Composition for providing grease and water resistant properties without use of a fluorinated compound, method of making the composition, and pulp molded article made by the method thereof

Abstract

A food-safe composition and resulting article with grease and water resistance properties comprised of a petroleum wax based aqueous emulsion, a food-safe coating formulation, and an alkyl ketene dimer (AKD), wherein the composition exhibits grease and water resistant properties without a fluorinated compound present in the composition. A method of making the composition and a method of using the composition to form pulp molded articles such as food-safe containers and other pulp-based food packaging and utensils are provided.

What is claimed is: 
     
         1 . An article comprising:
 a natural fiber,   an alkyl ketene dimer (AKD), and   a petroleum wax based aqueous emulsion,   wherein the article is a pulp-molded article.   
     
     
         2 . The article according to  claim 1 , wherein the article is shaped. 
     
     
         3 . The article according to  claim 1 , wherein the article does not comprise a fluorinated compound. 
     
     
         4 . The article according to  claim 1 , wherein the article is food-safe. 
     
     
         5 . The article according to  claim 1 , wherein the natural fiber is a sugarcane fiber. 
     
     
         6 . The article according to  claim 5 , wherein the sugarcane fiber is a bleached or white sugarcane fiber 
     
     
         7 . The article according to  claim 5 , wherein the sugarcane fiber is an unbleached sugarcane fiber. 
     
     
         8 . The article according to  claim 1 , wherein the food-safe coating formulation further comprises a component selected from the group consisting of vinyl acetate-vinyl alcohol polymer; 1,2-benzisothiazolin-3-one; dipropylene glycol; and a combination thereof. 
     
     
         9 . The article according to  claim 1 , wherein the article comprises at least 95 weight % of a natural fiber, and wherein the weight percentage is based on dry weight formulation of the article. 
     
     
         10 . The article according to  claim 1 , wherein the article comprises at least 0.15 weight % of an alkyl ketene dimer (AKD), and wherein the percentage is based on dry weight formulation of the article. 
     
     
         11 . The article according to  claim 1 , wherein the article comprises at least 0.1 weight % of a wax, and wherein the weight percentage based on dry weight formulation of the article. 
     
     
         12 . The article according to  claim 1 , wherein the article exhibits grease resistant properties. 
     
     
         13 . The article according to  claim 1 , wherein the article is suitable for food contact. 
     
     
         14 . The article according to  claim 1 , wherein the article is formed as one of a tray, a container, a lid, a cup, a plate, a bowl, and a utensil. 
     
     
         15 . The article according to  claim 1 , wherein the article is compostable in an industrial composting facility. 
     
     
         16 . The article according to  claim 1 , wherein the article has a thickness of less than 2 millimeters. 
     
     
         17 . The article according to  claim 1 , wherein the article has a thickness of at least 0.5 millimeters. 
     
     
         18 . The article according to  claim 1 , wherein the article exhibits water resistant properties. 
     
     
         19 . The article according to  claim 1 , wherein the article further comprises a component selected from the group consisting of a retention aid, a sizing agent, a pigment, dye, other colorant, and a combination thereof.