Molded fibers

Abstract

In accordance with embodiments of the present disclosure, the present invention is directed to improvements to molded fiber products. A first sealant layer can be applied to a prepressed biodegradable molded fiber or to biodegradable molded fiber which has not been prepressed. After the sealant layer has been applied, a heat press process is applied. A biodegradable paint can be applied to the first sealant layer. A sealer or binder can be mixed with paint before it is applied to the first sealant layer. A second sealant layer can be applied to the paint layer. Any binder mixed with the paint, as well as the first and second sealant layers respectively can comprise a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. Preferably, the first sealant layer, the paint layer, and the second sealant layer add less than 10% of total non-biodegradable weight to the total weight of the molded fiber product.

What is claimed is: 
     
         1 . A method for providing a high quality molded fiber product, the method comprising:
 providing a prepressed molded fiber which is biodegradable;   applying a sealant to a top surface of the molded fiber to form a sealant layer; and   applying a heat press process to the molded fiber and sealant layer.   
     
     
         2 . The method of  claim 1 , wherein the sealant is a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. 
     
     
         3 . The method of  claim 2 , wherein the sealant layer adds less than 10% of total non-biodegradable weight to a total weight of the molded fiber product. 
     
     
         4 . The method of  claim 1 , further comprising applying a biodegradable paint to a top surface of the sealant layer after said heat press process. 
     
     
         5 . The method of  claim 4 , wherein the biodegradable paint is mixed with a natural, synthetic or oil based binder before the paint is applied. 
     
     
         5 . The method of  claim 5 , wherein the sealant layer and the paint mixed with a binder adds less than 10% of total non-biodegradable weight to a total weight of the molded fiber product. 
     
     
         7 . A method for providing a high quality molded fiber product, the method comprising:
 providing a molded fiber which is not prepressed and is biodegradable;   applying a sealant to a top surface of the molded fiber to form a sealant layer; and   applying a heat press process to the molded fiber and the sealant layer.   
     
     
         8 . The method of  claim 7 , wherein the sealant is a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. 
     
     
         9 . The method of  claim 8 , wherein the sealant layer adds less than 10% of total non-biodegradable weight to a total weight of the molded fiber product. 
     
     
         10 . The method of  claim 7 , further comprising applying a biodegradable paint to a top surface of the sealant layer after said heat press process. 
     
     
         11 . The method of  claim 10 , wherein the biodegradable paint is mixed with a natural, synthetic or oil based binder before the paint is applied. 
     
     
         11 . The method of  claim 11 , wherein the sealant layer and the paint mixed with a binder adds less than 10% of total non-biodegradable weight to a total weight of the molded fiber product. 
     
     
         13 . A method for providing a high quality molded fiber product, the method comprising:
 providing a prepressed molded fiber which is biodegradable;   applying a sealant to a top surface of the molded fiber to form a first sealant layer;   applying a heat press process to the molded fiber and the first sealant layer;   applying a biodegradable paint layer to a top surface of the first sealant layer after said heat press process; and   applying a second sealant to a top surface of the biodegradable paint layer to form a second sealant layer.   
     
     
         14 . The method of  claim 13 , wherein the first and second sealants respectively comprise a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. 
     
     
         15 . The method of  claim 14 , wherein the first sealant layer, paint layer, and second sealant layer add less than 10% of total non-biodegradable weight to the total weight of the molded fiber product. 
     
     
         16 . A method for providing a high quality molded fiber product, the method comprising:
 providing a molded fiber which is not prepressed and is biodegradable;   applying a sealant to a top surface of the molded fiber to form a first sealant layer;   applying a heat press process to the molded fiber and the first sealant layer;   applying a biodegradable paint layer to a top surface of the first sealant layer after said heat press process; and   applying a binder to a top surface of the biodegradable paint layer to form a second sealant layer.   
     
     
         17 . The method of  claim 16 , wherein the first and second sealants respectively comprise a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. 
     
     
         18 . The method of  claim 17 , wherein the sealant layer, paint layer, and second sealant layer add less than 10% of total non-biodegradable weight to the total weight of the molded fiber product. 
     
     
         19 . A high quality molded fiber product comprising:
 a molded fiber which is biodegradable;   a sealant layer on a top surface of the molded fiber; and   wherein a heat press process was applied to the molded fiber and the sealant layer.   
     
     
         20 . A high quality molded fiber product comprising:
 a molded fiber which is biodegradable;   a sealant layer on a top surface of the molded fiber,   wherein a heat press process was applied to the molded fiber and the sealant layer; and   a biodegradable paint layer on a top surface of the sealant layer.   
     
     
         21 . A high quality molded fiber product comprising:
 a molded fiber which is biodegradable;   a first sealant layer on a top surface of the molded fiber,   wherein a heat press process was applied to the molded fiber and the first sealant layer;   a biodegradable paint layer on a top surface of the first sealant layer; and   a second sealant layer on a top surface of the paint layer.   
     
     
         22 . The molded fiber of  claim 21 , wherein the first and second sealant layers respectively comprise a natural, synthetic, oil based, or biodegradable polymer sealant, or a combination thereof. 
     
     
         23 . The molded fiber of  claim 21 , wherein the biodegradable paint layer was premixed with a natural, synthetic or oil based binder. 
     
     
         24 . The molded fiber of  claim 21 , wherein the first sealant layer, the paint layer, and the second sealant layer add less than 10% of total non-biodegradable weight to the total weight of the molded fiber product. 
     
     
         25 . A high quality molded fiber product comprising:
 a molded fiber which is biodegradable;   a first sealant layer on a top surface of the molded fiber,   a biodegradable paint layer on a top surface of the first sealant layer; and   a second sealant layer on a top surface of the paint layer.   
     
     
         26 . The molded fiber of  claim 25 , wherein the first sealant layer, the paint layer, and the second sealant layer add less than 10% of total non-biodegradable weight to the total weight of the molded fiber product.