WO2018033212A1

WO2018033212A1 - Method for manufacturing a molded article from pulp, molded article made of pulp, and apparatus for manufacturing such a molded article

Info

Publication number: WO2018033212A1
Application number: PCT/EP2016/069629
Authority: WO
Inventors: Olaf Starken; Gian Armand Juliana De Belder; Wiebke VAN DER VEEN
Original assignee: Mayr-Melnhof Karton Ag
Priority date: 2016-08-18
Filing date: 2016-08-18
Publication date: 2018-02-22

Abstract

The invention relates to a method for manufacturing a molded article (10) from pulp (42), wherein the article (10) comprises at least one integrally formed article body (12), the method comprising at least the steps of: Introducing pulp (42) into a mold (24), wherein the mold (24) comprises at least one first cavity (26) for forming said article body (12) and at least one second cavity (28) for forming at least one holding means (14) to said integrally formed article body (12); and forming said molded article (10) with said holding means (14) within the mold (24). In a preferred embodiment, the molded article is a container with a handle.

Description

Method for Manufacturing a Molded Article from Pulp, Molded Article made of Pulp, and Apparatus for Manufacturing such a Molded Article

Description

The invention relates to a method for manufacturing a molded article from pulp. Moreover, the invention relates to a molded article made of pulp, and an apparatus for manufacturing such a molded article. Molded articles, such as, for example, bottles for containing mediums, in particular liquids and solids, are well-known from the prior art. For example, EP 2 524 876 B1 shows a blow molded article for containing at least 1 .5 liters of a detergent composition, the article comprising a body having a top and a bottom. The article further comprises an opening proximal to said top. Moreover, the article comprises a non-through holding means integrally located on at least one side of said body and positioned between said top and said bottom. The known blow molded articles are made of plastic resin material. The different types of plastic packaging might have several disadvantages associated with their raw materials and their recycling possibilities. Moreover, US 4 846 359 A1 shows a multi-layered plastic bottle having a body and a through holding means formed by a handle element which, on both of its ends, is connected to the body thereby forming the through holding means as a closed through holding means. The known methods are not suitable to manufacture pulp molded articles with a more complex contour such as, for example, a grip feature.

Further, WO 2009/153558 A1 discloses a container made of paper pulp comprising a hollow shell including a dispensing aperture and a bag or liner provided within the hollow shell. Further, the container comprises a handle portion. The hollow shell includes two portions that are joined by an interconnecting hinge or web. When the hollow shell is in an open configuration, said two portions lay side by side. WO 2009/133355 A1 discloses a method of forming such a container. A disadvantage of such known container is the fact, that there always remain lateral edges at the interconnecting zone between the two portions of the hollow shell. This leads to a poor visual appearance and a poor haptic appearance of the surface of the molded article. Also, by means of this method a liquid tight container can only be achieved via introducing an inner bag made of plastic which leads to a time- and cost-consuming process. In addition to a poor visual appearance and a poor handle-ability, the consumer is requested to separate the inner plastic bag from the connected paper pulp halves to allow proper disposal/recycling. This additional step might be perceived by consumers as a real hassle that could complicate proper recycling of this hybrid pack and is not a key enabler to further motivate consumers to recycle packs. To guarantee Circular Economies in the future, consumers' lives should be made as easy as possible, e.g. just dispose in the collection bin, without further request to dismantle hybrid packages.

In a first attempt to improve the visual appearance of a container, WO 2012/139590 A1 discloses an apparatus for producing a container defining a container geometry, the apparatus comprising a frame comprising a base supporting at least one mold, the mold including an opening, a pulp material feeding device configured to reciprocally enter the mold via the opening, a pulp reservoir in communication with the pulp material feeding device, the pulp reservoir configured to hold a pulp material, a pulp pressure reservoir configured to provide pressure so as to deliver the pulp material from the pulp reservoir via the pulp material feeding device to the at least one mold, an expandable device configured to be inserted into the at least one mold via the opening, wherein the expandable device have a geometry corresponding to the container geometry.

It is an objective of the present invention to provide a method for manufacturing a molded article from pulp, such a molded article made of pulp, and an apparatus for manufacturing such a molded article so that both a particularly advantageous visual appearance and a particularly advantageous haptic appearance of the molded article can be realized. It is another objective of the present invention to provide a method for manufacturing a molded article from pulp which is able to more easily produce pulp molded articles with a more complex contour.

These objectives are solved by a method having the features of patent claim 1 , a molded article having the features of patent claim 12 and an apparatus having the features of patent claim 17. Advantageous embodiments with expedient developments of the invention are indicated in the other patent claims.

A first aspect of the present invention relates to a method for manufacturing a molded article from pulp, wherein the article comprises at least one integrally formed article body. The method according to the present invention comprises a first method step of introducing pulp into a mold, wherein the mold comprises at least one first cavity for forming said article body. Moreover, the mold comprises at least one second cavity for forming at least one holding means to said integrally formed article body. Preferably, in the method, both the article body and the holding means are made of said pulp.

The method according to the present invention further comprises a second method step of forming said molded article with said holding means within the mold. By means of the method according to the present invention both a particularly advantageous visual appearance and a particularly advantageous sensorial feel, in particular surface feel, can be realized since ridges and edges impairing the visual appearance and the feel of the molded article can be avoided as at least the article body is integrally formed. Usually, conventional molded articles made of pulp and formed by at least two hollow shells connected with each other have ridges and/or edges which result from respective methods for manufacturing said conventional molded articles. Such ridges and edges impair both the visual appearance and the feel of the respective conventional molded article. Since, according to the present invention, at least the article body and/or the holding means are integrally formed such ridges and edges can be avoided. Further, the use of a renewable, biodegradable and/or recyclable raw material, namely pulp, is particularly advantageous in contrast to other raw materials like plastics. The term "integrally formed" means that the article body is formed as one piece, preferably in one production step.

Moreover, by means of the method according to the present invention, an ergonomic and sensorial advantage over conventional molded articles can be realized since particularly advantageous sensorial elements or features such as softness, appearance etc. can be realized. Furthermore, the method allows to use renewable and secondary raw materials, e.g. recycled material to manufacture the molded article. Further advantages are: providing easier end-of-life options (mono-component package to allow easy recycling, biodegradable packages pending final composition, etc.), and enabling the consumer benefit of an easier handling of large containers by means of the holding means which can be made of advantageous raw material which is easy to recycle.

For example, a particularly low roughness of the article's surface can be realized by means of the method according to the present invention, wherein, for example, the roughness is in a range from 0.5 micrometer to 20 micrometers. Thus, a particularly good feel and visual appearance can be realized.

For example, said holding means is a grip feature, handle or grip by means of which the molded article can be handled in a convenient and/or preferred by a person. In this regard, for example, the person can grasp the holding means by means of at least one hand so that the person can move the molded article via the holding means. With respect to a conventional molded article being, for example, a hybrid article having an inner plastic pouch contained within a pulp shell and/or made of a plastic material and, for example, formed by at least two hollow shells connected with each other, a person grasping and thus touching the conventional molded article, in particular the holding means of the conventional molded article can feel at least one edge of the conventional molded article so that the feel, in particular the surface feel, of the molded article is impaired by the edge. This problem can be avoided by means of the method according to the present invention. Thereby, both a particularly good first moment of truth and a particularly good second moment of truth can be realized. For example, the molded article is a consumer good and/or product or configured to contain at least one consumer good and/or product.

