GB2626753A

GB2626753A - Molded fiber packaging

Info

Publication number: GB2626753A
Application number: GB2301404.6A
Authority: GB
Inventors: Dijkstra Peter; Amar Missoum Karim; Rotllant Daurella Lucas; Simon Roca Oriol
Original assignee: Hewlett Packard Development Co LP
Current assignee: Hewlett Packard Development Co LP
Priority date: 2023-01-31
Filing date: 2023-01-31
Publication date: 2024-08-07
Also published as: GB202301404D0; WO2024163097A1

Abstract

Packaging component 100 comprising molded fiber 102 having an interior 106 and an exterior 108 surface, and a film 104 comprising a first portion 104a bonded to the interior surface 106, and a second portion 104b extending beyond an edge 110 of the interior surface 106 and foldable over the edge 110 to abut the exterior surface 108 of the molded fiber. The packaging component may comprise a bottle, the edge connecting a base and neck of the bottle. The film may comprise a third portion extending beyond a second edge. The film may be a plastic with a thickness of 20 µm to 150 µm. A container comprising first and second molded fiber parts, first and second films bonded to respective interior surfaces of the first and second films, and a seam at which the first and second film are bonded. A method of bonding a first portion of a film to a surface, trimming the film is disclosed.

Description

MOLDED FIBER PACKAGING

BACKGROUND

[0001] Objects may be formed from a fibrous material in a fiber molding process. The fibrous material may be cardboard and/or paper, and in some examples, it may be recycled cardboard and/or paper. Fiber molding processes include wet pulp molding processes and dry fiber molding processes. Pulp molded objects are often used as packaging, for example packaging of electrical appliances, produce such as eggs or fruit, or direct food contact packaging such as single use plates, cups, sip lids or clam shell containers. To provide packaging suitable for wet products, such as drinks and some types of food, an additive, a waterproof layer or a coating may be added to the pulp molded packaging.

BRIEF DESCRIPTION OF DRAWINGS

[0002] Non-limiting examples will now be described with reference to the accompanying drawings, in which: [0003] Fig. 1 is a cross section of an example of a packaging component; [0004] Fig. 2 shows an example of a packaging component; [0005] Figs. 3A to 3C are examples of packaging components; [0006] Figs. 4A to 4C are examples of packaging component; [0007] Fig. 5A shows an example of a container; [0008] Fig. 5B is a cross section of an example of a container; [0009] Fig. 6 is a cross section of an example of a container; [0010] Fig. 7 is a flowchart of an example of a method for forming a packaging component; [0011] Fig. 8 is a flowchart of an example of a method for forming and assembling a bottle; and [0012] Figs. 9A, 9B, 9C and 9D are a plan views and a cross section view of example apparatus for assembling packaging components.

DETAILED DESCRIPTION

[0013] A molded fiber object may be an object formed using a wet pulp molding process or a dry fiber molding process.

[0014] In a wet pulp molding process, the object may be formed on a pulp molding die comprising a screen and a form which supports the screen. The screen may comprise a plurality of small openings, or pores, which allow liquid to flow through. The screen may be separable from the form. The form may comprise any element which provides structural support for the screen which helps it to maintain its shape while forming an object. The form may also comprise holes or channels through which fluids may flow to and from the screen. In some examples the pulp molding die may be formed from a metallic material or from a plastic material. In some examples they may be manufactured using machining techniques, such as CNC (Computer Numerical Control) milling or additive manufacturing. The screen may be a woven mesh formed from a plurality of fine metal wires.

[0015] Wet pulp molding processes may comprise covering the screen of a pulp molding die with a slurry, or pulp, comprising a liquid component, such as water, and a solid, fibrous material. The screen of the pulp molding die may comprise a surface having a shape which corresponds to the shape of a surface of an object to be formed using the die. The die may be submersed in a bath of the slurry to cover the screen of the die. The screen of the pulp molding die may comprise pores (i.e. small holes, or porous zones) in the surface which allow the liquid component of the slurry to pass through, but are sufficiently small that the solid, fibrous material accumulates on the surface of the screen to form the object. The formed object may then be dried, for example by heating in an oven or between metal dies, to form the finished molded fiber object.

[0016] In other examples a dry molded fiber process may be used to form a molded fiber object. In a dry molding process loose, dry fibers may be provided between sheets of a tissue material and the object may be formed from the fibrous material by applying heat and/or pressure to the sheets of tissue material while the sheets of tissue material and layer of fibers is on a mold.

[0017] In order to reduce the amount of plastics used in packaging and to increase the ease of recycling packaging, molded fiber has been used as packaging for a wide variety of products. However, molded fiber objects are often formed from materials, such as recycled paper or cardboard, which are susceptible to damage when exposed to moisture. Therefore, providing molded fiber packaging for wet products may be challenging. To provide molded fiber packaging for wet products, a waterproof layer may be added to the surface of the packaging, for example a coating or a film. However, a film may be difficult to apply to some molded fiber packaging, for example due to its geometry. Furthermore, the water resistance of some coatings may not be sufficient to contain some wet products, in particular for prolonged time periods. In other examples, waterproof packaging may be provided within the molded fiber packaging, for example by providing a plastic container within the molded fiber packaging. However, this results in substantial quantities of plastic being used and can increase the complexity of recycling the packaging because the plastic container and folded fiber packaging may have to be separated before recycling.

