GB2619050A - System for and method of manufacturing a receptacle - Google Patents

Abstract

Method and system for manufacturing a receptacle using an expandable member 19, comprising inserting the expandable member 19 into a cavity of a mould 15, forming the receptacle 22 from a component being a fibre suspension or partially formed receptacle by a process that comprises expanding the expandable member 19 within the cavity, the cavity containing the component, to urge the component against the inner surface of the mould, and moving the expandable member 19 relative to the cavity while at least partially expanded such that the receptacle 22 is carried between the cavity and a second location 44 by the expandable member 19, and removing the expandable member 19 from within the receptacle 22. The second location 44 may be a cavity of a second mould. The receptacle 22 may be carried from the second location 44 to the cavity. The second location 44 may be a cavity of a second mould for partially forming the receptacle.

Description

SYSTEM FOR AND METHOD OF MANUFACTURING A RECEPTACLE

TECHNICAL FIELD

The present invention relates to methods and systems of manufacturing moulded receptacles. The receptacle is moulded 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 mould and a layer is 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 at least some water out of the fibre suspension, resulting in a bottle being formed. This process of removing water is commonly known as "dewatering" Further drying processes may then be performed to fully dry the bottle.

SUMMARY

As mentioned, the use of expandable bladders (also known as expandable members or inflatable members) in forming pulp-moulded receptacles is known. As part of a forming step, the expandable member is inserted into, and expanded within, a mould. As mentioned, this compresses the fibre suspension against the inside of the mould. The expandable member may then be contracted/deflated and withdrawn from the partially formed or fully formed receptacle. The partially or fully formed receptacle is then separated from the mould and moved to the next stage of the manufacturing process.

Because these receptacles are formed from a fibre suspension, they are delicate and may still contain a high percentage of liquid, such as water, which makes them heavy. As a result, moving the receptacle (whether it be partially or fully formed), poses particular challenges. Traditional gripping mechanisms used in assembly lines may be unsuitable for moving these fragile receptacles. For example, due to the nature of a receptacle still containing a moderate percentage of water, the receptacle is wet/soft so requires the gripper to be very precise so as not to deform the receptacle while still maintaining sufficient grip to prevent the receptacle from falling. This requires costly machinery and precise calibration. On the other hand, while humans are generally more capable of delicate manoeuvring operations, moving a receptacle by hand means the process is limited to operating only when a person is available. This is unsuitable for high volume manufacturing.

To overcome these problems, the inventors have designed a system where the expandable member is further used to transport the receptacles from one location to another. The expandable member therefore has a dual purpose -it can help form the receptacle and also transport the receptacle. This removes the need for additional equipment.

As such, according to a first aspect of the present invention, there is provided a method of manufacturing a receptacle using an expandable member, the method comprising: inserting the expandable member into a cavity of a mould; forming the receptacle from a component, wherein the component is a fibre suspension or a partially formed receptacle, by a process that comprises expanding the expandable member within the cavity, the cavity containing the component, so as to urge the component against an inner surface of the cavity; moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member; and removing the expandable member from within the receptacle or the partially formed receptacle. By remaining at least partially expanded, the expandable member may grip the receptacle from within the receptacle. The expandable member can be moved by an expandable member operation mechanism, for example.

In some examples, the expandable member operation mechanism comprises a movement mechanism and may further comprise a fluid control system. The movement mechanism may comprise an arm or other mechanical elements and is configured to move the expandable member to a different location. In a particular example, a support may be used to support the expandable member and the expandable member operation mechanism may couple to (or comprise) the support. As will be described below, the fluid control system is configured to supply and/or remove fluid from within the expandable member to cause the expandable member to expand and/or contract.

Since the receptacle is formed around the expandable member, the expandable member can carry the receptacle without needing to grasp the receptacle, thereby reducing the likelihood of damaging the receptacle. Dependent upon the level of expansion of the expandable member, the pressure used to carry the receptacle or partially formed receptacle may be distributed relatively evenly within the receptacle, decreasing the pressure on any singular point, thereby reducing the potential to cause damage to the receptacle.

As such, according to the first aspect of the present invention, the expandable member can both: (i) form or partially form a receptacle, and (ii) move the receptacle or partially formed receptacle, during manufacture.

In some example processes, an expandable member is used at several stages of the manufacturing process. For example, in a first stage, a fibre suspension is introduced into a mould, and the expandable member is used to initially form the shape of the receptacle and remove a percentage of liquid, such as water, from the fibre suspension. This first stage forms a receptacle precursor or embryo, and the receptacle may therefore be known as a partially formed receptacle because further manufacturing steps (such as drying steps) are taken before the receptacle is fully formed. The mould may be known as a first mould or initial mould or primary mould, in some examples. This first stage may be known as a dewatering stage.

An expandable member may also be used in a second stage of manufacturing (the expandable member may be a different expandable member used in the first stage or may be the same expandable member). For example, after the receptacle has been partially formed in a first mould (as above), the partially formed receptacle may be moved into a second mould. The second mould may be heated, in some examples, and thus this process may be known as a "thermoforming" stage. This heated mould can remove additional liquid from the receptacle. In this second stage, an expandable member may be inserted into the partially formed receptacle while in the second mould and be used to urge the partially formed receptacle against a cavity wall of the second mould. The second mould may be known as a further mould or a thermoforming mould or a secondary mould, in

some examples.

In one example, the expandable member is an inflatable member, and so when the expandable member is expanded, the inflatable member is inflated Similarly, when the expandable member is contracted, the inflatable member is deflated.

