WO2018033208A1

WO2018033208A1 - Method for manufacturing a molded article from pulp, molded article made of pulp, and apparatus for manufacturing such a molded article

Info

Publication number: WO2018033208A1
Application number: PCT/EP2016/069610
Authority: WO
Inventors: Olaf Starken; Gian Armand Juliana De Belder; Wiebke VAN DER VEEN
Original assignee: Mayr-Melnhof Karton Ag
Priority date: 2016-08-18
Filing date: 2016-08-18
Publication date: 2018-02-22

Abstract

The invention relates to a method for manufacturing a molded article (10) from pulp (46), wherein the molded article (10) comprises at least one article body (12), the method comprising at least the steps of: introducing at least on parison (32) into an open mold (22), wherein the mold (22) comprises at least two movable mold parts (24, 26) which, in an assembled condition (A), form at least one cavity (34); closing the mold (22); expanding the parison (32) by means of a fluid thereby pressing the parison (32) against inner walls of the mold (22) and creating from the parison (32) an inner body (42) of said article body (12), said inner walls bounding said cavity (34); releasing the inner body (42) from the mold (22); and coating at least a portion of an outer surface (44) of the inner body (42) with pulp (46) thereby forming an outer layer (48) of the article body (12), the outer layer (48) being made of the pulp (46). 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 prior art. For example, EP 2 524 876 B1 shows a blow molded article for containing at least 1 .5 liters of a detergent composition, the article comprising a body having a top and a bottom. The article further comprises an opening proximal to said top. Moreover, the article comprises a non-through holding means integrally located on at least one side of said body and positioned between said top and said bottom. The known blow molded articles are made of plastic resin material. The different types of plastic packaging might have several disadvantages associated with their raw materials and their recycling possibilities.

Moreover, US 4 846 359 A1 shows a multi-layered plastic bottle having a body and a through holding means formed by a handle element which, on both of its ends, is connected to the body thereby forming the through holding means as a closed through holding means.

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 12 and an apparatus having the features of patent claim 17. Advantageous embodiments with expedient developments of the invention are indicated in the other patent claims.

A first aspect of the present invention relates to a method for manufacturing a molded article from pulp, wherein the article comprises at least one article body. The method according to the present invention comprises a first method step of introducing at least one parison in an open mold. Said mold comprises at least two movable mold parts which, in an assembled condition, form at least one cavity.

The method according to the present invention further comprises a second method step of closing the mold. For example, the mold is closed in such a way that said mold parts are moved towards each other. In order to open the mold so that, for example, the parison can be introduced into the open mold, said mold parts are moved away from each other.

The method according to the present invention further comprises a third method step of expanding the parison by means of a fluid, in particular a gas such as, for example, compressed air. Thus, for example, the parison is inflated by means of the fluid. In the following, the parison is also referred to as an inner element. Hence, said inner element comprises said parison. For example, said inner element bounds or has at least one volume in which said fluid is introduced so as to expand the inner element while the inner element is arranged in the mold, in particular in said cavity. For example, by introducing the inner element into the mold and by closing the mold the inner element is arranged in said cavity so that, by introducing said fluid into said inner element, the inner element is expanded within the cavity.

By expanding the inner element the inner element is pressed or compressed against inner walls of the mold, said inner walls bounding said cavity. Thus, the inner walls are used to form the inner element. Moreover, by expanding the inner element an inner body or an inner layer of said article body is created from the inner element, i.e. from the parison.

This step is typically conducted by introduction of a blow pin into the parison, in particular after cutting the parison at the end of the third step, as clearly described in Rosato's handbook on blow molding (ISBN:9781569903438).

Moreover, the method according to the present invention further comprises a fourth method step of releasing the inner body from the mold, in particular the cavity. For this purpose, for example, the mold is opened by moving the mold parts away from each other. Thus, the inner body can be removed from the mold.

The method according to the present invention further comprises a fifth method step of coating at least a portion of an outer surface of the inner body with pulp thereby forming an outer layer of the article body, the outer layer being made of the pulp. This means the article body, in its manufactured condition, comprises at least the inner body as an inner layer and said outer layer made of pulp, said outer layer enclosing the inner body at least partially. Preferably, at least a major portion of said outer surface of the inner body is coated with pulp so that the outer layer encloses at least a major portion of the outer surface and, thus, the inner body.

Preferably, after coating the outer surface, in a sixth method step, the pulp is dried, i.e. dewatered at least partially or completely. A parison can be obtained by classical methodologies such as extrusion blow molding (as referred in Rosato's handbook on blow molding; ISBN:9781569903438) where plastic(s) are molten by means of an extruder and turned into a molten tube by means of a head tooling system installed at the end of the extruder. Proper choice of head tooling provides flexibility in parison characteristics such as - but not limited to - wall thicknesses. Both shuttle and wheel types of blow molding machinery are to be considered. Other means of producing parisons do exist. Of particular interest is the formation of a parison by starting off with plastic film rolls. The parison's thickness can be tailored by a proper thickness selection of the started film.

Important to note is that the plastic film thickness might have a critical role to develop fully-recyclable packs. Pending the plastic material, it might be favorable to increase thickness in those cases where the plastic material is fully compatible with paper recycling streams (e.g. biodegradable plastics such as - but not limited to - those that degrade in the paper recycling process, whereas in other cases the thickness of the plastic film has to be limited to ensure recyclability of the pulp containers in the paper streams (e.g. using standard plastics such as - but not limited to - polyolefin-based materials, polyesters and derivatives thereof. Both petrol based, renewable plastics as recycled plastics can be used for the invention.