The person can handle and, thus, use the article particularly advantageously, in particular easily, by means of the holding means. Therein, a smooth surface is rather a first moment of truth benefit. Hence the holding means beneficial for said second moment of truth and hard ridges and edges which result from joining two hollow shells especially in the handle area can have a negative impact. Since, by means of the method according to the present invention, ridges and edges impairing the visual appearance and the surface feel of the molded article can be avoided, and the holding means can be provided, both an excellent first moment of truth and an excellent second moment of truth can be realized. Moreover, the molded article manufactured by the method according to the present invention can be handled, i.e. moved particularly easily since the molded article has said holding means which can be grasped by a person.

Preferably, the molded article is a container such as a bottle, said container being configured to contain a medium, in particular a solid and/or a liquid. For example, said liquid can be water, a detergent composition or a different liquid. Preferably, said medium is a consumer good which can be stored in the article. For example, the molded article has a capacity of at least 25 milliliters, in particular at least 0.5 liter and preferably at least 1 .5 liters, for storing said medium. For example, said solid can be a powder or a product comprising, for example, granulate and/or solid beads. The medium be in any physical form including solid, liquid, gel or paste.

For example, the holding means comprises an insertion direction in which a person can insert at least one of their fingers or thumb into the holding means so as to grasp the holding means. In this regard, the holding means can be configured as a through holding means which is also referred to as an open handle, open grip or through handle. Being a through handle the holding means is not limited in said insertion direction so that, for example, the through holding means comprises at least one through opening or gripping aperture through which a person can put at least one of their fingers. Thus, for example, the holding means can be grasped all around with respect to the circumferential direction of the holding means. Thus, the term "through handle" or "open handle" refers to any handle through which a person can put one or more fingers to allow an easy handling hence improving convenience and said second moment of truth (in-use phase). Alternatively, the holding means can be configured as a non-through holding means which is also referred to as a closed handle or closed grip. Such a non-through holding means is limited in the insertion direction by, for example, at least one wall of the molded article. For example, the non-through holding means comprises opposing depressions or receptacles which are arranged on both sides of said wall. In other words, the opposing depressions or receptacles are separated from one another by the wall so that the holding means is configured as a non-through holding means. In a through holding means said wall is not present thereby forming a completely open space through which fingers and/or a thumb can be inserted.

Moreover, the open or through holding means can be completely closed in its longitudinal extension so that, for example, at least one handle element of the holding means is connected to the article body at both ends. Such an open handle is, for example, also referred to as a two-side connected open handle. Alternatively, the through or open holding means can be open with respect to its longitudinal extension so that a first end of said handle element is connected to the article body and the other end of the handle element is arranged at a distance from the article body. Such an open handle is also referred to as a one-side connected open handle.

In an advantageous embodiment of the invention the second cavity is at least partially filled with the pulp before, during and/or after the first cavity is at least partially filled with the pulp. Thereby, for example, edges impairing the visual appearance and the feel of the molded article can be avoided.

For example, the holding means can be, at least in a portion, hollow so that the holding means is configured as a hollow component. Thus, for example, said medium can be stored in the holding means. Hence, the holding means has at least one first receiving space for receiving at least a portion of said medium. Alternatively or additionally, the article body has at least one second receiving space for receiving at least a portion of said medium so at last a portion of the medium can be stored in the article body. Preferably, the first receiving space is fluidically connected to the second receiving space so that the medium can be stored both in the article body and in the holding means. In order to realize an advantageous structural strength of the molded article, in a preferred embodiment of the invention, the second cavity is fully filled with the pulp. Thus, for example, the holding means is formed as a massive holding means so that a particularly high stiffness of the holding means can be realized. Thus, the molded article can be handled, i.e. moved via the holding means in a particularly advantageous way. Since, for example, the holding means is configured as a massive component the holding means is not hollow. This is particularly advantageous for articles having a great size or capacity, in particular greater than 1 .5 liters, for storing said medium.

In a further embodiment of the invention the second cavity is filled with a prefabricated holding means or with at least one part of a prefabricated holding means, in particular before filling the first cavity with the pulp. Thus, for example, a particularly high stiffness of the holding means can be realized. For example, the holding means or at least one part of the holding means is provided as a prefabricated component which is inserted into the second cavity. The prefabricated component is a component which is fabricated or manufactured independently of the article body, particularly before or after the article body is manufactured. For example, the prefabricated component is formed and, thus, connected to the article body within the mold. This means the prefabricated component forms the holding means or at least a portion of the holding means.

For example, within the mold, the pulp for forming the article body is brought into contact with at least one portion of the prefabricated component arranged in the second cavity. Thus, for example, the article body is connected to the prefabricated component, in particular while the article body is manufactured from the pulp. For example, the prefabricated holding means can be made (but not necessary) of the same material as the article body. For example, the prefabricated component can be made of paper, plastics, rubber, etc. or a combination thereof. For example, the handle can be hollow or solid. Preferably, said holding means, in particular the prefabricated component, is manufactured from pulp, in particular paper pulp, for environmental and recycling advantages.

In a further advantageous embodiment of the invention the pulp is sprayed into the mold. Thereby, the pulp can be distributed particularly equally within the mold and an equal wall thickness of the molded article can be realized. Moreover, the amount of pulp needed for manufacturing the molded article can be kept low. Moreover, shorter drying times and, thus, faster production cycles can be realized In a particularly advantageous embodiment of the invention at least one expandable device is introduced into the first cavity and/or the second cavity, in particular after the method step of introducing the pulp into the mold. For example, the expandable device is configured as an inflatable device which is also referred to as a balloon. For example, the expandable device can be configured as an expandable compressing device. The expandable device can be made of a flexible and/or elastic material. For example, the expandable device is made of a plastic material, in particular silicone or latex. The expandable device can be permeable or non-permeable. For example, the pulp is introduced into the first cavity and/or the second cavity. The at least one expandable device is expanded, in particular inflated, so as to compress the pulp thereby forming walls of the article body and/or the holding means. In other words, for example, the expandable device is expanded by inflating the expandable device. For example, the expandable device can be inflated by introducing a fluid into the expandable device. Preferably, from the expandable device an inner protective layer of the molded article is created. In other words, preferably, the expanded expandable device forms said inner protective layer bounding said receiving space of the article body. Thus, in a state in which said medium is contained in the receiving space of the article body, the inner protective layer is arranged between the medium and the pulp forming the article body so that the pulp forming the article body is protected from the medium by means of the inner protective layer. For example, the expandable device is made of a plastic material.

Preferably, the at least one expandable device is inflated so as to compress and dewater and/or dry the pulp. For example, the pulp is dewatered and/or dried by means of a fluid by means of which the expandable device is inflated in such a way that the fluid is introduced into the expandable device. Preferably, the fluid is heated, wherein the heated fluid is introduced into the expandable device so as to inflate the expandable device. Thus, for example, the pulp is dewatered and/or dried by means of the heated fluid which can be a liquid or a gas.

For example, the expandable device is permeable, wherein a heated fluid such as, for example, heated air, is conveyed or pressed through or into the pulp so as to drive out water from the pulp and, thus, dry the pulp. For example, the water can flow through and into the permeable expandable device. Alternatively or additionally, at least a portion of the mold is permeable so that water can flow out of the pulp and through the mold. Moreover, for example, the heated fluid is introduced into the expandable device and can flow through the expandable device and through or into the pulp thereby dewatering and/or drying the pulp.

