Pulp container with fused junction and method of making same
Molded pulp containers with fused junctions and methods of making of same are provided. The present invention provides a pulp container, comprising a molded pulp body, wherein the body comprising a bottom and at least one side wall forming a cavity, wherein the at least one side wall comprising a upper rim, a neck, wherein the neck comprising a upper closure part and a lower rim, a fused junction, wherein a part of the upper rim of the at least one sidewall of the body and a part of the lower rim of the neck are aligned and fused together. The fused junction may be formed by ultrasonic welding.
1 . A method of fabricating a pulp container, the method comprising:
generating a first part shell, wherein the first part shell comprising a first rim surrounding a first depression;
generating a second part shell, wherein the second part shell comprising a second rim surrounding a second depression;
laminating an interior surface of at least one of the first part shell and the second part shells with a polymer film, which extends to the first rim and the second rim;
aligning the first part shell and the second part shell, wherein the first rim and the second rim are aligned and the first depression and the second depression form a cavity,
wherein aligning the first part shell and the second part shell placing the at least one interior surface laminated with the polymer film between a contact interface of the first rim and the second rim; and
ultrasonic welding the first rim and the second rim forming a container.
2 . The method recited in claim 1 , wherein the first part shell and the second part shell comprise at least a part of wood product, paper, pulp, or molded pulp.
3 . The method recited in claim 1 , wherein the polymer film comprises at least one of thermoplastic or bioplastic, or a combination thereof.
4 . The method recited in claim 1 , wherein the polymer film comprises bio-degradable thermoplastic.
5 . The method recited in claim 1 , wherein the polymer film comprises at least one of polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), ethylene-vinyl alcohol (EVOH), polyamide (Nylon, PA), ionomers (EAA, EMAA), ethylene vinyl acetate (EVA), polyacrylic acid (PAA), or cellulose acetate.
6 . The method recited in claim 1 , wherein generating the first part shell and the second part shell is by vacuum forming.
7 . The method recited in claim 1 , wherein laminating at least one of the first part shell and the second part shell is by heating a polymer film and applying vacuum on an exterior side of the at least one of the first part shell and the second part shell shells.
8 . The method recited in claim 1 , wherein the ultrasonic welding is by 0.1-6 bar of pressure, welding frequency is 15-50 KHz.
9 . The method recited in claim 1 , wherein the polymer film comprising a plurality of polymer layers.
10 . The method recited in claim 1 , wherein the polymer film is metalized.
11 . The pulp container recited in claim 10 , wherein metalized layer comprises Aluminum.
12 . A method of joining a pulp component to a second component, comprising
providing a pulp component comprising a flat first rim;
providing a second component comprising a flat second rim;
aligning the first rim with the second rim, wherein at least one of the first rim and the second rim comprising a polymer layer; and
ultrasonic welding the first rim to the second rim.
13 . The method of claim 12 , wherein the first rim is coated with a polymer.
14 . The method of claim 12 , wherein the second component comprising at least a part of wood product, paper, or pulp.
15 . The method of claim 14 , wherein the second rim is coated with a polymer.
16 . The method of claim 15 , wherein the polymer comprises at least one of thermoplastic or bioplastic, or a combination thereof.
17 . The method of claim 15 , wherein the polymer comprises at least one of polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), ethylene-vinyl alcohol (EVOH), polyamide (Nylon, PA), ionomers (EAA, EMAA), ethylene vinyl acetate (EVA), polyacrylic acid (PAA), or cellulose acetate.
18 . The method of claim 12 , wherein the second component comprising a polymer.
19 . The method of claim 18 , wherein the polymer comprises at least thermoplastic and/or bioplastic.
20 . The method of claim 18 , wherein the polymer comprises at least one of polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), ethylene-vinyl alcohol (EVOH), polyamide (Nylon, PA), ionomers (EAA, EMAA), ethylene vinyl acetate (EVA), polyacrylic acid (PAA), or cellulose acetate.
21 . The method of claim 12 , wherein the ultrasonic welding is by 0.1-6 bar of pressure, welding frequency is 15-50 KHz.
22 . The method of claim 12 , wherein the ultrasonic welding simultaneously removes excess material from the first and second rim.