[0018] Fig. 1 shows a cross section of an example of a packaging component 100.

The packaging component 100 may be arranged such that it may be assembled with other packaging components to form packaging for a product or products. For example, when assembled, the packaging component 100 may form one side or portion of a packaging for a product(s) and at least one other packaging component may form further side(s) or portion(s) of the packaging, such as a bottom portion or base portion of a bottle.

[0019] In this example, the packaging component 100 comprises a molded fiber component 102 and a film 104. The molded fiber component 102 comprises an interior surface 106 and an exterior surface 108. The interior surface 106 may be a surface which is intended to face towards product(s) intended to be carried by the packaging whereas the exterior surface 108 may be intended to face away from the product(s) intended to be carried by the packaging and to face towards the outside environment. In other examples, these may simply be termed first and second surfaces. As shown in Figure 1, in some examples the exterior surface 108 may be substantially parallel to the interior surface 106, for example forming opposite sides of a thickness of the molded fiber material from which the molded fibre component 102 is formed. In some examples a portion of each of the interior and exterior surfaces 106, 108 may be parallel i.e. the thickness of the molded fiber component may be substantially constant at this portion.

[0020] As used herein, a film may refer to a thin layer of material. The film 104 may provide resistance to moisture and may substantially cover the interior surface 106 of the molded fiber component 102. In this example the film 104 comprises a first portion 104a bonded to the interior surface 106 of the molded fiber component 102. The first portion 104a of the film 104 may be bonded to at least a portion of the interior surface 106 of the molded fiber component 102. For example, the first portion 104a of the film 104 may be bonded to the entirety or a majority of the interior surface 106 of the molded fiber component 102. The first portion 104a of the film may be bonded to the interior surface 106 using, for example, a lamination process.

[0021] The film 104 also comprises a second portion 104b extending beyond an edge 110 of the interior surface 106. In other words, an edge of the film 104 is not aligned with an edge 110 of the molded fiber component 102. The second portion 104b is foldable over the edge 110 to abut the exterior surface 108 of the molded fiber component 102. The portion of the exterior surface 108 which is substantially parallel to the interior surface 106 may be a portion of the exterior surface 108 which the second portion 104b of the film 104 abuts against when folded over the edge 110. Fig.1 shows it in its folded position. While Fig.1 shows the second portion 104b in its folded position, the film 104 may be flexible, such that the second portion 104b can extend away from the surfaces 106, 108. In some examples the second portion 104b of the film 104 may be bonded to the exterior surface 108 of the molded fiber component 102 however in other examples the second portion 104b of the film 104 is not bonded to the exterior surface 108 of the molded fiber component 102. When the second portion 104b of the film 104 is not bonded to the exterior surface 108 of the molded fiber component 102, during assembly of the packaging component 100 with another packaging component, the second portion 104b of the film 104 may be bonded to the exterior surface 108 as part of the assembly process. Bonding the first portion 104a of the film 104 to the interior surface 106 without bonding the second portion 104b of the film 104 to the exterior surface 108 may simplify manufacture of the packaging component 100.

[0022] The second portion 104b of the film 104 may extend beyond the edge 110 of the interior surface 106 by a sufficient amount such that it may be used to form a seal and bond the molded fiber component 102 to another molded fiber component. For example, the second portion 104b of the film 104 may extend between 1mm and 15mm from the edge 110 of the interior surface 106. In some examples the film 104 may extend at least 1mm, or at least 2mm, or at least 3mm, or at least 4mm from the edge 110 of the interior surface 106. In an example, the second portion 104b of the film 104 extends around 4.5mm from the edge 110 of the interior surface 106. In some examples the film 104 may extend beyond the edge 110 of the interior surface 106 by a greater amount, for example it may extend to cover a substantial portion of the exterior surface 108. In such examples the film 104 may be bonded to the exterior surface 108 to provide moisture resistance to the exterior surface 108. However, providing exterior moisture resistance in this way increases the amount of plastic used in the packaging component 100. Therefore, to provide moisture resistance to the exterior surface 108, a moisture resistant coating may be applied to the exterior surface 108 or a hydrophobic additive, such as alkyl ketene dimer (AC), may be applied to molded fiber component 102.

[0023] By providing a packaging component 100 as described herein, packaging which is suitable for wet products may be provided which is simple to manufacture. For example, the film 104 may be bonded to the molded fiber component 102 prior to or after trimming the film 104 to size. The interior surface 106 of the molded fiber component 102 may also be more readily accessible prior to assembly of the packaging component 100 with another packaging component, and therefore it may be simpler to bond the film 104 to the molded fiber component 102 prior to assembly. Furthermore, the second portion 104b of the film 104 may be utilized in assembly of the packaging as described in further detail below.