Also, by means of the method according to the present invention, the molded article can be realized as a liquid-tight container only by introducing an inner bag in the form of the parison which can be made out of plastic. The parison can be made out of plastic but can be produced in a very thin manner. Furthermore, the molded article can be produced by a one-step-approach versus a two-step-approach conventionally needed so that the molded article can be manufactured particularly easily and, thus, in a time- and cost-effective way.

For example, the parison is configured as a plastic parison. The parison can either be a monolayer (e.g. same material) parison, a multi-layer (several layers of different plastic materials) parison and/or comprises a blend of materials. This flexibility allows to tailor the parison according the product needs (such as but not limited to product packaging compatibility requirements including perfume loss, O2, H2O, CO2 losses/ingress into packaging, etc.).

For example, the parison is made of one plastic film sheet which, for example, is formed by means of a forming shoulder. For example, the plastic film sheet has edges which are welded together to form, for example, a film roll, a film tube or said parison. For example, sad plastic film sheet is rolled off a role.

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. In other words, sensory elements (such as but not limited to softness) can be obtained by means of pulp slurry composition (including but not limited to fiber type and/or additives). Moreover, for example, surface finishes of the molded article can be realized in a need-based manner. Preferably, plastics contained in the parison and potentially providing issues during paper recycling (such as polyolefins) are limited to five percent by weight to so that the molded article can be recycled in a particularly advantageous way.

Preferably, the parison is very thin. Moreover, the parison can be made of a biodegradable plastic. Since, preferably, the parison can be very thin, material usage can be kept particularly low. 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, in particular the outer layer of the article body, is made of pulp such ridges and edges can be avoided. Further, the use of a renewable, biodegradable and/or recyclable raw material, namely pulp, is particularly advantageous in contrast to other raw materials like plastics. The term "integrally formed" means that the article body is formed as one piece, preferably in one production step.

For example, a person can grasp the article body by means of at least one or more of their finger so that the person can move the molded article in convenient or preferred way. With respect to a conventional molded article made of pulp a person grasping and, thus, touching the article body of the conventional molded article can feel said edges or ridges so that the feel, in particular the surface feel, of the molded article is impaired. 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 can have 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.

Preferably, said inner body is inherently stable and has an outer form corresponding to an inner form of the cavity. Preferably, the inner body I very thin and/or configured as or made of at a degradable product such as biodegradable plastics, algae etc. For example, coating the inner body with said pulp provides an adequate stability of the molded article wherein, for example, the inner body can act as a protective layer and, thus, a barrier protecting the pulp from the medium contained in the molded article and/or the medium from the pulp and/or environmental influences. By using the pulp, a particularly good sensorial feel, e.g. softness can be realized. Moreover, by providing a holding means, particularly good ergonomics can be realized since the molded article can be handled easily thus enabling the consumer benefit of an easier handling of a large containers which can be made of advantageous raw material which is easy to recycle.

Preferably, the molded article, in particular the article body comprises at least one receiving space for receiving said medium. Said receiving space is bounded by the inner body. Thus, in a state in which said medium is contained in the receiving space, the inner body is arranged between said medium and said outer layer, i.e. the pulp. Thus, the inner body acts as an inner protective layer protecting the outer layer and, thus, the pulp forming the outer layer from a direct contact with the medium contained in the receiving space. Hence, the medium can be stored in the receiving space in a particularly advantageous manner.

For example, different plastic types can be used for the parison for different barrier requirements. For example, the protection provided by the parison is used or required to avoid product - packaging interactions and to provide enough barrier against the surrounding atmosphere: ingredient (such as perfume and others) losses, H2O, CO2, O2 losses or ingress, etc. Thus, moreover, a product contained in the receiving space can be protected from the environment or environmental influences by means of the inner element. In order to protect the pulp particularly advantageously from the medium and/or to protect the medium from its surroundings, in particular environmental influences, the inner element is preferably made of at least one plastic material. For example, the parison can comprise one layer only or a plurality of layers which are, for example, made of different kinds of plastics. Thus, the parison can comprise a multi-layer and/or blend system comprising at least two different plastic materials. Moreover, the inner element can be used as a forming means to form the pulp around the inner element. Thus, at least one wall is manufactured from the pulp, wherein said wall manufactured from the pulp forms the article body and, for example, the receiving space. By means of the inner element an at least substantially even wall thickness of said wall manufactured from the pulp can be realized so that the weight and the costs of the molded article can be kept particularly low. Moreover, the molded article can be manufactured in a particularly cost-effective way. For example, the molded article is pulp based and can comprise at least one plastic material, in particular a standard plastic material, wherein, for example, the non-pulp material in the molded article is limited to 5% at the most with respect to the overall material used to manufacture the molded article to ensure recycle-ability. 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 foam starch.

Alternatively or additionally, the pulp can comprises fibers or fiber solids such as, e.g. natural fibers, natural bamboo fibers and/or straw fibers and/or coconut fibers and/or synthetic fibers such as plastic fibers and/or treated fibers and/or untreated fibers and/or nano-cellulose. For example, said treated fibers are fibers which are treated in such a way so that said treated fibers are waterproof and/or water-resistant. Preferably, the pulp is a fibrous pulp comprising at least one of the aforementioned kinds of fibers. Furthermore, the pulp can comprise at least one or a plurality of additives. In an advantageous embodiment of the invention at least said portion of the outer surface of the inner body is coated with pulp by dipping the inner body into a pulp bath. Thus, the outer surface of the inner body can be coated with pulp at least substantially equally so that, for example, an at least substantially even wall thickness of the outer layer can be realized in a time- and cost-effective way. Preferably, the step of dipping the inner body into said pulp bath is followed by a drying step by means of which the pulp sticking to the inner body is dried at least partially, in particular completely.

