded receptacle), further moulding the wet precursor in a mould to produce a further-moulded receptacle, coating the further-moulded receptacle to produce a coated moulded receptacle, drying the coated moulded receptacle to produce a dried receptacle, and applying a closure to the dried receptacle.

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 I wt% to 5wt% (by dry mass of fibres). In examples, the one or more additives includes a shorting agent, such as alkylketene dimer (AKD). The hydrated pulp fibres typically comprise AKD in an amount of 0.4wt?/0 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 (e.g. 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.

The resultant processed pulp is stored in a vat 12 in a relatively concentrated form (e.g. a solid fibres content of lwt% to 5wt%) to reduce a required storage space. 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 0.5we't. to 5wt,1/0, or 0.1wt% 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. 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 dewatering agent 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.

In this example, the porous first mould 15 comprises two half-moulds that are movable towards and away from each other, in this case using a hydraulic ram. In this example, each of the half-moulds is a monolithic or unitary tool formed by additive manufacturing (e.g., 3D-printing) that defines a mould profile, and, when the half-moulds are brought into contact with each other, their respective mould profiles cooperate to define the mould cavity in which the wet precursor or moulded receptacle is to be formed. Each half-mould may itself define a smaller moulding cavity and, when brought into cooperation with a second half-mould, the smaller moulding cavities may combine to provide the overall mould cavity. The two half-moulds 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, the porous first mould 15 may comprise more than two splits, such as three, four or six splits, that cooperate to define the moulding cavity.

In Figure 1, the fibre suspension (also known as slurry) is top-filled into the porous 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 mould 15, with excess suspending liquid being drawn through the porous mould 15 under vacuum via a line 18 into a tank 17. Shot mass may be controlled by measuring (e.g., 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 (e.g. 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 mould 15 is stopped and the porous 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 mould 15 to form an embryo of the moulded receptacle.

IS In one form, in order to remove further suspending liquid (e.g., water) from the embryo, and form or consolidate the three-dimensional shape of the receptacle, an impermeable inflation element 19, e.g., a collapsible bladder (also known as an expandable or inflatable member/element), is inserted into the porous mould 15 and expanded to act as an internal high-pressure core structure for the porous mould 15. This process strengthens the wet embryo so that it can be handled, and displaces water from in between the fibres, thereby increasing the efficiency of a subsequent drying process. The inflation element 19 is actuated and regulated using a hydraulic pump 20. The pump 20 has a cylinder that displaces a fluid in a line 21 into the inflation element 19, to expand the inflation element 19 radially and into conformity with the mould cavity. Fluid within the line 21 is preferably non-compressible, such as water. Water also has the advantage over other non-compressible liquids that any leaking or bursting of the bladder 19 will not introduce a new substance to the system (since the suspending liquid is already water, or predominantly water).

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

According to Figure 1, the formed but unfinished receptacle 22 is subsequently transported to a second moulding station where, in a, e.g., 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 receptacle 22, a pressuriser is engaged. For example, a bladder 26 (e.g., a thermoforming bladder 26) is inserted into the receptacle 22. The bladder 26 is expanded via a line 27 by a pump 28 to supply pressurised fluid, e.g., air, water, or oil.

Optionally, during supply, the pressurised fluid is heated with e.g. a heater or, alternatively, is cooled with e.g. a heat exchanger. An external mould block 24 of the mould 25, and/or the mould 25 itself, may also, or alternatively, be heated. A state of the moulded receptacle 22 after thermoforming is considerably more rigid, with more compressed side walls, compared with the state at demoulding from the porous mould 15.

A drying stage 29 (e.g., a microwave drying process or other drying process) is performed downstream of the thermoforming, as shown. In one example, the drying stage 29 is performed before thermoforming. However, moulding in the mould 25 requires some water content to assist with bonding during the compression process. Figure 1 illustrates a further drying stage 30 after the drying stage 29, which may utilise hot air circulated onto the moulded receptacle 22, e.g., in a "hot box". In some examples, microwave or other drying processes may be performed at plural stages of the overall manufacturing process.