Thus, the first cavity is used to form the article body from the pulp contained in the first cavity. Alternatively or additionally, the second cavity is used to form the holding means from the pulp contained in the second cavity. Preferably, the expandable device is inflated after the method step of introducing the pulp into the mold, i.e. into the first and/or second cavity. For example, said walls are wall portions bounding said receiving space of the article body and/or their holding means, wherein in the receiving space said medium, in particular said liquid, can be stored.

Preferably, within the scope of the present invention, said pulp can be a pulp slurry. For example, said pulp is configured as or comprises a paper pulp being, for example, a lignocellulosic fibrous material prepared by, for example, chemically and/or mechanically separating cellulose fibers from wood, fiber crops or paper, in particular waste paper. Alternatively or additionally, the pulp is configured as or comprises starch or foamed starch.

Alternatively or additionally, the pulp can comprises fibers or fiber solids such as, e.g. natural fibers, natural bamboo fibers and/or straw fibers and/or coconut fibers and/or synthetic fibers such as plastic fibers and/or treated fibers and/or untreated fibers and/or nano-cellulose. For example, said treated fibers are fibers which are treated in such a way so that said treated fibers are waterproof and/or water-resistant. Preferably, the pulp is a fibrous pulp comprising at least one of the afore-mentioned kinds of fibers. Furthermore, the pulp can comprise at least one or a plurality of additives.

In a particularly advantageous embodiment of the invention the method comprises the step of drying the pulp within the mold. Preferably, the pulp is not completely dried, but dried until a predefined amount of moisture of the pulp is reached. Thus, the pulp is not completely dry but adequately wet so that, for example, the pulp can be formed in a need-based manner. For example, the pulp is dried by heating the mold. For example, the pulp can be dried by heating the expandable device which, for example, is heated by introducing the heated fluid into the expandable device. Alternatively, the pulp is dried in a second operation, wherein, for example, the pulp is dried outside the mold. For example, the pulp can be dried in a component being different from the mold, wherein said component can be an oven. For example, the pulp can be dried completely, wherein, for example, the pulp is completely dried in an external oven which is different from the mold.

Furthermore, the pulp, in particular the article is dried by using fast drying methods such as (but not limited to) impulse drying and/or radiation technologies including microwave and UV (ultraviolet radiation) and/or by applying at least partially a vacuum to an outer part of a permeable mold thereby removing fluid from the pulp.

In order to form the holding means in a particularly advantageous way, in a further embodiment of the invention, the pulp for forming the holding means is pushed to the inside of the mold after the step of drying the pulp at least partially. In a further embodiment of the invention the pulp is further dried, in particular within the mold, after pushing the pulp for forming the holding means to the inside of the mold. Preferably, the pulp is completely dried. Thus, by pushing the pulp to the inside of the mold the holding means can be formed in a need-based manner. Then, by further drying the pulp, the form of the holding means can be fixed in order to realize a high stiffness and stability of the holding means. In other words, the pulp can be further dried in a second step, in particular within the mold and/or outside the mold.

In a further embodiment of the invention, after drying the pulp, in particular after drying the pulp partially, pushing the pulp to the inside of the mold and further drying the pulp, at least one portion of the pulp for forming the holding means is punched out so as to create the holding means as a through holding means (open handle). By punching out the pulp for forming the holding means at least one through opening of the holding means can be created thereby forming a completely open space through which a person grasping the holding means can insert their fingers and/or thumb so that the person can grasp and handle the molded article in a particularly comfortable way.

In order to realize a particularly high stiffness and stability of the holding means, in a preferred embodiment of the invention, the pulp for forming the holding means is compressed and shaped after filling the second cavity with pulp. Thus, for example, a defined geometry of the holding means can be created in a need-based manner. Preferably, the pulp for forming the holding means is compressed, shaped and dried so that the pulp can be dried particularly fast. For example, the pulp for forming the holding means is compressed and shaped by means of at least one heated tool so that, for example, the pulp can be shaped and dried at the same time. Moreover, a short drying time can be realized by increasing the contact area between the heated tool and the pulp. A second aspect of the present invention relates to a molded article made of pulp so that said molded article is a pulp molded article. The molded article according to the present invention comprises at least one integrally formed article body and at least one holding means formed with the article body. In a preferred embodiment, the holding means is open (e.g. through open handle or one-side connected open handle). The inventive molded article has a particularly advantageous visual appearance and a particularly advantageous feel and/or ergonomics, in particular surface feel, since there are no ridges and edges impairing the visual appearance and the feel of the molded article as at least the article body is integrally formed. Usually, conventional molded articles made of pulp have ridges and/or edges which limit ergonomics and result from respective methods for manufacturing said conventional molded articles. Such ridges and edges impair both the visual appearance and the feel of the respective conventional molded article. Since, according to the present invention, at least the article body and/or the holding means are integrally formed such ridges and edges can be avoided. In particular, tailor made handles are possible so that particularly advantageous ergonomics can be realized.

Further, the use of a renewable, biodegradable and/or recyclable raw material, namely pulp or paper pulp, is particularly advantageous compared to other raw materials like plastics or hybrid packs. With respect to the molded article according to the present invention, the molded article having the article body and the holding means, there is no need to separate a plastic pouch from a pulp shell for recycling purposes. In preferred embodiments of the invention, the molded article according to the present invention said holding means is an open or through holding means or a non-through holding means. Further, it is possible that the holding means comprising an at least partially hollow and/or massive form. Furthermore, the holding means can comprise an at least partially structured gripping surface. Examples for suitable holding means are disclosed for example in EP 2 524 876 B1 and US 4 846 359 A1 . Further improvements in aesthetics and softness can be achieved through proper selected pulp raw materials and/or additives.

Advantages and advantageous embodiments of the first aspect of the present invention are to be regarded as advantages and advantageous embodiments of the second aspect of the present invention and vice versa.

In a preferred embodiment of the invention, the molded article according to the present invention is manufactured by a method according to the present invention.

A third aspect of the present invention relates to an apparatus for manufacturing a molded article made of pulp, the apparatus being used in a method according to the present invention, wherein the apparatus comprises at least a mold comprising at least one first cavity for forming an integrally formed article body and at least one second cavity for forming at least one holding means to said article body. Advantages and advantageous embodiments of the first and second aspects of the present invention are to be regarded as advantages and advantageous embodiments of the third aspect of the present invention and vice versa. Common techniques to make said molded article liquid proof (as those well known to people skilled in the art) can be applied onto the resulting article.

Further advantages, features, and details of the invention derive from the following description of preferred embodiments as well as from the drawings. The features and feature combinations previously mentioned in the description as well as the features and feature combinations mentioned in the following description of the figures and/or shown in the figures alone can be employed not only in the respective indicated combination but also in any other combination or taken alone without leaving the scope of the invention.

