WO2018033209A1

WO2018033209A1 - Method for manufacturing a molded article from pulp, molded article made of pulp, and apparatus for manufacturing such a molded article

Info

Publication number: WO2018033209A1
Application number: PCT/EP2016/069611
Authority: WO
Inventors: Olaf Starken; Gian Armand Juliana De Belder; Wiebke VAN DER VEEN
Original assignee: Mayr Melnhof Karton AG
Current assignee: Mayr Melnhof Karton AG
Priority date: 2016-08-18
Filing date: 2016-08-18
Publication date: 2018-02-22
Anticipated expiration: 2019-02-18

Abstract

The invention relates to a method for manufacturing a molded article (10) from pulp (42), wherein the article (10) comprises at least one 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 after the step of introducing the pulp (42) into the mold (24): Rotating and/shaking the mold so as to coat at least a portion of the inside of the mold (24) with the pulp (42) thereby forming walls of the article body (12). 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.

Pulp articles such as containers for containing liquids and/or solids are well-known in the art. In order to make these containers fit for purpose to contain liquids and/or solids (such as - but not limited to - liquid tightness, product packaging compatibility, etc.), they typically contain one or more inner coating(s) and/or an inner plastic bag(s) for containing the content (hybrid pack where plastic bag is contained in a pulp clamshell). Both methodologies involve more than one step. This invention aims to make pulp containers in an easier process, in particular in one process only, allowing to produce such articles at higher conversion speeds (and therefore in a more economical way).

Molded articles, such as, for example, bottles for containing mediums, in particular liquids and/or solids, are well-known from the general 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 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 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. Further, WO 2009/153558 A1 discloses a container made of 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.

In addition to a poor visual appearance (FMOT = First Moment Of Truth) and a poor handle-ability (SMOT = Second Moment Of Truth), 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 13, and an apparatus having the features of patent claim 19. 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 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.

The method according to the present invention further comprises a second method step of, after the first method step, rotating and/or shaking the mold so as to coat at least a portion of the inside of the mold with the pulp thereby forming walls of the article body. In other words, by rotating and/or shaking the mold while the mold contains the pulp, inner walls of the mold are coated with the pulp contained in the mold. For example, said inner walls bound or form at least a portion of the first cavity. Thus, said inner walls are used to form the pulp thereby forming the article body.

For example, at least one means is used to keep pulp in place while the mold is rotated and/or shaken. For example, said means is a vacuum or a vacuum action by means of which the pulp can be kept in place while rotating and/or shaking the mold containing the pulp, so that, for example, at least a portion of the mold is evacuated to create said vacuum

In a preferred embodiment of the invention, the mold comprises at least one second cavity for forming at least one holding means to said article body, the method comprising, after the step of introducing the pulp into the mold: rotating and/or shaking the mold so as to coat at least a portion of the inside of the mold with the pulp thereby forming walls of the article body and the holding means. The method further comprises a method step of forming said molded article with said holding means within the mold. Preferably, both the article body and the holding means are manufactured from said pulp. Moreover, preferably, the article body and the holding means are formed in one piece. For example, said inner walls bound or form at least a portion of the first cavity and/or the second cavity. Thus, said inner walls are used to form the pulp thereby forming the article body and/or the holding means. For example, a second element or a second composition acting as a barrier can be introduced into the mold and applied to the pulp arranged in the mold, in particular before cooling down and demolding the pulp or the molded article. For example, the second element is introduced into the mold after the pulp is introduced into the mold and after rotating and/or shaking the mold containing the pulp Thus, for example, after rotating and/or shaking the mold containing the mold the second element or composition is introduced into the mold. Thereafter, the mold is rotated and/or shaken again so as to rotate and/or shake the pulp and the second composition which are both contained in the mold so as to coat the pulp contained in the mold, in particular so as to coat inner walls of the pulp contained in the mold with the second composition or element.

Preferably, the pulp contained in the mold is dewatered and, thus, dried. For example, for dewatering the pulp, the pulp is pressed or compressed. Alternatively or additionally said vacuum applied to the mold is dewatering the pulp. Alternatively or additionally, the pulp contained in the mold is heated and, thus, dewatered or dried. For example, the pulp can be dried at least partially, in particular completely.