The moulded receptacle 22 is then subjected to a coating stage during which, in this example, a spray lance 31 is inserted into the moulded receptacle 22 and applies one or more surface coatings to internal walls of the moulded receptacle 22. In another example, the moulded receptacle 22 is instead filled with a liquid that coats the internal walls of the moulded receptacle 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 receptacle 22, e.g., a beverage, detergent, pharmaceutical product, etc. In some examples, the further drying stage 30 is performed after the coating stage (or both before and after the coating stage) In this example, the moulded receptacle 22 is then subjected to a curing process 34, which can be configured or optimised dependent on the coating, e.g., drying for twenty-four hours at ambient conditions or by a flash drying method. In some examples, e.g., where 1 0 the further drying stage 30 occurs after the coating stage, the curing process 34 may be omitted.

At an appropriate stage of production (e.g., during thermoforming, or before or after coating) a closure or mouth forming process may be performed on the moulded receptacle 22. For example, as shown in Figure 1, a neck fitment 35 may be affixed. In some examples, an exterior coating is applied to the moulded receptacle 22, as shown in the further coating stage 32. In one example, the moulded receptacle 22 is dipped into a liquid that coats its outer surface, as shown in Figure 1. One or more further drying or curing processes may then be performed. For example, the moulded receptacle 22 may be allowed to dry in warm air. The moulded receptacle 22 may therefore be fully formed and ready to accept contents therein.

In contrast to the comparative example process described above in relation to Figure 1, the present invention relates to an alternate method of forming a receptacle from a fibre suspension. In particular, the present invention relates to the deposition of a fibre suspension along one or more predetermined paths to form a receptacle, rather than drawing the fibre suspension under vacuum into a porous mould. Other processes from Figure 1, such as the drying processes, may also be implemented in embodiments of the present invention.

Figures 2A-2C therefore depict a first example receptacle forming system 200 at various points in time as a receptacle is being formed by the system 200. In particular, Figure 2A depicts the system 200 at a first time, where the system 200 comprises a support surface 202 and a depositing element 204 that is in fluid communication with a container 206 that stores a fibre suspension therein. Between the depositing element 204 and the container 206 extends a line 208 through which the fibre suspension can flow. Fibre suspension flowing into the depositing element 204 can be extruded through an opening in the depositing element 204, such as the nozzle 220.

The depositing element 204 is moveable along one or more predetermined paths relative to the support surface 202 and can deposit the fibre suspension along the one or more predetermined paths as it moves, to form the receptacle 210 from the fibre suspension on the support surface 202. Figure 2A shows a portion of the receptacle 210 as it is being formed.

The system 200 further comprises a controller 213, such as one or more processors, and a computer readable medium 215, such as memory. In this example, the controller 213 and computer readable medium 215 are housed in a computing device 211. The computing device 211 and therefore the controller 213 is communicatively coupled to the depositing element 204 and controls operation of the depositing element 204, such IS as movement of the depositing element 204 and/or the supply of fibre suspension to and/or from the depositing element 204. The computer readable medium 215 stores program instructions for causing the controller 213 to control the receptacle forming system 200. In this example, the computing device 211 is wirelessly coupled to the depositing element 204, but in other examples, a wired connection may be present.

In this particular example, the system 200 further comprises one or more guide rails 212a, 212b, 212c (collectively referred to using the reference numeral 212), that can facilitate movement of the depositing element 204. For example, the system 200 comprises four vertically extending guide rails (with only two vertical guide rails 212a, 212b visible in Figure 2A), and three horizontally extending guide rails (with only one horizontal guide rail 212c visible in Figure 2A). Figure 3A, for example, shows the other two vertical guide rails 212d, 212e and the other two horizontal guide rails 2121, 212g that are hidden from view in Figure 2A. To move relative to the support surface 202, the depositing element 204 moves horizontally along guide rail 212c, and guide rails 2121 212g move vertically along guide rails 212a, 212b, 212d, 212e. For example, the depositing element 204 can move in a first (horizontal) dimension 214 (such as along an x-axis 214) in first direction (such as towards the right-hand side of the guide rail 212c) and a second direction (such as towards the left-hand side of the guide rail 212c). Similarly, the depositing element 204 can move in a second (horizontal) dimension 216 (such as along a z-axis 216) in first direction (such as into the page of Figure 2A) and a second direction (such as out of the page of Figure 2A). Furthermore, the depositing element 204 can move in a third (vertical) dimension 218 (such as along a y-axis 218) in first direction (such as towards the top of the guide rails 212a, 212b and away from the support surface 202) and a second direction (such as towards the bottom of the guide rails 212a, 212b and towards the support surface 202).

