Articles having a starch-bound cellular matrix reinforced with uniformly dispersed fibers

• US 5,683,772 A
• Filed: 12/09/1994
• Issued: 11/04/1997
• Est. Priority Date: 08/11/1992
• Status: Expired due to Term

• Current Assignee: Earthshell Spe, LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Andersen, Per Just, Hodson, Simon K.
• Primary Examiner(s): McCamish, Marion E.
• Assistant Examiner(s): COPENHEAVER, BLAINE R
• Application Number:
  US08/353,543
• Time in Patent Office: 1,061 Days
• Field of Search: 428/34.5, 428/35.6, 428/35.7, 428/36.4, 428/36.5, 428/53, 428/220, 428/312.2, 428/312.4, 428/312.6, 428/313.9, 428/314.4, 428/317.9, 428/319.3 , 428/339, 428/532, 428/310.5, 524/4, 524/425, 524/446, 524/447, 524/451, 524/498, 524/650, 206/524.3, 206/524.6, 206/524.7
• US Class Current: 428/36.4
• CPC Class Codes: B01F 23/511 characterised by the composition of the liquids or solids
• CPC Class Codes: B01F 23/56 by introducing solids in liquids, e.g. dispersing or dissolving
• CPC Class Codes: B05C 1/0826 the work being a web or sheets B05C1/0804, B05C1/0808, B05C1/0813, B05C1/0817, B05C1/0821, B05C1/10, B05C1/12 take precedence
• CPC Class Codes: B05C 1/0834 the coating roller co-operating with other rollers, e.g. dosing, transfer rollers
• CPC Class Codes: B05C 3/18 only one side of the work coming into contact with the liquid or other fluent material B05C3/02 takes precedence
• CPC Class Codes: B05C 5/0245 for applying liquid or other fluent material to a moving work of indefinite length, e.g. to a moving web B05C5/0241, B05C5/0254, B05C5/027, B05C5/0283 take precedence
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: B27N 3/007 and at least partly composed of recycled material
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 1/52 specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cementby wrapping on to mandrels B28B1/42
• CPC Class Codes: B28B 11/00 Apparatus or processes for treating or working the shaped or preshaped articles specially adapted for tubular articles B28B21/92; decoration or surface treatment in general B05, B44; compacting concrete in situ in connection with building E04G21/06; drying F26
• CPC Class Codes: B28B 11/003 the shaping of preshaped articles, e.g. by bending B28B11/08 takes precedence
• CPC Class Codes: B28B 11/008 Blow moulding, e.g. with or without the use of a membrane
• CPC Class Codes: B28B 11/24 for curing, setting or hardening processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00
• CPC Class Codes: B28B 11/245 Curing concrete articles B28B11/242 takes precedence
• CPC Class Codes: B28B 13/021 by fluid pressure acting directly on the material, e.g. using vacuum, air pressure
• CPC Class Codes: B28B 13/06 Removing the shaped articles from moulds by means incorporated in, or carried by, the moulds B28B7/10
• CPC Class Codes: B28B 23/00 Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objectsB28B21/00 takes precedence; in units for prefabricated buildings B28B7/22
• CPC Class Codes: B28B 23/0081 Embedding aggregates to obtain particular properties
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B28B 3/00 : Producing shaped articles from the material by using presses shaping on moving conveyors B28B5/00; Presses specially adapted therefor presses in general B30B
• CPC Class Codes: B28B 3/02 : wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
• CPC Class Codes: B28B 3/126 : on material passing directly between the co-operating rollers
• CPC Class Codes: B28B 3/20 : wherein the material is extruded extrusion moulding of plastics B29C48/00
• CPC Class Codes: B28B 3/2645 : using means for inserting reinforcing members
• CPC Class Codes: B28B 7/42 : for heating or cooling, e.g. steam jackets , by means of treating agents acting directly on the moulding material
• CPC Class Codes: B28C 7/02 : Controlling the operation of the mixing
• CPC Class Codes: B29C 2043/3433 : using dispensing heads, e.g. extruders, placed over or apart from the moulds
• CPC Class Codes: B29C 2043/3615 : Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
• CPC Class Codes: B29C 2043/3621 : a plurality of individual elements acting on the material in the same or diferent directions, e.g. making tubular T-joints, profiles
• CPC Class Codes: B29C 2043/3623 : coupled on a support, e.g. plate
• CPC Class Codes: B29C 2043/3689 : on a support table, e.g. flat disk-like tables having moulds on the periphery
• CPC Class Codes: B29C 2049/4608 : Nitrogen
• CPC Class Codes: B29C 2795/007 : after shaping
• CPC Class Codes: B29C 33/10 : with incorporated venting means
• CPC Class Codes: B29C 33/20 : Opening, closing or clamping
