CPC D21J 1/04 (2013.01) [B05B 1/02 (2013.01); B05B 1/06 (2013.01); B05B 13/0221 (2013.01); B05D 1/02 (2013.01); B29C 41/50 (2013.01); B65D 1/34 (2013.01); B65D 25/34 (2013.01); B65D 81/3453 (2013.01); D21H 5/0005 (2013.01); D21H 5/0047 (2013.01); D21H 17/17 (2013.01); D21H 17/28 (2013.01); D21J 1/06 (2013.01); D21J 1/10 (2013.01); D21J 7/00 (2013.01); B05B 1/044 (2013.01); B05D 2203/22 (2013.01)] | 7 Claims |
1. A method of manufacturing a microwave bowl of the type characterized by a substantially flat, circular, bottom region bounded by a circumferential sidewall, comprising the steps of:
providing a wire mesh mold approximating the shape of the bowl;
preparing an aqueous fiber based slurry comprising at least one of hardwood virgin fiber and softwood virgin fiber;
adding an embedded moisture barrier to the slurry;
immersing the mold in the slurry;
drawing a vacuum across the mold within the slurry until a desired thickness of fiber particles accumulates at a surface of the mold;
removing the accumulated particles from the mold;
drying and pressing the accumulated particles in a press to thereby form the bowl;
transferring the bowl from the press to a coating station; and
applying a topical oil barrier layer to at least a portion of the bowl at the coating station;
wherein the coating station comprises a spray system and a conveyor configured to move the bowl along a direction of travel underneath the spray system, and the spray system comprises: a first nozzle configured to discharge a full cone spray pattern onto the bottom region of the bowl; and a second nozzle configured to discharge a hollow cone spray pattern onto the inside surface of the circumferential sidewall.
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