[0024] Moreover, by providing a packaging which may be assembled from packaging components such as packaging component 100, the packaging components may be assembled after shipping, thereby allowing a higher density of packaging to be shipped and improving the efficiency of transport. For example, multiple packaging components 100 may be stacked and/or nested and shipped to a location where they are to be assembled and, in some examples filled with a product(s). In comparison, if the packaging were assembled prior to shipping, such nesting of packaging would not be possible, and each package would use more space when shipping. Therefore, the packaging component 100 described herein may allow both the financial and environmental costs of shipping to be reduced by improving efficiency by allowing more packaging to be shipped within a particular volume.

[0025] In some examples the film 104 of the packaging component 100 is a plastic with a thickness of less than 150pm. For example, the film 104 may be a plastic with a thickness of 20pm to 150pm, for example 50pm to 100pm. The film may be a plastic film, for example it may comprise polyethylene terephthalate or polyethylene.

[0026] In some examples the quantity of plastic used may be less than a threshold proportion of the entire packaging component 100. For example, the quantity of plastic may be less than 10% of the total mass of the packaging component, or it may be less than 5% of the total mass of the packaging component. When the mass of plastic is less than a threshold e.g. less than 10% or less than 5%, in some locations the packaging component 100 may be recycled with a paper or card recycling stream, thereby simplifying recycling of the packaging component 100. In comparison, packaging which comprises more than a threshold (e.g. 10%) plastics may have to be disassembled by a user prior to disposing of the packaging, whereas packaging which has less than the threshold can simply be disposed of without disassembly. In some examples the film may be a non-plastic film, for example it may be a latex film or a biofilm.

[0027] In this example the cross section of the packaging component 100 is U-shaped, however in other examples the cross section of the packaging component 100 may have another shape. For example, it may have an arc shaped or semi-circular cross section, for example when the packaging component 100 is intended to be assembled to form a cylindrical, bottle-shaped or conical packaging. In other examples, the packaging component 100 may comprise walls, which may comprise flat wall(s), which are angled relative to one another.

[0028] Fig. 2 shows a packaging component 200 wherein the packaging component is a part of a bottle. The packaging component 200 may be a molded fiber packaging component as described in relation to Fig. 1. In this example the packaging component 200 is half a side wall of the bottle, including half of a neck 202 of the bottle.

Such a packaging component 200 may be assembled with a similar packaging component to form side walls and a neck 202 of a bottle. In some examples a base of the bottle may be formed by assembling the packaging component 200 with a base part of the bottle, which may be formed in a similar manner to the packaging component 200 i.e. a molded fiber component bonded to a film. In other examples the packaging component may also comprise a portion of, or the entirety of, a base of the bottle. In some examples a base packaging component may be assembled with the packaging component 200 to form a bottle.

[0029] A first portion of a film is also bonded to an interior surface of the packaging component 200. As described in relation to Fig. 1, a second portion 208 of the film extends beyond an edge 204 of the interior surface and is foldable over the edge to abut the exterior surface of the molded fiber component. In this example the edge 204 connects the neck 202 and a bottom edge 206 of the packaging component 200 (or, when formed, a base of the bottle), in other words the edge 204 is a substantially vertical edge between the bottom and top of the packaging component 200. In this example the film extends beyond this substantially vertical edge 204 and at other edges of the interior surface of the packaging component 200 the film is aligned with these other edges. However in some examples the film may extend beyond other edges of the interior surface of the packaging component 200 in a similar manner to the how the second portion 208 of the film extends beyond the edge 204 between the neck 202 and bottom edge 206.

[0030] In some examples, in addition or as an alternative to sealing molded fibre components together, a portion of the film (the second portion 208) which extends beyond an edge 204 of the interior surface may be used to secure other components to the molded fibre component. For example, a portion of the film which extends beyond the neck 202 may provide a feature for facilitating attachment of a lid, seal or top to the bottle. For example, a flanged portion may be provided at the top of the molded fiber component to provide a flat surface at the top of the bottle for attachment of a seal. This flat surface may provide an example of an exterior surface. For example, the flanged portion may extend away from the neck 202, substantially perpendicular to side walls of the packaging component 200. The extending portion of the film may be foldable over the edge to abut the surface of flanged portion of the molded fiber component. Thus, in such an example, the flanged portion comprises an exterior surface, and the interior and exterior surfaces are substantially non-parallel, or substantially perpendicular. A portion of the film may extend over this flanged portion. When the packaging component 200 is assembled to form a bottle, a lid may be attached by bonding a film across the flanged portion to seal the neck 202 of the bottle. The lid may be formed from a similar or different film to the film bonded to the molded fiber component of the packaging component 200, or may comprise a plurality of layers, one of which comprises a film to be attached to the film of the molded fibre packaging component 200, and may be attached in a similar manner. For example energy, such as pressure and/or heat, may be applied to the film where it contacts the flanged portion at the neck 202 of the bottle. In some examples this lid may be provided with a protruding tab so that a user can easily pull the tab to remove the lid from the bottle.