The expandable member may be shaped similar to the shape of the receptacle to be formed. In particular, the expandable member may be generally cylindrical in shape, with a narrower cylindrical section at an end closest to an opening of the receptacle.

As briefly mentioned, a receptacle, or moulded receptacle is an object comprising a receptacle cavity that can receive an entity, such as a liquid, for holding. For example, a receptacle may be known as a moulded receptacle, an article, a bottle, or a container for containing fluids (such as a liquid) or solids (such as pharmaceutical or other tablets/capsules).

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 220m1 and 600m1. In a further example, the receptacle has a diameter of about 68mm, a height of about 196mm and a volume of about 522m1.

Inserting the expandable member into a cavity of a mould may comprise passing/lowering the expandable member into the mould through an opening of the mould.

A cavity can mean an empty space within an object. The cavity of the mould may be defined by the inner walls of the mould. This cavity is distinct from a cavity of the receptacle or partially formed receptacle, which is defined by the walls of the receptacle or partially formed receptacle.

In some examples, the cavity of the mould has apertures formed on or through the walls defining the cavity. This allows liquid to pass from within the cavity to outside of the cavity, and therefore outside the mould, and the liquid may be collected by a liquid measurement system or other means. The apertures may therefore extend from the cavity to an outer surface of the mould.

The mould may also comprise an opening through which the component (such as the fibre suspension or partially formed receptacle) can be received A layer or coating of the fibre suspension can be applied to the inner wall of the cavity (the "mould cavity wall"). This initial layer/coating may have a first thickness, and after the expandable member has been expanded, the receptacle/fibre suspension may have a second thickness that is less than the first thickness, owing to the compaction of the fibres and removal of some of the liquid.

A mould can be a hollow container used to give shape to the fibre suspension or partially formed receptacle when it cools, dries, or hardens. The mould may be a two-or three-part mould and comprise features to enable the mould parts to link and unlink.

A fibre suspension can be a liquid composition comprising organic or cellulose fibres and/or can include constituents such as paper pulp. The liquid in the suspension may comprise water. Other additives may be present in the fibre suspension.

The term "a partially formed receptacle" may refer to a receptacle that has been through at least one of the forming stages of the process but is not a fully formed product. It may have taken the shape of a mould.

In certain examples, the method may further include introducing the component into the cavity of the mould. In examples where the component is a fibre suspension, introducing the fibre suspension into the cavity of the mould may comprise spraying, inserting, or drawing the fibre suspension into the mould. In some instances, the fibre suspension may be introduced under vacuum (i.e., a vacuum is applied to the mould or cavity).

In examples where the component is a partially formed receptacle, introducing the partially formed receptacle into the cavity of the mould may comprise inserting or placing the partially formed receptacle into the cavity of the mould. The partially formed receptacle may be "unfinished" and have been formed in another mould using the same or a different expandable member. The expandable member is then used to urge the partially formed receptacle against the inner surface of the cavity. The partially formed receptacle may be heated in some examples. For example, the inner walls of the cavity of the mould may be heated.

At least partially expanded, as referred to above, may mean that the expandable member is expanded at or above a pressure of 1 atm (101kPa), to avoid damaging the receptacle or partially formed receptacle. At least partially expanded may mean that the expandable member has a cross-sectional width equal to or greater than a part/portion of the receptacle or partially formed receptacle. For example, the expandable member may have a cross-sectional width equal to or greater than a neck portion of the receptacle or partially formed receptacle. In one example, the neck portion may have a cross-sectional width of between about 35mm and about 40mm, such as about 37mm. In another example, the neck portion may have a cross-sectional width of about 20 mm. Alternatively, the neck portion may have a cross-sectional width of between about 20mm and about 40mm. In certain examples, the expandable member may have a cross-sectional width that is greater than a neck portion of the receptacle or partially formed receptacle by between about Omm and about 5mm, or between about Omm and about 2mm (depending upon how resilient the receptacle or partially formed receptacle is) In some examples, the expandable member, once at least partially expanded, abuts only the neck portion of the receptacle or partially formed receptacle. In other examples, the expandable member, once at least partially expanded, abuts the neck portion of the receptacle or partially formed receptacle and a body portion of the receptacle or partially formed receptacle (thereby holding the receptacle in a more stable manner). In a further example, the expandable member, once at least partially expanded, abuts the neck portion of the receptacle or partially formed receptacle and a shoulder portion of the receptacle or partially formed receptacle (the shoulder portion being an upper surface of the body portion).

The term "carried" refers to any means of supporting the partially or fully formed receptacle by the expandable member. For example, carrying or suspending the receptacle or partially formed receptacle from the expandable member can mean that the expandable member will not pass through an opening of the receptacle, such that the expandable member supports the receptacle or partially formed receptacle.

In certain examples, moving the expandable member comprises moving the receptacle or partially formed receptacle between a first location (such as the mould cavity) and a second location. In a particular example, moving the expandable member comprises moving the receptacle or partially formed receptacle from the first location to the second location. The second location may be away from the first location. In another example, moving the expandable member comprises moving the receptacle or partially formed receptacle from the second location to the first location. In a particular example, the second location may be a second mould, such as a cavity of the second mould. As such, in some examples, the receptacle or partially formed receptacle is moved from the mould (such as a first mould used to partially form the receptacle) to another mould (such as a second mould used to further form the receptacle).