The drawings show in:

Fig. 1 a schematic view of a first embodiment of an inventive method for manufacturing a molded article from pulp, wherein the article comprises at least one article body and at least one holding means;

Fig. 2 a schematic view of a second embodiment of the method according to the invention; Fig. 3 a schematic view of a third embodiment of the method according to the invention; a schematic view of a fourth embodiment of the method according to the invention; a schematic front view of a first embodiment of the molded article according to the invention; a schematic front view of a second embodiment of the molded article according to the invention; a schematic front view of a third embodiment of the molded article according to the invention; Fig. 8 a schematic view of a fifth embodiment of the method according to the invention; Fig. 9 a schematic view of a sixth embodiment of the method according to the invention;

Fig. 10 a schematic view of a seventh embodiment of the method according to the invention;

Fig. 1 1 a schematic view of an eighth embodiment of the method according to the invention; and

Fig. 12 a schematic view of a ninth embodiment of the method according to the invention.

In the figures the same elements or elements having the same functions are indicated by the same reference signs.

Fig. 1 shows in a schematic view a first embodiment of a method for manufacturing a molded article 10 (See Figs. 6 to 8) from pulp. In other words, the molded article 10 is made of pulp so that the molded article 10 is a pulp molded article. As can be seen from Figs. 6 to 8 the molded article 10 is a container in the form of a bottle comprising at least one receiving space for receiving or storing a medium, in particular a solid and/or a liquid. For example, the molded article 10 has a capacity of at least 25 milliliters, in particular of at least 0.5 liter and preferably of at least 1 .5 liters, for storing said medium. The molded article 10 comprises at least one article body 12 and at least one holding means 14 connected to the article body 12. For example, the article body 12 and the holding means 14 are formed in one piece. As an alternative, the article body 12 and the holding means 14 are configured as separate components which are connected with each other. Preferably, both the article body 12 and the holding means 14 are made of pulp. The pulp is a slurry which is also referred to as a pulp slurry. For example, said pulp is or comprises a paper pulp being, for example, a lignocellulosic fibrous material prepared by, for example, chemically and/or mechanically separating cellulose fibers from wood, fiber crops or paper, in particular waste paper. The paper slurry contains at least pulp fiber having an average fiber length of 0.4 to 8 millimeters (mm), preferably 0.4 to 4.0 mm. Moreover, the pulp can contain further fibers such as, for example, nano- fibers which are shorter. The pulp is a fibrous pulp comprising fibers. For example, the pulp comprises synthetic fibers and/or natural fibers. The pulp can comprise cellulose fibers and/or plastic fibers and/or coconut fibers and/or bamboo fibers and/or treated fibers and/or untreated fibers and/or nano-cellulose and potentially at least one or a plurality of additives such as starch.

For example, the article body 12 comprises or bounds said receiving space for containing said medium. Alternatively or additionally, the holding means 14 comprises or bounds a second receiving space for storing a medium, in particular a liquid or a solid. Preferably, when both the article body 12 and the holding means 14 comprise or bound at least one receiving space respectively, said receiving spaces are fluidically connected with each other.

The article body 12 comprises at least one inlet 16 (See Figs. 6 to 8) having at least one inlet opening which cannot be seen in the figures. Said inlet opening opens into said receiving space bound by the article body 12 so that said receiving space bound by the article body 12 can be filled with said medium via said inlet opening. A cap 18 is connected to the inlet 16 so that said inlet opening is closed by the cap 18. The cap 18 is reversibly connected to the inlet 16 which means that the cap 18 can be attached to and detached from the inlet 16 in a non-destructive way so that the inlet opening can be closed and opened by the cap 18 in a need-based manner.

As can be seen from Fig. 1 , a tool 20 is used for manufacturing the molded article 10. For example, said tool 20 comprises at least one tool element 22. For example, the tool 20 comprises at least two tool elements which are, for example, tool halves. For example, said tool 20 is or forms or is part of an apparatus for manufacturing the molded article 10, wherein said apparatus is used in said method. The tool 20 comprises at least one mold 24 used to manufacture and form the molded article 10, in particular the article body 12 and the holding means 14. As will be described in greater detail below, in said method, the pulp 42 is introduced into the mold 24. The mold 24 comprises at least one first cavity 26 for forming the article body 12. Moreover, the mold 24 comprises at least one second cavity 28 for forming the holding means 14 to the article body 12. Moreover, in said method, the molded article 10 is formed with the holding means 14 within the same mold 24. By introducing the pulp 42 into the mold 24, the pulp 42 is introduced into the first cavity 26 and/or the second cavity 28.

In a first method step S1 of the first embodiment of the method for manufacturing a molded article 10 the second cavity 28 is filled with the pulp 42 before the first cavity 26 is filled with the pulp 42. In other words, in the first method step S1 , the second cavity 28 is filled with the pulp 42 before the pulp 42 is introduced into the first cavity 26. In the first embodiment, the second cavity 28 is completely filled with the pulp 42 so that, for example, the holding means 14 is formed as a massive holding means which does not have any receiving space for receiving said medium. For example, the pulp 42 is introduced into the second cavity 28 by means of at least one injection lance 33 having at least one or a plurality of outlet openings through which the pulp 42 is spayed out of the injection lance 33. Further, the first embodiment comprises a second method step S2 which succeeds the first method step S1 . In the second method step S2 the pulp 42 is introduced into the first cavity 26 after the second cavity 28 had been completely filled with pulp 42. As can be seen from Fig. 1 , the pulp 42 is sprayed into the first and second cavities 26 and 28. Preferably, the pulp 42 is sprayed into the mold 24, in particular into the first cavity 26 so that the pulp 42 sprayed into the first cavity 26 in the second method step S2 comes into contact with first walls or first wall portions of the mold 24, said first walls or first wall portions bounding the first cavity 26 at least partially. By introducing the pulp 42 into the second cavity 28 the pulp 42 comes into contact with second walls or second wall portions of the mold 24, the second walls or second wall portions bounding the second cavity 28 comprising the holding means 14 at least partially.

Moreover, preferably, the second cavity 28 is connected, in particular fluidically connected, to the first cavity 26. In the first embodiment, the second cavity 28 is fluidically connected to the first cavity 26 in two areas 30. Thus, in the second method step S2, the pulp 42 sprayed into the first cavity 26 in the second method step S2 comes into contact with the pulp 42 contained in the second cavity 28 in said areas 30. The pulp 42 introduced into the first cavity 26 forms the article body 12. Moreover, the pulp 42 contained in the second cavity 28 forms the holding means 14. Since the pulp 42 forming the article body 12 can come into contact with the pulp 42 forming the holding means 14 the article body 12 can be connected to the holding means 14. In other words, the holding means 14 can be formed to the article body 12 resulting in an integrally formed article 10.

For spraying the pulp 42 into the mold 24, in particular the first cavity 26, at least one injection lance 31 is used. The injection lance 31 is introduced into the mold 24, in particular the first cavity 26, at least partially, the injection lance 31 has at least one outlet opening through which, for example by means of compressed air, the pulp 42 is sprayed. For example, the injection lance 31 has a plurality of outlet openings through which, for example by means of compressed air, the pulp 42 is sprayed. The pulp 42 flows through the injection lance 31 and its outlet openings so that the pulp 42 can leave the injection lance 31 . Thus, the pulp 42 is sprayed against said first walls of the mold 24 by means of compressed air and the injection lance 31 . The injection lance 31 is fluidically connected to a pulp source (not shown).

Preferably, the injection lance 31 is rotated about at least one rotation axis in relation to the mold 24, in particular whilst spraying the pulp 42 into the mold 24. For example, said rotation axis coincides with or extends parallel to the longitudinal extension of the injection lance 31 .

