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`US 20070110928Al
`
`c19) United States
`c12) Patent Application Publication
`Bried et al.
`
`c10) Pub. No.: US 2007/0110928 Al
`May 17, 2007
`(43) Pub. Date:
`
`(54) CONTAINER WITH A ONE-PIECE BODY
`
`Publication Classification
`
`(76)
`
`Inventors: David K. Bried, Brentwood, TN (US);
`Gregory A. Pace, Nunnelly, TN (US);
`George B. Houk, Murfreesboro, TN
`(US); Martin Barker, Rochdale (GB)
`
`(51)
`
`Int. Cl.
`B31B 1100
`B31B 49100
`
`(2006.01)
`(2006.01)
`
`Correspondence Address:
`FITCH EVEN TABIN AND FLANNERY
`120 SOUTH LA SALLE STREET
`SUITE 1600
`CHICAGO, IL 60603-3406 (US)
`
`(21) Appl. No.:
`
`11/363,601
`
`(22) Filed:
`
`Feb. 28, 2006
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/657,310, filed on Feb.
`28, 2005.
`
`(52) U.S. Cl. ............................ 428/34.1; 264/299; 493/51
`
`(57)
`
`ABSTRACT
`
`A container body, comprising a single fiber structure molded
`into the container body having an integral bottom portion
`and an integral side portion; an open cavity defined by the
`bottom portion and the side portion; and the side portion
`being perpendicular to the bottom portion such that a
`rectangular label is mountable to the side portion without
`creases.
`
`17
`
`19
`
`15
`
`32
`
`20
`
`26
`
`11
`
`22
`
`25
`
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`Patent Application Publication May 17, 2007 Sheet 1 of 10
`
`US 2007/0110928 Al
`
`1~
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`15
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`11111111
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`16
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`FIG. 1
`
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`Patent Application Publication May 17, 2007 Sheet 2 of 10
`
`US 2007/0110928 Al
`
`-35
`
`22
`
`38
`
`16
`
`40
`
`34
`
`FIG. 2
`
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`Patent Application Publication May 17, 2007 Sheet 3 of 10
`
`US 2007/0110928 Al
`
`14
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`20 25
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`12
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`
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`Patent Application Publication May 17, 2007 Sheet 4 of 10
`
`US 2007/0110928 Al
`
`17
`
`32
`
`11 I
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`I I I
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`22
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`
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`Patent Application Publication May 17, 2007 Sheet 5 of 10
`
`US 2007/0110928 Al
`
`17
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`~ ~~
`
`19
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`15
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`32
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`20
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`26
`
`24
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`25
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`
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`Patent Application Publication May 17, 2007 Sheet 6 of 10
`
`US 2007/0110928 Al
`
`~19
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`20
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`28
`30
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`16
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`15
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`
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`Patent Application Publication May 17, 2007 Sheet 7 of 10
`
`US 2007/0110928 Al
`
`19 ~
`
`20
`
`28
`30
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`25
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`
`RJRV 1013
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`Patent Application Publication May 17, 2007 Sheet 8 of 10
`
`US 2007/0110928 Al
`
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`I
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`Patent Application Publication May 17, 2007 Sheet 9 of 10
`
`US 2007/0110928 Al
`
`4
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`17
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`
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`Patent Application Publication May 17, 2007 Sheet 10 of 10
`
`US 2007/0110928 Al
`
`130
`132
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`
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`US 2007/0110928 Al
`
`May 17, 2007
`
`1
`
`CONTAINER WITH A ONE-PIECE BODY
`
`[0001] This application claims the benefit of U.S. Provi(cid:173)
`sional Application No. 60/657,310, filed on Feb. 28, 2005.
`
`FIELD OF THE INVENTION
`
`[0002] The invention is directed to a container with a
`one-piece body, and a method of making thereof; more
`particularly, a one-piece, molded fiber body having non(cid:173)
`drafted sidewalls and a method of making such body.
`
`BACKGROUND OF THE INVENTION
`
`[0003] Fabricating parts, such as bodies of containers,
`using a molding operation is a cost effective method to mass
`produce such parts. Injection molding, vacuum forming, and
`other molding operations are common examples of methods
`suitable to mass produce typical bodies for containers. When
`considering such methods, the design of the part as well as
`the material used are two factors that may affect the fabri(cid:173)
`cation process.