[0031] Fig. 3A, Fig. 3B and Fig. 3C show an upper section of a first packaging component 300 similar to the packaging component 200 described in relation to Fig. 2. Fig 3C shows the upper section of the first packaging component 300 of Figs. 3A and 3B assembled with a second packaging component 320.

[0032] In this example the first packaging component 300 comprises a molded fiber component and a film. An interior surface 302 of the molded fiber component comprises a first edge 304 and a second edge 306. The film comprises a first portion 308a, a second portion 308b and a third portion 308c, wherein the first portion 308a is bonded to the interior surface 302 of the molded fiber component as described previously. The second portion 308b of the film extends beyond the first edge 304 of the interior surface 302 of the molded fiber component as described in relation to Figs. 1 and 2.

[0033] The film further comprises the third portion 308c, which extends beyond the second edge 306 and is foldable over the second edge 306. Therefore, in this example the molded fiber component of the first packaging component 300 comprises two edges 304, 306 each of which have a portion of the film extending beyond the edge. As shown in Fig. 3A the second and third portions 308b, 308c are not bonded to the exterior surface 310, however, in other examples they may be bonded to the exterior surface 310.

[0034] Fig. 3B shows the first packaging component 300 of Fig. 3A, however in this Figure the second and third portions 308b, 308c of the film are folded over the second edge 306 to abut the exterior surface 310 of the molded fiber component.

[0035] Fig. 3C shows the first packaging component 300 of Figs. 3A and 3B assembled with a second packaging component 320. In this example the second packaging component 320 comprises a molded fiber component with flanged portions 322a, 322b which are shaped to receive the first and second edges 304, 306 of the molded fiber component of the first packaging component 300, respectively. In other words, the flanged portions 322a, 322b provide a widened opening to the second packaging component 320, which otherwise has similar dimensions to the first packaging component 300, such that they can receive the edges 304, 306 of the first packaging component within the opening, and without deformation of either packaging component 300, 320. This forms a seam region where the components overlap one another. In other examples, this seam region may be formed in some other way, for example by partially deforming at least one packaging component 300, 320, or providing different dimension such that one component is formed to have a larger radius than the other component. The second packaging component 320 may also comprise a film bonded to an interior surface of the molded fiber component in a similar manner to the first packaging component 300, however, in some examples, the film of the second packaging component 320 does not comprise portions extending beyond an edge of the molded fiber component of the second packaging component 320.

[0036] When the first and second packaging components 300, 320 are assembled the second and third portions 308b, 308c of the film of the first packaging component 300 contact the film of the second packaging component 320 between the molded fiber component of the first packaging component 300 and the flanged portions 322a, 322b. The films of the first and second packaging components 300, 320 may be bonded together and may be bonded to an exterior surface of the molded fiber component of the first packaging component 300 and an interior surface of the molded fiber components of the second packaging component 320 to form seals under the flanged portions 322a, 322b and to bond the molded fiber components and films together. Therefore, providing a seal in this way allows the packaging components to be joined together and the seals to be formed in a single operation.

[0037] Bonding the films of the first and second packaging components 300, 320 may comprise at least one of: applying a force at the seam, impulse heating the seam, hot sealing the seam, heating the seam using radio frequency radiation, and bonding the seam using ultrasound, or some other form of sealing, such as using adhesive or glue. Hot sealing may comprise heating the seam using a sealing clamp which is continuously heated whereas impulse heating may heat the seam using a clamp which is heated when the clamp contacts the seam. Other bonding mechanisms may be used as well.

[0038] Fig. 4A, Fig. 4B and Fig. 40 also show an upper section of a first packaging component 400 similar to the packaging component 200 described in relation to Fig. 2.

Fig 40 shows the upper section of the first packaging component 400 of Figs. 4A and 4B assembled with a second packaging component 420.

[0039] In this example the first packaging component 400 comprises a molded fiber component and a film. An interior surface 402 of the molded fiber component comprises a first edge 404 and a second edge 406. The film comprises a first portion 408a and a second portion 408b, wherein the first portion 408a is bonded to the interior surface 402 of the molded fiber component as described previously. The second portion 408b of the film extends beyond the first edge 404 of the interior surface 402 of the molded fiber component as described in relation to Figs. 1, 2 and 3A.

[0040] In contrast with the example of Fig. 3A, an edge of the film is aligned with the second edge 406 of the interior surface 402 of the molded fiber component. In other words, this edge of the film does not extend beyond or overlap the second edge 406 of the molded fiber component. In this example, the second edge 406 of the molded fiber component is located on a flanged portion 410.