Further, the first embodiment comprises a third method step S3 which, for example, succeeds the second method step S2. In the third method step S3 at least one expandable device 32 is introduced into the mold 24. For example, the expandable device 32 is configured as an inflatable device which is also referred to as a balloon. In the first embodiment, the expandable device 32 is introduced into the first cavity 26 after the step of introducing the pulp 42 into the first cavity 26. Moreover, in the first embodiment, no expandable device is introduced into the second cavity 28. The expandable device 32 is flexible and/or elastically deformable, wherein the expandable device 32 bounds at least one volume. For example, the expandable device 32 can be made of a permeably or non-permeable material so that the expandable device can be permeable or non-permeable. In the third method step S3, the expandable device 32 is expanded by inflating the expandable device 32. The expandable device is inflated by, for example, introducing a medium such as a fluid into said volume of the expandable device 32. For example, said fluid can be a gas and/or a liquid or comprise at least one gas and/or a liquid. In other words, a medium such as a fluid is introduced into the expandable device 32 so as to inflate the expandable device 32. Preferably, said medium which is introduced into the expandable device 32 is air, in particular compressed air. By inflating the expandable device 32, the expandable device 32 is expanded so that the pulp 42 which had been sprayed into the first cavity 26 is pushed against said first walls. Moreover, the pulp 42 contained in the first cavity 26 is pushed against the pulp 42 contained in the second cavity 28 in the areas 30. Moreover, by inflating the expandable device 32 the pulp 42 contained in the first cavity 26 is compressed thereby forming walls of the article body 12, said walls of the article body 12 comprising an inner surface 86 bounding said receiving space of the article body 12 and an outer surface 84.

Moreover, for example, by inflating the expandable device 32 the pulp 42 will be compressed and dewatered and/or dried. Preferably, the medium to be introduced into the expandable device 32 is heated so that the heated medium is introduced into the expandable device 32. Thus, expandable device is dewatered and/or dried by means of the heated medium. Compressing the pulp is carried out to realize a nice and smooth surface but also for drying and/or dewatering reasons. Preferably, the mold 24, in particular the tool element 20 and/or the tool elements is or are permeable. Thus, by compressing the pulp, moisture is pressed out of the pulp 42 and through the moisture permeable mold 24.

For example, the medium used to inflate and, thus, expand the expandable device 32 can be heated so that the expandable device 32 is inflated and, thus, expanded by a heated medium such as, for example, a heated gas which can be heated air. For example, if the expandable device 32 is permeable, the heated medium can flow through the expandable device 32 and into the pulp 42 so that the heated medium is pressed into and/or through the pulp 42 so as to drive out water from the pulp 42 and, thus, dry the pulp 42. Furthermore, for example, at least a portion of the mold 24 is evacuated or set under a vacuum so that the pulp 42 is sticking more easily to the mold 24, in particular to inner walls of the mold 24, and so that the pulp 42 can be dewatered, said inner walls bounding the cavity 26. Preferably, the mold 24 comprises or is made of a permeable material through which the moisture from the pulp 42 can escape or, in particular by means of the vacuum, withdrawn as illustrated by arrows in Fig. 1 , step S3. Preferably, the mold 24 is permeable or made of a permeable material so that moisture can be sucked out of the pulp 42 by means of the vacuum as illustrated by arrows pointing to the outside of the mold 24 in Fig. 1 , step S3

For example, after and/or while the expandable device 32 is inflated the pulp 42 contained in the cavity 26 and/or 28 is heated and thus dried. Moreover, for example, after and/or whilst drying the pulp 42 the expandable device 32 is deflated and moved out of the mold 24. For example, after drying the pulp 42 within the mold 24 the molded article 10 can be removed from the mold 24. After that, for example, the holding means 14 and/or the article body 12 can go through an additional drying step. For example, in order to heat the pulp 42 contained in the mold 24, the mold 24 is heated. Alternatively or additionally, the expandable device 32 is heated in order to heat the pulp 42. For example, in order to heat the expandable device 32, the heated medium is introduced into the expandable device 32 so as to inflate the expandable device by means of the heated medium.

The first embodiment of the method for manufacturing comprises an optional fourth method step S4 in which at least a portion of the holding means 14 or the pulp 42 forming the holding means 14 is compressed in order to form the holding means 14. For this purpose at least two tool elements 34 are used. The holding means 14 or the pulp 42 forming the holding means 14 is compressed and, thus, formed by means of the tool elements 34. For example, the tool elements 34 are stamps which are pressed into the pulp 42 forming the holding means 14 at least partially as illustrated by arrows 36. The stamps compose or comprise, for example, two fingers 38 respectively which are pressed into the holding means 14 or the pulp 42 forming the holding means 14 respectively thereby forming lateral channels 40 in the holding means 14. For example, before forming the channels 40 the pulp 42 is not completely dried so that the channels 40 can be formed in a need-based manner. After forming the channels 40 the pulp 42 is further, in particular completely, dried so as to realize a particularly high stiffness of the molded article 10. The channels 40 result in a structured surface of the holding means 14 thereby improving the grip and the haptic of the holding means 14. Preferably, the tool elements 34, in particular the fingers 38, are heated so that the heated fingers 38 are pressed into the pulp 42 forming the holding means 14 so as to heat and, thus, dry the pulp 42 and, thus, the holding means 14 particularly fast via increasing the contact area between the heated tool and the pulp. Moreover, the fingers 38 are used to create a great stiffness of the holding means 14.

Fig. 2 shows a second embodiment of the method for manufacturing the molded article 10. In a first method step S1 pulp 42 for forming the article body 12 and pulp 42 for forming the holding means 14 are simultaneously sprayed into the mold 24, i.e. into the cavities 26 and 28. In other words, in the second embodiment, both cavities 26 and 28 are simultaneously filled with pulp 42 at least partially. For this purpose an injection lance 31 is used so that the pulp 42 is sprayed into both cavities 26 and 28 by means of the injection lance 31 . For example, the injection lance 31 has at least one or a plurality of nozzles through which the pulp 42 is sprayed out of the injection lance 31 . In the second embodiment, the holding means 14 is formed as a massive component so that, in the second embodiment as well, the second cavity 28 is completely filled with pulp 42. However, the integrally formed article body 12 is formed as a hollow component so that, in the completely manufactured state of the article 10, the inner surface 86 of the wall of the article body 12 bounds said receiving space for receiving the medium. As can be seen from Fig. 2, S1 the pulp 42 will be sprayed towards the inner walls of the cavity 26 and into said cavity 28.

Moreover, in the second method step S2, an expandable device 32 is introduced into the first cavity 26. Moreover, the expandable device 32 is inflated so as to push the pulp 42 contained in the first cavity 26 against the first walls bounding the first cavity 26. Moreover, by inflating the expandable device 32, the pulp 42 contained in the first cavity 26 is pushed against portions of the pulp 42 contained in the second cavity 28 so that the holding means 14 can be formed to the article body 12 within the mold 24. By pushing the pulp 42 contained in the first cavity 26 against the first walls and against portions of the pulp 42 contained in the second cavity 28 the pulp 42 contained in the first cavity 26 is compressed. By compressing the pulp 42 contained in the first cavity 26 the pulp 42 is shaped since the pulp 42 follows the form of the mold 24, in particular the first cavity 26. Consequently, the inner and outer surfaces 86, 84 of the wall of the integrally formed article body 12 will be formed. Preferably, the pulp 42 contained in the first cavity 26 is compressed after the method step of completely filling the second cavity 28 with the pulp 42. Moreover, in the second embodiment, the tool elements 34 are used to compress and shape the holding means 14, in particular to manufacture the channels 40 and to decrease the drying time via increasing the contact area between the heated tool elements 34 and the pulp.

