Method for the manufacturing a 3-dimensional shaped product from a fluff pulp material and such product

Abstract

The present invention relates to a method for manufacturing a 3-dimensional shaped product from a fluff pulp material and such product. The method according to the invention comprises the steps of: providing a fluff pulp material; providing an air-laid flow of fluff pulp material to a 3-dimensional shaped mould; forming the product in the mould; and releasing the 3-dimensional shaped product from the mould.

Claims

1. A method for manufacturing a three-dimensional shaped product from a fluff pulp material, the method comprising: providing a fluff pulp material; providing one or more additives to the fluff pulp material; providing an air-laid flow of fluff pulp material; compacting the air-laid flow of fluff pulp material; providing the compacted flow of fluff pulp material directly to a three-dimensional shaped mould; shaping the fluff pulp material in the mould; and releasing the three-dimensional shaped product from the mould, wherein compacting the air-laid flow of fluff pulp material increases the strength of the three-dimensional shaped product released from the mould, wherein the one or more additives comprises a biodegradable aliphatic polyester in the range of 0.5-20 wt %, and wherein biodegradable aliphatic polyester is polybutylene succinate (PBS).

2. The method according to claim 1, wherein providing the fluff pulp material comprises defibrizing raw material.

3. The method according to claim 1, wherein the step of providing an air-laid flow of fluff pulp material comprises providing a blanket-shaped flow.

4. The method according to claim 3, wherein shaping the fluff pulp material in the mould comprises the step of punching the product out of the blanket-shaped flow and providing it to the mould.

5. The method according to claim 4, further comprising the step of feeding a remaining portion of the fluff pulp material to the providing step of the fluff pulp material.

6. The method according to claim 3, further comprising the step of feeding a remaining portion of the fluff pulp material to the providing step of the fluff pulp material.

7. The method according to claim 1, further comprising the step of mixing the fluff pulp material with pulp material originating from recycled paper material.

8. The method according to claim 1, wherein the one or more additives comprises a biodegradable biopolymer.

9. The method claim 1, further comprising the step of providing a finishing layer to the moulded product.

10. A method for manufacturing a three dimensional shaped product from a fluff pulp material, the method comprising: providing a fluff pulp material; providing one or more additives to the fluff pulp material; providing an air-laid flow of fluff pulp material; compacting the air-laid flow of fluff pulp material; providing the compacted flow of fluff pulp material to a three-dimensional shaped mould; shaping the fluff pulp material in the mould; and releasing the three-dimensional shaped product from the mould, wherein providing the fluff pulp material comprises defibrizing raw material, further comprising the step of compacting the fluff pulp material before providing it to the mould, wherein the one or more additives comprises a biodegradable aliphatic polyester in the range of 0.5-20 wt %, wherein biodegradable aliphatic polyester is polybutylene succinate (PBS), wherein the step of providing an air-laid flow of fluff pulp material comprises providing a blanket-shaped flow to the mould, and wherein compacting the air-laid flow of fluff pulp material increases the strength of the three-dimensional shaped product released from the mould.

11. The method according to claim 10, wherein shaping the fluff pulp material in the mould comprises the step of punching the product out of the blanket-shaped flow and providing it to the mould.

12. The method according to claim 11, further comprising the step of feeding a remaining portion of the fluff pulp material to the providing step of the fluff pulp material.

13. The method according to claim 12, further comprising the step of providing one or more additives to the fluff pulp material, wherein the one or more additives comprises a biodegradable biopolymer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

(2) FIG. 1 shows a inlay tray according to the invention;

(3) FIGS. 2A and 2B shows a packaging unit according to the invention;

(4) FIG. 3 shows an example of an alternative food packaging product according to the present invention;

(5) FIGS. 4A and 4B shows an example of a further alternative food packaging product according to the present invention;

(6) FIGS. 5A and 5B shows further packaging units for eggs according to the present invention; and

(7) FIG. 6 shows a summary of a schematic overview of the manufacturing method of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(8) Product 1 (FIG. 1) relates to an inlay tray for a mobile phone. Product 1 comprises outer edge 3 and recess 5 that is adapted to the size of the specific type of mobile phone. Product 1 is manufactured from a fluff pulp material and preferably comprises a biopolymer.

(9) Product 2 relates to a packaging unit (FIGS. 2A and 2B) that in use carries or holds eggs and comprises cover part 4 and bottom part 6. Bottom part 6 is provided with back surface 8, sides 10 and front surface 12, and bottom surface 14. Cover part 4 is provided with back surface 16, side surfaces 18, front surface 20 and top surface 22. In the illustrated embodiment transition 24 is provided between top surface 22 and back and front surfaces 16, 20.

(10) In the illustrated embodiment, top surface 22 of cover part 4 is provided with groove 26 comprising a number of openings 28. Openings 28 are defined by two adjacent arch-shaped edges 30, 32 having a larger thickness as compared to the average thickness of cover part 4. Side surfaces 18 of cover part 4 are provided with denest nocks or denest elements 34. In the illustrated embodiment, bottom part 6 is provided with similar elements 36 mirroring denest elements 34. Hinge 38 connects back surface 16 of cover part 4 with back surface 8 of bottom part 6. Lock 40 comprises nose-shaped lock element 42 that is connected to flap 44 of bottom part 6. Cover part 4 is provided with openings 46 that capture lock elements 42 therewith defining lock 40.

