Application US20200181849

IMPROVED PULP DISPOSABLE TRAY
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US20200181849

1. A three dimensional molded object, the molded object comprising: (4) (2)

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.

2. The three dimensional molded object of claim 1, wherein the binding substance comprises alkyl ketene dimer. (0)

3. The three dimensional molded object of claim 1, wherein the three-dimensional molded object further comprises: (6) (2)

a film laminate portion comprising a film selected from the group consisting of polyester, polyethylene teraphthalate (PET), polypropylene (PP), polyethylene (PE) and a bio film,

wherein the film laminate is between about 0.02 and 0.2 mm thick and applied by heat press atop the molded pulp portion without glue between the molded pulp portion and the film laminate.

4. The three dimensional molded object of claim 3, wherein the film laminate is applied by subjecting the molded pulp portion to a temperature between 140 and 200° Celsius and applying a negative pressure for a time of 5 to 60 seconds. (0)

5. The three dimensional molded object of claim 3, wherein the film laminate is at least partially recyclable, at least partially degradable, and comprises at least 50% recycled raw material. (0)

6. The three dimensional molded object of claim 3, wherein the molded pulp portion is obtained or obtainable by subjecting wet cellulose fibers to a temperature between 120 and 180° C. and a pressure between 1.5 and 3 bars. (0)

7. The three dimensional molded object of claim 3, wherein the molded object further comprises an overwrapped film, or a film covering an upper open part for placing food in or on the three dimensional molded object. (1) (0)

13. The three dimensional molded object of claim 3, wherein the bio-film comprises polylactic acid (PLA). (0)

14. The three dimensional molded object of claim 3, wherein the film laminate comprises a heat seal layer. (0)

11. The three dimensional molded object of claim 1, wherein the three dimensional molded object is a food tray. (0)

12. The three dimensional molded object of claim 1, wherein the three dimensional molded object is packaging for food products. (0)

8. A process for producing a three dimensional molded cellulose tray, the process comprising the following steps: (6) (7)

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.

9. The process of claim 8, further comprising applying a film laminate to the finished molded cellulose trays, by a heated press at a temperature between 140 and 200° Celsius for a time of 5 to 60 seconds, wherein the film laminate comprises a film with a heat seal layer. (0)

10. A three dimensional molded cellulose tray suitable for use in the fabrication of a food tray, obtained or obtainable by the process of claim 8. (0)

16. The process of claim 8, wherein the suspension of wet cellulose fibers comprises at least 96% water and less than 4% of the cellulose fibers. (0)

17. The process of claim 8, wherein the binding substance comprises an alkyl ketene dimer. (0)

18. The process of claim 8, wherein the preparation of cellulose preparation of step c) is absorbed by means of vacuum pressure. (0)

19. The process of claim 8, wherein the three dimensional molded cellulose tray is a food tray. (0)

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Application US20200181849

IMPROVED PULP DISPOSABLE TRAY

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