FIBER-BASED CUP DESIGN, CHEMISTRY AND TOOLING
A fiber-based, plastic-free drinking cup is formed by providing a fiber-based slurry comprising a hydrophobic additive and a strength additive, then forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum. The fiber-based slurry may include a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight. In particular, the fiber-based slurry may include about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.
1 . A method of manufacturing a plastic-free, pulp-based drinking cup, comprising:
providing a fiber-based slurry comprising a hydrophobic additive and a strength additive; and
forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum;
wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.
2 . The method of claim 1 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight.
3 . The method of claim 1 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.
4 . The method of claim 1 , wherein the strength additive comprises a starch.
5 . The method of claim 1 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD).
6 . The method of claim 1 , wherein the form press assembly is a thermoform wet press.
7 . The method of claim 1 , wherein the form press assembly is a dry press.
8 . A pulp-based, plastic free drinking cup formed via a process consisting of:
providing a fiber-based slurry comprising a hydrophobic additive and a strength additive; and
forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum;
wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.
9 . The drinking cup of claim 8 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight.
10 . The drinking cup of claim 8 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.
11 . The drinking cup of claim 8 , wherein the strength additive comprises a starch.
12 . The drinking cup of claim 8 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD).
13 . The drinking cup of claim 8 , wherein the form press assembly is a thermoform wet press.
14 . The drinking cup of claim 8 , wherein the form press assembly is a dry press.
15 . A slurry for use in manufacturing a plastic-free, pulp-based drinking cup, the slurry comprising:
a fiber-based slurry comprising a hydrophobic additive and a strength additive;
wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.
16 . The slurry of claim 15 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight.
17 . The slurry of claim 16 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.
18 . The slurry of claim 15 , wherein the strength additive comprises a starch.
19 . The slurry of claim 15 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD).
20 . The slurry of claim 15 , wherein the form press assembly is a thermoform wet press.