By means of the method according to the present invention both a particularly advantageous visual appearance and a particularly advantageous feel, in particular surface feel, of the molded article can be realized since ridges and edges impairing the visual appearance and the feel of the molded article can be avoided. Usually, conventional molded articles made of pulp 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, the article body and/or the holding means is made of pulp material 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.

Preferably, the article body and/or the holding means are integrally formed. Moreover, preferably, the article body and the holding means are formed in one piece. The term "integrally formed" means that the article body and/or holding means is formed as one piece, preferably in one production step.

For example, for those cases where there is an additional need for a barrier such as - but not limited to- liquid tightness, CO2, H2O, O2, perfume, etc., a fourth method step might be provided. For example, the fourth method step comprises at least - but not limited to- applying a coating internally and/or externally by techniques known by those skilled in the art. Another alternative coating means would be to apply a coating composition before demolding the molding article, and apply once more a rotomolding operation. This means that, for example, an inner surface and/or an outer surface of the molded article can be coated by at least one coating which is used as, for example, a barrier to protect the pulp and/or the medium from environmental influences.

For example, said holding means is a handle or grip by means of which the molded article can be handled by a person in a convenient and preferred way. In this regard, for example, the person can grasp the holding means by means of at least one or more of their fingers so that the person can move the molded article via the holding means. Alternatively or additionally, the person can grasp and, thus, handle the article body by means of at least one hand. With respect to a conventional molded article made of plastic material or pulp formed by at least two hollow shells a person grasping and, thus, touching the holding means and/or the article body 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 conventional molded article is impaired by said 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. 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.

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 holding means which can be made of advantageous raw material which is easy to recycle.

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 during SMOT (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 opened 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. By means of the holding means the consumer benefit of a particularly easy handling of the molded article can be realized, especially when the molded article is a large container, wherein the molded article can be made of an advantageous raw material which is easy to recycle. Moreover, for example, the holding means can be formed by a recess in the mold thereby forming the holding means as a small grip feature. Additionally or alternatively, at least one boxing mold in which the grip area is somewhat deeper can be used. A further advantage of this invention over the prior art is that secondary operations to make the molded article liquid-tight can be avoided so that the molded article can be manufactured in a particularly time- and cost-effective way.

For example, the method step of rotating the mold is a method step of a rotomolding process by means of which at least a portion of the article body and/or the holding means is formed. By rotating and/or shaking the mold containing the pulp, the pulp within the mold is caused to disperse and stick to wall portions of the mold, i.e. to at least a portion of the inside of the mold. For example, said wall portions bound the first and/or second cavities at least partially. Preferably, in order to maintain even thickness throughout the respective cavity, the mold is rotated about at least two rotation axes which extend angularly to each other. For example, the rotation axes extend at least substantially perpendicularly to each other.

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. 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.

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 aforementioned kinds of fibers. Furthermore, the pulp can comprise at least one or a plurality of additives.

Also by means of the method according to the present invention, the molded article can be configured as a liquid-tight container by introducing an inner bag made out of plastic into the article body and/or the holding means, the inner bag acting, for example, as the afore-mentioned barrier.

In a particularly advantageous embodiment of the invention, after and/or during the method step of introducing the pulp into the mold, the mold is heated while containing the pulp. By heating the mold, the pulp contained in the mold is heated and, thus, dried. Thus, for example, the extent of moisture contained in the pulp can be at least reduced. Preferably, the mold and, thus, the pulp contained within the mold are heated while the mold is rotated and/or shaken and/or after rotating and/or shaking the mold. Preferably, in order to maintain even thickness throughout the respective cavity, the mold continues to rotate and/or shake at all times during heating the mold so as to avoid sagging or deformation also during a possible subsequent cooling phase. Thus, an at least substantially even wall thickness of the article body and/or the holding means can be realized.

In a further advantageous embodiment of the invention, after and/or during rotating and/or shaking the mold, the mold is cooled while containing the pulp. Thus, the pulp contained in the mold is cooled. Preferably, the mold and, thus, the pulp are cooled after rotating and/or shaking the mold contained in the pulp. Preferably, the process of cooling the mold and, thus, the pulp contained in the mold is conducted while the mold is rotated and/or shaken. Preferably, the mold is cooled after heating the mold. By cooling the mold the molded article can be released from the mold particularly easily so that both, a particularly advantageous visual appearance and a particularly advantageous feel of the molded article can be realized. For example, the roughness of the mold, the composition of the pulp and/or additives in the pulp can be used as additional means to influence sensorial elements such as - but not limited to - softness of the molded article.