[0041] Fig. 4B shows the first packaging component 400 of Fig. 4A, however in this Figure the second portion 408b of the film is folded over the first edge 404 to abut the exterior surface 412 of the molded fiber component.

[0042] Fig. 4C shows the first packaging component 400 of Figs. 4A and 4B assembled with a second packaging component 420. In this example each of the first and second packaging components 400, 420 comprise a molded fiber component with one flanged portion 410, 422. The flanged portion 422 of the second molded fiber component of the second packaging component 420 is shaped to receive the first edge 404 of the molded fiber component of the first packaging component 400. Similarly, the flanged portion 410 of the molded fiber component of the first portion is shaped to receive an edge of the molded fiber component of the second packaging component 420.

[0043] The second packaging component 420 also comprises a film bonded to an interior surface of the molded fiber component in a similar manner to the first packaging component 400, and extending beyond an edge.

[0044] When the first and second packaging components 400, 420 are assembled the second portion 408b of the film of the first packaging component 400 contacts the film of the second packaging component 420 between the molded fiber component of the first packaging component 400 and the flanged portion 422 of the second packaging component 420. The films of the first and second packaging components 400, 420 may be bonded in a similar manner to the films of the first and second packaging components 300, 320 described in relation to Figure 3C.

[0045] The films of the first and second packaging components 400, 420 may be bonded together and may be bonded to an exterior surface 412 of the molded fiber component of the first packaging component 400 and an interior surface of the molded fiber components of the second packaging component 420 to form a seal under the flanged portion 422 of the second packaging component 420. A seal may also be formed in a similar manner under the flanged portion 410 of the molded fiber component of the first packaging component 400. In this example the molded fiber component of the first and second packaging components 400, 420 may be substantially the same i.e. they have a flanged portion at one edge and an overlapping film portion at another edge. This may allow the molded fiber components of first and second packaging components 400, 420 to be manufactured using the same tools (e.g. they may be formed on the same die). In comparison the molded fiber components of the first and second packaging components described in Figs. 3A, 3B, and 3C are different and therefore would be manufactured using different tools.

[0046] The first and second packaging components 300, 320, 400, 420 may be further assembled with other packaging components to form packaging. For example, a base part may be bonded to the first and second packaging components 300, 320, 400, 420 to form a base of the packaging. Other processes such as applying seals, filling the packaging or applying exterior coatings may be performed.

[0047] Fig. 5A shows an example of a container 500 comprising a first molded fiber part 502 and a second molded fiber part 504. A first film 506 is bonded to an interior surface of the first molded fiber part 502 and a second film 508 is bonded to an interior surface of the second molded fiber part 504. The first and second molded fiber parts 502, 504 are bonded together at a seam 512 comprising a portion of the first film 506 which is bonded to an exterior surface of the first molded fiber part 502 and to the second film 508 between the first and second molded fiber parts 502, 504.

[0048] In this example the first and second molded fiber parts 502, 504 are bonded at a seam on both sides of the container 500. For example, the seam may extend from the neck of the bottle, along a side of the bottle to a base of the bottle, along the base of the bottle and along an opposing side of the bottle to the neck of the bottle. In such an example, each of the first and second molded fiber parts 502, 504 may comprise a side wall of the container and a portion of the base of the container. Therefore in some examples the first and second molded fiber parts 502, 504 may be bonded by a single seam. In other examples the first and second molded fiber parts 502, 504 may be bonded by more than one seam. For example they may be bonded by a first seam on one side of the container 500 and by a second seam 514 on an opposing side of the container 500.

[0049] The first and second molded fiber parts 502, 504 may be molded fiber components as described in Figs. 1, 2, 3A-C or 4A-C. In some examples the first and second molded fiber parts 502, 504 may be substantially identical parts, for example as escribed in relation to Fig. 4C however in other examples they may be different, as described, for example in Fig. 3C.

[0050] The container 500 shown in Fig 5A is a bottle, however, in other examples the container may be any other type of packaging, for example a cup, a bowl or a box. The container 500 may be open at its top, or neck, in some examples the container 500 may be intended to be used with a cap, a lid or other sealing component.

[0051] Fig. 5B shows a cross section of another example of a container 520. The container 520 comprises a first molded fiber part 522, a second molded fiber part 524, a first film bonded to an interior surface of the first molded fiber part 522 and a second film bonded to an interior surface of the second molded fiber part 524 as described in relation to Fig. 5A. The container 520 further comprises a base part 526, wherein the base part 526 comprises a third molded fiber part and a third film bonded to the third molded fiber part. The third film may be bonded to an interior surface of the third molded fiber part, such that when the base part 526 is assembled with the first and second molded fiber parts 522, 525 a film is provided on all interior sides and base of the container.

[0052] In this example the third molded fiber part of the base part 526 is substantially circular to fit into the substantially cylindrical lower part of the container 520, however in other examples the container may be a different shape and therefore the base part may have a corresponding different shape.