Fig. 3 shows a third embodiment of the method for manufacturing the molded article 10. For example, in the third embodiment, the tool 20 comprises the tool element 22 and a second tool element 54. In a first method step S1 of the third embodiment the tool 20 is open. As can be seen from Fig. 3 the cavities 26 and 28 are bounded by the tool elements 22 and 54, in particular in a state in which the tool 20 is closed. Respective first portions of the first and second cavities 26 and 28 are bounded by the tool element 22, wherein respective second portions of the first and second cavities 26 and 28 are bounded by the tool element 54.

In the first method step S1 a prefabricated component 56 for forming the holding means 14 is provided and introduced into the second cavity 28 or in the first portion of the second cavity 28, the first portion of the second cavity 28 being formed by the tool element 22. The prefabricated component 56 is introduced into the second cavity 28 or the first portion of the second cavity 28 while the tool 20 is open and before the article body 12 is formed. The at least two tool elements 22 and 54 are used in order to take the molded article 10 out of the mold 24 after forming the molded article 10. Preferably, at least two tool elements are used in the other embodiments. Thus, the prefabricated component 56 is introduced into the cavity 28 or the first portion of the second cavity 28 while the tool 20 and thus the mold 24 are open. Said prefabricated component is manufactured independently of the article body 12. Particularly, the prefabricated component is manufactured and introduced into the second cavity 28 before the article body 12 is manufactured by means of the mold 24. In other words, in the third embodiment, the second cavity 28 is filled with a prefabricated holding means formed by said prefabricated component 56. Particularly, the prefabricated component 56 or holding means is introduced into the second cavity 28 before the first cavity 26 is filled with the pulp 42 and before the tool 20 is closed.

In the first method step S1 the prefabricated component 56 (prefabricated holding means) is introduced into the first portion of the second cavity 28, in particular whilst the tool 20 is open.

In a second method step S2 the tool 20 is closed after introducing the component 56 into the cavity 28 or the first portion of the second cavity 28 thereby introducing the prefabricated component 56 (prefabricated holding means) into the second portion of the second cavity 28. For example, the tool 20 and thus the mold 24 are closed by moving the tool elements 22 and 54 towards each other. For opening the tool 20 and thus the mold 24, the tool elements 22 and 54 are moved away from each other.

In a third method step S3 the pulp 42 for forming the article body 12 is introduced, in particular sprayed, into the mold 24, in particular the first cavity 26. In the third method step S3 the pulp 42 is introduced, in particular sprayed, into the first cavity 26 whilst the prefabricated component 56 for forming the holding means 14 is arranged in the second cavity 28. Thus, the pulp 42 sprayed into the first cavity 26 comes into contact with the prefabricated component 56 in the areas 30 in which, as described above, the second cavity 28 is fluidically connected to the first cavity 26. Thus, the prefabricated component 56 for forming the holding means 14 can be connected to the article body 12, in particular within the mold 24. Preferably, the third method step S3 of the third embodiment succeeds the second method step S2 of the third embodiment.

In a fourth method step S4 succeeding the third method step S3 an expandable device 32 is introduced into the first cavity 26 after the step of introducing the pulp 42 into the first cavity 26. Moreover, in the fourth method step S4, the expandable device 32 is inflated thereby pushing the pulp 42 contained in the first cavity 26 against the first walls and the prefabricated component 56 or portions of the prefabricated component 56 so that the pulp 42 contained in the first cavity 26 is compressed, dewatered and bound to or pushed against the component 56.

For example, the prefabricated component 56, i.e. the prefabricated holding means 14 can be made of the same material as the article body 12 and/or pulp 42 or carton tube so that, for example, the prefabricated component 56 can be configured as a tube, in particular a carton or paper tube. For example, the prefabricated component 56 is merged to the article body 12. For example, the prefabricated component 56 is a massive component which does not have any receiving space for storing said medium. Alternatively, the prefabricated component 56 can be configured as a hollow component so that the medium to be contained or stored in the molded article 10 can be stored at least partially in the holding means 14, i.e. the hollow prefabricated component. Further, the prefabricated component 56 can be made of plastics, rubber, etc. For example, if the component 56 is hollow in order to form the holding means 14 as a hollow holding means, mold 24 can comprises at least one or a plurality of action valves which close during pulp injection.

Fig. 4 shows a fourth embodiment of the method for manufacturing the molded article 10. In a first method step S1 the pulp 42 for forming both the article body 12 and the holding means 14 is introduced, in particular sprayed, into the mold 24 by means of at least one injection lance 31 . As described with regard to the first embodiment, for example, the injection lance 31 is rotated about at least one rotation axis in relation to the mold 24, in particular the tool 20, whilst spraying the pulp 42 into the mold 24. Thus, the first and/or second walls of the mold 24 are coated with the pulp 42 at last substantially evenly.

As can be seen from Fig. 4 the mold 24 has two recess areas or second cavities 28 for forming the holding means 14. In other words, for example, the second cavities 28 are formed by respective recesses of the first cavity 26. In the first method step S1 , the pulp 42 is sprayed against the second walls bounding the respective second cavities 28 so that the pulp 42 sprayed into the second cavities sticks to the second walls. Thus, the cavities 28, in particular the second walls bounding the cavities 28, are coated with the pulp 42 at the same time as the pulp 42 is sprayed into the first cavity 26 so as to coat the first walls bounding the first cavity 26 with the pulp 42. Thus, the pulp 42 sticks to the first walls bounding the first cavity 26 is at least partially filled with the pulp 42. Moreover, the second cavities 28 are fluidically connected to the first cavity 26. After the cavities 26 and 28, i.e. the first and second walls are coated with the pulp 42, in a second method step S2 which is succeeding the first method step S1 , an expandable device 32 is introduced into the mold 24, in particular into the first cavity 26 and/or the second cavities. Moreover, in the second method step S2, the expandable device 32 is expanded by inflating the expandable device 32 thereby pushing the pulp 42 against the first walls bounding the first cavity 26 and the second walls bounding the second cavities 28. Moreover, since the second cavities 28 are fluidically connected to the first cavity 26 in areas 30, by inflating the expandable device 32, expandable device 32 reaches out into the second cavities 28 and, thus, pushes the pulp 42 contained in the second cavities 28 against said second walls bounding the second cavities 28.

Thus, the pulp 42 contained in the mold 24 is compressed and dewatered and the pulp 42 for forming the holding means 14 can be connected to the pulp 42 forming the article body 12 so that the holding means 14 can be connected with or formed to the article body 12, in particular within the mold 24.

