Method of forming a sand base article using a decomposable binder and the article formed thereby

• US 5,108,677 A
• Filed: 05/01/1990
• Issued: 04/28/1992
• Est. Priority Date: 10/17/1988
• Status: Expired due to Fees

• Current Assignee: E. Khashoggi Industries, LLC
• Original Assignee: John Ayres
• Inventors: Ayres, John
• Primary Examiner(s): Theisen, Mary Lynn
• Application Number:
  US07/517,204
• Time in Patent Office: 728 Days
• Field of Search: 264/112, 264/118, 264/119, 264/330, 264/129, 264/294, 264/291, 264/292, 220/DIG. 30
• US Class Current: 264/112
• CPC Class Codes: A63B 43/00 Balls with special arrangements
• CPC Class Codes: B29C 2793/00 Shaping techniques involving a cutting or machining operation
• CPC Class Codes: B29C 48/00 Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor extrusion blow-moulding B29C49/04
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 51/00 Shaping by thermoforming , i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014
• CPC Class Codes: B29C 51/002 characterised by the choice of material
• CPC Class Codes: B29C 67/24 characterised by the choice of material
• CPC Class Codes: B29K 2003/00 Use of starch or derivatives as moulding material
• CPC Class Codes: B29K 2503/04 Inorganic materials
• CPC Class Codes: B29K 2995/0059 Degradable
• CPC Class Codes: B29L 2031/712 Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: F41J 1/01 Target discs characterised by their material, structure or surface, e.g. clay pigeon targets characterised by their materialF41J5/044 takes precedence
• CPC Class Codes: F42B 12/74 of the core or solid body
• CPC Class Codes: Y10S 220/30 Biodegradable

Abstract

The method includes the steps of mixing the sand and the decomposable binder to form a dough-like consistency, forming the dough-like mixture into a sheet. Cutting the sheet into silhouette shapes and then drying the shapes to form a rigid article suitable for a variety of purposes. The preferred article is coated with a decomposable waterproof sealant. Method of forming planar frangible targets as well as formed three-dimensionsl tableware and food containers are disclosed.

Claims

1. A method of forming a container comprising the steps of:

mixing sand and a decomposable binder together to form a dough-like consistency mixture;

extruding the dough-like mixture into a thin sheet;

cutting a silhouette-shaped preform from the thin sheet;

drawing the silhouette-shaped preform into an article the shape of the container; and

coating the article with a sealant to prevent moisture absorption.

2. The method of claim 1 wherein the decomposable binder used in the mixing step is formed by combining by weight 30-40% starch, 20-30% salt, 1-3% oil, and water.

3. The method of claim 1 further comprising applying a layer of paint to at least a portion of the article surface.

4. The method of claim 1 wherein the decomposable binder used in the mixing step is formed by combining by weight 25%-60% starch, 5-30% grain flour, 1/2-5% petroleum lubricant and water.

5. The method of claim 1 further comprising the step of heating the article for a sufficient time and to a sufficient temperature to dry the mixture.

6. A method of forming a disposable food container, comprising the steps of:

mixing sand and a non-toxic, biodegradable, water-soluble binder together to form a dough-like consistency mixture;

forming the dough-like mixture into an article the shape of the container;

heating the shaped article for a sufficient time and to a sufficient temperature to dry the mixture; and

coating the dried article with a non-toxic, wax-based sealant to prevent moisture absorption.

7. The method of claim 6 wherein the step of forming further comprises extruding the dough-like mixture into a thin sheet, cutting a silhouette shaped pre-form out of the thin sheet and drawing the silhouette shaped pre-form into the three dimensional shape of the container to be formed.

8. The method of claim 7 further comprising applying a layer of paint to at least a portion of the article surface, prior to the coating step.

9. The method of claim 6 wherein the decomposition binder used in the mixing step is formed by combining by weight, 30%-40% starch, 20%-30% salt, 1%-3% oil, and water.

10. The method of claim 6 wherein the decomposable binder used in the mixing step is formed by combining by weight, 25%-60% starch, 5%-30% grain flour, 1/2-5% petroleum lubricant and water.

11. The method of claim 6 wherein the step of coating the dried article is carried out using a sealant having a melting point above 212°

F.