• CPC Class Codes: B29C 33/36 : continuously movable in one direction, e.g. in a closed circuit B29C49/0021 takes precedence
• CPC Class Codes: B29C 39/003 : characterised by the choice of material
• CPC Class Codes: B29C 39/42 : Casting under special conditions, e.g. vacuum
• CPC Class Codes: B29C 43/00 : Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor by liberation of internal stresses B29C61/006
• CPC Class Codes: B29C 43/003 : characterised by the choice of material
• CPC Class Codes: B29C 43/02 : of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 43/06 : continuously movable in one direction, e.g. mounted on chains, belts
• CPC Class Codes: B29C 43/08 : with circular movement , e.g. mounted on rolls, turntables
• CPC Class Codes: B29C 43/24 : Calendering
• CPC Class Codes: B29C 43/34 : Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: B29C 43/36 : Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 43/38 : with means to avoid flashes B29C43/40 takes precedence
• CPC Class Codes: B29C 44/0407 : by regulating the temperature of the mould or parts thereof, e.g. cold mould walls inhibiting foaming of an outer layer
• CPC Class Codes: B29C 44/3402 : Details of processes or apparatus for reducing environmental damage or for working-up compositions comprising inert blowing agents or biodegradable components
• CPC Class Codes: B29C 45/0013 : using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29C 49/0005 : characterised by the material
• CPC Class Codes: B29C 49/6605 : Heating the article, e.g. for hot fill
• CPC Class Codes: B29C 51/002 : characterised by the choice of material
• CPC Class Codes: B29C 51/04 : Combined thermoforming and prestretching, e.g. biaxial stretching
• CPC Class Codes: B29C 51/10 : Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 53/063 : combined with folding
• CPC Class Codes: B29C 53/58 : helically
• CPC Class Codes: B29C 55/18 : by squeezing between surfaces, e.g. rollers
• CPC Class Codes: B29C 67/202 : comprising elimination of a solid or a liquid ingredient
• CPC Class Codes: B29C 67/24 : characterised by the choice of material
• CPC Class Codes: B29C 67/242 : Moulding mineral aggregates bonded with resin, e.g. resin concrete shaping ceramic compositions without binder or water-setting cementitious material B28B; compositions per se C04B
• CPC Class Codes: B29C 70/025 : with particular filler
• CPC Class Codes: B29C 70/12 : using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29C 70/50 : for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: B29C 71/0009 : using liquids, e.g. solvents, swelling agents spectacle cases, e.g. for cleaning contact lenses A45C11/04; disinfecting or sterilising contact lenses A61L12/00, using liquid substances A61L2/20; cleaning involving the use of liquid in general B08B3/00; for hydrating contact lenses B29D11/00067
• CPC Class Codes: B29K 2003/00 : Use of starch or derivatives as moulding material
• CPC Class Codes: B29K 2005/00 : Use of polysaccharides or derivatives as moulding material
• CPC Class Codes: B29K 2089/00 : Use of proteins, e.g. casein, gelatine or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2093/00 : Use of natural resins, e.g. shellac, or derivatives thereof, as moulding material B29K2001/00, B29K2003/00, B29K2005/00, B29K2007/00 and B29K2089/00 take precedence
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29L 2024/00 : Articles with hollow walls
• CPC Class Codes: B29L 2031/608 : Honeycomb structures
• 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: B29L 2031/7132 : Bowls, Cups, Glasses
• CPC Class Codes: B31B 2105/0022 : Making boxes from tubular webs or blanks, e.g. with separate bottoms, including tube or bottom forming operations
• CPC Class Codes: B31B 50/32 : in circular paths
• CPC Class Codes: B31D 1/005 : making bottoms or caps
• CPC Class Codes: B32B 13/02 : with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 27/04 : as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/14 : characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B65D 11/02 : of curved cross-section thermally insulated B65D81/3813
• CPC Class Codes: B65D 2301/20 : made of plastic material
• CPC Class Codes: B65D 2565/385 : especially suited for or with means facilitating recycling
• CPC Class Codes: B65D 43/162 : the container, the lid and the hinge being made of one piece B65D43/161 takes precedence
• CPC Class Codes: B65D 5/00 : Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper rigid pallets with side walls B65D19/02
• CPC Class Codes: B65D 65/38 : Packaging materials of special type or form
• CPC Class Codes: B65D 65/466 : Bio- or photodegradable packaging materials