[0053] In order to provide a leak free container, in this example the third film is bonded to the first film and the second film to provide a seal 528 at a base of the container. Bonding the first, second and/or third films may comprise at least one of: applying a force at the seam, impulse heating the seam, hot sealing the seam, heating the seam using radio frequency radiation, and bonding the seam using ultrasound, or some other form of sealing such as using adhesive or glue.

[0054] In this example, there are two points where the base part 526 meets both first and second molded fiber parts 522, 525. At these points, the first, second and third films are bonded together at a "triple point". Such a point may be particularly prone to leaks. To reduce the likelihood of a leak at these points, in some examples, the third film may be thicker than the first and/or second films. The thicker third film provides more material to be melted and fill any voids thereby reducing probability of a leak. In other examples, another of the films may be locally thickened in such a region, or an additional film may be overlaid on one of the first, second or third films to provide a local area of increased thickness.

[0055] The base part 526 comprises a recessed portion 530. In this example, the base part is substantially circular and the recessed portion 530 is substantially annular in shape. The recessed portion 530 may assist assembly of the container 520. For example to form the seal 528 heat, pressure or other energy type (e.g. ultrasound, radio frequency radiation) may be applied to opposing sides of the seal. The recessed portion allows a mold, die, heating element or the like to apply such energy to the seal 528 through the base part 526.

[0056] Fig. 6 shows a cross section of a container 600 showing how a first molded fiber part 602, a second molded fiber part 604, a first film 606 bonded to an interior surface of the first molded fiber part 602 and a second film 608 bonded to an interior surface of the second molded fiber part 604 are bonded together.

[0057] As described in relation to Fig. 5, the container 600 comprises a first molded fiber part 602, a second molded fiber part 604, a first film 606 and a second film 608. In this example the first and second molded fiber parts 602, 604 are bonded together at a first seam 610 and at a second seam 612. In this example the seams 610, 612 comprise, in order from the interior to the exterior of the container 600 (i.e. along the dashed line 614): a portion of the first film 606 bonded to the interior surface of the first molded fiber part 602, the first molded fiber part 602, a portion of the first film 606 bonded to the exterior surface of the first molded fiber part 602, the second film 608 and the second molded fiber part 604. Although this example shows first and second seams 610, 612, in other examples there may one seam or more than two seams. In some examples there may be a different arrangements of seams, for example a seam may not run vertically form a top to a base of the container 600 and may instead run substantially parallel to a base of a container or may be arranged in any other suitable way.

[0058] In this example the first molded fiber part 602 and the second molded fiber part 604 each comprise a flanged portion to receive the other of the first molded fiber part 602 and the second molded fiber part 604. However in other examples one of the molded fiber parts 602, 604 may not have a flanged portion while the other molded fiber part may have more than one flanged portion, for example as described in relation to Fig. 3C.

[0059] As used herein, the term flanged is used to describe a portion of a molded fiber part or component which provides a widened cross-section to assist assembly. In this example, the first and second molded fiber parts 602, 604 have the same internal dimension, so it would not be possible for their edges to nest within each other without distortion if they were not provided with the flanged portions. Therefore the flanged portions provide an altered internal dimension to assist assembly of the molded fiber parts 602,604 by allowing them to nest along the seams 610, 612. In other examples, the widened cross section could be provided in some other way, or a distortion may be permitted during assembly.

[0060] Fig. 7 is an example of a method 700, which may comprise a method for forming a packaging component. The packaging component may be a packaging component as described in any of Figs. 1,2, 3A-C, 4A-C or may be a part of the container described in any of Figs. 5A-B or 6.

[0061] The method 700 comprises, in block 702, bonding a first portion of a film to a surface of a molded fiber component to form a packaging component. For example, the first portion of the film may be bonded to the surface of the molded fiber component using a lamination process. Lamination may comprise laying the film on the molded fiber component and causing the film to conform to the shape of the surface of the molded fiber component by applying a force to the film. For example, air pressure may be used to "blow" the film to conform with the surface or a vacuum may be used to draw the film onto the surface so that the shape of the film conforms to contours of the surface. The film may be heated to cause the first portion of the film to bond with the molded fiber component.

[0062] In other examples plug assist lamination may be used to bond the first portion of the film to the molded fiber component. Plug assist lamination may comprise stretching a portion of film on a fame and placing the frame over the molded fiber component. A plug may then be pressed against the film to stretch the film towards the molded fiber component. Heat and a pressure gradient may then be applied to cause the first portion of the film to conform to and bond with the surface of the molded fiber component.

[0063] The method 700 comprises, in block 704, trimming the film such that a second portion of the film extends beyond an edge of the molded fiber component when the first portion of the film is bonded to the surface. Trimming (i.e. cutting) the film may be performed either prior to, or after, bonding the first portion of the film to the molded fiber component. For example, the film may be trimmed to the appropriate dimensions and shape and then boned to the molded fiber component as described above with the second portion of the film overhanging an edge of the molded fiber packaging component. In other examples the first portion of the film may be bonded to the molded fiber component then the film may be trimmed when the film is bonded to the molded fiber component.