`
`[0004] When molding a container, the draft of the con(cid:173)
`tainer sidewalls often affects the performance of the mold
`and may limit the design that can be fabricated. Draft is the
`outward angle or taper of a molded structure or of the
`corresponding mold cavity or core. That is, draft is the angle
`between the direction of ejection of a part from the mold and
`the surface of the mold. For example, cake pans are drafted
`by being wider at the top than at the bottom. A proper draft
`angle may be important to facilitate part removal or to
`prevent sticking of the part to the mold, which may create
`drag marks during part ejection. For this reason, molded
`containers usually have drafted or tapered side portions.
`Such design limitation is often a shortcoming that restricts
`the design or shape that can be fabricated by molding.
`
`[0005] A non-drafted, one-piece container, such as one
`having side walls perpendicular to a bottom wall, are desired
`for many reasons. The traditional, drafted container, such as
`one with a wider top than bottom, often creates difficulty
`with the application of a label to an outside side wall of the
`container. A square or rectangular shaped label, for example,
`usually cannot be applied to the sidewall of a drafted
`container cleanly or easily. Such combination (i.e., drafted
`container and rectangular label) may result in a label with
`wrinkles, creases, or bends that creates an unpleasing
`appearance. To achieve a flat label, the drafted container
`usually requires a conic-shaped label that is often difficult to
`apply in a correct orientation; therefore, creating a skewed
`label that also presents an unpleasing appearance.
`
`[0006] Non-drafted containers are usually difficult to
`mold; therefore, other factors, such as material characteris(cid:173)
`tics, may also be considered to impart more flexibility into
`the molding process. In some cases, optimizing the mold
`design with the material to be molded allows fabrication of
`parts with less or no draft. However, such improvements are
`usually only limited to specific materials. For example,
`cellulose container one-piece bodies with non-drafted sides
`have previously been difficult to achieve because of the
`traditional limitations due to mold design.
`
`[0007]
`In some instances, however, cellulose bodies for
`containers are desired because of consumer preference, easy
`of handling, or improved material storage. It is similarly
`desired to fabricate cellulose bodies for containers with
`
`non-drafted walls for ease of label application. Because the
`molding of non-drafted cellulose bodies for containers has
`previously been difficult, prior attempts to fabricate such
`non-drafted bodies for cellulose containers have focused on
`bonding multiple components. For instance, bonding two or
`more separate cellulose parts with a suitable glue, adhesive,
`or other fixative is a common method to form a non-drafted
`cellulose body for a container. A flat circular bottom wall, for
`example, can be glued to an annular sidewall to form a body
`for a container having non-drafted walls. However, even this
`configuration has several shortcomings. Such multiple com(cid:173)
`ponent structures lack strength and the bond may separate
`causing container body failure.
`
`[0008]
`It is common, for example, that the bond between
`the structures may weaken or even separate upon contacting
`moisture. In addition, the separate components are often
`laminated fiberboard sheets that can delaminate upon con(cid:173)
`tacting moisture. Moreover, fabrication of such multiple(cid:173)
`component bodies for containers is costly and complicated
`requiring multiple parts, adhesives, alignment issues, and
`additional process steps.
`
`[0009] There is therefore a need for a new one-piece,
`molded fiber container body having non-drafted sidewalls,
`and an economical and ecological method of making such
`container body.
`
`SUMMARY OF THE INVENTION
`
`[0010] One aspect of the invention is a container body that
`includes a single fiber structure molded into the container
`body having an integral bottom portion and an integral side
`portion; an open cavity defined by the bottom portion and
`the side portion; and the side portion being perpendicular to
`the bottom portion. That is, the angle between the side
`portion and the bottom portion is about 90±2°. In other
`words, the side portion has a draft angle of between about 0°
`and 2°. With such configuration, a rectangular label may be
`mountable to the side portion without creases.
`
`[0011] Another aspect of the invention is a method of
`forming such containers. The method includes the steps of
`(1) drawing fibers into a first-cavity mold; (2) forming the
`fibers into an initial body shape within the first-cavity mold;
`(3) transferring the initial body shape to at least one further
`cavity mold; and (4) forming the initial body shape into the
`container body within the at least one further cavity mold. In
`this method, the first-cavity mold preferably has a draft of
`about 1.5° or less. The at least one further-cavity mold may
`have a draft less than or equal to the draft of the first-cavity
`mold and, preferably, has a draft of about 0°. In another
`aspect of the method, the first-cavity mold and the at least
`one further-cavity mold may include a porous liner, which
`may be a weld-free screen.