(11) In the illustrated embodiment, bottom part 6 is provided with a number of product receiving compartments 48, cones 50 and separating walls 52. Cone 50 extends from the bottom of bottom part 6 in an upward direction. Cover part 4 comprises cone support 54. Inner surface 58 of packaging unit 2 comprises PBS material, optionally as film layer or alternatively blended and/or integrated with the fibres of the moulded pulp material.

(12) In the illustrated embodiment, packaging unit 2 comprises twelve product receiving compartments 48 that are provided in two rows of six compartments 48. Individual compartments 48 are separated from each other by walls 52 and cones 50. It will be understood that other configurations can also be envisage in accordance to the invention.

(13) Packaging unit 2 may also be configured to receive other products, such as tomatoes, kiwis.

(14) It will be understood that other types of food packaging units can also be envisaged in accordance with the present invention. As a further example, bottle divider 101 (FIG. 3) is illustrated. Also, bottle divider 102 may comprise a film layer of PBS and/or may comprise an amount of PBS that is blended into the moulded pulp.

(15) A further example in accordance with the present invention is cover 202 (FIG. 4A), for example for an ice cup. Another example of a packaging unit according to the invention is sip lid 302 (FIG. 4B). Cover 202 and sip lid 302 comprise a film layer of PBS and/or may comprise an amount of PBS that is blended into the moulded pulp. This renders cover 202 and sip lid 302 water or liquid repellent. One of the further advantages of the use of PBS is the reduction or prevention of the liquid entering or migrating into the sip lid material during use. Another advantage is the constancy of size or dimensional stability. In this specific case this prevents sip lid 302 loosening from a cup or beaker for hot beverages such as coffee, tea or soup, or cold beverages such as carbonated drinks, and cup 202 from loosening from an ice cup, for example. It will be understood that such lids 302 can also be applied to other food containers. For example, lids 302 can be applied to containers for milkshakes, for example. Further details and examples of lids 302 are disclosed in WO 2010/064899, including embodiments with specific flanges and notches.

(16) Sip lid 302 is preferably coated with a PBS liner. As mentioned, sip lids 302 can be used for cups and milkshakes. Also, sip lids can be applied to so-called ready meal trays (for example for pizza, wraps, fish, meat, lobster, pasta, . . . ) and act as a (digital) printable and barrier seal, for example.

(17) It will be understood that other designs for packaging units in accordance with the invention can be envisaged. For example, containers 402, 502 (FIGS. 5A and 5B) illustrate different designs for egg cartons capable of holding eggs P.

(18) Other examples of food packaging products may relate to cup carriers, cups, plates and other table ware etc.

(19) When manufacturing 602 a 3-dimensional shaped product 1, 2, 102, 202, 302, 402, 502 (FIG. 6) a fluff pulp material is prepared in preparation step 604. Optionally, an amount of PBS and/or PLA and/or another biopolymer is blended or mixed into the pulp material in mixing step 606. Further treatments involve defibrization and/or shredding 608, compacting 610, providing the pulp to the mould 612, optionally involving punching, moulding 614, optionally heat treatment 616, and releasing the product 618 to provide 3-dimensional shaped product 1, 2, 102, 202, 302, 402, 502. In the illustrated embodiment a recycle step is shown. In one of the presently preferred embodiments of the invention, the pulp that is provided to the mould in step 612 has a dry matter content above 10 wt %. The length of the cellulose fibers is preferably chosen in relation to the intended use of the 3-dimensional product. Process conditions in the manufacturing are preferably chosen in relation to pulp composition, preferably taken the type and amount of additives into account.

(20) It will be understood that this schematic overview of a manufacturing method of the invention is exemplary and different steps can be included, such as adding further agents and/or additives, providing a biopolymer as a separate layer. Such separate layer may come into contact with a food product. Optionally, also several post-moulding operations may optionally be performed in relation to unit 1, 2, 102, 202, 302, 402, 502 optionally including, but not limited to, labelling including in-mould labelling, marking including printing and digital printing, testing. In several of the preferred embodiments, the compostable biofilm is at least arranged on the food contact area of the product containing part of the packaging unit. In preferred embodiments this film is capable of being used in a microwave or oven as a so-called ovenable film. Preferably, the biofilm is capable of withstanding temperatures up to 170 C., 190 C., or even higher. This biofilm preferably comprises an amount of PBS and/or MFC and/or biodegradable aliphatic polyester that may comprise an amount of one or more of PHB, PHA, PCL, PLA, PGA and PHBV. Especially a combination of a compostable packaging unit involving in-mould drying further improves the sustainability as compared to conventional packaging units. The (digital) printable properties enable printing of packaging and/or food characteristics/information. This may obviate the use of separate sleeves, for example. In addition, it enables the application of prints, for example a fish & chips (newspaper) print on the packaging unit.

(21) The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.