Dispensing capsule and method and apparatus of forming same

Abstract

In one example, a process for manufacture of a pulp-based dispensing capsule is disclosed. The process includes providing one or more mesh tool sets that are each contoured to one or more preform shapes of the dispensing capsule. Note that each preform shape is a partially shaped version of a final form shape of the pulp-based dispensing capsule. The process also includes providing a holding tank containing a suspension that includes water and pulp fibres; and arranging the mesh tool sets to allow immersion into and withdrawal of the mesh tool sets from the suspension. The process also includes applying a vacuum to the mesh tool sets so as to draw pulp fibres from the suspension onto the mesh tool sets while immersed in the suspension to form a preform pulp fibre mat; and in a second toolset, deforming each preform shape in the preform pulp fibre mat towards the final form shape by the application of pressure.

1 . A process for manufacture of a pulp-based dispensing capsule, the process comprising:
 a) providing one or more mesh tool sets that are each contoured to one or more preform shapes of the dispensing capsule, each preform shape being a partially shaped version of a final form shape of the pulp-based dispensing capsule;   b) providing a holding tank containing a suspension that includes water and pulp fibres;   c) arranging the mesh tool sets to allow immersion into and withdrawal of said mesh tool sets from said suspension;   d) applying a vacuum to said mesh tool sets so as to draw pulp fibres from the suspension onto said mesh tool sets while immersed in said suspension to form a preform pulp fibre mat; and   e) in a second toolset, deforming each preform shape in the preform pulp fibre mat towards the final form shape by the application of pressure.   
     
     
         2 . The process according to  claim 1 , wherein each mesh tool set is contoured to include a plurality of said preform shapes that each correspond with one of a male or female profile, and the process further comprises:
 providing a transfer tool set adapted to lift sections of said preform pulp fibre from said mesh tool sets; and   using the transfer tool set to transfer the preform pulp fibre mat to the second toolset.   
     
     
         3 . The process according to  claim 2 , wherein said transfer tool set includes a male or female profile and is adapted to engage with what will become the interior or exterior of said dispensing capsule. 
     
     
         4 . The process according to  claim 3 , further including multiple steps of applying heat and pressure to the preform pulp fibre to dry the pulp and define the final dimensions and configuration of the final form shape of said dispensing capsule. 
     
     
         5 . The process according to  claim 1 , wherein the second toolset is configured such that the deformation of each preform shape in the pulp fibre mat towards the final form shape by the second toolset involves at least one of the:
 increasing in the draft angle of the preform shape,   increasing the depth of the preform shape, and   decreasing the wall thickness of the preform shape.   
     
     
         6 . The process according to  claim 1 , wherein the second toolset is shaped to reflect the final shape and dimensions of the pulp based products. 
     
     
         7 . The process according to  claim 1 , wherein the second toolset is shaped correspond with a second preform, and the process further comprises:
 providing a third toolset; and   applying pressure and/or heat to second preforms in the third toolset to thereby form the pulp based products.