Moreover, after compressing the pulp 42 by means of the expandable device 32 at least a portion of the pulp 42 contained in the mold 24 is dried only to a certain extent. Preferably, at least the pulp 42 contained in the second cavities 28 is dried only to a certain extent. In other words, at least a portion of the pulp 42 contained in the mold 24, in particular at least the pulp 42 contained in the second cavities 28 is dried until a predefined amount of moisture of the pulp 42 is reached which means that after drying the pulp 42 the pulp 42 is still humid or moist. Thus, in the second method step S2 a first process of drying at least a portion of the pulp 42 contained in the mold 24 is conducted, wherein, in the first process of drying at least a portion of the pulp 42, the pulp 42 or said portion is not completely dried so that, after the first process of drying, the pulp 42 or said portion is still humid wet. Thus, at least said portion of the pulp 42 has an adequate or sufficient degree of flexibility for a third method step S3 in which a shaping procedure is carried out. The pulp 42 contained in the second cavities 28 form protrusion which are also referred to as ears. In the third method step S3 succeeding the second method step S2 the dried but still moist or humid pulp 42 for forming the holding means 14, i.e. said protrusions are pushed to the inside of the mold 24 which is illustrated by arrows 58. By pushing the pulp 42 for forming the holding means 14 to the inside of the mold 24 the pulp 42 contained in the respective second cavities 28 is pushed or moved towards each other. After pushing the pulp 42 contained in the respective cavities 28 to the inside of the mold 24 and, in particular, towards each other, a second process of drying the pulp 42 contained in the mold 24 is conducted, wherein the second process of drying is conducted after the first process of drying. This means, in the second process of drying, the pulp 42 is further dried so that the extent of moisture contained in the pulp 42 is further reduced. This means, in the first process of drying the pulp 42 contained in the mold 24, the extent of moisture contained in the pulp 42 is reduced from a first value to a second value different from zero. Moreover, in the second process of drying the pulp 42 contained in the mold 24 the extent of moisture contained in the pulp 42 is further reduced from the second value to a third value which can be zero or different from or close to zero.

After pushing the pulp 42 contained in the cavities 28 to the inside of the mold 24 and towards each other and after the second process of drying the molded article 10, which may be contained in the mold 24, has a state which is indicated by Z1 in Fig. 4. In the state Z1 the holding means 14 is configured as a closed or non-through holding means which will be described in greater detail below. In the state Z1 the molded article 10 can be used as such. However, preferably, the closed holding means is converted into an open or through holding means. In order to convert the closed holding means into an open or through holding means, a fourth method step S4 succeeding the third method step S3 is conducted.

In the fourth method step S4 succeeding the third method step S3 the pulp 42 for forming the holding means 14, in particular the closed holding means, is punched out so as to create the holding means 14 as a through holding means. For example, the pulp 42 for forming the holding means 14 is punched out by means of at least one mechanical action such as pinching and/or drilling and/or cutting and/or laser cutting etc. By punching out the pulp 42 at least a portion 60 of the pulp 42 is separated, in particular cut, from the remaining pulp 42 for forming the article body 12 and the holding means 14. Moreover, by punching out the pulp 42, at least one through opening 62 of the holding means 14 is created thereby creating the holding means 14 as an open or through holding means. By creating the through opening 62 a completely open space through which a person can insert their fingers and/or thumb is created. Thus, the person can grasp the holding means 14 in a particularly comfortable way. In Fig. 4, the molded article 10 and the mold 24 are shown in different views, i.e. from different angles. The respective rightmost drawings are partial side views of the molded article 10, wherein the remaining drawings are sectional back or front views

Fig. 5 shows a first embodiment of the molded article 10. In the first embodiment of the molded article 10 the holding means 14 is configured as an open through holding means which is also referred to as an open handle, open holding means or open grip, wherein the holding means 14 is configured as a one-side connected open handle or a one-side connected through holding means. Since the through holding means comprises the at least one through opening 62 a person grasping the holding means 14 can wrap their fingers completely around the holding means 14 in the area of the through opening 62. Thus, the person can grasp the holding means 14 particularly tight so that the person can handle the molded article 10 via the holding means 14 particularly advantageously.

Moreover, the holding means 14 is, in its longitudinal extension, open at only one location 64. This means the holding means 14 according to the first embodiment of the molded article 10 is not completely closed in its longitudinal extension. Therein, a first end 66 of the holding means 14 is connected to the article body 12. However, the second end 68 of the holding means 14 is not connected to the article body 12, but arranged at a distance from the article body 12 so that the through holding means 14 according to Fig. 5 is configured as a one-side connected through holding means. Fig. 6 shows a second embodiment of the molded article 10. In the second embodiment, the holding means 14 is also configured as a through holding means, i.e. an open handle, through handle, through grip or open grip. Thus, the open holding means or through holding means has at least one through opening 62 through which a person can put one or more of their fingers. However, the holding means 14 according to the second embodiment is connected to the article body 12 at both ends 66 and 68. Thus, the holding means 14 is completely closed in its longitudinal extension so that the holding means 14 is configured as a two-side connected through holding means which is also referred to as a two-side connected open handle. Moreover, the holding means 14 can be formed integral with the article body 12 so that, for example, the article body 12 and the holding means 14 are formed in one piece.

Fig. 7 shows a third embodiment of the molded article 10. In the third embodiment the holding means 14 is configured as a non-through holding means which is also referred to as a closed handle, closed integral grip or closed grip. The non-through holding means does not comprise any through opening through which a person can put their fingers. The non-through holding means has lateral receptacles which are arranged on opposite sides of the holding means 14. From said receptacles a first one of said receptacles can be seen in Fig. 8, the first receptacle being indicated by 70. The receptacles are also referred to as depressions.

In the non-through holding means the holding means 14 or the respective receptacle is or are limited in the insertion direction by a wall 72 of the molded article 10, the wall 72 being arranged between said receptacles. Thus, said receptacles are separated from one another by means of the wall 72. The wall 72 is, for example, made of the pulp 42, wherein, for example, the wall 72 is formed in one piece with the holding means 14 and/or the article body 12. Since the wall 72 is recessed with respect to at least one wall portion 74 of the holding means 14 the wall 72 bounds or limits the receptacles. In other words, the wall forms a bottom of the receptacles. Moreover, since the wall 72 is recessed with respect to the wall portion 74, a person can insert at least one of their fingers into the respective receptacle until said at least one finger comes into contact with the wall 72. Thus, the person can grasp the holding means 14 particularly tight. For example, the third embodiment of the method for manufacturing the article body 10 shown in Fig. 7 corresponds to the state Z1 shown in Fig. 4 so that, for example, the portion 60 which is punched out in the fourth method step S4 forms, in the state Z1 , the wall 72. Moreover, for example, by punching out the wall 72 the non-through holding means is converted into a through holding means.