It will be appreciated that in other examples, the movement of the depositing element 204 can be facilitated by other means, such as a robotic/moveable arm or there may be a greater or fewer number of guide rails 212.

In this way, the depositing element 204 can move in three dimensions 214, 216, 218 and can deposit fibre suspension in one or more predetermined paths as it moves to form the receptacle 210. In this particular example, the depositing element 204 is controlled to move in one or more spiral and/or helical paths to deposit the fibre suspension in the desired locations to form the receptacle.

In Figure 2A, the base of the receptacle 210 has been formed (visible in Figure 3A), and a wall of the receptacle 210 has started to be formed by the depositing element 204. The base of the receptacle extends substantially in the first and second dimensions, whereas the wall extends in the first, second and the third dimensions 214, 216, 218.

Figure 2B shows the system of Figure 2A at a later point in time. Here, the depositing element 204 has continued to move along the one or more predetermined paths while depositing the fibre suspension, such that further layers of the fibre suspension have been formed. At this particular moment in time, in contrast to the position shown in Figure 2A, the depositing element 204 has moved in an upwards direction along the third (vertical) dimension 218, towards the right along the first (horizontal) dimension 214 and into the page along the second (horizontal) dimension 216 Figure 2B illustrates the helical path taken by the depositing element 204 as it moves and deposits the fibre suspension.

Figure 2C shows the system of Figure 2B at a later point in time. Here, the depositing element 204 has continued to move along the one or more predetermined paths while depositing the fibre suspension, such that further layers of the fibre suspension have been formed. At this particular moment in time, the receptacle 210 is fully formed. The wall(s) of the receptacle 210 have a height in the third dimension 218. The receptacle 210 therefore has a width extending in the first dimension 214, a depth extending in the second dimension 216, and a height extending in the third dimension 218. In examples where the receptacle 210 is rotationally symmetrical about a longitudinal axis of the receptacle, the receptacle 210 may have the width equal to the depth. In examples where the receptacle 210 has a circular base, the width may be a diameter. In this example, the receptacle has a diameter of about 68mm, a height of about 196mm and a volume of about 550m1.

Figure 3A depicts a top-down view of the system 200 at a time prior to that shown in Figure 2A. At this moment in time, a wall of the receptacle 210 has not yet started being formed. Instead, the depositing element 204 is forming a base 210a of the receptacle 210 by depositing the fibre suspension in a spiral shape. In this example, the path taken by the depositing element 204 is in an anticlockwise direction.

Figure 3B depicts a top-down view of the system 200 at a time corresponding to that shown in Figure 2B. At this particular moment in time, the wall 210b of the receptacle 210 started to be formed. As show in Figure 3B and 2C, the receptacle is rotationally symmetrical about an axis (such as a longitudinal axis) in the direction of the height (such as the third dimension 218). The wall 210b therefore comprises a helix of the fibre suspension (where the layers are made up of the helically extruded fibre suspension).

As mentioned, in some examples, the fibre suspension may be extruded in a single predetermined path, or plural predetermined paths. In a particular example, the receptacle wall 210b comprises plural closed loops/paths of the dried fibre suspension, the closed loops comprising the layers. Each loop or path may be in a single layer, for example.

Figures 4A-4C and 5 depict a second example of the system 200. In contrast to the system of Figures 2A-3B, the system 200 additionally includes a receptacle mould 222 against which the fibre suspension may be deposited. The mould 222 therefore acts as a support as the wall(s) of the receptacle 210 are being formed. In this particular example, the fibre suspension is being deposited against an outer surface of the receptacle mould 222, such that the mould 222 is inside the receptacle 210. As shown, the receptacle mould 222 is a three-dimensional object having a width extending in a first dimension 214, a depth extending in a second dimension 216, and a height extending in a third dimension 218.

As was described in Figure 2A, at the point in time shown in Figure 4A, the base of the receptacle 210 has been formed and a wall of the receptacle 210 has started to be formed by the depositing element 204. In this example, the fibre suspension is applied directly against the surface of the mould 222. As will be explained later, in other examples, the fibre suspension may be deposited against a coating that has been applied to the surface of the mould 222 before the fibre suspension is deposited.

