Pulp fibre material processing tool for use in a thermoforming process

A pulp fibre material processing tool for use in a thermoforming process to form a moulded product from wet pulp fibre material, the tool comprising:

• two or more moulds that each have a moulding surface that is shaped to substantially define a portion of the external surface of the moulded product, at least one of the moulds being a displaceable mould that is displaceable between a first position that corresponds with the maximum separation of the moulds, and a second position that corresponds with the minimum separation of the moulds;
• and fluid extraction paths that extend through at least one of the moulds through which fluid is transportable away from the respective moulding surface;
• an actuator assembly that is configured to displace the displaceable mould, and that includes at least one actuator to effect displacement of the displaceable mould;
• and
• a fluid extraction system that includes:
• a suction subsystem that is in communication with the fluid extraction paths and is configured to induce a negative pressure in the fluid extraction paths, and
• a heating subsystem that is configured to heat at least the mould having the fluid extraction paths,
• the fluid extraction system being configured to simultaneously reduce the moisture content of the pulp fibre material by inducing negative pressure in the fluid extraction paths and drawing fluid, including liquid component of the wet pulp fibre material, that is at the moulding surface of the respective mould through the fluid extraction paths via the suction subsystem, and transfer heat to the pulp fibre material by heating the mould having the fluid extraction paths;
• wherein at least one of the moulds includes
• a first layer that is substantially rigid so as to form a support member of the mould, and that is in communication with the heating subsystem so that in use of the tool an elevated temperature is induced in the first layer by the heating subsystem, and
• a second layer that in use of the tool to form a moulded product from wet pulp fibre material is between the first layer and the wet pulp fibre material, and
• wherein the second layer is formed of a material that has interconnected internal voids forming part of the fluid extraction paths and has a lower heat transfer coefficient than the first layer.