Fiber-based cup design, chemistry and tooling

Abstract

A fiber-based, plastic-free drinking cup is formed by providing a fiber-based slurry comprising a hydrophobic additive and a strength additive, then forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum. The fiber-based slurry may include a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight. In particular, the fiber-based slurry may include about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.

1 . A method of manufacturing a plastic-free, pulp-based drinking cup, comprising:
 providing a fiber-based slurry comprising a hydrophobic additive and a strength additive; and   forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum;   wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.   
     
     
         2 . The method of  claim 1 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight. 
     
     
         3 . The method of  claim 1 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight. 
     
     
         4 . The method of  claim 1 , wherein the strength additive comprises a starch. 
     
     
         5 . The method of  claim 1 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD). 
     
     
         6 . The method of  claim 1 , wherein the form press assembly is a thermoform wet press. 
     
     
         7 . The method of  claim 1 , wherein the form press assembly is a dry press. 
     
     
         8 . A pulp-based, plastic free drinking cup formed via a process consisting of:
 providing a fiber-based slurry comprising a hydrophobic additive and a strength additive; and   forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum;   wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.   
     
     
         9 . The drinking cup of  claim 8 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight. 
     
     
         10 . The drinking cup of  claim 8 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight. 
     
     
         11 . The drinking cup of  claim 8 , wherein the strength additive comprises a starch. 
     
     
         12 . The drinking cup of  claim 8 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD). 
     
     
         13 . The drinking cup of  claim 8 , wherein the form press assembly is a thermoform wet press. 
     
     
         14 . The drinking cup of  claim 8 , wherein the form press assembly is a dry press. 
     
     
         15 . A slurry for use in manufacturing a plastic-free, pulp-based drinking cup, the slurry comprising:
 a fiber-based slurry comprising a hydrophobic additive and a strength additive;   wherein the fiber-based slurry comprises a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight.   
     
     
         16 . The slurry of  claim 15 , wherein the fiber-based slurry comprises 20-80% bleached hardwood with the balance being bleached softwood, the strength additive is 1.0-6.0% of the dry pulp weight, and the hydrophobic additive is 1.0-6.0% of the dry pulp weight. 
     
     
         17 . The slurry of  claim 16 , wherein the fiber-based slurry comprises about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight. 
     
     
         18 . The slurry of  claim 15 , wherein the strength additive comprises a starch. 
     
     
         19 . The slurry of  claim 15 , wherein the hydrophobic additive comprises alkyl ketene dimer (AKD). 
     
     
         20 . The slurry of  claim 15 , wherein the form press assembly is a thermoform wet press.