In the method according to the present invention, the article body can be formed from paper pulp and equipped with the inner body all in one process versus producing barrier in separate step so that the article body can manufactured in a time- and cost-effective way. Moreover, a great feel due to no ridges can be realized,

Preferably, the inner body has a rough outer surface so the pulp is sticking to the inner body. For example, the inner body is be charged electrically so that fibers of the pulp are drawn to the article body. For example, after coating the outer surface with the pulp, the pulp is dried. For example, the pulp on the inner body is dried by means of an external oven. Alternatively or additionally, the pulp on the inner body is pressed or compressed and, thus, dewatered or dried. For example, the pulp on the inner body is dewatered by means of a further tool.

For example, the ratio between the pulp, in particular its mass, and the wall thickness of the inner body can be tailored in order to ensure recyclability of the total article body, e.g. compatible with the paper recycling streams.

In a further advantageous embodiment of the invention at least said portion of the outer surface of the inner body is coated with pulp by reintroducing the inner body into a second mold comprising at least one second cavity dimensioned so as to form a gap between the outer surface of the inner body and an inner surface of the second mold, the inner surface of the second mold bounding said second cavity at least partially. This means the inner body is arranged in the second cavity in such a way that a gap between the inner body, in particular the outer surface of the inner body, and the inner surface of the second cavity exists. For example, starch or foamed starch is used and, for example, arranged on and around the inner body. For example, the starch is baked by microwaves. 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.

Moreover, the outer surface of the inner body is coated with pulp by introducing the pulp into the gap. Thus, an at least substantially even wall thickness of the outer layer can be realized thereby realizing a particularly advantageous visual appearance and surface feel of the article body.

Preferably, the step of introducing the pulp into the is followed by a drying step by means of which the pulp sticking to the inner body is dried at least partially, in particular completely.

For example, the parison is made of or comprises at least one film sheet, in particular at least one plastic film sheet, the film sheet being formed by means of at least one forming element and welded together at edges together to form a film roll, or film tube or parison, in particular before introducing the parison into the mold.

In a further advantageous embodiment of the invention at least one reservoir containing at least one plastic material is provided. Moreover, the parison is created from the plastic material while introducing the parison into the mold, i.e. into the first mold. Thus, a particular advantageous process of manufacturing the article body can be realized.

In order to realize a particularly advantageous, time- and cost-effective process of manufacturing the article body, in a further embodiment, the parison is created from the plastic material by extruding. For example, the parison is made by an extruder melting the plastic material. Preferably, the inner body is produced very thin, wherein strength or stability is provided by the pulp, e.g. starch or foamed starch the outer surface of the inner body is coated with. For example, the parison is made of at least one plastic film sheet which, for example, is formed by means of a forming shoulder. For example, the plastic film sheet has edges which are welded together to form, for example, a film roll, a film tube or said parison. For example, said plastic film sheet is rolled off a role. Thus, the parison is made of or comprises at least one film sheet, in particular at least one plastic film sheet, the film sheet being formed by means of at least one forming element such as a forming shoulder and welded together at edges to form a film roll or a film tube or a parison. Said edges can be welded together via a heated element. By welding the edges together, the parison or film sheet bound a volume in which the fluid can be introduced so as to inflated and, thus, expand the parison.

In a further advantageous embodiment of the invention at least one gas such as air, in particular compressed air, is used as the fluid so that the inner element can be expanded particularly advantageously.

In order to realize a particularly advantageous visual appearance and surface feel and/or handling of the molded article, in a further embodiment of the invention, the mold, i.e. the first mold and/or the second mold comprises at least one further cavity for forming at least one holding means to said article body within the mold. In other words, at least one of said molds comprises said further cavity for forming at least one holding means to said article body within the at least one mold.

For example, said holding means is a handle or grip by means of which the molded article can be handled by a person. In this regard, for example, the person can grasp the holding means by means of at least one or more of their fingers one hand so that the person can move the molded article via the holding means. Thus, the person can move or handle the molded article particularly easily thereby creating a particularly advantageous feel of the molded article. Preferably, the holding means is made of pulp, wherein, for example, the holding means and the article body can be formed in one piece.

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

In order to realize a particularly advantageous surface feel and/or a particularly advantageous stiffness of the holding means, in a further embodiment of the invention, the further cavity is filled with a prefabricated component for forming the holding means or at least one part of the holding means, wherein the prefabricated component is connected to the article body, in particular the outer layer. Preferably, the prefabricated component is connected with the article body, in particular the outer layer, within said mold comprising said further cavity in which the prefabricated component is arranged. For example, the prefabricated component can be made of plastics, rubber, etc..

Preferably, said holding means is manufactured from pulp and/or plastics so that a particularly advantageous surface feel can be realized since edges and ridges can be avoided.

For example, the pre-fabricated holding means can be made (but not necessary) of the same material as the article body. In the above cases, the handle can be hollow or solid. 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 pulp for environmental and recycling advantages.