Fig. 8 shows a fifth embodiment of the method for manufacturing the article body 10, wherein, for example, the fifth embodiment of the method can be used for the tool 20 comprising at least the tool element 22 or the tool 20 comprising the two tool elements 22 and 54. In the fifth embodiment the inflatable device 32 is part of a forming means 76 used to push the pulp 42 against the inner surfaces of the first and second walls of the mold 24, and, thus, compressing the pulp 42. Further, the forming means 76 comprises a forming element 78 which is also referred to as a finger. Furthermore, the expandable device 32 is connected via an inflating lance 80 to a medium source such as a fluid source (not shown). For example, the forming means 76, in particular the expandable device 32 and/or the forming element 78, is pre-shaped. As can be seen from Fig. 8, the expandable device 32 comprising a base element, the finger (forming element 78) protruding from the base element. Particularly, the expandable device 32 is inserted into the first cavity 26 so that the expandable device 32 is used to push the pulp 42 contained in the first cavity 26 against the first walls of the mold 24. At the same time, the forming element 78 is inserted into the second cavity 28 so that the forming element 78 is used to push the pulp 42 contained in the second cavity 28 against the second walls of the mold 24. Preferably, the forming element 78 has a volume in which a medium such as a fluid can be introduced to inflate the forming element 78. Preferably, the volume of the forming element 78 is fluidically connected to the volume of the inflatable device 32 so that, for example, the expandable device 32 and the forming element 78 can be inflated simultaneously. Thus, for example, the forming element 78 is also configured as an expandable device which can be inflated and thus expanded for pushing the pulp 42 contained in the second cavity 28 against the second walls bounding the second cavity 28. In Fig. 8, the forming means 76 is used to form the holding means 14 being connected to the article body 12 at both ends of the holding means 14. The forming means 76 and, thus, the expandable element 32 and the forming element 78 are used to compress the pulp 42 so that the forming means 76 and, thus, the expandable device 32 and the forming element 78 are used as compressing devices. Preferably, the respective compressing device is not only used to push the pulp 42 against respective walls of the mold 24, but also heated for drying purpose, i.e. to dry the pulp 42 at least partially. In order to heat the respective compressing device, said medium for inflating the respective compressing device is heated and the heated medium is introduced into the respective compressing device so as to heat the respective compressing device and, via the respective compressing device, the pulp 42 thereby, for example, drying the pulp.

Fig. 9 shows a sixth embodiment of the method for manufacturing the article body 10 in which the forming means 76 comprising the expandable device 32 and the forming element 78 is used to form the holding means 14 being connected to the article body 12 at the end 66 only, wherein the other end 68 is arranged at a distance from the article body 12. This means, in the sixth embodiment, the holding means is completely closed in its longitudinal extension, wherein in the seventh embodiment, the holding means 14 is open at one location so that one end of the holding means 14 is arranged at a distance from the article body 12 while the other end of the holding means 14 is connected to the article body 12.

Fig. 10 shows a seventh embodiment of the method for manufacturing the article body 10. In the eighth embodiment the forming means 76 comprises a plurality of expandable devices 32 which are introduced into the first cavity 26. Moreover, the forming means 76 comprises the forming element 78 which is also configured as an expandable device, wherein the forming element 78 is arranged in the second cavity 28 at least partially. As shown in Fig. 10, a first portion of the forming element 78 is arranged in the first cavity 26 and a second portion of the forming element 78 is arranged in the second cavity 28.

After introducing the forming means 76 into the cavities 26 and 28 the expandable devices 32 and the forming element 78 are inflated and thus expanded by a medium, in particular a fluid such as a gas, e.g. air, or a liquid. For this purpose an inflating lance 80 is used by means of which the fluid is introduced into the forming means 76, i.e. into the expandable devices 32 and the forming element 78. Thereby the pulp 42 contained in the cavities 26 and 28 is pressed or pushed against the inner surfaces of the first and second walls of the mold 24 respectively. Moreover, as described above, the forming means 76 can be heated by heating said medium and introducing the heated medium into the forming means thereby heating and/or drying the pulp 42.

Fig. 1 1 shows an eighth embodiment of said method for manufacturing the article body 10. In the ninth embodiment, for example, the holding means 14 is combined with at least one stripe 90 which can be folded to prevent hard edges. For example, the stripe 90 is made of kraft paper or another strong material which can be introduced into the mold 24 as described with respect to Fig. 3, in particular similar to an in-mold labeling process, or applied at a later point in time.

Fig. 12 shows a ninth embodiment of the method for manufacturing the article body 10. In the ninth embodiment the holding means 14 is configured as a hinged holding means. In other words, for example, the holding means 14 is hinged to the article body 12. Thus, the holding means 14 can be rotated about a rotation axis in relation to the article body 12. In the ninth embodiment shown in Fig. 12, the holding means 14 can be flapped down and, thus, rotate in the relation to the article body 12 so that the end 68 comes into contact with a corresponding portion 82 of the article body 12, wherein the end 68 is fixed to the portion 82 by, for example, by snapping and/or notching and/or gluing and/or welding.

Claims

1 . A method for manufacturing a molded article (10) from pulp (42), wherein the article (10) comprises at least one integrally formed article body (12), the method comprising at least the steps of:

- Introducing pulp (42) into a mold (24), wherein the mold (24) comprises at least one first cavity (26) for forming said integrally formed article body (12) and at least one second cavity (28) for forming at least one holding means (14) to said article body (12); and

- Forming said molded article (10) with said holding means (14) within the mold (24).

2. The method according to claim 1 ,

wherein the second cavity (28) is at least partially filled with the pulp (42) before, during and/or after the first cavity (26) is at least partially filled with the pulp (42).

3. The method according to claim 2,

wherein the second cavity (28) is fully filled with the pulp (42).

4. The method according to claim 1 ,

wherein, particularly before filling the first cavity (26) with the pulp (42), the second cavity (28) is filled with a prefabricated holding means (56) or with at least one part of a prefabricated holding means (56).

5. The method according to any one of the preceding claims,

wherein the pulp (42) is sprayed into the mold (24).

6. The method according to any one of the preceding claims,

wherein, in particular after the step of introducing the pulp (42) into the mold (24), at least one expandable device (32) is introduced into the first cavity (26) and/or the second cavity (28), wherein the expandable device (32) is inflated so as to compress the pulp (42) thereby forming walls of the article body (12) and/or the holding means (14).

7. The method according to any one of the preceding claims,

wherein the method comprises the step of drying the pulp (42) within the mold (24), in particular until a predefined amount of moisture of the pulp (42) is reached.

8. The method according to claim 7,

wherein, after the step of drying the pulp (42), the pulp (42) for forming the holding means (14) is pushed to the inside of the mold (24).

9. The method according to claim 8,

wherein, after pushing the pulp (42) for forming the holding means (14) to the inside of the mold (24), the pulp (42) is further dried, in particular within the mold (24).

10. The method according to claim 9,

wherein, after drying the pulp (42), at least one portion of the pulp (42) for forming the holding means (14) is punched out so as to create the holding means (14) as a through holding means.

1 1 . The method according to any one of the preceding claims,

wherein, after filling the second cavity (28) with pulp (42), the pulp (42) for forming the holding means (14) is compressed and shaped.

12. A molded article (10) made of pulp (42), the molded article (10) comprising at least one integrally formed article body (12) and at least one holding means (14) formed with the article body (12).

13. The molded article (10) according to claim 12,

wherein the holding means is a through holding means or a non-through holding means.

14. The molded article (10) according to claim 12 or 13,

wherein the holding means comprising an at least partially hollow and/or massive form.

15. The molded article (10) according to claim 12, 13 or 14,

wherein the holding means comprising an at least partially structured gripping surface.

16. The molded article (10) according to any one claims 12 to 15,

wherein the molded article (10) is manufactured by a method according to any one of claims 1 to 1 1 .

17. An apparatus for manufacturing a molded article (10) made of pulp (42), the apparatus being used in a method according to any one of claims 1 to 1 1 , wherein the apparatus comprises at least a mold (24) comprising at least one first cavity (26) for forming an article body (12) and at least one second cavity (28) for forming at least one holding means (14) to said article body (12).