`
`[0012] A "container" means within this disclosure a
`"closed container including a container body or body and a
`container lid or lid". "Body" and "lid" may contain the same
`or different material.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0013] FIG. 1 depicts a side elevational view of an exem(cid:173)
`plary fiber container body illustrated without a lid;
`
`[0014] FIG. 2 depicts a top plan view of the body of FIG.
`1 without a lid;
`
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`US 2007/0110928 Al
`
`May 17, 2007
`
`2
`
`[0015] FIG. 3 depicts a bottom perspective view of the
`body of FIG. 1;
`
`[0016] FIG. 4 depicts a perspective view of the body of
`FIG. 1 shown with the lid on the body;
`
`[0017] FIG. 5 depicts an exploded perspective view of the
`container body of FIG. 1 illustrated with the lid connected
`to the body by ghost lines;
`
`[0018] FIG. 6 depicts a cross-sectional view of the body of
`FIG. 1 and separate lid connected to the body by ghost lines;
`
`[0019] FIG. 7 depicts a cross-sectional view of the body of
`FIG. 1 and separate lid connected to the body by ghost lines
`after the optional coating of the inside walls of the body with
`a wax;
`
`[0020] FIG. 8 depicts a cross-sectional view of the body of
`FIG. 1 with a lid connected to the body after the optional
`coating of the inside walls of the body with a wax and the
`optional application of a label on the horizontal outside
`walls of the body and the lid;
`
`[0021] FIG. 9 depicts a detailed cross-sectional view of
`the container body and lid as generally indicated in FIG. 8;
`and
`
`[0022] FIG. 10 depicts a schematic view of a container
`body trimming and lid recess forming operation.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`[0023] There is provided a non-drafted, fiber container
`body that is formed from a single fiber structure and has an
`integral bottom portion and an integral side portion. The
`portions define an open cavity. The side portion is non(cid:173)
`drafted by being perpendicular to the bottom portion. That
`is, the angle between the side portion and the bottom portion
`is about 90°±2°. In this configuration, the container may
`receive a rectangular shaped label that may be mounted to
`the side portion without creases, wrinkles, folds, or the like.
`It is preferred that the container is formed from pulp fibers
`and has a cylindrical shape.
`
`[0024]
`In the embodiment, the side portion, which may be
`flat, may be tapered, outwardly from a perpendicular con(cid:173)
`figuration with the bottom portion between about 0° and
`about 2°±1°. Preferably, the side portion is tapered out(cid:173)
`wardly from perpendicular about 0° ± 1 °. In one embodiment,
`the body is about 0.068 to about 0.055 inches thick; how(cid:173)
`ever, other thicknesses are possible depending on container
`design and intended use.
`
`[0025]
`In another embodiment, the side portion may be
`divided into multiple portions. For example, the side portion
`may further include a body portion or lower side portion
`extending upwardly from the bottom portion, a neck portion
`or upper side portion recessed inwardly from the body
`portion, and a shoulder portion interposed between and
`joining the body portion to the neck portion. The neck
`portion is for receiving a lid. For example, the container may
`further include a lid that has a top wall and a side wall.
`Generally, the lid side wall may slide over the neck portion
`such that an outside surface of the lid side wall is flush with
`an outside surface of the body portion. Preferably, if used,
`the neck portion is recessed between about 0.03 and about
`0.01 inches.
`
`[0026] Referring to FIGS. 1 to 5, there is illustrated a
`container 5 that includes a fiber container body 1 embodying
`features of the present invention. In general, body 1 includes
`a single structure formed from fibers that has both a bottom
`portion 14 and a side portion 16 that combine to define an
`open cavity 15. An upper edge 20 of the side portion 16
`defines an open mouth of the cavity 15. Preferably, the body
`1 has a non-drafted side portion 16; that is, the side portion
`16 is perpendicular to the bottom portion 14. In other words,
`the angle between the side portion 16 and the bottom portion
`14 is about 90°±2°. The container 5 includes the body 1, and
`optionally, includes a lid 4, which is receivable by sliding
`over an upper edge 20 of the side portion 16 within a lid
`recess or sleeve 24. The lid 4, which may be a metal or a
`metal alloy, preferably contains tin, aluminum, or the like.