Figure 4B shows the system of Figure 4A at a later point in time. Here, the depositing element 204 has continued to move along the one or more predetermined paths around the mould 222 while depositing the fibre suspension against the surface of the mould 222, such that further vertically stacked layers of the fibre suspension have been formed.

Figure 4C shows the system of Figure 4B at a later point in time. Here, the IS depositing element 204 has continued to move along the one or more predetermined paths while depositing the fibre suspension, such that further layers of the fibre suspension have been formed. At this particular moment in time, the receptacle 210 is fully formed, and the receptacle mould 222 is contained within the receptacle 210. From here, the receptacle mould 222 may be collapsed, and removed from within the receptacle 210, such as via an opening 210c of the receptacle 210. The cross-sectional width of the mould 222 may therefore be reduced to a size smaller than the cross-sectional width of the opening 210c. Figure 5 depicts a top-down view of the system 200 at a time corresponding to that shown in Figure 4A. At this moment in time, a wall 210a of the receptacle 210 has started being formed, and only partially extends around the receptacle mould 222 in the first and second dimensions 214, 216.

Although Figures 4A-5 show the receptacle being formed from the base upwards, in a specific example, the receptacle is formed from the top downwards, such as starting at the neck portion of the receptacle and moving down, before finally forming the base. In another example, the receptacle mould may be inverted, and the receptacle may be formed from either the base of the mould (working downwards) or from the neck of the mould (working upwards).

As mentioned, after the receptacle 210 has been formed, the mould 222 may be removed from inside the receptacle 210. An example collapsible mould 222 is depicted in Figures GA and 6B. In this particular example, the mould 222 is an expandable/inflatable member 222 (which may be similar to the bladders 19, 26 shown in Figure 1). Figure 6A shows the inflatable member 222 in a deflated state, where the cross-sectional width (measured in either or both the first and second dimensions 214, 216) is narrower than the cross-sectional width of the opening 210c of the receptacle. In this example, the inflatable member 222 is connected to a support 224 through which a fluid, such as a liquid (e.g., water), can flow. The fluid can fill the inflatable member 222 such that its cross-sectional width increases to a desired size. Once inflated, the fluid may be retained within the inflatable member 222 and the depositing element 204 may begin depositing the fibre suspension against the surface of the inflatable member 222. Figure 6B shows the inflatable member 222 in an expanded state, and the depositing element 204 depositing fibre suspension to form a plurality of vertically stacked layers supported IS by the inflatable element 222. As shown, each layer extends in the first and second dimensions 214, 216 (around the outer surface of the inflatable member 222) and further layers are stacked on top of each other in the third dimension 218.

As mentioned, in some examples, a coating layer may be applied to an inner and/or outer surface of the receptacle. Figure 7 shows a cross-section through the receptacle 210 and a receptacle mould 222 in an example where the depositing element 204 comprises a first nozzle 220 (or first depositing element) and a second nozzle 226 (or second depositing element). The first nozzle 220 is operable to deposit the fibre suspension, and the second nozzle 226 is operable to deposit a coating 228 (or coating material) onto the surface of the receptacle mould 222. In other examples, there may be separate depositing elements, rather than a single depositing element 204 depositing both the fibre suspension and a coating. The second nozzle 226 is controlled to deposit the coating 228 onto the surface of the mould 222 before the fibre suspension is deposited by the first nozzle 220, such that the fibre suspension (forming the wall 210b of the receptacle) is deposited onto the coating 228. Figure 7 shows fibre suspension being deposited by the first nozzle 220 against a previously deposited layer of the coating 228.

The coating 228 therefore forms a thin coating layer between the fibre suspension and the surface of the receptacle mould 222. When the formed receptacle 210 is eventually separated from the receptacle mould 222, the coating 228 adheres to the fibre suspension to form a coating layer of the receptacle 210. In the example of Figure 7, the coating layer is formed on an inner surface of the receptacle 210.

