Disclosed is a method to form arbitrarily shaped, uniform, lightweight, thermally insulating and acoustically absorptive automotive components with controllable density, thickness, porosity, and surface integrity. The method is based on natural cellulosic fibers such as those found in cardboard and paper and uses a thermoplastic fiber and particle slurry to form fusible components. The method produces components having the benefit of commercially available thermoformed fiber mats or open-cell extruded foam components with excellent acoustical properties, enhanced thermal insulation, and are light weight, which limits engine inefficiency, and the high cost of such products so as to allow large scale implementation.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises one or more of a moisture barrier, an oil barrier, and a vapor barrier.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises one or more of a moisture barrier, an oil barrier, and a vapor barrier.

The document relates to a tool for producing a 3D molded product from a pulp slurry, comprising a pair of molds having respective product faces, that are configured to face each other and to press a pulp layer therebetween, said product faces providing a 3D shape for molding the 3D molded product, said product faces presenting a respective outer product face edge, defining an outermost limit of a forming area of mold. At least one of the product faces, as seen from the product face edge and inwardly towards a center of gravity of the product face, presents an outer zone (Z1) having effectively no porosity, and an inner zone (Z4) having a porosity of 40-75%, wherein a first intermediate zone (Z2) is arranged between the outer zone (Z1) and the inner zone (Z4), and has a porosity that is greater than that of the outer zone (Z1) and less than that of the inner zone (Z4).

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

A method and a device for manufacturing a fibre moulding for drinks packaging containers having an improved structure and surface quality. The method includes the following steps: dipping of a forming wire arranged on a toolholder into a pulp slurry, lifting of the toolholder in order to move the covered forming wire completely out of the pulp slurry, compressing of the fibre material in an area of the circumferential edge of the forming wire through inflating of a circumferential collar, relaxing of the pressure in the collar, and removing of the fibre moulding. A device for manufacturing of a fibre moulding is also provided.

A method and a device for manufacturing a fibre moulding for drinks packaging containers having an improved structure and surface quality. The method includes the following steps: dipping of a forming wire arranged on a toolholder into a pulp slurry, lifting of the toolholder in order to move the covered forming wire completely out of the pulp slurry, compressing of the fibre material in an area of the circumferential edge of the forming wire through inflating of a circumferential collar, relaxing of the pressure in the collar, and removing of the fibre moulding. A device for manufacturing of a fibre moulding is also provided.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.