`The lid 4 includes a top wall 17 and a side wall 19. The lid
`4 can be any common lid 4 known in the art.
`[0027] More specifically, the body 1 is preferably a single
`structure that is formed or molded into the desired shape
`from cellulose, pulp, pulp fibers, or the like. That is, the
`bottom portion 14 and the side portion 16 are integrally
`formed into the single structure, preferably in a molding
`operation or other suitable forming operation. The bottom
`portion 14 and the side portion 16 form a single piece body
`to define the cavity 15. In a more preferred embodiment,
`body 1 forms an right circular cylinder having an open top,
`where the bottom portion 14 has a circular or disk shape
`forming the base or bottom wall of the cylinder and the side
`portion 16 is an integral, annular wall forming the side of the
`cylinder.
`[0028] Preferably, the side portion 16 is non-drafted. That
`is, the side portion 16 is perpendicular to the bottom portion
`14. While such orientation is preferred, for purposes of this
`description, non-drafted also means that the side portion 16
`may also have a slight outward taper. For example, the side
`portion 16 may taper outwardly away from a perpendicular
`orientation with the bottom portion 14 from about 2° to
`about 0°. In other words, the angle between the bottom
`portion 16 and the side portion 14 may be between 90° and
`92°. However, it is most preferred that the side portion 16
`taper outwardly from perpendicular about 0°±1 ° or, in other
`words, it is most preferred that the side portion 16 forms an
`angle with the bottom portion 14 of about 90°.
`[0029] The side portion 16 defines a side boundary of the
`cavity 15. That is, the side portion 16 extends upwardly a
`predetermined height from an edge 22 of the bottom portion
`14 and terminates in the upper edge 20. Preferably, the side
`portion 16 is also the annular wall of the cylindrical body 1.
`The side portion 16 is preferably from about 0.068 to about
`0.055 inches thick; however, such thickness may vary. The
`side portion may comprise a single portion or have multiple
`portions with varying thicknesses as previously mentioned.
`Preferably, the side portion 16 is about ¼ inches high;
`however, other heights are appropriate depending on the
`container desired or the intended use.
`[0030] As shown in FIG. 1, the side portion 16 preferably
`includes multiple sections, such as the lid recess or sleeve 24
`and a body portion 25. If divided into multiple portions, the
`lid recess 24 is the upper section of the side portion 16 and
`the body portion 25 is the lower section of the side portion
`16. The body portion 25 is flat and extends upwardly from
`the bottom edge 22 and joins with the lid recess 24, as is
`more fully described below.
`
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`US 2007/0110928 Al
`
`May 17, 2007
`
`3
`
`[0031] The lid recess 24 allows body 1 to receive the lid
`4. Preferably, the lid recess 24 is recessed a sufficient
`distance so that an outside surface 26 of the lid side wall 19
`is flush with an outside surface of the body portion 25 when
`the lid 4 is received on the container body 1. The lid recess
`24 allows the outside diameter of a received lid 4 to be flush
`with the outside diameter of the container body portion 25.
`
`[0032] The lid recess 24 may be formed by compressing,
`trimming, filing, or shaving the top section of the side
`portion 16 to form the recess 24. Preferably, the lid recess 24
`is recessed between about 0.030 and about 0.010 inches and,
`most preferably, about 0.010 inches. After formation, the lid
`recess 24 includes a neck portion 28 that extends down(cid:173)
`wardly from the upper edge 20, an outwardly extending
`landing portion 30, and a shoulder portion 32 that transitions
`the landing portion 30 to the body portion 25.
`
`In alternative embodiment, the container body 1
`[0033]
`may have a side portion 16 with only one section. In such
`alternative embodiment, the container body 1 would not
`have the lid recess 24. In this form of the container body 1,
`any lid 4 used with container body 1 would not be flush with
`the side portion 16 and the outside diameter of the container
`body 1 would be slightly less than the inside diameter of the
`lid 4 in order for the container body 1 to accept the lid 4.