In the examples of Figures 4A-7, the receptacle mould 222 is a male mould. In other examples, however, the mould 222 may be a female mould. Figure 8 depicts a cross section of an example female mould 222, where mould 222 comprises a cavity 230 and the cavity 230 comprises an inner surface 232 (also known as a mould cavity wall). The mould 222 further comprises a mould opening 234. Accordingly, in examples where the receptacle mould 222 is a female mould, the depositing element 204 is operable to deposit the fibre suspension against the inner surface 232 of the mould 222. To allow the depositing element 204 to enter the cavity 230, the depositing element may be attached to a moveable arm 236, which can facilitate movement of the depositing element 204 in three dimensions (in contrast to the guide rails 212 discussed earlier).

In the example of Figure 8, the depositing element 204 also includes first 220 and second nozzles 226 for depositing fibre suspension and a coating, respectively. Thus, a coating may be applied to the inner surface 238 so that a coating layer is formed on an outer surface of the receptacle 210.

After the receptacle 210 has been formed, the mould 222 may be separated from the receptacle 210. In this example, the mould 222 is a split mould comprised of two half moulds 222a, 222b. The two half moulds 222a, 222b may therefore be separated from each other, leaving the receptacle 210 behind.

In the example of Figure 8, the cavity 230 has a main body portion 230a (also known as a first portion) and a neck portion 230b (also known as a second portion). The neck portion 230b may be used to form the neck of the receptacle 210/bottle. The fibre suspension can be applied to both the first and second portions of the cavity 230.

In some examples, after the fibre suspension has been deposited on the inner surface of the cavity 230, an expandable member (such as the expandable member 26 shown in Figure 1) is expanded inside the mould cavity 230 to compress the fibre suspension against the inner surface of the mould 222. In some examples, the mould is a thermoforming mould, such as mould 25 shown in Figure 1 The mould 222 may be heated, in some examples.

As discussed above, the depositing element 204 deposits the fibre suspension to form a plurality of vertically stacked layers. For example, different layers are depicted in Figures 6B, 7 and 8, with alternating layers shown with different shading for visibility.

These layers combine to form a wall 210b of the receptacle 210.

Figure 9A depicts a close up of a first layer 240 of fibre suspension, shown with lined shading, and a second layer 242 of fibre suspension, shown with dotted shading. The second layer 242 is being deposited on top the first layer 240, the first layer 240 having been deposited earlier. For example, the depositing element 204 may move around the receptacle (or receptacle mould 222, if present) in a helical fashion and each whole "turn" deposits a new layer of fibre suspension.

In the example of Figure 9A, as the layers are deposited, certain parts/portions of each layer extend into at least one other adjacent layer. By having adjacent layers extend IS into each other, the cohesion of the layers can be improved, thereby increasing the structural integrity of the receptacle. In Figure 9A, each layer comprises a plurality of layer protrusions that extend into an adjacent layer. For example, the first layer 240 comprises a plurality of layer protrusions 240a, 240b, 240c that extend in a first (upwards) direction along the third (vertical) dimension 218, and the second layer 242 comprises a plurality of layer protrusions 242a, 242b that extend in a second (downwards) direction along the third dimension 218. The plurality of layer protrusions of the first layer 240a, 240b, 240c extend into the second layer 242, and the plurality of layer protrusions of the second layer 242a, 242b extend into the first layer 240. In this example, the layer protrusions are portions of the fibre suspension. Figure 9A shows the depositing element 204 as it is continuing to deposit fibre suspension in the second layer 242, and fibre suspension will be deposited into the space between the layer protrusions 240b, 240c of the first layer 240 to form a further layer protrusion of the second layer 242.

In other examples, such as that shown in Figure 6B, each layer of fibre suspension has a relatively constant height (measured in the third dimension 218), and no layer protrusions are formed. In Figure 9A, each layer has a variable height at different points around the layer.

Figure 9B depicts another example in which certain parts/portions of each layer extend into at least one other adjacent layer. In contrast to Figure 9A, the layer protrusions of each layer are the fibres comprised in the fibre suspension, rather than more precise or specific portions of the fibre suspension. Figure 9B shows the first and second layers 240, 242 with a substantially constant height, but with fibres extending out of each layer. For example, the first layer 240 has fibres extending in the first (upwards) direction along the third (vertical) dimension 218, and the second layer 242 has fibres that extend in a second (downwards) direction along the third dimension 218. The fibres (forming layer protrusions) of the first layer 240 extend into the second layer 242, and similarly the fibres of the second layer 242 extend into the first layer 240.