For example, the holding means comprises a second receiving space for receiving at least a portion of said medium so that the medium can be stored in the holding means at least partially. Preferably, the second receiving space is fluidically connected to the first receiving space of the article body so that said medium can be introduced into both receiving spaces particularly easily. Alternatively, the holding means can be configured as a massive component or massive holding means so that the holding means is not hollow and, thus, does not have a receiving space for receiving said medium.

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 open space through which fingers and/or a thumb can be inserted.

Moreover, the 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. Alternatively, the through 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.

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.

A second aspect of the present invention relates to a molded article made of pulp. The molded article is manufactured by a method according to the present invention. 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 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 integrally formed. Usually, conventional molded articles made of plastic materials or 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, according to the present invention, at least the article body and/or the holding means are integrally formed such ridges and edges can be avoided. Further, the use of a renewable, biodegradable and/or recyclable raw material, namely pulp, is particularly advantageous compared to other raw materials like plastics. In present invention, plastics can be used for the inner body, wherein, for example, the amount of plastics can be reduced in comparison with conventional articles and creating a chance to introduce plastic from renewable resource or degradable plastics which are normally more expensive in comparison to conventional plastics.

In order to realize a particularly advantageous surface feel, the molded article comprises at least one holding means which is, preferably, made of pulp.

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 pulp molded article in particular a molded article according to the second aspect of the invention. The apparatus according to the third aspect of the present invention is used in a method according to the first aspect of the present invention, wherein the apparatus comprises at least one mold having at least two movable mold parts which, in an assembled condition, form at least one cavity for forming at least one layer of the article body. For example, said layer is said inner body. Preferably, said mold parts are in said assembled condition when the mold parts and, thus, the mold overall are closed so that the mold parts form or bound said cavity for forming the inner body when the mold is closed.

In a preferred embodiment of the third aspect of the present invention the apparatus further comprises means for introducing a parison into the mold in an open condition of the mold. The mold is in its open condition when the mold is open, i.e. the mold parts are open. For example, the parison bounds a volume in which a fluid such as a gas or a liquid can be introduced so as to inflate or expand the parison. The apparatus further comprises means for inflating said parison in a closed condition of the mold thereby creating an inner body of the article body. In order to convert the mold from its open condition to its closed condition the mold parts are closed thereby arranging the parison in the cavity of the mold. Thus, the fluid such as a gas, in particular compressed air, is introduced into said volume thereby expanding the parison or the plastic film sheets while the parison is arranged in the cavity. Thereby the parison is pressed against inner walls of the mold, said inner walls bounding said cavity. Thus, said cavity is used for forming the inner body. The apparatus further comprises means for coating at least a portion of an outer surface of the inner body with pulp thereby forming an outer layer of the article body, the outer layer being made of the pulp. Preferably, the apparatus further comprises means of drying the pulp, in particular after coating the outer surface with the pulp.

Preferably, the apparatus comprises means for drying the pulp stick to the inner body.

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

Fig. 1 a schematic view of a first embodiment of an inventive method for manufacturing a molded article from pulp, wherein at least one inner element such as a parison is or expanded by means of a fluid;

Fig. 2 a schematic view of a second embodiment of the method according to the invention;

Fig. 3 a schematic view of a third embodiment of the method according to the invention;

Fig. 4 a schematic view of a fourth embodiment of the method according to the invention; Fig. 5 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;

Fig. 7 a schematic front view of a third embodiment of the molded article according to the invention;

Fig. 8 a schematic view of a fifth embodiment of the method according to the invention; Fig. 9 a schematic view of a sixth embodiment of the method according to the invention;

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

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

Fig. 12 a schematic 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. 5 to 7, 1 1 and 12) from pulp. In other words the molded article 10 is made of pulp so that the molded article 10 is a pulp molded article. As can be seen from Figs. 5 to 7, 1 1 and 12 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. 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 and at least one holding means 14 connected to the article body 12 at least indirectly. For example, the article body 12 and the holding means 14 are formed in one piece. As an alternative the article body 12 and the holding means 14 are configured as separate components which are connected with each other. For example, both the article body 12 and the holding means 14 are made of pulp.

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 solid and/or 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 non-destructive way so that the inlet opening can be closed and opened by the cap 18 in a need-based manner. As can be seen from Fig. 1 , a tool 20 is used for manufacturing the molded article 10, in particular the article body 12. The tool 20 comprises a mold 22 having two movable mold parts 24 and 26 which are also referred to as tool elements. As illustrated by arrows 28 in Fig. 1 , the mold parts 24 and 26 (tool elements) can be moved away from each other thereby opening the mold 22 or the mold parts 24 and 26. Moreover, as illustrated by arrows 30, the mold parts 24 and 26 can be moved towards each other thereby closing the mold 22 or the mold parts 24 and 26. For example, said tool 20 and, thus, the mold 22 and the mold parts 24 and 26 are parts of an apparatus for manufacturing the molded article 10, in particular the article body 12, wherein said apparatus is used in said method. As will be described in greater detail below, the mold 22 is used to manufacture at least the article body 12, in particular an inner body for forming or producing the article body 12.

In a first method step S1 of said method an inner element in the form of a parison 32 is introduced into the mold 22 in an open condition of the mold 22. In other words, in the first embodiment, said inner element is said parison 32 which is introduced into the mold 22 while the mold 22 is open. The mold 22 can be closed by moving the mold parts 24 and 26 towards each other. When the mold parts 24 and 26 or the mold 22 is closed, the mold 22 is in its closed condition in which the mold parts 24 and 26 are in an assembled condition A.