Accordingly, in a first example, the component is the fibre suspension and the moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises moving the expandable member relative to the cavity while at least partially expanded, such that the partially formed receptacle is carried from the cavity to the second location, wherein the second location is away from the mould. In this example, a partially formed receptacle is formed by expanding the expandable member within the cavity. The second location may be a further stage in the manufacturing process, e.g., the thermoforming station or a drying station. The second location may be a second moulding station, comprising a second mould. The second location may be a cavity of a second mould for further forming of the receptacle. The second moulding station is separate from (i.e., positioned away from) the first moulding station.

In a second example, the component is the partially formed receptacle and moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle is carried from the cavity to the second location, wherein the second location is away from the mould. In this example, a receptacle is formed by expanding the expandable member within the cavity. The second location may be a further stage in the manufacturing process, e.g., a drying station. Thus, the receptacle may be moved from a thermoforming mould to another location.

In a third example, the component is the partially formed receptacle and moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises moving the expandable member relative to the cavity while at least partially expanded, such that the partially formed receptacle is carried from the second location to the cavity, wherein the second location is away from the mould. In this example, a partially formed receptacle is moved into the cavity from a second location. The second location may be an earlier stage in the manufacturing process, e.g., a primary mould. In one particular example, the second location is a cavity of a second mould for partially forming the receptacle. The second mould in this example precedes the first mould, hence the partially formed receptacle is moved from the second (initial, primary) mould to the first (further, thermoforming) mould. Thus, the partially formed receptacle can be moved from one mould to another mould without human intervention.

In certain examples, expanding the expandable member within the cavity causes liquid to be forced out of the component. The expandable member therefore performs two functions: it helps reduce the liquid content of the component and is used to carry the receptacle.

In certain examples, the expanding the expandable member comprises supplying a fluid into the expandable member. In certain examples, the method comprises removing only a portion of the fluid from the expandable member before moving the expandable member, such that the expandable member is in a partially contracted state during the movement of the expandable member. Removing some of the fluid (and therefore partially contracting the expandable member) may help reduce the force applied by the expandable member to an inside of the receptacle or partially formed receptacle, so that the receptacle or partially formed receptacle is not damaged as it is being moved.

A liquid is optionally used as the fluid as liquids are non-compressible and provide an increased level of control of expansion of the expandable member. Optionally, the liquid is water, preventing contamination in the event of a rupture of the expandable member. In another example, the expandable member may be mechanically expanded, for example using a mechanism inside the expandable member to increase the volume occupied by the expandable member.

In certain examples, the method further comprises releasing the receptacle or partially formed receptacle from the cavity prior to moving the expandable member, wherein the portion of the fluid is removed from the expandable member before releasing the receptacle or partially formed receptacle from the cavity. Removing the portion of the fluid before releasing the receptacle or partially formed receptacle from the mould I0 prevents, or lessens the chances of, the expandable member distorting the receptacle or partially formed receptacle as the mould is no longer providing a reactive force against the outwards pressure created by the expanded member.

Releasing the formed receptacle or partially formed receptacle from the mould may comprise separating parts of the mould such that a partially or fully formed receptacle is no longer constrained by the mould. Releasing the formed receptacle or partially formed receptacle from the mould may comprise any other means of freeing the moulded receptacle from the mould.

In an example, the mould is formed via a 3D printing or other additive manufacturing technique and is a two-part mould.

In some examples, removing the expandable member from within the receptacle or partially formed receptacle further comprises removing the expandable member from within the mould (or another mould) In certain examples, during the movement of the expandable member, the expandable member has a cross-sectional width that is greater than a cross-sectional width of an opening of the receptacle or partially formed receptacle. Thus, the expandable member is too wide to pass through the opening of the receptacle or partially formed receptacle, which provides a means of carrying the receptacle or partially formed receptacle.

In certain examples, the removing of the expandable member from within the receptacle or partially formed receptacle comprises at least partially contracting the expandable member. In certain examples, the at least partially contracting the expandable member comprises at least partially contracting the expandable member such that the expandable member has a cross-sectional width that is less than a cross-sectional width of an opening of the receptacle or partially formed receptacle. The expandable member may then be withdrawn from within the receptacle or partially formed receptacle through the opening.

II

In certain examples, the expandable member is directly or indirectly connected to an expandable member operation mechanism, the expandable member operation mechanism comprising at least a movement mechanism. Accordingly, the moving the expandable member comprises moving the expandable member operation mechanism (such as the movement mechanism) relative to the mould. The expandable member operation mechanism (or more particularly the movement mechanism) is capable of moving the expandable member and therefore the receptacle or partially formed receptacle between different locations.

According to a second aspect of the present invention, there is provided a system for manufacturing a receptacle, the system comprising: a mould having a cavity, the cavity containing a component in use, wherein the component is a fibre suspension or a partially formed receptacle; an expandable member; and an expandable member operation mechanism configured to: (i) cause insertion of the expandable member into the cavity of the mould; (ii) cause expansion of the expandable member within the cavity, so as to urge the component against an inner surface of the cavity, during a process to form the receptacle from the component; (iii) cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member; and (iv) cause removal of the expandable member from within the receptacle or partially formed receptacle.

In a first example, the component is the fibre suspension, and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the partially formed receptacle is carried from the cavity to the second location, wherein the second location is away from the mould. In certain examples, the system further comprises a second mould having a cavity for further forming of the receptacle, and wherein the second location is the cavity of the second mould.

In a second example, the component is the partially formed receptacle, and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the receptacle is carried from the cavity to the second location, wherein the second location is away from the mould.

In a third example, the component is the partially formed receptacle, and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the partially formed receptacle is carried from the second location to the cavity, wherein the second location is away from the mould. In certain examples, the system further comprises a second mould having a cavity for partially forming the receptacle, and wherein the second location is the cavity of the second mould.

