Methods and Apparatus For Manufacturing Fiber-Based Produce Containers

Abstract

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.