Methods and Apparatus For Manufacturing Fiber-Based Produce Containers
Methods and apparatus for manufacturing vacuum forming a produce container using a fiber-based slurry. The slurry includes a moisture barrier comprising alkylketene dimer in the range of about 4% by weight, and a cationic liquid starch component in the range of 1%-7% by weight.
1 . (canceled)
2 . (canceled)
3 . (canceled)
4 . (canceled)
5 . (canceled)
6 . (canceled)
7 . (canceled)
8 . (canceled)
9 . (canceled)
10 . (canceled)
11 . (canceled)
12 . (canceled)
13 . (canceled)
14 . (canceled)
15 .
16 . A slurry for use in vacuum forming a fiber-based produce container, comprising:
a moisture barrier comprising AKD in the range of about 4% by weight; and
a cationic liquid starch component in the range of 1%-7% by weight.
17 . The slurry of claim 16 , comprising a fiber base of at least one of: softwood (SW); bagasse; bamboo; old corrugated containers (OCC); and newsprint (NP).
18 . The slurry of claim 16 comprising a fiber base including old corrugated containers (OCC) in the range of about 70% and newsprint (NP) in the range of about 30%.
19 . A vacuum formed food container made from a slurry comprising:
a moisture barrier component comprising long chain diketenes in the range of about 4% by weight;
a cationic liquid starch component in the range of 1%-7% by weight; and
at least one geometric feature for enhancing structural rigidity.
20 . The food container of claim 19 , wherein the geometric feature comprises a horizontally extending shelf disposed in the range of about 30%-50% below a top of a container side wall.
21 . The slurry of claim 16 , wherein the moisture barrier comprises alkyltene dimer (AKD) 80.
22 . The slurry of claim 16 , wherein the moisture barrier comprises long chain diketenes.
23 . The slurry of claim 16 , further comprising a coloring agent comprising one of a cationic dye and a fiber reactive dye.
24 . The slurry of claim 16 , further comprising a dye absorption agent comprising one of salt and soda ash.
25 . The slurry of claim 16 , wherein the starch component comprises one of Topcat L98, Hercobond, and Topcat L95.
26 . The slurry of claim 16 , wherein the starch component comprises a polyamide epichlorohydrin (PAE) resin.
27 . The slurry of claim 16 , further comprising Kymene 577 in the range of 1%-4% by weight.
28 . The food container of claim 19 , wherein the geometric feature comprises a horizontally extending shelf disposed in the range of about 30%-50% below a top of the food container side wall.
29 . The food container of claim 28 , wherein the shelf defines an upper wall portion exhibiting a first draft angle in the range of about 6-8°, and a lower wall portion exhibiting a second draft angle in the range of about 4-6°.
30 . The food container of claim 29 , further comprising at least one rib extending from the bottom of the container upwardly and terminating at the shelf.
31 . The food container of claim 30 , further comprising a second rib extending upwardly from the shelf and terminating between the shelf and the top of the wall.
32 . The food container of claim 31 , wherein the second rib terminates in one of a rounded or squared geometrical shape.
33 . The food container of claim 19 , wherein the geometric feature comprises a rolled edge terminating in a circumferential overhanging skirt.
34 . The food container of claim 33 , wherein the skirt exhibits a length of about 1.5 mm.
35 . A fiber-based, vacuum formed produce container made from a slurry comprising an alkyltene dimer (AKD) based moisture barrier component in the range of 1%-10% by weight and a starch component in the range of 1%-7% by weight, the container comprising a horizontally extending shelf disposed in the range of about 30%-50% below a top of a container side wall, and at least one structural rib.