Granted Patent
B2
US 12,428,788 · App. 17/754,609 · Granted Sep 30, 2025
Molded pulp products incorporating surface enhanced pulp fibers and methods of making the same
Assignee:
Domtar Paper Company, LLC
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Abstract
In a particular implementation, a method of pulp product manufacture includes spraying a surface enhanced pulp fiber (SEPF) coating on at least a portion of a molded pulp product, the SEPF coating comprising SEPF having a length weighted average fiber length that is at least 0.20 millimeters (mm) and an average hydrodynamic specific surface area that is at least 10 square meters per gram (m 2 /g).
Claims (15)
1. A method of pulp product manufacture, the method comprising:
spraying a surface enhanced pulp fiber (SEPF) coating on at least a portion of a molded pulp product, the SEPF coating making up between approximately 5% to 15% of the total weight of the molded pulp product and comprising SEPF comprising fibrillated fibers and having a length weighted average fiber length that is at least 0.20 millimeters (mm) and an average hydrodynamic specific surface area that is at least 10 square meters per gram (m 2 /g); and
performing a thermoforming process on the molded pulp product after spraying the SEPF coating on the molded pulp product, wherein a dwell distance between a thermoforming tooling of the molded pulp product is set from approximately 100 micrometers to 500 millimeters so as to reduce damage to the SEPF coating.
2. The method of claim 1 , where spraying the SEPF coating on the at least a portion of the molded pulp product comprises spraying the SEPF coating on an inner surface of the molded pulp product.
3. The method of claim 1 , where spraying the SEPF coating on the at least a portion of the molded pulp product comprises spraying the SEPF coating on an outer surface of the molded pulp product.
4. The method of claim 1 , where spraying the SEPF coating on the at least a portion of the molded pulp product comprises spraying the SEPF coating on an inner surface and an outer surface of the molded pulp product.
5. The method of claim 1 , where spraying the SEPF coating comprises:
providing the molded pulp product to one or more nozzles; and
ejecting the SEPF coating from the one or more nozzles onto the molded pulp product.
6. The method of claim 1 , further comprising performing a molding process on a layer of pulp to form the molded pulp product, where the molding process comprises an injection molding process, a compression molding process, a transfer molding process, an extrusion molding process, a blow molding process, a dip molding process, a rotational molding process, a foam molding process, or a combination thereof.
7. The method of claim 1 , further comprising performing a drying process, on the molded pulp product after spraying the SEPF coating on the molded pulp product.
8. The method of claim 1 , further comprising setting a spray time of the SEPF coating to control an amount of the SEPF coating that is deposited on the molded pulp product.
9. The method of claim 8 , where the spray time is approximately 35 to 90 seconds, and where the amount of the SEPF coating that is deposited on the molded pulp product is approximately 90 to 300 grams per square meter (g/m 2 ).
10. The method of claim 1 , wherein the spraying is initiated based on a trigger from a photoelectric object sensor.
11. The method of claim 1 , wherein the SEPF coating comprises a sustainable coating.
Assignments (3)
SECURITY INTEREST
Recorded Jan 30, 2025
From: RESOLUTE FP US INC.; EAM CORPORATION; DOMTAR PAPER COMPANY, LLC
To: BANK MANDIRI (EUROPE) LIMITED, AS THE COLLATERAL AGENT
Reel/Frame 070059/0666 →
CORRECTIVE ASSIGNMENT TO CORRECT THE THE ASSIGNOR'S FIRST NAME IN THE COVER SHEET (FROM HARSHAND TI HARSHAD) PREVIOUSLY RECORDED AT REEL: 059912 FRAME: 0311. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT.
Recorded Nov 4, 2022
From: PANDE, HARSHAD; JABRANE, TARIK
To: DOMTAR PAPER COMPANY, LLC
Reel/Frame 061881/0962 →
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded May 9, 2022
From: PANDE, HARSHAND; JABRANE, TARIK
To: DOMTAR PAPER COMPANY, LLC
Reel/Frame 059912/0311 →
Continuity (2)
Provisional Application
62911896
· Oct 7, 2019
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