In certain examples, the movement mechanism is further configured to move the expandable member and receptacle or partially formed receptacle between the second location and a third location. The third location may be a drying station or oven, or other storage place within the manufacturing process.

In certain examples, the expandable member operation mechanism comprises a fluid control system configured to supply a fluid into the expandable member to cause the expansion of the expandable member. The fluid control system may also be configured to subsequently remove only a portion of the fluid from the expandable member before the movement of the expandable member is caused, such that the expandable member is in a partially contracted state while carrying the receptacle or partially formed receptacle.

In certain examples, the expandable member operation mechanism comprises a fluid control system that may be configured to supply a fluid into the expandable member to cause the expansion of the expandable member, and subsequently remove at least some of the fluid from the expandable member to contract the expandable member into a contracted state to cause the removal of the expandable member from within the receptacle or partially formed receptacle. The fluid control system that controls the expansion and contraction of the expandable member is therefore used to deposit the receptacle. This can be controlled by varying the amount of fluid inside the expandable member.

The fluid control system may supply only a portion of fluid in order to partially expand the expandable member sufficient to support the receptacle or partially formed receptacle during movement of the movement mechanism. In an example, the fluid is supplied via a fluid line. In other examples, the fluid control system fully fills the expandable member with fluid in order to expand the expandable member.

In certain examples, the fluid control system may be configured to supply a fluid into the expandable member and maintain a volume of fluid within the expandable member while the expandable member operation mechanism moves the expandable member and the receptacle, such that the expandable member has a cross-sectional width that is greater than a cross-sectional width of an opening of the receptacle or partially formed receptacle.

In some examples, the expandable member operation mechanism comprises a movement mechanism to move the expandable member. The expandable member operation mechanism (or more particularly the movement mechanism) may be configured to move the expandable member while the expandable member is in a contracted state within the receptacle, such that the expandable member is withdrawn from within the receptacle, thus depositing the receptacle at a particular location. The fluid control system that controls the expansion and contraction of the expandable member is therefore used in combination with the movement mechanism to collect and deposit the receptacle. This can be controlled by varying the amount of fluid inside the expandable member. The fluid control system may withdraw all supplied liquid from the expandable member to decrease the volume occupied by the expandable member to facilitate the removal of the expandable member from the receptacle or partially formed receptacle.

In certain examples, a fluid line of the fluid control system is provided through the movement mechanism. This prevents the tangling of the fluid line when moving the receptacle or partially formed receptacle.

In certain examples, the system may further comprise a demoulding system configured to release the receptacle or partially formed receptacle from the cavity. This may be done before the expandable member operation mechanism moves the expandable member and the receptacle relative to the mould. In certain examples, the fluid control system is configured to remove the portion of fluid before the dem oul di ng system releases the receptacle from the mould.

In certain examples, the expandable member is made from an elastomer, for example rubber. Elastomers provide the expandable member with good elastic properties for the expansion of the expandable member. Further, elastomers are soft so conform to the shape of the mould as it is expanded within the cavity and provide a relatively even pressure to the component in the mould.

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 a schematic view of an example process for making a receptacle from paper pulp; Figure 2A shows a cross-section of an example mould and an example expandable member being introduced into the cavity of the mould; Figure 2B shows a cross-section of an example mould and an example expandable member having been introduced into the cavity of the mould; Figure 2C shows a cross-section of an example mould and an example expandable member having been expanded within the cavity of the mould; Figure 2D shows a cross-section of an example mould and an example expandable member having been partially contracted within the cavity of the mould; Figure 2E shows a cross-section of an example mould haying been separated from the receptacle or partially formed receptacle, the example expandable member in a partially expanded state within the receptacle or partially formed receptacle; Figure 2F shows a cross-section of an example receptacle or partially formed receptacle being carried by the example expandable member, Figure 2G shows the cross-section of an example receptacle or partially formed receptacle being placed at a location using the expandable member, Figure 2H shows the cross-section of an example expandable member having been further contracted to a contracted state, Figure 3 shows a cross-section of an example partially formed receptacle being received in a mould, Figure 4 shows a flow diagram of a method of manufacturing a receptacle using an expandable member, according to a first example; and Figure 5 shows a flow diagram of a first method of manufacturing a receptacle using an expandable member, according to a second example

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 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 exemplary 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 partially 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. 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.

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 Swt% (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% 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 0.5wt% to 5wt%, or 0.1wt% to 1 wt%, 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 (also referred to as the 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.

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 expandable member 19, e.g., a collapsible bladder, 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 expandable member 19 is actuated and regulated using a fluid control system comprising a hydraulic pump 20. The pump 20 has a cylinder that displaces a fluid in a line 21 into the expandable member 19, to expand the expandable member 19 radially and into conformity with the mould cavity. Fluid within the line 21 is optionally non-compressible, such as water. Water also has the advantage over other non-compressible liquids that any leaking or bursting of the expandable member 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 optionally 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 15 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, an expandable member 26 (e.g., a thermoforming bladder 26) is inserted into the receptacle 22. The expandable member 26 is inflated 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 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.

Figures 2A-2H illustrate the use of an expandable member within a mould according to first and second examples. As discussed above, the present invention relates to use of an expandable member to both help form a receptacle and carry the receptacle (or a partially formed receptacle) between two locations, one of the locations being a mould. In the first example of Figures 2A-2H, the expandable member is used to carry a partially formed receptacle from a cavity of a mould to a second location. The mould may be mould 15 described above. In some examples, the second location is a second mould (such as mould 25 described above). In the second example of Figures 2A-2H, the expandable member is used to carry a receptacle from a cavity of a mould to a second location. The mould may be mould 25 described above. Figure 3 depicts a third example in which the expandable member is used to carry the receptacle or partially formed receptacle to a mould (such as mould 25).

