Methods and apparatus for manufacturing high-strength fiber-based beverage holders
Methods and apparatus for vacuum forming a beverage carrier yoke are described. The yoke comprises a number (e.g., four or six) collars interconnected by a web, and each collar exhibits dimensions—including a nominal diameter and a substantially uniform thickness—selected to improve strength and increase comfort. The yoke is produced using a slurry comprising a moisture barrier and a fiber base.
1. A vacuum-formed carrier for holding cylindrically shaped containers, comprising:
a plurality of collars interconnected by a web, wherein each collar exhibits a nominal diameter of about 1.95 inches and the web exhibits a substantially uniform thickness in a range of 0.01 to 0.05 inches;
wherein the plurality of collars comprises a fiber-based material produced using a slurry including at least one of old corrugated containers (OCC) and newsprint (NP), a moisture barrier additive in an amount of about 4.0% by weight; a wet strength additive in an amount of about 4.0% by weight; and a dry strength additive in an amount of about 4.0% by weight;
wherein the wet strength additive comprises a polyamidoamine-epichlorohydrin (PAE) resin; and the dry strength additive comprises a cationic modified polyamine water soluble polymer.
2. The vacuum-formed carrier of claim 1 , wherein the moisture barrier additive comprises alkyl ketene dimer (AKD).
3. The vacuum-formed carrier of claim 1 , wherein the substantially uniform thickness is 0.05 inches.
4. A method of manufacturing a yoke configured to carry beverage cans, comprising:
providing a wire mesh mold in a shape of the yoke;
immersing the wire mesh mold into a fiber-based slurry including a moisture barrier additive;
drawing a vacuum across the wire mesh mold to cause fiber particles to accumulate at a wire mesh mold surface; and
removing the wire mesh mold and accumulated fiber particles from the fiber based slurry; and
subsequently drying the fiber particles to yield the yoke;
wherein the yoke comprises a plurality of collars interconnected by a web, wherein each collar exhibits a nominal diameter of about 1.95 inches and the web exhibits a substantially uniform thickness in a range of 0.01 to 0.05 inches.
5. The method of claim 4 , wherein the moisture barrier additive is in a range of 0.5% to 10% by weight.
6. The method of claim 4 , wherein the moisture barrier additive comprises alkyl ketene dimer (AKD).
7. The method of claim 4 , wherein the moisture barrier additive comprises alkyl ketene dimer 80 (AKD 80)[79].
8. The method of claim 4 wherein the fiber-based slurry comprises a fiber base of about 70% old corrugated containers (OCC) and about 30% newsprint (NP).
9. The method of claim 4 , wherein the fiber-based slurry further comprises a strength additive in a range of 1.5% to 4% by weight.
10. The method of claim 4 , wherein the strength additive comprises a starch component.
11. The method of claim 4 , wherein:
the moisture barrier additive comprises alkyl ketene dimer (AKD) in an amount of about 4%; and
the fiber-based slurry comprises old corrugated containers (OCC) and newsprint (NP).
12. A method of manufacturing a carrier for cylindrically shaped containers, comprising:
providing a wire mesh mold in the shape of the carrier;
immersing the wire mesh mold into a fiber-based slurry;
drawing a vacuum across the wire mesh mold to cause fiber particles to accumulate at a wire mesh surface; and
removing the wire mesh mold and accumulated fiber particles from the fiber-based slurry; and
subsequently drying the accumulated fiber particles to yield the carrier;
wherein the fiber-based slurry comprises:
a fiber base including at least one of old corrugated containers (OCC) or newsprint (NP);
a moisture barrier additive in an amount of about 4% by weight;
a wet strength additive in an amount of about 4% by weight; and
a dry strength additive in an amount of about 4% by weight,
wherein the carrier comprises a plurality of collars interconnected by a web, wherein each collar exhibits a nominal diameter of about 1.95 inches and the web exhibits a substantially uniform thickness of about 0.05 inches.
13. The method of claim 12 , wherein:
the moisture barrier additive comprises alkyl ketene dimer (AKD);
the wet strength additive comprises a polyamidoamine-epichlorohydrin (PAE) resin; and
the dry strength additive comprises a cationic modified polyamine water soluble polymer.