For example, the mold is part of an apparatus for manufacturing the molded article, the apparatus comprising at least one cooling element for cooling the mold and, thus, the pulp contained in the mold. For example, the cooling element comprises at least one duct which is, for example, configured as a cooling duct through which a cooling medium such as a cooling fluid, in particular a cooling liquid can flow. For example, the duct extends in the mold. For example, for cooling the mold, said cooling medium is conveyed through the duct.

Alternatively or additionally, said apparatus comprises at least one heating element for heating the mold and, thus, the pulp contained in the mold. For example, said heating element is configured as an electrical heating element which can be arranged in the mold at least partially. Alternatively or additionally, said heating element can comprise at least one duct through which a heating medium such as a heating fluid, in particular a heating liquid can flow so that the mold and, thus, the pulp contained in the mold can be heated by said heating medium. For example, said duct for heating the mold can be used as said duct for cooling the mold so that, for example, the same duct can be used for heating and cooling the mold. For heating the mold, the heating medium is conveyed through the duct which, for example, extends at least partially in the mold. Preferably, the article body and/or the holding means is equipped with at least one layer which is, for example, made of a material different from the pulp. For example, said layer is made of a plastic material. For example, said layer can act as a barrier or barrier for protecting the pulp and/or the medium contained in the molded article from environmental influences. For example, an outer surface and/or an inner surface of the article body and/or the holding means is at least partially coated with said layer. Preferably, the surface is coated with the layer by rotomolding, i.e. by rotating and/or shaking the mold, in particular before cooling down and demolding the molded article. For example, said layer is formed by said second element or second composition described above.

For example, after shaking and/or rotating the mold, the molded article is removed from the mold, wherein, before or after removing the molded article from the mold, i.e. before or after demolding the molded article, the molded article is equipped with said layer which, for example, can act as a barrier coating.

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 particular 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 said 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, in particular 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.

In this regard, for example, 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 within the mold. Hence, 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 pulp for forming the article body and, thus, the article body is brought into contact with the prefabricated component by rotating and/or shaking the mold. Preferably, the mold is rotated and/or shaken after introducing the prefabricated component into the second cavity.

In a further advantageous embodiment of the invention, after and/or during rotating and/or shaking the mold, the pulp within the mold is dried, in particular until a predefined amount of moisture of the pulp is reached. Thus, the pulp is not completely dry, but adequately wet or humid so that, for example, the pulp can be formed in a need-based manner. This means, by drying the pulp, the extent of moisture contained in the pulp is reduced, wherein, preferably, the pulp is not completely dried. For example, the pulp is dried by heating the mold and, thus, the pulp.

For example, a compression device is used to dewater and, thus, dried the pulp at least partially. For this purpose, in particular after introducing the pulp into the mold. The compression device is introduced into the mold. Then, the compression device is, for example inflated and, thus, expanded thereby pressing the pulp contained in the mold against inner walls of the mold and/or compressing the pulp. Preferably, the mold comprises or is made of a permeable material through which the moisture from the pulp can escape. Alternatively or additionally, the pulp contained in the mold can be dewatered and, thus, dried by means of a vacuum. For this purpose, for example, at least a portion of the mold is evacuated or set under a vacuum by means of which moister can be withdrawn from the pulp. For example, the mold is permeable or made of a permeable material so that moisture can be sucked out of the pulp by means of the vacuum.

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 method step of drying the pulp. In a further embodiment of the invention the pulp is further dried within the mold after pushing the pulp for forming the holding means to the inside of the mold. 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 a further embodiment of the invention, after 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. By punching out the pulp for forming the holding means, at least one through opening of the holding means can be realized 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. For example, the pulp for forming the holding means 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 at least a portion of the pulp is separated, in particular cut, from the remaining pulp for forming the article body and the holding means. In order to realize a particularly high stiffness and stability of the holding means and/or in order to enable a fast drying of the pulp, in a preferred embodiment of the invention, the pulp for forming the holding means is compressed and shaped, in particular after forming the holding means. 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. In a further advantageous embodiment of the invention, the mold comprises at least two mold parts which, after rotating and/or shaking the mold, are moved away from each other to release the molded article from the mold. Thus, the molded article can be removed from the mold in a particularly advantageous way so that both a particularly good visual appearance and a particularly good surface feel of the molded article can be realized.