Accordingly, although Figures 2A-H depict the mould as mould 15 and the expandable member as expandable member 19, it will be appreciated that the same principles can be applied to the mould 25 and expandable member 26 depicted in Figure 1. It will also be appreciated that expandable member 19 and expandable member 26 can be the same expandable member. Figures 2A-2H and 3 are provided in a cross-sectional view to aid understanding.

In more detail, Figure 2A illustrates a system for manufacturing a receptacle, the system comprising a mould 15. At this particular moment in time, a component, in this case a fibre suspension 8, is located inside the mould 15. As described in Figure 1, the fibre suspension 8 can be supplied into the mould 15 under vacuum. After the fibre suspension 8 has been introduced into the mould 15, the expandable member 19 can be inserted into the mould 15.

As shown in Figure 2A, the mould 15 comprises a cavity 36 in which the fibre suspension 8 is located. The cavity 36 of the mould 15 comprises a mould cavity wall 40 (i.e., the cavity 36 has an inner wall), and the fibre suspension 8 is applied to the cavity wall 40. In some examples, the cavity 36 comprises apertures (not shown) that allows liquid to pass therethrough. The apertures may extend from the mould cavity wall 40 and through the mould 15 to an outer surface of the mould. The mould 15 may be referred to as a first mould, a primary mould, or a dewatering mould, in some examples.

In the example of Figure 2A, the cavity 36 has a main body portion 36a (also referred to as a first portion) and a neck portion 36b (also referred to as a second portion). The neck portion 36b may be used to form the neck of a receptacle/bottle. The main body portion 36a may be used to form a body portion of the receptacle.

In this example, the mould 15 is formed from two separate half-moulds. Each half-mould may itself be referred to as a mould in certain examples, and each half-mould may define a cavity having a mould cavity wall (onto which the fibre suspension 8 may be applied). When the two half-moulds are brought together, the two cavities form the larger cavity 36 in the mould 15. In other examples, the mould 15 may comprise more than two parts. As shown in Figure 2A, the mould 15 is situated at a first location 43 (such as a first moulding station) that is remote/away from a second location 44. As will become apparent, the second location may be a second moulding station comprising a second mould, in some examples.

The mould IS has a first opening 38 into the mould 15/cavity 36. The fibre suspension 8 can be introduced into the cavity 36 via the first opening 38. Similarly, the expandable member 19 can also be introduced into the mould 15 (or more specifically the cavity 36) via the first opening 38. Figure 2A shows the expandable member 19 in a contracted state but extending into the cavity 36.

At one end 19a of the expandable member 19, the expandable member 19 is connected to, and therefore supported by a support 10. In this particular example, the support 10 comprises a holder 42 coupled to the expandable member 19. The expandable member 19 may be secured to the holder via a fixing element, such as a Jubilee clip. In some examples, the holder 42 comprises a rod (not shown) that extends into the expandable member 19 and into the cavity 36 to help provide rigidity to the expandable member 19 while it is being inserted into the cavity 36. A fluid, such as air, water, or oil, can flow into the expandable member 19 via the holder 42 to expand the expandable member 19 within the cavity 36. Connected to the holder 42 is the line 21 through which the fluid flows from the hydraulic pump 20 shown in Figure 1.

The support 10 is connected to a movement mechanism 45, which may be part of an expandable member operation mechanism As will be explained below, the expandable member operation mechanism may further comprise a fluid control system configured to supply the fluid into the expandable member 19 to cause expansion of the expandable member 19. The fluid control system may comprise the line 21 and the hydraulic pump 20, for example. The fluid control system may further be configured to extract/remove the fluid from the expandable member 19 to cause contraction of the expandable member 19 In the example of Figure 2A, the movement mechanism 45 is a mechanical arm, for example a robotic arm. The movement mechanism 45 is configured to move the expandable member 19 by moving the support 10 to which the expandable member 19 is attached. In some examples, the support 10 is omitted and the movement mechanism 45 is directly coupled to the expandable member 19. Figure 2A shows the support 10 being lowered towards the mould 15 and therefore the expandable member 19 being lowered into the cavity 36 of the mould 15 via the opening 38. As such, the expandable member operation mechanism (and in particular the movement mechanism 45) causes insertion of the expandable member 19 into the cavity 36 of the mould 15.

Figure 2B shows the system at a point in time after that depicted in Figure 2A. At this point in time, the movement mechanism 45 has continued to move the expandable member 19 into the cavity 36, such that the support 10 and the mould 15 are in abutment.

The support 10 is held against the mould 15 by the movement mechanism 45 during the forming of the receptacle or partially formed receptacle. In this particular example, the expandable member 19 is used to partially form a receptacle from the fibre suspension 8 contained within the cavity 36.

Figure 2C shows the system at a point in time after that depicted in Figure 2B, and depicts a process of partially forming the receptacle from the fibre suspension 8. At this moment in time, the expandable member 19 has been expanded within the cavity 36 (thereby increasing its cross-sectional width) such that it fills the entire cavity 36.