In a second method step S2 the mold 22 is closed by moving the mold parts 24 and 26 towards each other. As a consequence, the mold parts 24 and 26 are in their assembled condition A in which the mold parts 24 and 26 form or bound at least one first cavity 34. By introducing the parison 32 (inner element) in the first method step S1 and by closing the mold 22 in the second method step S2 the parison 32 is arranged in the cavity 34.

In the open condition of the mold 22 the mold parts 24 and 26 form a passage 36, wherein the parison is introduced into the mold 22 in the open condition of the mold 22 in such a way that opposing wall portions 33 of the parison 32 are arranged in said passage 36. By closing said mold 22 the passage 36 is closed, wherein the passage 36 is closed while said wall portions 33 are arranged in the passage 36. Thereby said wall portions 33 which, in the open condition of the mold 22, are arranged at a distance from each other come into contact. Preferably, said wall portions are connected with each other. For example, the wall portions 33 are connected and sealed with each other by heating and melting the wall portions and by closing the passage 36. For example, by connecting said wall portions 33 the parison 32 has or bounds a volume 38. In a third method step S3 of said method the parison 32 is expanded while the parison 32 is arranged in the cavity 34. The parison 32 is expanded by means of fluid such as a gas, wherein, for example, air, in particular compressed air, is used as said fluid. For expanding the parison 32 said fluid is introduced into the parison 32, in particular into the volume 38 so that, for example, the parison 32 is inflated and, thus, expanded in the cavity 34. For introducing said gas into the parison 32 a blow pin 40 is used. The blow pin 40 has at least one or a plurality of outlet openings, wherein said fluid can flow through the blow pin 40 and said outlet opening. The gas can flow through the outlet opening and, thus, out of the blow pin 40 and into the parison 32, in particular the volume 38. Preferably, the blow pin 40 is fluidically connected to a fluid source (not shown).

For example, the parison 32 is made by extruding, wherein the parison 32 is made of a plastic material which is molten and extruded. The plastic material of the parison 32 forms the wall portions 33. In the third step S3 the mold 22 is closed in a state in which the plastic of the parison 36 and, thus, the parison 36 itself are still warm and, thus, easily deformable. Hence, the wall portions 33 can be pressed together by closing the mold 22 thereby connecting and sealing the wall portions 22. Moreover, for example, the parison 36 already is or forms a tube so that there is no need to heat or melt or seal wall portions.

Alternatively, said inner element (parison 32) comprises or is made of at least one plastic film or plastic film sheet. The plastic film is rolled off a roll 68 and, coming from the roll 68, formed by means of at least one forming element such as, for example, a forming shoulder. By forming the plastic film, the parison 32 is formed from the plastic film sheet. For example, side portions or edges of the plastic film connected and sealed by welding so that the parison 32 is, for example, a tube. Thus, the parison 32 has the volume 38 into which the fluid can be introduced so as to inflate and expand the parison 32.

By inflating and, thus, expanding the parison 32 the parison 32 is pressed or compressed against inner walls of the mold 22, wherein said inner walls bound the cavity 34. Thus, the cavity 34 or said inner walls bounding the cavity 34 is or are used to form the parison 32. By expanding the parison 32 an inner body 42 of the article body 12 is created from the parison 32. Preferably, the parison 32 is made of a plastic material so that the inner body 42 is made of plastic. Preferably, the inner body 42 is very thin and can be used as a protective layer or an inner barrier.

For inflating, for example, the wall portions 33 of the parison produced from at least one plastic film or plastic sheets are heated and/or molten. For example, the mold parts 24 and 26 are closed, and the inner element (parison 36) is heated and expanded by said fluid.

In a fourth method step S4 of the method the inner body 42 is released from the mold 22. For this purpose, for example, the mold 22 is opened by moving the mold parts 24 and 26 away from each other. Preferably, the inner body 42 is inherently stable and has an outer form which corresponds at least substantially to an inner form of the cavity 34.

In a fifth method step S5 at least a portion of an outer surface 44 of the inner body 42 is coated with pulp 46 thereby forming an outer layer 48 of the article body 12, the outer layer 48 being made of the pulp 46. As can be seen from Fig. 1 , the inner body 42 is an inner layer of the article body 12. Moreover, at least a major portion of the outer surface 44 or the complete outer surface 44 of the inner body 42 is coated with the pulp 46 so that the outer layer 48 encloses at least a major portion of the outer surface 44 or the inner body 42. In the first embodiment shown in Fig. 1 , the outer surface 44 of the inner body 42 is coated with the pulp 46 by dipping the inner body 42 into a pulp bath 50. In other words, the inner body 42 is dipped into the pulp bath 50 in the fifth method step S5 thereby coating the outer surface 44 with the pulp 46. In a sixth method step S6 the inner body 42 is removed from the pulp bath 50. The inner body 42 forms a plastic inner bottle which is coated with the pulp 46 thereby creating the outer layer 48. Preferably, the outer surface 44 is rough so that the pulp 46 sticks to the outer surface 44 and, thus, the inner body 42.

For example, the inner body 42 can be electrically and/or electrostatically charged electrically so the pulp 46, in particular its fibers, is or are drawn to the inner body 42. Preferably, after coating the outer surface 44, the pulp 46 on the inner body 42 is dried by, for example, an external oven. Alternatively or additionally, the pulp 46 on the inner body 42 is pressed or compressed, in particular to dewater the pulp 46.