• CPC Class Codes: C04B 14/06 : Quartz; Sand
• CPC Class Codes: C04B 14/064 : Silica aerogel
• CPC Class Codes: C04B 14/10 : Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 : Kaolin
• CPC Class Codes: C04B 14/18 : Perlite
• CPC Class Codes: C04B 14/202 : Vermiculite
• CPC Class Codes: C04B 14/22 : Glass ; Devitrified glass
• CPC Class Codes: C04B 14/24 : porous, e.g. foamed glass
• CPC Class Codes: C04B 14/28 : of calcium
• CPC Class Codes: C04B 14/303 : Alumina
• CPC Class Codes: C04B 14/386 : Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 : Glass
• CPC Class Codes: C04B 14/46 : Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/02 : Cellulosic materials cellulosic waste materials, e.g. sawdust, rice husks, C04B18/24
• CPC Class Codes: C04B 18/24 : Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/248 : from specific plants, e.g. hemp fibres
• CPC Class Codes: C04B 18/26 : Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 20/002 : Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 2103/408 : Dispersants
• CPC Class Codes: C04B 22/002 : Water
• CPC Class Codes: C04B 22/04 : Metals, e.g. aluminium used as blowing agent
• CPC Class Codes: C04B 22/124 : Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 24/00 : Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
• CPC Class Codes: C04B 24/008 : Aldehydes, ketones
• CPC Class Codes: C04B 24/02 : Alcohols; Phenols; Ethers
• CPC Class Codes: C04B 24/06 : containing hydroxy groups
• CPC Class Codes: C04B 24/085 : Higher fatty acids
• CPC Class Codes: C04B 24/14 : Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/34 : Natural resins, e.g. rosin C04B24/243 takes precedence
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 26/00 : Compositions of mortars, concrete or artificial stone, containing only organic binders , e.g. polymer or resin concrete mechanical aspects of moulding polymer or resin concrete B29C67/242
• CPC Class Codes: C04B 26/02 : Macromolecular compounds
• CPC Class Codes: C04B 26/026 : Proteins or derivatives thereof
• CPC Class Codes: C04B 26/28 : Polysaccharides or derivatives thereof
• CPC Class Codes: C04B 28/00 : Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 38/0006 : Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 40/00 : Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 40/0032 : Controlling the process of mixing, e.g. adding ingredients in a quantity depending on a measured or desired value B28C7/00 takes precedence
• CPC Class Codes: C04B 40/006 : involving the elimination of excess water from the mixture
• CPC Class Codes: C04B 40/0616 : preformed, e.g. bandages
• CPC Class Codes: C04B 41/45 : Coating or impregnating paints C09D, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements ion-implantation C04B41/0027
• CPC Class Codes: C04B 41/61 : Coating or impregnation
• CPC Class Codes: C04B 7/527 : obtaining cements characterised by fineness, e.g. by multi-modal particle size distribution
• CPC Class Codes: C08J 2303/00 : Characterised by the use of starch, amylose or amylopectin or of their derivatives or degradation products
• CPC Class Codes: C08J 9/0085 : Use of fibrous compounding ingredients C08J9/0076 takes precedence
• CPC Class Codes: C08J 9/12 : by a physical blowing agent
• CPC Class Codes: C08L 1/28 : Alkyl ethers
• CPC Class Codes: C08L 1/286 : substituted with acid radicals, e.g. carboxymethyl cellulose [CMC] C08L1/282 takes precedence
• CPC Class Codes: C08L 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 3/00 : Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
• CPC Class Codes: C08L 3/02 : Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C08L 5/02 : Dextran; Derivatives thereof
• CPC Class Codes: C08L 5/12 : Agar or agar-agar , i.e. mixture of agarose and agaropectin; Derivatives thereof
• CPC Class Codes: C08L 5/14 : Hemicellulose; Derivatives thereof
• CPC Class Codes: C08L 89/06 : derived from leather or skin , e.g. gelatin
• CPC Class Codes: C08L 97/02 : Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E05D 1/02 : made of one piece
• CPC Class Codes: E05Y 2900/602 : for containers
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y02W 90/10 : Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/17 : Three or more coplanar interfitted sections with securing means
• CPC Class Codes: Y10T 428/249961 : With gradual property change within a component
• CPC Class Codes: Y10T 428/249976 : Voids specified as closed
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249989 : Integrally formed skin
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/2915 : including textile, cloth or fabric