As mentioned, a fluid, such as water or air, is introduced into the expandable member 19 via the fluid line 21 of the fluid control system. In this particular example, the fluid line 21 is provided through the movement mechanism 45. The introduction of the fluid causes the expandable member 19 to be expanded. The expandable member 19, optionally made of an elastomer such as rubber, inflates to a fully expanded state and provides a pressure against the fibre suspension 8, urging the fibre suspension 8 against the mould cavity wall 40. This expansion forces water out of the fibre suspension 8 and through apertures in the mould wall 40 that provide a path for the liquid content of the fibre suspension 8 to escape. This reduces the water content of the fibre suspension 8, drying the fibre suspension sufficiently to create a partially moulded receptacle conforming to the shape of the mould cavity 36. As such, the expandable member operation mechanism (and in particular the fluid control system) causes expansion of the expandable member 19 within the cavity 36, so as to urge the fibre suspension 8 against the inner surface 40 of the cavity 36.

Figure 2D shows the system at a point in time after that depicted in Figure 2C. At this moment in time, the fluid control system has caused a portion of the fluid to be removed from the expandable member 19, such as via the fluid line 21. This causes the expandable member 19 to contract, and it is now in a partially contracted/expanded state. Enough fluid is still retained within the expandable member 19 that the expandable member 19 has a cross-sectional width 76 greater than the cross-sectional width 74 of the opening 38 of the mould 15 and/or an opening of the partially formed receptacle 22. The pressure of the fluid within the expandable member 19 may be at a pressure required to expand the expandable member 19 to have a cross-sectional width 76 equal to or greater than the cross-sectional width 74 of the opening 38.

As shown in Figure 2D, the partially formed receptacle 22 remains against the mould cavity wall 40 as the expandable member contracts. From the position shown in Figure 2D, separate parts of the mould 15 can be separated to release the partially formed receptacle 22. For example, the two halves of the mould 15 can be moved in the direction of the arrows shown in Figure 2D. Figure 2D therefore shows a first half 15a of the split mould 15 moving away from the partially formed receptacle 22 in one direction, and the second half 15b of the split mould 15 moving away from the partially formed receptacle 22 in the opposite direction. As will be understood by the person skilled in the art, the mould 15 may be separated from the partially formed receptacle 22 in any other suitable manner. To facilitate the release of the partially formed receptacle, a demoulding system (not shown) may cause separation of the two halves 15a, 15b, of the mould 15.

Figure 2E shows the system at a point in time after that depicted in Figure 2D. At this moment in time, the two halves 15a, 15b of the mould 15 are shown separated from the partially formed receptacle 22. Due to the cross-sectional width of the expandable member 19 being larger than the cross-sectional width of the opening of the partially formed receptacle 22, the partially formed receptacle 22 is suspended from the expandable member 19, and is therefore being carried by the expandable member 19.

From here, the expandable member 19 can be moved by the movement mechanism 45 of the expandable member operation mechanism. As mentioned, the expandable member 19 remains partially expanded while being moved. Accordingly, the cross-sectional width 76 of the expandable member 19 in the cavity 70 of the partially formed receptacle 22 remains greater than the cross-sectional width 74 of the opening 72 of the partially formed receptacle 22. The cross-sectional width 74 of the opening 72 may alternatively be referred to as the cross-sectional width 74 of a neck portion of the partially formed receptacle 22. As the expandable member 19 is moved, the partially formed receptacle 22 also moves. As such, the expandable member operation mechanism (and in particular the movement mechanism 45) causes movement of the expandable member 19 relative to the cavity 36 (and therefore the mould 15) while the expandable member is at least partially expanded, such that the partially formed receptacle 22 is carried between the cavity 36 and the second location 44 by the expandable member 19.

At this point in time, the partially formed receptacle 22 is rigid enough to withstand being carried by the expandable member 19 despite the liquid/water content still being relatively high, such as between about 70% and about 75% liquid content by weight Figure 2F shows the system at a point in time after that depicted in Figure 2E. At this moment in time, the partially formed receptacle 22 is being carried/transported from the first location 43 (such as the mould 15) to the second location 44 away from the first location 43. The second location 44 may be a further downstream processing station, such as the thermoforming station shown in Figure 1. Accordingly, in a particular example, the second location 44 is a cavity of a second mould for further forming of the receptacle, such as mould 25. Alternatively, the second location 44 may be a temporary location for storage while ongoing processes are completed. In further examples, the second location 44 may be a drying location, such as a microwave or oven as shown in Figure 1.

Figure 2G shows the system at a point in time after that depicted in Figure 2F. At this moment in time, the partially formed receptacle 22 is being deposited at the second location 44. The movement mechanism 45 has therefore lowered the partially formed receptacle 22 onto a surface. In this example, the second location is a storage location where the partially formed receptacle may be kept while other processes are being completed.

Figure 211 shows the system at a point in time after that depicted in Figure 2G. From here, the expandable member 19 can be removed from within the partially formed receptacle 22, such that the partially formed receptacle can be deposited at the second location 22. To achieve this, expandable member operation mechanism (or more particularly the fluid control system) is configured to at least partially contract the expandable member by extracting/removing enough fluid such that the expandable member has a cross-sectional width 76 that is less than a cross-sectional width 74 of an opening 72 of the partially formed receptacle 22. The expandable member 19 may then be withdrawn from within the partially formed receptacle 22 through the opening 72 by the movement mechanism 45. As such, the expandable member operation mechanism (and in particular the movement mechanism 45 and the fluid control system) causes removal of the expandable member 19 from within the partially formed receptacle 22.

From here, the expandable member 19 can be moved back to the first location 43 to partially form another receptacle in the mould 15. In some examples, the expandable member 19 is first moved to a cleaning station.