[0064] In some examples an edge of the molded fiber component may also be trimmed. For example, the molded fiber component may have an uneven or untidy edge and may not have the intended dimensions. For example, a molded fiber component may be formed with dimensions greater than the intended finished dimensions to allow a sacrificial portion to be trimmed off and disposed of to provide a neat, smooth edge of the molded fiber component.

[0065] In other types of packaging, a film may be bonded to a surface of a molded fiber component, then the film and an edge of the molded fiber component may be trimmed simultaneously to provide a film aligned with the trimmed edge of the molded fiber component. In contrast, to provide a film which extends beyond an edge of a molded fiber component as described herein, the molded fiber component and the film may be trimmed in different operations and/or by different cutting apparatus.

[0066] In some examples, the method may comprise, prior to the bonding and trimming, forming the molded fiber component using a fiber molding process. The fiber molding process may be wet fiber molding process or a dry fiber molding process.

[0067] Fig. 8 shows an example of a method 800, which may comprise a method for forming and assembling a bottle. Fig. 8 provides an example of the method 700 of Fig. 7.

[0068] The method 800 comprises, in block 702, bonding a first portion of a first film to a surface of a first molded fiber component to form a first packaging component and, in block 704, trimming the first film such that a second portion of the first film extends beyond an edge of the first molded fiber component when the first portion of the first film is bonded to the surface as described in relation to Fig. 7.

[0069] The method comprises, in block 802, assembling the first packaging component and a second packaging component to form a bottle. In this example the container is a bottle, however in other examples the container may be a cup, a bowl, a box, direct food contact packaging, a plate, a yoghurt cup, a clam shell container, a print agent container (e.g. a toner or ink cartridge) or any other type of packaging. The method 800 may also comprise forming the second packaging component in a similar manner to the first packaging component, for example as described in relation to Fig. 7 i.e. by forming a molded fiber component using a fiber molding process, trimming a film and bonding a portion of the film to the molded fiber component.

[0070] In this example, assembling the first packaging component and the second packaging component comprises bonding the second portion of the film of the first packaging component to a film of the second packaging component to form a seam. Prior to assembly, the second portion of the film may extend beyond an edge of the interior surface and may be foldable over the edge to abut the exterior surface of the molded fiber component. To assemble the first and second packaging components the film may be folded over the edge then the first and second packaging components may be brought into contact such that second portion of the film of the first packaging component is in contact with the film of the second packaging component. By using the bonding of the first and second films to join the first packaging component and the second packaging component, the use of glue or adhesive in the assembly may be avoided.

[0071] The method comprises, in block 804 bonding a film of a base packaging component to the film of the first packaging component and to the film of the second packaging component to provide a base of the bottle. The base packaging component may be a base part as described in relation to Fig. 5B. Prior to bonding the film of the base packaging component to the film of the first packaging component, the base packaging component may be inserted to an opening between the first and second packaging components.

[0072] Bonding the films may comprise at least one of applying a force at the seam, impulse heating the seam, hot sealing the seam, heating the seam using radio frequency radiation, and bonding the seam using ultrasound. In other examples, other methods of bonding may be used such as using adhesive or glue.

[0073] Fig. 9A is a plan view and Fig. 93 is a cross section, perpendicular to the plan view of Fig. 9A, of an apparatus 900 which may be used to assemble packaging components according to the method described in Fig. 8. Figs. 90 and 9D are further cross sections of example apparatus 900', 900" which may be used to assemble packaging components.

[0074] The apparatus 900 comprises a first form 902 and a second form 904 which are shaped to fit around a tool 906. The tool is shaped to fit within the first packaging component and a second packaging component when they are assembled to form a container 908 (drawn in dashed lines for clarity). To assemble the container 908, the first packaging component may be placed with the first form 902, then the tool 906 placed within the first packaging component. The second packaging component may then be placed on top of the tool 906 and the second form 904 placed on top of the second packaging component.

[0075] The apparatus 900 further comprises a first element 910 and a second element 912 with a shape corresponding to the shape of the tool 906. The first and second elements 910, 912 are moved towards the container 908, as indicated by the arrows in Fig. 93. The first and second elements 910, 912 may contact the container along a seam where the first and second packaging components are to be bonded. A force may be applied to the first and second elements 910, 912 to apply pressure along the seam. In some examples the elements 910, 912 may comprise heaters or be heated to apply heat along the seal to bond a film of the first packaging component to a film of the second packaging component. In some examples the elements may comprise a radio frequency module or an ultrasound module to apply radiation to the seam to bond the films. A base of the container may be bonded to the first and second packaging components in a similar manner.

[0076] Fig. 9C shows a cross section of an apparatus 900' which is similar to the apparatus 900 of Figs. 9A and 93, however in this example the apparatus 900' does not comprise the first and second elements 910, 912. Instead, the forms 902', 904' contact the container along a seam and apply a force to the seam when bonding the first and second packaging components. In this example the first and second packaging components may be arranged such that the seam is located at the top and bottom i.e. in the centre of the first and second forms 902', 904' so the forms 902', 904' are able to apply pressure to the seam.