Figure 9B depicts the depositing element 204 with an opening 244 (such as an opening of the nozzle 220) that is specifically designed to form the layer protrusions. In this example, the opening 244 has a specific shape to form the layer protrusions as the fibre suspension is deposited. In particular, the opening 244 is shaped to encourage the IS fibres of the fibre suspension to protrude from the surface of the fibre suspension. In this example, the depositing element 204 has an opening 244 with a rough edge/perimeter. Figure 9B shows the opening 244 looking into the opening.

In both Figures 9A and 9B, further layers comprising layer protrusions may be deposited on top of the first and second layers in a similar manner, such that there is a plurality of alternating first and second layers forming the receptacle wall 210b.

In some examples, the receptacle has multiple walls 210b that surround each other. Each wall extends in the first 214 and second dimensions 216 and has a height in the third dimension 218. Each wall is formed from fibre suspension. Accordingly, Figure 10 shows a cross section through a receptacle 210 as it is being formed. In this particular example, the receptacle 210 is free-standing, so is not supported by a receptacle mould.

In other examples, however, the fibre suspension is deposited against and is supported by a receptacle mould.

Figure 10 shows a first receptacle wall 246 and a second receptacle wall 248 being formed against the first receptacle wall 246 by the depositing element 204. For example, the first receptacle wall 246 is formed by depositing the fibre suspension in one or more first predetermined paths, and the second receptacle wall 248 is formed by depositing the fibre suspension in one or more second predetermined paths. In this example, the first receptacle wall 246 is formed before the second receptacle wall 248, but in other examples, they may be formed at substantially the same time.

In addition to forming two or more receptacle walls, the depositing element 204 also forms each wall as a plurality of vertically stacked layers. For example, the depositing element 204 may move around an axis, such as a longitudinal axis of the receptacle 210, in a clockwise or anticlockwise direction and each complete turn forms a new layer of the wall. The path(s) taken by the depositing element 204 may therefore be helical in nature.

In a specific example, the first and second receptacle walls 246, 248 are formed by moving/tracing the depositing element 204 in opposite directions. Figure 11 depicts a receptacle 210 (having a longitudinal axis 250 extending parallel to the third dimension 218), comprising first and second receptacle walls 246, 248. In this particular example, the first receptacle wall 246 forms an inner wall of the receptacle 210 and the second receptacle wall 248 forms an outer wall of the receptacle 210. The second receptacle wall 248 is therefore located further away from the axis 250 (which extends along the centre of the receptacle 210).

In this example, the depositing element 204 deposits fibre suspension forming the first receptacle wall 246 by moving in a first azimuthal direction, such as an anticlockwise direction (shown by arrow 252), around the axis 250. The depositing element 204 also deposits fibre suspension forming the second receptacle wall 248 in a second azimuthal direction, such as a clockwise direction, around the axis 250. As mentioned, this improves binding between the two layers. Further walls may also be formed, each alternating wall being formed in an opposite direction to the previously formed wall. The receptacle 210 is therefore rotationally symmetrical about the axis 250.

In the same way that the layers of the receptacle can be formed with layer protrusions to better bind adjacent layers together, the walls may also be formed with wall protrusions that extend into an adjacent wall to improve binding between adjacent walls, To improve binding between the two or more receptacle walls, the receptacle walls may be compressed together. Figure 11 therefore also depicts a wall compression element 256 operable to compress the first and second receptacle walls 246, 248 together. In this particular example, the wall compression element 256 comprises two components, in the form of two plates 256a, 256b. These plates are brought together, causing the first and second receptacle walls 246, 248 to be compressed between the plates 256a, 256b, In examples where the first and second receptacle walls 246, 248 are formed against a surface of a receptacle mould 222, the wall compression element 256 may compress the first and second receptacle walls 246, 248 against the surface of the mould 222. In such cases, the wall compression element 256 may comprise only one component, such as one plate 256a. It will be appreciated that in examples where the receptacle 210 comprises only a single receptacle wall, a wall compression element 256 may still be used to improve binding between the vertically stacked layers of fibre suspension. In a specific example, the wall compression element 256 may be an expandable member that expands inside a cavity 230 of the mould 222 to compress the wall(s).