In the above examples, the partially formed receptacle is shown being moved from a cavity of a mould 15 to a second location 44. However, as mentioned, in some examples, the partially formed receptacle 22 is moved from the mould 15 and is deposited directly into a second cavity of a second mould 25, as shown in Figure 3. As such, the second location may be a cavity of a second mould, such as mould 25. The second mould 25 may therefore be used to further form the receptacle 22. Figure 3 depicts the partially formed receptacle 22 being inserted into a cavity formed by two mould halves 25a, 25b of the second mould 25. Although not shown in Figure 3, the first location 43 may be the cavity 36 of the mould 15.

In another example, rather than being moved from a first mould, such as mould 15, into a second mould, such as mould 25, the partially formed receptacle 22 may be moved from a first location 43 to a mould, such as mould 25. Accordingly, the partially formed receptacle 22 may be carried from a particular location (such as the first location 43) to a cavity of the mould 25, where the particular location is away from the mould 25. Such a scenario is depicted in Figure 3. Accordingly, when the partially formed receptacle 22 is moved into the mould 25, it is at this point the expandable member 19 is inserted into the cavity of the mould 25. From here, the expandable member 19 can be used to form the receptacle from the partially formed receptacle by a process that comprises expanding the expandable member 19 within the cavity, so as to urge the partially formed receptacle against an inner surface of the cavity of the mould 25. After the receptacle has been formed, the expandable member 19 can be removed from within the receptacle. The expandable member 19 may therefore perform the function of expandable member 25 depicted in Figure 1.

In another example, the steps shown in Figures 2A-H are performed in a second mould, such as mould 25, rather than mould 15. Accordingly, rather than introducing a fibre suspension 8 into the mould and partially forming the receptacle, the component within the mould is a partially formed receptacle 22. From here, the expandable member can be used to further or fully form the receptacle from the partially formed receptacle. Accordingly, in such a scenario, the mould of Figures 2A-211 may instead be a second mould 25. In a particular example, the second mould 25 is non-porous and may be heatable to transfer heat to the partially formed receptacle 22. In this example, the expandable member may be the same or a different expandable member, such as expandable member 26, shown in Figure 1. As such, the expandable member can be is inserted into the cavity of the mould 25 (and also a cavity of the partially formed receptacle 22) by the movement mechanism 45, as in Figures 2A and 2B. The expandable member 19, 26 can then be expanded within the cavity via insertion of fluid via the fluid line 21, urging the partially formed receptacle 22 against the mould 25, as in Figure 2C. As discussed earlier in relation to Figure 2D, the expandable member 19, 26, has a portion of the fluid removed by the fluid control system, via the fluid line 21, to partially contract the expandable member. The mould 25 can then be detached from the receptacle. As was shown in Figure 2E, the formed receptacle can then be carried by the expandable member 19, 26 and movement mechanism 45, and as in Figures 2F and 2G. From here, the formed receptacle can then be deposited at a second location 44 away from the mould 25.

Figure 4 shows a flow diagram of a method 200 of manufacturing a receptacle using an expandable member. The method comprises, in block 202, inserting the expandable member into a cavity of a mould.

In block 204, the method comprises forming the receptacle from a component, wherein the component is a fibre suspension or a partially formed receptacle, by a process that comprises expanding the expandable member within the cavity, the cavity containing the component, so as to urge the component against an inner surface of the cavity. In some examples, expanding the expandable member within the cavity causes liquid to be forced out of the component.

In block 206, the method comprises moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member.

In block 208, the method comprises removing the expandable member from within the receptacle or partially formed receptacle. As discussed, removing the expandable member from within the receptacle or partially formed receptacle comprises at least partially contracting the expandable member. For example, the fluid control system removes at least some of the fluid from the expandable member to contract the expandable member into a contracted state to cause and/or allow the removal of the expandable member from within the receptacle or partially formed receptacle.

As mentioned, the mould in method 200 can be either a first mould, such as mould 15 or a second mould, such as mould 25. Similarly, the expandable member may be expandable member 19 or 26. In examples where the mould is mould 15, the component is a fibre suspension 8 and the expandable member 19 expanding within the cavity 36 of the mould 15 urges the fibre suspension 8 against the mould cavity wall 40, mechanically forcing water content from the fibre suspension 8. In examples where the mould is mould 25, the component is the partially formed receptacle 22, and expanding the expandable member 26 within the cavity of a mould 36 comprises expanding the expandable member 26 within the partially formed receptacle 22. The expansion of the expandable member 26 urges the partially formed receptacle against the mould cavity wall of the mould 25.

As discussed above, the fluid control system can control the level of expansion of the expandable member 19 by controlling the amount of fluid inside the expandable member. In some examples, after block 204 and before block 206, the method further comprises removing only a portion of the fluid from the expandable member, such that the expandable member is in a partially contracted state during the moving the expandable member. This can reduce the outward pressure provided by the expandable member 19 on the receptacle or partially formed receptacle 22.

In some examples, after block 204 and before block 206, the method further comprises releasing the receptacle or partially formed receptacle from the cavity. This may include releasing the partially formed receptacle 22 from the first mould 15 or releasing the receptacle 22 from the second mould 25. In examples where a portion of the fluid is removed from the expandable member before block 206, the portion of the fluid may be removed from the expandable member before releasing the receptacle or partially formed receptacle from the cavity.

It will be evident to a person skilled in the art that the steps may be performed in a different order.

For example, Figure 5 depicts a flow diagram of a method 300 of manufacturing a receptacle using an expandable member. In this example method, the inflatable member is inflatable member 26, and is used to move a partially formed receptacle from a particular location into a cavity of a mould, such as mould 25. The method comprises, in block 302, moving the expandable member 26 relative to a cavity of a mould 25 while at least partially expanded, such that a partially formed receptacle is carried from a particular location to the cavity of the mould 25, by the expandable member 26. In some examples, prior to block 302, the method comprises inserting the expandable member 26 into a partially formed receptacle. For example, the expandable member may be inserted into a cavity of the partially formed receptacle via an opening of the partially formed receptacle.

