Receptacle mould and a method of manufacturing a receptacle mould

Abstract

There is disclosed a receptacle mould defining a cavity in which a receptacle is mouldable. The receptacle mould comprises a guide channel for guiding, into the cavity, an expandable member that is usable to help mould the receptacle in the cavity. The guide channel has a first end and a second end, the second end opening into the cavity, and the expandable member is guidable through the guide channel from the first end to the second end and into the cavity. The guide channel has a first cross-sectional width at the first end and a second cross-sectional width at the second end, the second cross-sectional width being less than the first cross-sectional width.

What is claimed is: 
     
         1 . A receptacle mould defining a cavity in which a receptacle is mouldable, wherein the receptacle mould comprises a guide channel for guiding, into the cavity, an expandable member that is usable to help mould the receptacle in the cavity;
 wherein the guide channel has:
 a first end and a second end, the second end opening into the cavity, wherein the expandable member is guidable through the guide channel from the first end to the second end and into the cavity; 
 a first cross-sectional width at the first end; and 
 a second cross-sectional width at the second end, the second cross-sectional width being less than the first cross-sectional width. 
   
     
     
         2 . The receptacle mould of  claim 1 , wherein:
 the cavity has a third cross-sectional width where the second end of the guide channel opens into the cavity; and   the third cross-sectional width is greater than the second cross-sectional width by at least 4 mm.   
     
     
         3 . The receptacle mould of  claim 1 , wherein:
 the guide channel has an axis that is coaxial with an axis of the cavity.   
     
     
         4 . The receptacle mould of  claim 1 , wherein:
 the guide channel has a first cross-sectional shape at the first end;   the guide channel has a second cross-sectional shape at the second end; and   the first cross-sectional shape and the second cross-sectional shape are the same.   
     
     
         5 . The receptacle mould of  claim 4 , wherein:
 the cavity has a third cross-sectional shape where the second end of the guide channel opens into the cavity; and   the first cross-sectional shape, the second cross-sectional shape and the third cross-sectional shape are the same.   
     
     
         6 . The receptacle mould of  claim 1 , wherein:
 the second end of the guide channel comprises a fillet edge or a chamfered edge where the second end opens into the cavity.   
     
     
         7 . The receptacle mould of  claim 1 , wherein:
 the guide channel has a first surface gradient, relative to an axis that is perpendicular to an axis of the receptacle mould, at a first point, and a second surface gradient, relative to the axis that is perpendicular to the axis of the receptacle mould, at a second point, the first and second surface gradients being different and the first point being closer to the first end than the second point.   
     
     
         8 . The receptacle mould of  claim 7 , wherein the second surface gradient is greater than the first surface gradient. 
     
     
         9 . A method of manufacturing a receptacle mould, the method comprising:
 forming a cavity of the receptacle mould, the cavity being configured to mould a receptacle; and   forming a guide channel in the receptacle mould, the guide channel having:
 a first end and a second end, the second end opening into the cavity, wherein an expandable member is guidable through the guide channel from the first end to the second end and into the cavity; 
 a first cross-sectional width at the first end; and 
 a second cross-sectional width at the second end, the second cross-sectional width being less than the first cross-sectional width. 
   
     
     
         10 . The method of  claim 9 , wherein the forming the cavity comprises providing the cavity with a third cross-sectional width where the second end of the guide channel opens into the cavity, and wherein the third cross-sectional width is greater than the second cross-sectional width by at least 4 mm. 
     
     
         11 . The method of  claim 9 , wherein the forming the guide channel comprises providing the guide channel with:
 a first cross-sectional shape at the first end; and   a second cross-sectional shape at the second end, wherein the first cross-sectional shape and the second cross-sectional shape are the same.   
     
     
         12 . The method of  claim 11 , wherein the forming the cavity comprises providing the cavity with a third cross-sectional shape where the second end of the guide channel opens into the cavity, and wherein the first cross-sectional shape, the second cross-sectional shape and the third cross-sectional shape are the same. 
     
     
         13 . The method of  claim 9 , wherein the forming the guide channel comprises providing the second end of the guide channel with a fillet edge or a chamfered edge where the second end opens into the cavity. 
     
     
         14 . The method of  claim 9 , wherein the forming the guide channel comprises providing the guide channel with:
 a first surface gradient, relative to an axis that is perpendicular to an axis of the receptacle mould, at a first point; and   a second surface gradient, relative to the axis that is perpendicular to the axis of the receptacle mould, at a second point, the first and second surface gradients being different and the first point being closer to the first end than the second point.   
     
     
         15 . A method of moulding a receptacle, the method comprising:
 providing a receptacle mould, the receptacle mould having a cavity in which a receptacle is mouldable and a guide channel, wherein the guide channel has a first end and a second end, the second end opening into the cavity;   passing an expandable member into the cavity via the guide channel, the cavity housing a component on a surface thereof, the component being a fibre suspension or a partially formed receptacle, wherein the component has a wall thickness;   as the expandable member passes into the cavity, maintaining a distance, of at least twice the wall thickness, between the surface of the cavity and the expandable member at the second end of the guide channel; and   expanding the expandable member to compress the component against the surface.   
     
     
         16 . A method of moulding a receptacle, the method comprising:
 providing a receptacle mould, the receptacle mould having a cavity in which a receptacle is mouldable and a guide channel, wherein the guide channel has:
 a first end and a second end, the second end opening into the cavity; and 
 a first cross-sectional width at the first end and a second cross-sectional width at the second end, the second cross-sectional width being less than the first cross-sectional width; 
   passing an expandable member into the cavity via the guide channel, the cavity housing a component on a surface thereof, the component being a fibre suspension or a partially formed receptacle; and   expanding the expandable member to compress the component against the surface.   
     
     
         17 . The method of  claim 16 , wherein the component has a wall thickness, and wherein the method further comprises:
 as the expandable member passes into the cavity, maintaining a distance, of at least twice the wall thickness, between the surface of the cavity and the expandable member at the second end of the guide channel.   
     
     
         18 . The method of  claim 17 , wherein one of:
 the distance is at least 2.5 times the wall thickness; or   the distance is at least 3 times the wall thickness.   
     
     
         19 . The method of  claim 16 , further comprising introducing the component into the cavity of the receptacle mould under vacuum. 
     
     
         20 . A kit comprising a plurality of receptacle moulds according to  claim 1 , wherein the plurality of receptacle moulds are co-operable to mould the receptacle.