[0077] Fig. 9D shows a cross section of an apparatus 900" which is similar to the apparatus 900 of Figs. 9A and 9B, however in this example the elements 910", 912" of the apparatus 900" are slidably located within the forms 902", 904". In this example the first and second packaging components may be arranged such that the seam is located at the top and bottom i.e. adjacent to the first and second elements 910", 912". In use of the apparatus the forms may be pressed against the container 908" and the elements 910", 912" pressed against the seam to seal the seam as described above. In comparison with the apparatus 900' of Fig. 9C, the apparatus 900" is provided with elements 910", 912" which are separate elements which may therefore be pressed against the seal with a greater force in order to cause the seam to seal.

[0078] The present disclosure is described with reference to flow charts and/or block diagrams of the method, devices and systems according to examples of the present disclosure. Although the flow diagrams described above show a specific order of execution, the order of execution may differ from that which is depicted. Blocks described in relation to one flow chart may be combined with those of another flow chart.

[0079] In order to show the details of how the components are arranged, the various components shown in the figures may not be shown to scale and certain features may be enlarged relative to other features in order to more clearly illustrate the arrangement of the features.

[0080] While the method, apparatus and related aspects have been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the present disclosure. It is intended, therefore, that the method, apparatus and related aspects be limited only by the scope of the following claims and their equivalents. It should be noted that the above-mentioned examples illustrate rather than limit what is described herein, and that those skilled in the art will be able to design many alternative implementations without departing from the scope of the appended claims.

[0081] The word "comprising" does not exclude the presence of elements other than those listed in a claim, "a" or "an" does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims.

[0082] The features of any dependent claim may be combined with the features of any of the independent claims or other dependent claims.

Claims

CLAIMS1. A packaging component comprising: a molded fiber component comprising an interior surface and an exterior surface; and a film comprising: a first portion bonded to the interior surface of the molded fiber component; and a second portion extending beyond an edge of the interior surface and foldable over the edge to abut the exterior surface of the molded fiber component.
2. A packaging component as claimed in claim 1 wherein the packaging component is to form a part of a bottle.
3. A packaging component as claimed in claim 2 wherein the edge connects a neck and a base of the bottle, once formed
4. A packaging component as claimed in claim 1 wherein: the edge is a first edge; the interior surface of the molded fiber component comprises a second edge; and the film comprises a third portion extending beyond the second edge and foldable over the second edge to abut the exterior surface of the molded fiber component.
5. A packaging component as claimed in claim 1 wherein: the edge is a first edge; the interior surface of the molded fiber component comprises a second edge; and an edge of the film is aligned with the second edge of the interior surface of the molded fiber component.
6. A packaging component as claimed in claim 1 wherein the film is a plastic with a 30 thickness of 20pm to 150pm.
A container comprising: a first molded fiber part; a second molded fiber part; a first film bonded to an interior surface of the first molded fiber part; and a second film bonded to an interior surface of the second molded fiber part; wherein the first and second molded fiber parts are bonded together at a seam comprising a portion of the first film which is bonded to an exterior surface of the first molded fiber part and to the second film between the first and second molded fiber parts.
8. A container as claimed in claim 7 wherein the seam comprises, in order from the interior to the exterior of the container: a portion of the first film bonded to the interior surface of the first molded fiber part; the first molded fiber part; the portion of the first film bonded to the exterior surface of the first molded fiber part; the second film; and the second molded fiber part.
9. A container as claimed in claim 7, further comprising a base part, the base part comprising: a third molded fiber part; and a third film bonded to the third molded fiber part, wherein the third film is bonded to the first film and the second film to provide a seal at a base of the container.
10. A container as claimed in claim 7 wherein at least one of the first molded fiber part and the second molded fiber part comprises a flanged portion to receive the other of the first molded fiber part and the second molded fiber part.
11. A method comprising: bonding a first portion of a film to a surface of a molded fiber component to form a packaging component; and trimming the film such that a second portion of the film extends beyond an edge of the molded fiber component when the first portion of the film is bonded to the surface.
12. A method as claimed in claim 11 wherein the packaging component is a first packaging component, and the method further comprises: assembling the first packaging component and a second packaging component to form a bottle.
13. A method as claimed in claim 12, wherein assembling the first packaging component and the second packaging component comprises: bonding the second portion of the film of the first packaging component to a film of the second packaging component to form a seam.
14. A method as claimed in claim 13 further comprising: bonding a film of a base packaging component to the film of the first packaging component and to the film of the second packaging component to provide a base of the bottle.
15. A method as claimed in claim 13 wherein bonding the films comprises at least one of: applying a force at the seam; impulse heating the seam; hot sealing the seam; heating the seam using radio frequency radiation; and bonding the seam using ultrasound.