A second aspect of the present invention relates to a molded article made of pulp wherein the molded article according to the present invention comprises at least one integrally formed article body. Preferably, the molded article comprises at least one holding means formed with the article body. 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. The inventive molded article has a particularly advantageous visual appearance and a particularly advantageous feel, 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, preferably, integrally formed. Usually, conventional molded articles made of pulp 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, preferably, 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 compared to other raw materials like plastics. Preferably, the article body and/or the holding means are integrally formed. Moreover, preferably, the article body and the holding means are formed in one piece. The term "integrally formed" means that the article body and/or holding means is formed as one piece, preferably in one production step. In a preferred embodiment of a second aspect of the present invention, the molded article is manufactured by a method according to the present invention.

Preferably, the holding means is formed in one piece with the article body so that both, the article body and the holding means are manufactured from said pulp. Alternatively, the holding means is configured as a prefabricated component manufactured independently of the article body, the prefabricated component being connected to the article body. For example, the prefabricated component can be made of paper, plastics, rubber, etc. or a combination thereof. Preferably, said holding means, in particular the prefabricated component, is manufactured from paper pulp for environmental and recycling advantages.

In preferred embodiments of the invention, said holding means is a through holding means or a non- through holding means. Further, it is possible that the holding means comprises 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.

A third aspect of the present invention relates to an apparatus for manufacturing a molded article made of pulp, in particular a molded article according to the present invention. The apparatus is used in a method according to the present invention, wherein the apparatus comprises said mold having at least the first cavity. Moreover, the apparatus comprises means for rotating and/or shaking the mold. 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.

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 are taken alone without leaving the scope of the invention.

The drawings show in: 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; a schematic view of a second embodiment of the method according to the invention; a schematic view of a third 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; a schematic view of fourth embodiment of the method according to the invention; a schematic view of a fifth embodiment of the method according to the invention; a schematic view of a sixth embodiment of the method according to the invention; a schematic view of a seventh embodiment of the method according to the invention; and a schematic front view of a fourth embodiment of the molded article 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. 4 to 6 and 1 1 ) from pulp. In other words, the molded article 10 is, at least partially, made of pulp so that the molded article 10 is a pulp molded article. As can be seen from Figs. 4 to 6 and 1 1 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 liquid such as a gel or a paste.

For example, the molded article 10 has a capacity of at least 25 milliliters, in particular of at least 0.5 liters and preferably of at least 1 .5 liters, for storing said medium. The molded article 10 comprises at least one article body 12. Moreover, optionally, the molded article 10 comprises at least one holding means 14 connected to the article body 12. In an embodiment not shown in the figures, the molded article 10 does not comprise the holding means 14. For example, 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. Moreover, preferably, the article body 12 is integrally formed. Furthermore, preferably, the article 10 is integrally formed, wherein the article body 12 and the holding means 14 are formed in one piece.

For example, said 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 cellulosic fibers from wood, fiber crops or paper, in particular waste paper. For example, the paper slurry contains at least pulp fiber having an average fiber length of 0.4 to 8.0 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. Preferably, when both the article body 12 and the holding means 14 comprise or bound at least one receiving space respectively, the receiving spaces are fluidically connected with each other.

The article body 12 comprises at least one inlet 16 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-distractive 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, the tool 20 comprises at least one tool element 22. For example, the tool 20 comprises at least two tool elements. For example, the tool 20 is or forms or is part of an apparatus for manufacturing the molded article 1 0, wherein said apparatus is used in said method. The tool 20 comprise at least one mold 24 which, for example, comprises said at least two tool elements which are also referred to as mold parts. In the first embodiment, the mold 24 is used to manufacture and form both the molded article 10 and the holding means 14 from pulp 26.