Figure 12 depicts an example method 300 of forming a receptacle 210. The method 300 may be known as a fabrication method, in some examples. In block 302, the method comprises depositing a fibre suspension in one or more predetermined paths to form the receptacle from the fibre suspension. In some examples, the method is a method of forming a bottle, the method comprising depositing the fibre suspension in one or more predetermined paths to form the bottle from the fibre suspension.

Although the above examples show the depositing element 204 moving relative to the support surface 202, in other examples, the receptacle (such as the receptacle mould 222) is moved relative to a stationary depositing element. For example, the support surface 202 may move the receptacle mould 222. In some examples, both the depositing element 204 and the receptacle mould 222 and/or support surface 202 move relative to a further reference point.

Performing the method 300 therefore forms a receptacle 210. For example, Figures 2C and 4C both depict a receptacle that is obtained from the fabrication method. As discussed, after the method 300 has been performed, further steps may be taken to further process the receptacle. For example, the receptacle may be coated in a coating material (if not already coated). A lid or closure may also be applied to the receptacle.

The receptacle 210 formed according to the processes described above, and depicted in Figures 2C and 4C, therefore has a base 210a and one or more receptacle walls 210b extending from the base. The one or more walls 201b each comprise layers of fibre suspension (which may be partially or fully dried). As discussed, these layers are stacked sequentially in a direction of the height of the receptacle, such as along the third dimension 218.