For example, drying the pulp 46 is performed in an additional step, and can be performed (but not limited to) by using standard techniques such as at least one oven and/or using radiation such as UV curing, infrared, microwave, etc.

Moreover, in the first embodiment, at least one reservoir 52 containing at least on plastic material 54 is provided. In the first method step S1 the parison 32 is created from the plastic material 54 while introducing the parison 32 into the mold 22. Preferably, the parison 32 is created from the plastic material 54 by extruding. Thus, preferably, the reservoir 52 is part of an extruder by means of which the parison 32 is created by extruding. For example, the blow pin 48 can be used to form an inlet of the molded article 10 in a precise way, potentially from pulp but if required also from plastic.

For example, in a further or last stage or method step, remaining flash (neck part and/or bottom part and/or handle part) is removed by a deflashing station as clearly described in Rosato's handbook on blow molding: ISBN:9781569903438.

Fig. 2 shows a second embodiment of the method. In the second embodiment, after manufacturing the inner body 42, i.e. after the fourth method step S4, the outer surface 44 of the inner body 42 is coated with pulp 46 in the following way: In a fifth method step S5 the inner body 42 is reintroduced into a second mold 56 being different from the first mold 22. For example, in order to introduce the inner body 42 into the second mold 56, the second mold 56 comprises further mold parts which can be moved, in particular in relation to each other. For example, the further mold parts are moved away from each other thereby opening the second mold 56. In the following, the inner body 42 is arranged between the further mold parts. Then, the further mold parts are moved towards each other thereby closing the second mold 56 and arranging the inner body 42 in the second mold 56. When the second mold 56 is closed the mold parts form at least one second cavity 58 of the second mold 56, wherein the inner body 42 is arranged in the second cavity 58. The second cavity 58 is dimensioned so as to form a gap 60 between the outer surface 44 of the inner body 42 and an inner surface 62 of the second mold 56, the inner surface 62 bounding the second cavity 58 at least partially.

In a sixth method step S6 the pulp 46 for forming the outer layer 48 is introduced into said gap 60. Preferably, the pulp 46 is sprayed into the gap 60 and, thus, between the inner body 42 and the mold 56. For example, in a seventh method step not shown in the figures the article body 12 is released from the second mold 56.

For example, the pulp 46 is or can comprise starch or foamed starch. Alternatively or additionally, the gap 60 is evacuated or set under a vacuum so that the pulp 46 can be sucked into the gap 60 and dewatered. Preferably, the mold 22 comprises or is made of a permeable material through which the moisture from the pulp 46 contained in the gap 60 can escape or, in particular by means of the vacuum, withdrawn as illustrated by arrows in Fig. 2, step S6. Preferably, the mold 22 is permeable or made of a permeable material so that moisture can be sucked out of the pulp 46 by means of the vacuum as illustrated by arrows pointing to the outside of the mold 22 in Fig. 2, step S6. With respect to a state or condition in which said medium is contained in said receiving space of the article body 12, the inner body 42 is arranged between the medium and the outer layer 48 thereby protecting the outer layer 48 made of pulp from a direct contact with said medium. Thus, the medium can be stored particularly advantageously in the article body 12. Moreover, by manufacturing the outer layer 48 from pulp ridges and edges impairing both the visual appearance and the surface feel of the article body 12 can be avoided. As can be seen from Figs. 1 and 2 the parison 32 is an inner element being a hose or a tube into which the gas is introduced. Thereby the inner element is expanded and pressed against the inner walls bounding the cavity 34. Preferably, after the respective sixth method step S6, a seventh method step in the form of a drying step is carried out in which the pulp 46 on the inner body 42 is dried. For this purpose, for example, the pulp 46 on the inner body 42 is compressed and/or heated.

For example, the parison 36 is made by extruding, wherein the parison is made of a plastic material which is molten and extruded. The plastic material of the parison 36 forms the wall portions 33. In the second step S2 the mold 22 is closed in a state in which the plastic of the parison 32 and, thus, the parison 32itself are still warm and, thus, easily deformable. Hence, the wall portions 33 can be pressed together by closing the mold 22 thereby connecting and sealing the wall portions 22. Moreover, for example, the parison 32 already is or forms a tube so that there is no need to heat or melt or seal wall portions. Fig. 3 shows a third embodiment of the method. In the third embodiment, said inner element (parison 32) comprises or is made of at least one plastic film or plastic film sheet. The plastic film is rolled off a roll 68 and, coming from the roll 68, formed by means of at least one forming element such as, for example, a forming shoulder. By forming the plastic film, the parison 32 is formed from the plastic film sheet. For example, side portions or edges of the plastic film connected and sealed by welding so that the parison 32 is, for example, a tube. Thus, the parison 32 has the volume 38 into which the fluid can be introduced so as to inflate and expand the parison 32.