In a first method step S1 the pulp 26 is introduced into the mold 24. The mold 24 comprises at least one first cavity 28 for forming said article body 12 from the pulp 26. Moreover, the mold 24 comprises at least one second cavity 30 for forming the holding means 14 to the article body 12. In the first embodiment shown in Fig. 1 , the second cavity 30 is used to form the holding means 14 from the pulp 26. As can be seen from Fig. 1 , the pulp 26 is introduced into the first cavity 28 by at least one introducing means 31 . Alternatively or additionally, the pulp 26 can be introduced into the second cavity 30. For example, the introducing means is fluidically connected to a pulp source (not shown).

In a second method step S2 the mold 24 containing the pulp 26 is rotated so as to coat at least a portion of the inside of the mold 24 with the pulp 26 thereby forming walls of the article body 12 and the holding means 14. The second method step S2 succeeds the first method step S1 so that the mold 24 containing the pulp 26 is rotated after introducing the pulp 26 into the mold 24. Since, by means of the mold 24 and by rotating the mold 24, both the article body 12 and the holding means 14 are manufactured, in a third method step S3 the molded article 10 is formed with said holding means 14 within the mold 24. Moreover, in the first embodiment, the holding means 14 is formed in one piece with the article body 12.

By rotating the mold 24 first inner walls or first inner wall portions of the mold 24 are coated with the pulp 26, said first inner walls or first inner wall portions bounding the first cavity 28 at least partially. Thus, by coating said first inner walls with the pulp 26, walls of the article body 12 are formed. Moreover, by rotating the mold 24, second inner walls or second inner wall portions of the mold 24 are coated with the pulp 26, wherein said second inner walls or second inner wall portions form or bound the second cavity 30 at least partially. Thus, by coating said second inner walls or second inner wall portions walls of the holding means 14 are formed.

As illustrated in Fig. 1 by arrows 25, for example, the mold 24 is rotated about at least two rotation axes which, for example, extend angularly, in particular perpendicularly, to each other. Moreover, both the article body 12 and the holding means 14 are formed as hollow components so that both the article body 12 and the holding means 14 have receiving spaces for receiving a medium respectively, wherein said receiving spaces are fluidically connected with each other. As can be seen from Fig. 1 , said walls of the article body 12 comprise an inner surface 64 bounding a first receiving space of the article body 12, wherein said medium can be stored in the first receiving space. Moreover, said walls of the article body 12 have an outer surface 66. Furthermore, said walls of the holding means 14 have an inner surface 68 bounding a second receiving space of the holding means 14 so that said medium can be stored in the second receiving space. Additionally, said walls of the holding means 14 have an outer surface 70. Moreover, the receiving spaces are fluidically connected with each other so that the medium contained the first receiving space can flow from the first receiving space into the second receiving space and vice versa. In other words, in the first embodiment, the holding means 14 is hollow or configured as a hollow component having the second receiving space for storing at least a portion of said medium. Alternatively or additionally, the mold 24 is shaken thereby coating the inner walls of the mold 24 with the pulp 26. For example, at least a portion of the mold 24 is 24 or set under a vacuum so that the pulp 26 is sticking more easily to the mold 24, in particular to inner walls of the mold 24, and so that the pulp 26 can be dewatered, said inner walls bounding the cavity 28 and/or the cavity 30. Preferably, the mold 24 comprises or is made of a permeable material through which the moisture from the pulp 26 can escape when, for example, rotating and/or shaking the mold 24. Alternatively or additionally, the moisture of the pulp 26 can be withdrawn as illustrated by arrows in Fig. 1 , steps S2, S3. For example, the moisture of the pulp 26 is withdrawn by means of said vacuum. Preferably, the mold 24 is permeable or made of a permeable material so that moisture can escape and/or be sucked out of the pulp 24 by means of the vacuum as illustrated by the arrows pointing to the outside of the mold 24 in Fig. 1 , steps S2, S3. Moreover, alternatively or additionally, said vacuum is used to keep the pulp 26, in particular its fibers, in place while rotating and/or shaking the mold 24.

Moreover, in the second method step S2, the mold 24 and, thus, the pulp 26 contained in the mold 24 are heated which is illustrated by a schematically shown thermometer 32 and a corresponding arrow 34. Preferably, the mold 24 and, thus, the pulp contained within the mold 24 are heated while the mold 24 is rotated. By rotating the mold 24 to coat the inner walls or wall portions and, thus, the inside of the mold 24, said inside of the mold 24 is at least substantially evenly coated with the pulp 26. Thus, an at least substantially even wall thickness of both the article body 12 and the holding means 14 can be realized.