`
`[0034] Referring to FIGS. 1-3, the bottom portion 14
`defines a bottom surface of the cavity 15. That is, the bottom
`portion 14 extends between opposing surfaces of the side
`portion 16. The bottom portion 14, in one embodiment, is
`between about 0.068 to about 0.055 inches thick; however,
`other thicknesses are possible depending on the container or
`intended use. The bottom portion 14 may be a circular base
`or disk that, in a preferred embodiment, is about 2.5 inches
`in diameter; however, other sizes are suitable depending on
`the desired container body 1 or intended use.
`
`[0035] As best shown in FIG. 3, the bottom portion 14
`preferably includes a strengthening portion 34 and a
`recessed base portion 36. The strengthening portion 34
`imparts structural stiffness to the container body 10. To
`provide stiffness, the strengthening portion 34 may include
`multiple sections. For example, the strengthening portion 34
`may include a band portion 38 and a connecting portion 40.
`The band portion 38 extends inwardly along the general
`plane of the bottom portion 14 from the bottom edge 22 to
`form a flat annular band around the periphery of the bottom
`portion 14. The connection portion 40 is a second annular
`band that tapers inwardly to the cavity 15 and joins the band
`portion 38 to the recessed base portion 36. As a result, in this
`configuration, the base portion 36 is recessed inwardly from
`the band portion 38. While the strengthening portion 34 is
`illustrated as an exemplary structure to improve the con(cid:173)
`tainer body 1 stiffness, other common strengthening struc(cid:173)
`tures known in the art may also be used in the design of the
`container body 1.
`
`[0036] Container body 1 is formed from fibers, preferably
`from compressed cellulose, pulp, cardboard, pulp fiber or a
`mixture thereof that can be formed into the desired shape,
`such as the container body 1, and has a predetermined
`moisture level and thickness. In addition, the container body
`1 may also include corrugate, brown paper, clipboard,
`recycling paper, copy paper, printer paper, polymer fibers, or
`cotton fibers. The fibers are preferably blends of 40-60
`weight-% long cardboard fibers and 40-60 weight-% short
`
`cardboard fibers, which are compressed in a molding opera(cid:173)
`tion to the desired container body shape, as will be more
`fully described below. Optionally, the fibers may further
`include a blend of binders, emulsifiers, water proofing
`agents, or other suitable components known in the art for use
`with cellulose structures.
`
`[0037] Referring now to FIGS. 7-9, optional features of
`the container 5 will now be discussed. For example, the
`container body 1 may include a wax coating 6 and/or a label
`7. Referring to FIG. 7, if included on the container body 1,
`the wax coating 6 is preferably coated on an inside surface
`of the bottom wall 14 and an inside surface of the side wall
`16. As best shown in FIG. 7, if the wax coating is applied to
`the container body 1, it may also be wrapped around the top
`edge 20 and slightly down an outside surface of the lid
`recess 24.
`
`[0038] As illustrated in FIGS. 8-9, the container 5 may
`also include a label 7. If used, the label is preferably applied
`to the container 5 after the lid 4 is inserted onto the container
`body 1. Therefore, the label may be applied both to the
`outside surface of the side wall 16 of the body portion 25 of
`the container body 1 and also to the outside surface 26 of the
`side wall 19 of the lid 4. In this manner, the label 7 may be
`used to secure or seal the lid 4 to the container body 1.
`Preferably the label 7 is a generally rectangular-shaped label
`that can be applied to the container body side wall 16 and lid
`side wall 19 without creases, wrinkles, bends, or the like. As
`previously described, the label 7 can be applied without the
`creases, wrinkles, bends, or the like because the container
`body side wall 16 is non-drafted.
`
`[0039] The container body 1 is preferably sized and
`shaped as a traditional smokeless tobacco container body,
`but other sizes or shapes can be utilized as desired for other
`uses. The container body 1 is most preferably a cylindrical
`body having a diameter of about 2.0 to about 3.0 inches,
`preferably, about 2.5 inches and a height of about 0.5 to
`about 1.5 inches, preferably, about¼ inches. However, other
`sizes may also be suitable. In use, cavity 15 is preferably
`sized to receive a quantity of smokeless tobacco; however
`other materials may also be received in the container body
`1.
`
`[0040] A method of manufacturing the container body 1
`will now be discussed. In general, the container body 1 is
`molded or otherwise formed from fibers, like cellulose or
`pulp slurry, and a plurality of molding or forming steps. It is
`preferred that the container body 1 is formed in a three-step
`cavity molding or forming process. The method of fabricat(cid:173)
`ing the container body 1 will now be described.
