Inorganically filled, starch-bound compositions for manufacturing containers and other articles having a thermodynamically controlled cellular matrix
First Claim
1. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate, the starch-bound cellular matrix comprising:
- a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation; and
an inorganic aggregate dispersed throughout the starch-bound cellular matrix in a concentration in a range from about 20% to about 90% by weight of total solids within the starch-bound cellular matrix,wherein the starch-bound cellular matrix has a thickness less than about 1 cm and degrades after prolonged exposure to water.
3 Assignments
0 Petitions
Accused Products
Abstract
Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix are disclosed. Suitable inorganically filled mixtures are prepared by mixing together a starch-based binder, a solvent, inorganic aggregates, and optimal admixtures, e.g., fibers, mold-releasing agents, rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The inorganically filled mixtures have a predetermined viscosity and are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled cellular, structure matrix. The molded articles may be placed in a high humidity chamber to obtain the necessary flexibility for their intended use. The articles may be manufactured to have properties substantially similar to articles presently made from conventional materials like paper, paperboard, polystyrene, plastic, or other organic materials. They have especial utility in the mass-production of containers, particularly food and beverage containers.
-
Citations
157 Claims
-
1. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate, the starch-bound cellular matrix comprising:
-
a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation; and an inorganic aggregate dispersed throughout the starch-bound cellular matrix in a concentration in a range from about 20% to about 90% by weight of total solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 1 cm and degrades after prolonged exposure to water. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82)
-
-
83. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:
-
a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation; an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 20% to about 90% by weight of solids within the starch-bound cellular matrix; and fibers dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 2% to about 40% by volume of solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water. - View Dependent Claims (84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114)
-
-
115. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:
-
a starch binder selected from the group consisting of potato starch, corn starch, and waxy corn starch, the starch binder having been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation, the starch binder having a concentration in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix; an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix; and organic fibers dispersed throughout the starch-bound cellular matrix and included in an amount up to about 20% by volume of solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water. - View Dependent Claims (116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138)
-
-
139. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate, the starch-bound cellular matrix comprising:
-
a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation; and an inorganic aggregate dispersed throughout the starch-bound cellular matrix in a concentration in a range from about 20% to about 90% by weight of total solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 1 cm and degrades after prolonged exposure to water, wherein the article includes a coating on at least a portion thereof. - View Dependent Claims (140, 141, 142, 143, 144, 145, 146, 147, 148, 149)
-
-
150. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:
-
a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation; an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 20% to about 90% by weight of solids within the starch-bound cellular matrix; and fibers dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 2% to about 40% by volume of solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 6 mm, includes glycerin within a portion thereof, and degrades after prolonged exposure to water. - View Dependent Claims (151, 152, 153)
-
-
154. An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:
-
a starch binder selected from the group consisting of potato starch, corn starch, and waxy corn starch, the starch binder having been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation, the starch binder having a concentration in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix; calcium carbonate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix; and organic fibers dispersed throughout the starch-bound cellular matrix and included in an amount up to about 20% by volume of solids within the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water, wherein the article includes a coating on at least a portion thereof. - View Dependent Claims (155, 156, 157)
-
Specification