Alternatively or additionally, at least one compressing device can be introduced into the mold, in particular after introducing the pulp 26 into the mold 24 and before or after shaking and/or rotating the mold 24. For example, the compression device is an inflatable device which, when arranged in the mold 24, is inflated and, thus, expanded thereby pressing or compressing the pulp 26 in the mold 24. For example, the pulp 26 contained in the mold 24 is pressed against the inner walls of the mold 24 by means of the inflated compression device. By pressing or compressing the pulp 26 contained in the mold, the pulp 26 is dewatered and, thus, dried at least partially. For example, the pulp 26 is dried completely.

In an optional fourth method step S4 of the first embodiment, the mold 24 containing the pulp 26 and, thus, the pulp 26 are cooled which is illustrated by the thermometer 32 and a corresponding arrow 36. Thus, after heating the mold 24 and, thus, the pulp 26 contained in the mold 24, the mold 24 and, thus, the pulp 26 contained in the mold 24 are cooled. Preferably, said apparatus comprises at least one heating element configured to heat the mold 24 and, thus, the pulp 26 contained in the mold 24. For example, said heating element is configured as an electrically heating element which can be arranged in the mold 24 at least partially. Alternatively or additionally, said heating element comprise at least one duct through which a heating medium such as a heating liquid can flow so that the mold 24 and the pulp 26 contained in the mold 24 can be heated by said heating medium. Thus, said duct can be used as a heating duct.

Alternatively or additionally, said apparatus can comprise at least one cooling element for cooling the mold 24 and, thus, the pulp 26 contained in the mold 24. For example, the cooling element comprises at least one duct which is, for example, configured as a cooling duct through which a cooling medium such as a cooling liquid can flow. The respective duct can extend in the mold 24. For example, said cooling duct can be the afore-mentioned heating duct so that the same duct can be used for heating and cooling the mold 24. For heating the mold 24, said heating medium is conveyed through the duct. For cooling the mold 24 the cooling medium is conveyed through said duct. As an alternative, the holding means 14 can be manufactured from at least one prefabricated component which, for example, is manufactured independently of the article body 12. For example, the prefabricated component is inserted into the second cavity 30, in particular before rotating the mold 24. Alternatively, the prefabricated component can be inserted into the cavity 30 after rotating the mold 24.

Since the cavity 30 is fluidically connected to the cavity 28, the pulp 26 contained in the cavity 28 can come into contact with the prefabricated component arranged in the cavity 30. Particularly, the pulp 26 contained in the cavity 28 can be brought into contact with the prefabricated component arranged in the cavity 30 by rotating the mold 24 while the pulp 26 is contained in the first cavity 28 and the prefabricated component is contained in the second cavity 30. By bringing the pulp in contact with the prefabricated component or vice versa, the prefabricated component can be connected to the pulp and, thus, the article body 12.

Alternatively or additionally, the article body 12 and/or the holding means 14 is equipped with at least one layer which is, for example, made of a material different from the pulp 26. For example, said layer is made of a plastic material. For example, said layer can act as a barrier for protecting the pulp 26 and/or the medium contained in the molded article 10 from environmental influences. For example, an outer surface and/or an inner surface of the article body 12 and/or the holding means 14 is at least partially coated with said layer. Preferably, the surface is coated with the layer by rotomolding, i.e. by rotating and/or shaking the mold, in particular before cooling down and demolding the molded article. For example, the article body 12 and/or the holding means 14 is equipped with the layer after heating the pulp 26.

Fig. 2 shows a second embodiment of the method. For example, the second embodiment comprises a fifth method step S5 in which at least a portion of the holding means 14 or the pulp forming the holding means 14 is compressed in order to form the holding means 14. For this purpose, at least two tool elements 38 are used. The holding means 14 or the pulp 26 forming the holding means 14 is compressed and, thus, formed by means of the tool elements 38. For example, the tool elements 38 are stamps which are pressed into the pulp 26 forming the holding means 14 at least partially as illustrated by arrows 40. The stamps comprise two fingers 42 respectively which are pressed into the holding means 14 or the pulp forming the holding means respectively thereby forming lateral channels 44 in the holding means 14. For example, before forming the channels 44 the pulp 26 is not completely dried so that the channels 44 can be formed in a need-based manner. After forming the channels 44 the pulp 26 is further, in particular completely, dried so as to realize a particularly high stiffness of the molded article 10. The channels 44 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 38, in particular the fingers 42, are heated so that the heated finger 42 are pressed into the pulp 26 forming the holding means 14 so as to heat and, thus, dry the pulp 26 and, thus, the holding means 14 particularly fast. Moreover, the fingers 42 are used to create a great stiffness of the holding means 14.