`
`[0041] To form the container body 1 using the three-step
`process, preferably, three molding stages are completed
`using a first-cavity mold, a second-cavity mold, and a
`final-cavity mold. Each subsequent molding stage completes
`further container shaping and further water evacuation. In
`addition, the draft of each subsequent mold preferably
`decreases, where the final-cavity mold is, most preferably, a
`non-drafted mold. Each molding stage will now be
`described further.
`
`[0042] The first-cavity mold is a female mold or cavity
`that is positively drafted and in the shape of the outside
`surface of the container body 1. The first-cavity mold
`includes a bottom wall and a side wall to form the mold
`
`RJRV 1013
`Page 14
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`

`

`US 2007/0110928 Al
`
`May 17, 2007
`
`4
`
`cavity. The inside walls of the first-cavity mold are prefer(cid:173)
`ably lined with a porous material, such as a screen, mesh or
`the like, in the shape of the outside of the container body 1.
`In this first stage, the mold is positively drafted; that is, the
`mold cavity is tapered outwardly. The first-cavity mold has
`a draft of about 0.5° to about 2.5° and, preferably, about 1.5°.
`At this stage, any deposited fibers in the mold are moist and,
`therefore, a positive draft is preferred in order to aid the
`release of the fibers from the mold.
`[0043]
`In the first-molding stage, the first-cavity mold is
`inserted or submerged into the slurry tank for a predeter(cid:173)
`mined duration to load the cavity with the cellulose fibers.
`Preferably, the slurry tank includes an aqueous solution of
`about 0.1 weight percent to about 3 weight percent fibers.
`Once inserted in the slurry, to aid fiber loading, a vacuum
`may also be drawn on the first-cavity mold to help pull the
`cellulose fibers from the slurry tank and deposit such fibers
`into the mold. Once the fibers are deposited, the first-cavity
`mold forms an initial container body shape, which confirms
`to the shape of the container body 1, but may have a greater
`side portion draft or height than a finished container body 1.
`[0044] Once the first-cavity mold is removed from the
`slurry, a transfer core is inserted into the first-cavity mold.
`The transfer core is a male mold that conforms to the shape
`of the inside surface of the container body 1. As opposed to
`the porous material lining the first-cavity mold, the transfer
`core preferably has a smooth surface. In use, the transfer
`core has multiple functions. One function is to apply pres(cid:173)
`sure to the deposited fibers in each of the cavity molds, and
`another function is to transfer the formed container body
`shapes in each mold to the other cavity molds. The transfer
`core may also provide other functions as needed. After the
`pressing is completed in the first-cavity mold, the container
`body has a thickness of about 0.095 to about 0.079 inches.
`[0045] After the compression and moisture removal in the
`first-cavity mold, the transfer core then moves or transfers
`the initial container body shape to the other cavity molds. In
`the three-step embodiment, the transfer core moves the
`initial container body shape to the second-cavity mold for
`continued shaping and water evacuation prior to the final
`shaping. To aid in the release of the initial container body
`shape from the first-cavity mold onto the transfer core, a
`small burst of air may be employed through the mesh screen
`to help provide positive release of the initial container body
`shape from the first-cavity mold; however, any method
`known in the art to transfer a molded shape from a cavity to
`a core may be employed. The transfer core then inserts or
`places the initial container body shape into the second-cavity
`mold for further processing.
`[0046] The second-cavity mold, which is also a female
`mold or cavity, continues the shaping and the water evacu(cid:173)
`ation from the fibers. The second-cavity mold is similar to
`the first-cavity mold in many aspects. For instance, the
`second-cavity mold also has a bottom wall and a side wall
`to form a mold cavity, has a positive draft, and is preferably
`lined with the porous material. More specifically, the sec(cid:173)
`ond-cavity mold and the porous material therein also con(cid:173)
`form to the general shape of the outside of the container
`body 1 and have a draft equal to or less than the draft of the
`first-cavity mold. The second cavity mold has a draft of
`about 0.5 to about 2.5° and, preferably, about 1.5°.