The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

CLAIMS1. A receptacle forming system for forming a receptacle from a fibre suspension, the system comprising: a support surface; and a depositing element, for fluid communication with a container storing the fibre suspension therein, wherein the depositing element is: moveable along one or more predetermined paths relative to the support surface; and I 0 operable to deposit the fibre suspension along the one or more predetermined paths, to form the receptacle from the fibre suspension on the support surface.
2. The receptacle forming system of claim I, wherein: the depositing element is operable to deposit the fibre suspension against a surface of a receptacle mould to form the receptacle in a three-dimensional shape defined by the receptacle mould; the receptacle mould is a three-dimensional object having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension; and the one or more predetermined paths extend in the first, second and third dimensions.
3. The receptacle forming system of claim 2, wherein the receptacle mould comprises an outer surface, and wherein the depositing element is operable to deposit the fibre suspension against the outer surface of the receptacle mould.
4. The receptacle forming system of claim 2, wherein the receptacle mould comprises an inner surface, and wherein the depositing element is operable to deposit the fibre suspension against the inner surface of the receptacle mould.
5. The receptacle forming system of any of claims 2 to 4, comprising: a second depositing element operable to deposit a coating onto the surface of the receptacle mould; and wherein the depositing element is operable to deposit the fibre suspension along the one or more predetermined paths after the second depositing element has deposited the coating onto the surface, such that: the fibre suspension is deposited onto the coating, so that the coating is between the surface of the receptacle mould and the fibre suspension deposited; and I 0 when the receptacle is separated from the receptacle mould, the coating adheres to the fibre suspension to form a coating layer of the receptacle.
6. The receptacle forming system of any of claims I to 5, wherein: the receptacle has a three-dimensional shape haying a width extending in a first IS dimension, a depth extending in a second dimension, and a height extending in a third dimension; and the depositing element is operable to deposit the fibre suspension to form a plurality of layers, each layer extending in the first and second dimensions, and the plurality of layers being stacked in the third dimension.
7. The receptacle forming system of claim 6, wherein: the depositing element is operable to deposit: a first layer of fibre suspension comprising a plurality of layer protrusions that extend in a first direction along the third dimension; and a second layer of fibre suspension comprising a plurality of layer protrusions that extend in a second direction along the third dimension, the first and second directions being opposite to each other; and the plurality of layer protrusions of the first layer extend into the second layer, and the plurality of layer protrusions of the second layer extend into the first layer.
8. The receptacle forming system of claim 7, wherein the depositing element comprises an opening through which the fibre suspension is extruded, the opening being shaped to form the layer protrusions.
9, The receptacle forming system of any of claims 1 to 8, wherein: the receptacle has a three-dimensional shape haying a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension; and the depositing element is operable to deposit the fibre suspension to form: a first receptacle wall, the first receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension; and a second receptacle wall against the first receptacle wall, the second receptacle wall extending in the first and second dimensions, and haying a height extending in the third dimension.
10. The receptacle forming system of claim 9, wherein the depositing element is operable to deposit the fibre suspension to form: the first receptacle wall haying a plurality of receptacle wall protrusions that extend in a first direction along the first dimension; and the second receptacle wall haying a plurality of receptacle wall protrusions that extend in a second direction along the first dimension, the first and second directions being opposite to each other; and the plurality of receptacle wall protrusions in the first receptacle wall extend into the second receptacle wall, and the plurality of receptacle wall protrusions in the second receptacle wall extend into the first receptacle wall.
11. The receptacle forming system of claim 9 or 10, wherein: the depositing element is operable to deposit: fibre suspension forming the first receptacle wall along one or more predetermined paths in a first azimuthal direction around an axis extending in the third dimension; and fibre suspension forming the second receptacle wall along one or more predetermined paths in a second azimuthal direction around the axis, the first and second azimuthal directions being opposite to each other.
12. The receptacle forming system of any of claims 9 to 11, further comprising: a wall compression element operable to compress the first and second receptacle walls together.
13. The receptacle forming system of any of claims 1 to 12, wherein the depositing element is operable to form a base of the receptacle by depositing the fibre suspension in a spiral shape.
14. A method of forming a receptacle, the method comprising depositing a fibre suspension in one or more predetermined paths to form the receptacle from the fibre IS suspension
15. The method of claim 14, further comprising: providing a receptacle mould, the receptacle mould being a three-dimensional object haying a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension; wherein: the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against a surface of the receptacle mould to form the receptacle in a three-dimensional shape defined by the receptacle mould; and the one or more predetermined paths extend in the first, second and third dimensions.
16. The method of claim 15, wherein: the receptacle mould comprises an outer surface; the receptacle mould is collapsible and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against the outer surface of the receptacle mould; and the method further comprises: collapsing the receptacle mould after the receptacle is formed; and removing the receptacle mould from within the receptacle.
17. The method of claim 15, wherein: the receptacle mould comprises an inner surface; the receptacle mould is separable into two or more mould parts; and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension against the inner surface of the receptacle mould; and the method further comprises separating the receptacle mould into the two or more mould parts after the receptacle is formed
18. The method of any of claims 15 to 17, further comprising depositing a coating onto the surface of the receptacle mould; wherein the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension after depositing the coating onto the surface, such that the fibre suspension is deposited onto the coating, the coating then being between the surface of the receptacle mould and the fibre suspension deposited, and wherein the method further comprises separating the receptacle from the receptacle mould such that the coating adheres to the fibre suspension to form a coating layer of the receptacle.
19. The method of any of claims 14 to 18, wherein: the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension; and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension to form a plurality of layers, each layer extending in the first and second dimensions, the plurality of layers being stacked in the third dimension.
20. The method of claim 19, wherein: the depositing the fibre suspension to form the plurality of layers comprises: after depositing a first layer of fibre suspension, depositing a second layer of fibre suspension such that the first and second layers extend into each other.
21. The method of any of claims 14 to 20, wherein: the receptacle has a three-dimensional shape having a width extending in a first dimension, a depth extending in a second dimension, and a height extending in a third dimension; and the depositing the fibre suspension in the one or more predetermined paths comprises depositing the fibre suspension to form: a first receptacle wall, the first receptacle wall extending in the first and second dimensions, and haying a height extending in the third dimension; and a second receptacle wall against the first receptacle wall, the second receptacle wall extending in the first and second dimensions, and having a height extending in the third dimension.
22. The method of claim 21, wherein: the depositing the fibre suspension to form the first receptacle wall comprises depositing fibre suspension in a first azimuthal direction around an axis extending in the third dimension; and the depositing the fibre suspension to form the second receptacle wall comprises depositing fibre suspension in a second azimuthal direction around the axis extending in the third dimension, the first and second azimuthal directions being opposite to each other.
23. A computer readable medium storing program instructions for causing a controller of a receptacle forming system to control the receptacle forming system to implement the method of any of claims 14 to 22.
24. A receptacle obtainable or obtained from a fabrication method comprising the method of any of claims 14 to 23.
25. A receptacle comprising a base and a receptacle wall extending from the base, wherein the receptacle has a height, wherein the receptacle wall comprises layers of dried fibre suspension comprising fibres, and wherein the layers are stacked sequentially in a direction of the height of the receptacle.