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Application US20200181849
Published 2020-06-11
Improved Pulp Disposable Tray
The present invention solves the above mentioned technical problems by providing a three dimensional molded shape suitable for use in the fabrication of a food tray, the molded shape comprising a molded pulp portion with side walls and a bottom wall comprising virgin or recycled cellulose fibers and a film laminate portion comprising a polyester film with an amorphous polyester heat seal layer.
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- 1. A three dimensional molded object, the molded object comprising:
a molded pulp portion with side walls and a bottom wall comprising virgin or recycled cellulose fibers and a binding substance in a proportion between 0.2 and 1% relative to dry pulp in the molded pulp portion, wherein the total number of additives or components other than water or cellulose contained in the moulded pulp portion, including the binding substances, do not exceed a proportion greater than 1% relative to dry pulp in the molded pulp portion; and wherein the molded pulp portion is between about 0.2 mm and 1.5 mm thick in planar areas and about twice that thickness in non-planar areas or curved regions.
- 8. A process for producing a three dimensional molded cellulose tray, the process comprising the following steps:
a. obtaining a pulp comprising virgin or recycled cellulose fibers; b. wetting the cellulose fibers of step a) to form a suspension of wet cellulose fibers; c. adding a binding substance in a proportion between 0.2 and 1% of relative to dry pulp in the suspension to obtain a cellulose preparation; d. pouring the cellulose preparation of step c) into a forming box, where it is absorbed by first molds; e. moving the first forming box so that it is positioned facing a second forming box with second molds of opposite shape to a shape of the first molds, and having a contact surface temperature between 120° C. and 180° C. and with the cellulose adhered to the first forming box, which already has a tray shape, and moving said first forming box to said second forming box, so that both boxes are bolted down until they exert a pressure between 1.5 and 3 bars in the cellulose between the first and second molds to obtain a molded cellulose tray; f. optionally repeating step e) until the molded cellulose tray is dry and has a moisture of less than 7%; and g. obtaining the finished molded cellulose trays.