Moreover, the plastic film is introduced into the mold 22 in such a way that respective wall portions 33 of the plastic film are arranged in said passage 36. As described in regard to the parison 32, firstly, the wall portions 33 arranged in the passage 36 are arranged at a distance from each other. Secondly, the wall portions arranged in the passage 36 are connected and sealed with each other by closing the mold parts 24 and 26 thereby bounding the volume 38. For this purpose, for example, the wall portions 33 are heated and/or molten. For example, the mold parts 24 and 26 are closed, and the inner element (parison 36) is heated and expanded by said fluid Fig. 4 shows a fourth embodiment of the method. In the fourth embodiment, a further mold 70 is provided. For example, the further mold 70 is the second mold 56 or the first mold 22. Alternatively, the further mold 70 is third mold being different from the molds 22 and 56. As can be seen from Fig. 4, the mold 70 comprises at least one further cavity 72 for forming the holding means 14 to the article body 12 within the mold 70. Preferably, the holding means 14 is made of pulp so that, for example, pulp for forming the holding means 14 is introduced into the cavity 72. Moreover, the mold 70 has a cavity 74 in which the article body 12 is introduced. For example, the cavity 74 is the cavity 58. For example, in order to connect the holding means 14 to the article body 12 manufactured by the first, second or third embodiment of the method, the article body 12 manufactured by means of the first, second or third embodiment of the method is introduced into the cavity 74. For example, the cavities 72 and 74 are fluidically connected with each other so that the holding means 14 can come into contact with the article body 12, in particular the outer layer 48. Thus, the holding means 14 can be connected to the article body 12, in particular the outer layer 48, within the mold 70.

For example, pulp is introduced into the cavity 74. Afterwards, the article body 12 is introduced into the cavity 74 thereby connecting the pulp contained in the cavity 72 to the outer layer 48 contained in the cavity 74. Alternatively, the holding means 14 is manufactured from at least one prefabricated component. In this regard, for example, the cavity 74 is filled with a prefabricated component for forming the holding means 14 or at least one part of the holding means 14, wherein the pre-fabricated component is connected to the article body 12, in particular the outer layer 48. For example, the prefabricated component of the holding means 14 is made of pulp. Particularly, the holding means 14 can be made of carton or a carton tube. For example, the holding means 14, in particular the prefabricated component, is merged to the article body 12. For example, the cavity 74 is, at least on one area, fluidically connected to the cavity 72 so that, in particular by expanding the inner element, the pulp contained in the cavity 74 is brought into contact with the prefabricated component arranged in the cavity 72 thereby connecting the prefabricated component with the pulp contained in the cavity 74. Hence, the prefabricated component and thus the holding means 14 can be connected with the article body 12. For example, the holding means 14 can be massive or a massive component so that the holding means 14 does not have any receiving space for containing said medium. Alternatively, the holding means 14 can comprise at least one receiving space for storing said medium. Preferably, when both the article body 12 and the holding means 14 comprise receiving spaces respectively, said receiving spaces are fluidically connected with each other so that said medium can be stored in both receiving spaces and both receiving spaces can be filled with said medium in a particularly easy way, in particular via said inlet opening. For example, the holding means 14, in particular the prefabricated component, is made of pulp or carton wherein, for example, the holding means 14 is formed as a tube. Moreover, for example, the holding means 14, in particular the prefabricated component, is merged to the article body 12. Further, the prefabricated component can be made of plastics, rubber, etc. Fig. 5 shows a first embodiment of the molded article 10. In the first embodiment of the molded article 10 the holding means 14 is configured as a open through holding means which is also referred to as an open handle, open grip or open holding means, wherein the holding means 14 is configured as a one-side connected open handle or a one-side connected through holding means.. The through holding means comprises at least one through opening 76 so that a completely open space through which a person can insert their fingers and/or thumb exists. Thus, the person can grasp the holding means 14 in a particularly comfortable way. Since the through holding means comprises the at least one through opening 76 a person grasping the holding means 14 can wrap their fingers completely around the holding means 14 in the area of the through opening 76. 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 78. 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 80 of the holding means 14 is connected to the article body 12. However, the second end 82 of the holding means 14 is not connected to the article body 12, but arranged at a distance from the article body 12, so that the through holding means 14 according to Fig. 5 is configured as a one-side connected through holding means.

Fig. 6 shows a second embodiment of the molded article 10. In the second embodiment the holding means 14 is also configured as a through holding means, i.e. an open handle, through handle, through grip or open grip. Thus, the open holding means or through holding means has at least one through opening 76 through which a person can put one or more of their fingers. However, the holding means 14 according to the second embodiment is connected to the article body 12 at both ends 80 and 82. Thus, the holding means 14 is completely closed in its longitudinal extension so that the holding means 14 is configured as a two-side connected through holding means which is also referred to as a two-side connected open handle. Moreover, the holding means 14 can be formed integral with the article body 12 so that the article body 12 and the holding means 14 can be formed in one piece.

Fig. 7 shows at third embodiment of the molded article 10. In the third embodiment the holding means 14 is configured as a non-through holding means which is also referred to as a closed handle, closed integral grip or closed grip. The non-through holding means does not comprise any through opening through which a person can put their fingers. The non-through holding means has lateral receptacles which are arranged on opposite sides of the holding means 14. From said receptacles a first one of said receptacles can be seen in Fig. 7, the first receptacle being indicated by 83. 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. The receptacles are also referred to as depressions. Alternatively, the holding means 14 can be configured a blown handles by, for example, using a recess in the mold 22 or a boxed handle by a boxing operation inside the mold during formation of the inner body 42.

In other words, for example, the holding means 14 can be formed by a recess in the mold 22 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 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.