As can be seen from Fig.1 , the holding means 14, in the first embodiment, is manufactured as a through holding means which will be described in greater detail below. In this regard, the holding means 14 has a through opening 46 through which a person can put at least one of their fingers so that the holding means 14 can be grasped all around in its circumferential direction by the person.

Fig. 3 shows a third embodiment of the method. With regard to the third embodiment the holding means 14 can be manufactured as a non-through holding means not having any through opening through which a person can put the fingers. Fig. 3 shows a state Z1 of the molded article 10, wherein, in the state Z1 , the holding means 14 is configured as a non-through holding means. However, in order to transform the non- through holding means into a through holding means, the pulp for forming the holding means 14, in particular the non-through holding means, is punched out so as to create the holding means 14 as a through holding means. By punching out the pulp at least a portion 48 of the pulp is separated, in particular cut, from the remaining pulp for forming the holding means 14. Moreover, by punching out the pulp, in particular the portion 48, a through opening 46 of the holding means 14 is created thereby creating the holding means 14 as a through holding means which is also referred to as an open holding means, open grip or open handle. By creating the through opening 46 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.

Fig. 4 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 a 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 46 a person grasping the holding means 14 can wrap their fingers completely around the holding means 14 in the area of the through opening 46. 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 50. 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 52 of the holding means 14 is connected to the article body 12. However, the second end 54 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. 5 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 or open grip. Thus, the open holding means or through holding means has at least one through opening 46 through which a person can put their fingers. However, the holding means 14 according to the second embodiment is connected to the article body 12 at both ends 52 and 54. 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. Fig. 6 shows a third embodiment of the molded article 10. In the third embodiment the holding means 14 is configured as a non-trough holding means which is also referred to as a closed handle or closed grip. The non-through holding means does not comprise any through opening trough 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. 6, the first receptacle being indicated by 56. The holding means 14 has at least one insertion direction in which a person can insert at least one of their fingers into the respective receptacle, wherein the receptacles are also referred to as depressions.

In the non-through holding means the holding means 14 or the respective receptacle is limited in the insertion direction by a wall 58 of the molded article 10, the wall 58 being arranged between said receptacles. Thus, said receptacles are separated from one another by means of the wall 58. The wall 58 is, for example, made of the pulp, wherein, for example, the wall 58 is formed in one piece with the holding means 14 and/or the article body 12. Since the wall 58 is recessed with respect to at least one wall portion 60 of the holding means 14, the wall 58 bounds or limits the receptacles. In other words, the wall 58 forms a bottom of the receptacles. Moreover, since the wall 58 is recessed with respect to the wall portion 60, 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 58. Thus, the person can grasp the holding means 14 particularly tight. For example, the third embodiment shown in Fig. 6 corresponds to the state Z1 shown in Fig. 3, so that, for example, the portion 48 which is punched out forms, in the state Z1 , the wall 58. Moreover, for example, by punching out the wall 58 the non- through holding means can be converted into a through holding means.

Fig. 7 shows a fourth embodiment of the method. In the fourth embodiment, for example, the holding means 14 is combined with at least one stripe which can be folded to prevent hard edges. For example, the stripe is made of kraft paper or another strong material which can be introduced into the mold 24 as described above, in particular similar to an in-mold labeling process, or applied at a later point in time. Fig. 8 shows a fifth embodiment of the method. For example, in the fifth embodiment, the holding means 14 is hinged to the article body 12 so that the holding means 14 can be rotated about a rotation axis in relation to the article body 12. For example, the holding means 14 is formed in one piece with the article body 12. For example, the holding means 14 can be rotated about the rotation axis in relation to the article body 12 so that the end 50 comes into contact with the article body 12, in particular an area 62 of the article body 12. For example, the holding means 14 can be flapped down thereby bringing the end 50 in contact with the area 62. For example, the end 50 can be fixed to the article body 12, in particular the area 62 by, for example, nudging and/or clueing and/or welding.