`[0047] Once the initial container body shape is inserted
`into the second-cavity mold, shaping and water evacuation
`
`are continued through positive pressure, negative pressure,
`heat, or vacuum. More specifically, the transfer core may
`apply a positive pressure to further compress the initial
`container body shape to a thinner thickness. In addition, a
`negative pressure may also be applied to the initial container
`body shape by applying a pressing force on the second(cid:173)
`cavity mold opposite the force of the transfer core. In one
`aspect, the heat may be applied at the same time as the
`positive or negative pressure; however, in other aspects, the
`heat, positive pressure, and negative pressure may also be
`applied in various combinations or stages. As with the
`processing in the first-cavity mold, the vacuum, at similar
`levels, may further be drawn to help aid the water evacua(cid:173)
`tion.
`[0048] The combination of the pressure and heat in the
`second-cavity mold further compresses the initial shape and
`evacuates more moisture. The pressing, vacuum, and heat in
`the second-cavity mold can also vary depending on the
`cellulose fiber type, the slurry mixture composition, and/or
`the amount of cellulose fiber deposited in the mold. After the
`pressing is completed in the second-cavity mold, the con(cid:173)
`tainer body has a thickness of about 0.078 to about 0.069
`inches.
`[0049] After processing in the second-cavity mold, the
`transfer core then moves or transfers the initial container
`body shape to the final- or third-cavity mold. As with the
`transfer from the first-cavity mold, a small burst of air may
`be employed through the mesh screen to help provide
`positive release of the initial container body shape from the
`second cavity mold; however, any method known in the art
`to transfer a molded shape from a cavity to a core may be
`employed at this stage as well. The transfer core then inserts
`or places the initial container body shape into the final(cid:173)
`cavity mold for final processing.
`[0050] The final-cavity mold is also similar to the previous
`molds in many aspects. For instance, the final-cavity mold is
`also a female mold or cavity having a bottom wall and a side
`wall to define a mold cavity; however, the final-cavity mold
`preferably has less draft than the other molds and, most
`preferably, is non-drafted. As with the other cavity molds,
`the final-cavity mold may be lined with the porous material.
`The final-cavity mold and the porous material are also in the
`general shape of the outside of the container body 1.
`[0051] As indicated above, the final-cavity mold is pref(cid:173)
`erably non-drafted. That is, the final-cavity mold side walls
`are perpendicular to the final-cavity mold bottom wall.
`Preferably, the final-cavity mold has about 0° of draft. In this
`non-drafted configuration, to aid in the removal of the
`container, the porous liner material in the final-cavity mold
`may further include a release coating. The release coating
`may be a Teflon or similar release-type coating.
`[0052] The final shaping and water evacuation is com(cid:173)
`pleted in the final-cavity mold. Similar to the other stages,
`pressure and vacuum may be used to compress and evacuate
`moisture. As with the other molds, the pressure and vacuum
`can be simultaneous or sequential. The pressing and vacuum
`in the final-cavity mold can also vary depending on the
`desired thickness, the cellulose fiber type, the slurry mixture
`composition, and/or the amount of cellulose fiber deposited
`in the mold.
`[0053] After sufficient pressing and water evacuation, the
`cellulose container body 1 is formed. After the pressing is
`
`RJRV 1013
`Page 15
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`US 2007/0110928 Al
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`May 17, 2007
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`5
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`completed in the final-cavity mold, the final container body
`has a thickness of about 0.068 to about 0.055 inches. At this
`point, the cellulose container body 1 is removed from the
`final-cavity mold and ready for post-molding operations,
`such as trimming, forming the lid recess 24 or sleeve,
`waxing, filling, liding, or labeling.
`
`[0054] The height of the container body side wall 16 and
`lid recess 24 are preferably formed using a rotating mandrel
`110 as illustrated in FIG. 10. For example, the container
`body 1 is transported to a cutting and lid recess forming
`operation through a conveyer belt or other suitable trans(cid:173)
`portation device 100. The container body 1 is then trans(cid:173)
`ferred from the transportation device 100 to the rotating
`mandrel 110, which may have recesses or other securing
`structures 112 to hold the container body 1 along a periphery
`of the mandrel 110. To cut the container body 1 to the desired
`height, the mandrel 110 first rotates to a receiving position
`to accept the container body 1 from the transportation device
`100. Next, the mandrel 110 rotates further to a cutting
`position where the container body 1 engages a first cutting
`oper