In a particular example, the particular location is the mould 15.

In block 304, the method comprises inserting the expandable member 26 into the cavity of the mould 25. This can occur, for example, as the partially formed receptacle is also inserted into the cavity of the mould 25.

In block 306, the method comprises forming the receptacle from the partially formed receptacle, by a process that comprises expanding the expandable member 25 within the cavity (the cavity now containing the partially formed receptacle), so as to urge the partially formed receptacle against an inner surface of the cavity.

In block 308, the method comprises removing the expandable member from within the receptacle that has been formed in the mould 25.

Example embodiments of the present invention have been discussed, with reference to the examples illustrated However, it will be appreciated that variations and 3 1 modifications may be made without departing from the scope of the invention as defined by the appended claims

Claims (19)

1. CLAIMS1. A method of manufacturing a receptacle using an expandable member, the method comprising: inserting the expandable member into a cavity of a mould; forming the receptacle from a component, wherein the component is a fibre suspension or a partially formed receptacle, by a process that comprises expanding the expandable member within the cavity, the cavity containing the component, so as to urge the component against an inner surface of the cavity; moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member; and removing the expandable member from within the receptacle or partially formed receptacle.
2. 2. The method of claim 1, wherein the component is the fibre suspension; and the moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises: moving the expandable member relative to the cavity while at least partially expanded, such that the partially formed receptacle is carried from the cavity to the second location, wherein the second location is away from the mould.
3. 3. The method of claim 2, wherein the second location is a cavity of a second mould for further forming of the receptacle.
4. 4. The method of claim 1, wherein the component is the partially formed receptacle; and the moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises: 1.3 moving the expandable member relative to the cavity while at least partially expanded, such that the partially formed receptacle is carried from the second location to the cavity, wherein the second location is away from the mould.
5. 5. The method of claim 4, wherein the second location is a cavity of a second mould for partially forming the receptacle.
6. 6. The method of claim I, wherein the component is the partially formed receptacle; and the moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member, comprises: moving the expandable member relative to the cavity while at least partially expanded, such that the receptacle is carried from the cavity to the second location, wherein the second location is away from the mould.
7. 7. The method of any of claims 1 to 6, wherein the expanding the expandable member within the cavity causes liquid to be forced out of the component.
8. 8. The method of any of claims 1 to 7, wherein the expanding the expandable member comprises supplying a fluid into the expandable member; and the method further comprises removing only a portion of the fluid from the expandable member before the moving the expandable member, such that the expandable member is in a partially contracted state during the moving the expandable member.
9. 9. The method of claim 8, further comprising releasing the receptacle or partially formed receptacle from the cavity prior to the moving the expandable member, wherein the portion of the fluid is removed from the expandable member before the releasing the receptacle or partially formed receptacle from the cavity.
10. 10. The method of any of claims 1 to 9, wherein the removing the expandable member from within the receptacle or partially formed receptacle comprises at least partially contracting the expandable member.
11. 11. A system for manufacturing a receptacle, the system comprising: a mould having a cavity, the cavity containing a component in use, wherein the component is a fibre suspension or a partially formed receptacle; an expandable member; and an expandable member operation mechanism configured to: cause insertion of the expandable member into the cavity of the mould; cause expansion of the expandable member within the cavity, so as to urge the component against an inner surface of the cavity, during a process to form the receptacle from the component; cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the receptacle or the partially formed receptacle is carried between the cavity and a second location by the expandable member; and cause removal of the expandable member from within the receptacle or partially formed receptacle.
12. 12. The system of claim 11, wherein the component is the fibre suspension, and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the partially formed receptacle is carried from the cavity to the second location, wherein the second location is away from the cavity.
13. 13 The system of claim 12, wherein the system further comprises a second mould having a cavity for further forming of the receptacle, and wherein the second location is the cavity of the second mould.
14. 14. The system of claim 11, wherein the component is the partially formed receptacle; and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the partially formed receptacle is carried from the second location to the cavity, wherein the second location is away from the mould.
15. 15. The system of claim 14, wherein the system further comprises a second mould having a cavity for partially forming the receptacle, and wherein the second location is the cavity of the second mould.
16. 16. The system of claim 11, wherein the component is the partially formed receptacle; and the expandable member operation mechanism is configured to cause movement of the expandable member relative to the cavity while the expandable member is at least partially expanded, such that the receptacle is carried from the cavity to the second location, wherein the second location is away from the mould.
17. 17. The system of any of claims 11 to 16, wherein the expandable member operation mechanism comprises a fluid control system configured to: supply a fluid into the expandable member to cause the expansion of the expandable member; and subsequently remove only a portion of the fluid from the expandable member before the movement of the expandable member is caused, such that the expandable member is in a partially contracted state while carrying the receptacle or partially formed receptacle.
18. 18. The system of any of claims 11 to 17, wherein the expandable member operation mechanism comprises a fluid control system configured to: supply a fluid into the expandable member to cause the expansion of the expandable member; and subsequently remove at least some of the fluid from the expandable member to contract the expandable member into a contracted state to cause the removal of the expandable member from within the receptacle or partially formed receptacle.
19. 19 The system of any of claims 11 to 18, further comprising a demoulding system configured to release the receptacle or partially formed receptacle from the cavity.