Fig. 9 shows a sixth embodiment of the method. In the sixth embodiment, the holding means 14 is made from at least one piece of paper or cardboard stripe or pulp or rigid plastic. For example, the holding means 14, in particular the end 53 of the holding means 14, can be fixed to the article body 12, in particular to the area 62. For example, the end 53 can be fixed to the article body 12, in particular to the area 62 by notching and/or clueing and/or welding. Alternatively or additionally, the holding means 14 is attached to the article body 12 at the end 52 by at least one form fit which is, for example, created by the inlet 16 and the holding means 14 and/or the holding means 14 and the cap 18. For example, at the end 52 the holding means 14 is arranged between the article body 12 and the cap 18 so that the holding means 14 is attached to the article body 12 by means of the cap 18. Moreover, for example, the holding means 14 is rotated or screwed or snapped between the cap 18 and a thread by means of which the cap 18 can be screwed to the article body 12. In other words, for example, the holding means 14 is attached to the article body 12 by, for example, screwing and/or clamping and/or snapping. Moreover, Fig. 10 shows a seventh embodiment of the method. In the seventh embodiment the holding means 14 is configured as a prefabricated and, thus, separate component. In other words, the holding means 14 is a handle which is produced separately from the article body 12. Moreover, the holding means 14 is attached to the article body 12 by, for example, notching and/or gluing and/or welding.

Fig. 1 1 shows a fourth embodiment of the molded article 10. In the fourth embodiment, the molded article 10 does not comprise any holding means or grip feature.

Claims

Claims:

1 . A method for manufacturing a molded article (10) from pulp (42), wherein the article (10) comprises at least one 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

- after the step of introducing the pulp (42) into the mold (24): rotating and/or shaking the mold so as to coat at least a portion of the inside of the mold (24) with the pulp (42) thereby forming walls of the article body (12).

2. The method according to claim 1 ,

wherein the mold (24) comprises at least one second cavity (28) for forming at least one holding means (14) to said article body (12), the method comprising: - after the step of introducing the pulp (42) into the mold (24): rotating and/or shaking the mold so as to coat at least a portion of the inside of the mold (24) with the pulp (42) thereby forming walls of the article body (12) and the holding means (14); and

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

3. The method according to claim 1 or 2,

wherein, after and/or during the step of introducing the pulp (42) into the mold (24), the mold (24) is heated while containing the pulp (42).

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

wherein, after and/or during rotating and/or shaking the mold (24), the mold (24) is cooled while containing the pulp (42).

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

wherein the article body (12) and/or the holding means (14) is equipped with at least one layer.

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

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

wherein, after and/or during rotating and/or shaking the mold (24), the pulp (42) within the mold (24) is dried, 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 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 claim,

wherein, after rotating and/or shaking the mold (24), the pulp (42) for forming the holding means (14) is compressed and shaped.

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

wherein the mold (24) comprises at least two mold parts which, after rotating and/or shaking the mold (24), are moved away from each other to release the molded article (10) from the mold (24).

13. A molded article (10) made of pulp (42), the molded article (10) comprising at least one integrally formed article body (12), wherein the molded article (10) is manufactured by a method according to any one of claims 1 to 12.

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

wherein the holding means (14) is formed in one piece with the article body (12).

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

wherein the holding means (14) is configured as a prefabricated component manufactured independently of the article body (12), the prefabricated component being connected to the article body (12).

16. The molded article (10) according to any one of claims 13 to 15,

wherein the holding means (14) is a through holding means or a non-through holding means.

17. The molded article (10) according to any one of claims 13 to 16,

wherein the holding means (14) comprises an at least partially hollow and/or massive form.

18. The molded article (10) according to any one of claims 13 to 17,

wherein the holding means (14) comprises an at least partially structured gripping surface.

19. An apparatus for manufacturing a molded article (1 0) made of pulp (42), the apparatus being used in a method according to any one of claims 1 to 12, wherein the apparatus comprises:

- the mold (14) having at least the first cavity (26); and

- means for rotating and/or shaking the mold (24).