In the non-through holding means the holding means 14 of the respective receptacle is limited in the insertion direction by a wall 84 of the molded article 10, the wall 84 being arranged between said receptacles. Thus, said receptacles are separated from one another by means of the wall 84. The wall 84 is, for example, made of the pulp, wherein, for example, the wall 84 is formed in one piece with the holding means 14 and/or the article body 12, in particular the outer layer 48. Since the wall 84 is recessed with respect to at least one wall portion 86 of the holding means 14 the wall 84 bounds or limits the receptacles. In other words, the wall 84 forms a bottom of the receptacles. Moreover, since the wall 84 is recessed with respect to the wall portion 86, a person can insert at least one of their fingers into one of the respective receptacle until said at least one finger comes into contact with the wall 84. Thus, the person can grasp the holding means 14 particularly tight.

Fig. 8 shows a fifth embodiment of said method. In the fifth 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 90 is made of kraft paper or another strong material which can be introduced into the mold 22 as described with respect to Fig. 4, in particular similar to an in-mold labeling process, or applied at a later point in time.

Fig. 9 shows a sixth embodiment of the method. In the sixth embodiment the holding means 14 is hinged to the article body 12 so that, for example, the holding means 14 can be rotated about at least one rotation axis in relation to the article body 12. Thus, the holding means 14 can be rotated about the rotation axis in relation to the article body 12 in such a way that the end 82 comes into contact with a region 88 of the article body 12, in particular the outer layer 48. In other words, for example, the holding means 14 is flapped down so that the end 82 touches the article body 12 in the region 88. Moreover, for example, the end 82 is fixed to the article body 12, in particular the region 88. Preferably, the end 82 is fixed to the article body 12 by nudging and/or gluing and/or welding. 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 an eighth embodiment of the method. In the eighth embodiment the holding means 14 is provided in such a way that the holding means 14 is made of at least one piece of paper or cardboard stripe or pulp or rigid plastic. For example, the end 82 of the holding means 14 can be attached to the article body 12, in particular the region 88, by, for example, glueing and/or notching and/or welding. At the opposite end 80, for example, the holding means 14 is also attached to the article body 12. For example, the end 80 is glued and/or notched and/or welded to the article body 12. Alternatively or additionally, the holding means 14 is attached to the article body 12 at the end 80 by at least one form fit which is, for example, create by the inlet 16 and the holding means 14 and/or the holding means 14 and the cap 18. For example, at the end 80 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. Fig. 12 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

1 . A method for manufacturing a molded article (10) from pulp (46), wherein the molded article (10) comprises at least one article body (12), the method comprising at least the steps of:

- introducing at least on parison (32) into an open mold (22), wherein the mold (22) comprises at least two movable mold parts (24, 26) which, in an assembled condition (A), form at least one cavity (34);

- closing the mold (22);

- expanding the parison (32) by means of a fluid thereby pressing the parison (32) against inner walls of the mold (22) and creating from the parison (32) an inner body (42) of said article body (12), said inner walls bounding said cavity (34);

- releasing the inner body (42) from the mold (22); and

- coating at least a portion of an outer surface (44) of the inner body (42) with pulp (46) thereby forming an outer layer (48) of the article body (12), the outer layer (48) being made of the pulp (46).

2. The method according to claim 1 ,

wherein at least said portion of the outer surface (44) of the inner body (42) is coated with pulp by dipping the inner body (42) into a pulp bath (50).

3. The method according to claim 1 ,

wherein at least said portion of the outer surface (44) of the inner body (42) is coated with pulp (46) by:

- reintroducing the inner body (42) into a second mold (56) comprising at least one second cavity (58) dimensioned so as to form a gap (60) between the outer surface (44) of the inner body (42) and an inner surface (62) of the second mold (56), the inner surface (62) of the second mold (56) bounding said second cavity (58) at least partially; and

- introducing the pulp (46) into the gap (60).

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

wherein the parison (36) is made of at least one plastic material.

5. The method according to any one of claims 1 to 3,

wherein the method further comprises:

- providing at least one reservoir (52) containing at least one plastic (54) material; and

- from the plastic (54) material, creating the parison (32) while introducing the parison (32) into the mold (22).

6. The method according to claim 5,

wherein the parison (32) is created from the plastic (54) material by extruding.

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

wherein a gas such as air, in particular compressed air, is used as the fluid.

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

wherein the mold (22, 56, 70) comprises at least one further cavity (72) for forming at least one holding means (14) to said article body (12) within the mold (22, 56, 70).

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

wherein the further cavity (72) is filled with a prefabricated component for forming the holding means (14) or at least one part of the holding means (14), wherein the prefabricated component is connected to the article body (12).

10. The method according to claim 9 or 10,

wherein the holding means (14) is manufactured from pulp.

1 1 . A molded article made of pulp,

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

12. The molded article according to claim 12,

wherein the molded article (10) comprises at least one holding means (14) which is, preferably, made of pulp.

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

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

14. The molded article (10) according to any one of claims 12 to 14,

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

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

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

16. An apparatus for manufacturing a pulp molded article (10), the apparatus being used in a method according to any one of claims 1 to 1 1 , wherein the apparatus comprises at least one mold (22) having at least two movable mold parts (24, 26) which, in an assembled condition (A), form at least one cavity (34) for forming at least one layer of the article body (12).

17. The apparatus according to claim 17,

wherein the apparatus further comprises:

- means for introducing a parison (32) into the mold (22) in an open condition of the mold (22);

- means for inflating said parison (32) in a closed condition of the mold (22) thereby creating an inner body (42) of the article body (12); and

means for coating at least a portion of an outer surface (44) of the inner body (42) with pulp (46) thereby forming an outer layer (48) of the article body (12), the outer layer (48) being made of the pulp (46).