Abstract

Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a starch-bound cellular matrix reinforced with substantially uniformly dispersed fibers. High strength articles that have adequate flexibility and toughness immediately or very shortly after being demolded without the need for subsequent conditioning are molded from compositions having a starch-based binder and fibers that are uniformly dispersed by means of a high yield stress fluid fraction within the starch-based composition. In a two-step mixing process, a preblended mixture is formed by gelating a portion of the starch-based binder or other thickening agent in water to form a liquid phase having high yield stress into which the fibers are substantially uniformly dispersed. The fibers preferably have an average length of at least about 2 mm and an aspect ratio of at least about 25:1. The remaining starch-based binder, water, and other desired admixtures, such as mold-release agents, inorganic fillers, rheology-modifying agents, plasticizers, integral coating or sealing materials, and dispersants, are added to the preblended mixture to form a moldable starch-based composition, which is molded between heated molds to produce form-stable articles having a desired shape and a selectively controlled foamed structural matrix. Such articles can replace articles presently made from conventional materials like paper, paperboard, polystyrene, plastic, or other organic-based materials and have especial utility in the mass-production of containers, particularly food and beverage containers.

Claims

1. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix of starch-based binder and inorganic aggregate, the matrix comprising a starch-based binder, an inorganic aggregate filler, and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average aspect ratio greater than about 25:

1, the inorganic filler having a concentration greater than about 20% by weight of the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 1 cm, wherein the starch-bound cellular matrix degrades after prolonged exposure to water.

2. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix is formed without a separate conditioning step.

3. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix includes less than about 5% by weight of a synthetic polymer.

4. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix includes less than about 2% by weight of a synthetic polymer.

5. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix includes no synthetic polymer.

6. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength greater than about 1 MPa.

7. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength greater than about 2 MPa.

8. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength greater than about 0.75 MPa.

9. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength greater than about 1 MPa.

10. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy greater than about 300 J/m².

11. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy greater than about 600 J/m².

12. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to density in a range of about 0.5 MPa/(g/cm³) to about 60 MPa/(g/cm³).

13. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to density in a range from about 1 MPa/(g/cm³) to about 40 MPa/(g/cm³).

14. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to density in a range from about 2 MPa/(g/cm³) to about 20 MPa/(g/cm³).

15. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to density in a range from about 0.5 MPa/(g/cm³) to about 30 MPa/(g/cm³).

16. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to density in a range from about 0.75 MPa/(g/cm³) to about 20 MPa/(g/cm³).

17. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to density in a range from about 1 MPa/(g/cm³) to about 12 MPa/(g/cm³).

18. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to density in a range from about 1000 (J/m²)/(g/cm³) to about 10,000 (J/m²)/(g/cm³).

19. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to density in a range from about 2000 (J/m²)/(g/cm³) to about 7500 (J/m²)/(g/cm³).

20. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to density in a range from about 3000 (J/m²)/(g/cm³) to about 5000 (J/m²)/(g/cm³).

21. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to weight fraction of the starch-based binder in a range from about 5 MPa/(wt. fraction of starch-based binder) to about 100 MPa/(wt. fraction of starch-based binder).

22. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to weight fraction of the starch-based binder in a range from about 10 MPa/(wt. fraction of starch-based binder) to about 75 MPa/(wt. fraction of starch-based binder).

23. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a flexural strength normalized with respect to weight fraction of the starch-based binder in a range from about 20 MPa/(wt. fraction of starch-based binder) to about 60 MPa/(wt. fraction of starch-based binder).

24. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to weight fraction of the starch-based binder in a range from about 3 MPa/(wt. fraction of starch-based binder) to about 50 MPa/(wt. fraction of starch-based binder).

25. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to weight fraction of the starch-based binder in a range from about 4 MPa/(wt. fraction of starch-based binder) to about 30 MPa/(wt. fraction of starch-based binder).

26. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a tensile strength normalized with respect to weight fraction of the starch-based binder in a range from about 5 MPa/(wt. fraction of starch-based binder) to about 20 MPa/(wt. fraction of starch-based binder).

27. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to weight fraction of the starch-based binder in a range from about 2000 (J/m²)/(wt. fraction of starch-based binder) to about 30,000 (J/m²)/(wt. fraction of starch-based binder).

28. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to weight fraction of the starch-based binder in a range from about 3000 (J/m²)/(wt. fraction of starch-based binder) to about 15,000 (J/m²)/(wt. fraction of starch-based binder).

29. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a fracture energy normalized with respect to weight fraction of the starch-based binder in a range from about 5000 (J/m²)/(wt. fraction of starch-based binder) to about 10,000 (J/m²)/(wt. fraction of starch-based binder).

30. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article has a strain before failure in a range from about 1% to about 15%.

31. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article has a strain before failure in a range from about 1% to about 10%.

32. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article has a strain before failure in a range from about 1% to about 5%.

33. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a density in a range from about 0.05 g/cm³ to about 1 g/cm³.

34. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a density in a range from about 0.1 g/cm³ to about 0.5 g/cm³.

35. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix has a density in a range from about 0.15 g/cm³ to about 0.25 g/cm³.

36. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix includes an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

37. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 36, wherein the outer skin portion includes virtually no pinholes.

38. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 36, wherein the cross-sectional area of pinholes within the outer skin portion that are large enough to allow passage of moisture is less than about 15% the cross-sectional area of the outer skin portion.

39. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 36, wherein the cross-sectional area of pinholes within the outer skin portion that are large enough to allow passage of moisture is less than about 10% the cross-sectional area of the outer skin portion.

40. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 36, wherein the cross-sectional area of pinholes within the outer skin portion that are large enough to allow passage of moisture is less than about 5% the cross-sectional area of the outer skin portion.

41. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder includes an unmodified starch that has been gelatinized during molding.

42. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder includes a potato starch or potato starch derivative that has been gelatinized during molding.

43. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder includes a waxy corn starch or waxy corn starch derivative that has been gelatinized during molding.

44. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has an amylose content less than about 45%.

45. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has an amylose content less than about 35%.

46. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has an amylose content less than about 25%.

47. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder includes a modified starch.

48. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder includes a starch that has been modified by a process selected from the group consisting of esterification, ethefification, oxidation, acid hydrolysis, cross-linking, and enzyme conversion.

49. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has a concentration in a range from about 10% to about 80% by weight of the cellular matrix.

50. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

51. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the starch-based binder has a concentration in a range from about 40% to about 60% by weight of the cellular matrix.

52. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers include naturally occurring organic fibers.

53. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers include cellulosic fibers.

54. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers are derived from at least one fiber source selected from the group consisting of plant leaves, stems, husks, shells, and fruits.

55. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers are derived from a fiber source selected from the group consisting of hemp, cotton, sisal, abaca, and bagasse.

56. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers are derived from hardwood.

57. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers are derived from softwood.

58. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers include inorganic fibers.

59. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers are derived from a material selected from the group consisting of glass, graphite, silica, ceramic, and metal.

60. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers include recycled paper fibers.

61. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have a concentration in a range from about 2% to about 80% by weight of the cellular matrix.

62. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have a concentration in a range from about 4% to about 40% by weight of the cellular matrix.

63. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have a concentration in a range from about 5% to about 20% by weight of the cellular matrix.

64. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an aspect ratio of at least about 100:

1.

65. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an aspect ratio of at least about 250:

1.

66. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an average length in a range from about 0.3 mm to about 2 mm.

67. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an average length of at least about 2 mm.

68. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an average length of at least about 3.5 mm.

69. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the fibers have an average length of at least about 6.5 mm.

70. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler includes calcium carbonate.

71. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler is selected from the group consisting of sand, gravel, rock, limestone, sandstone, glass beads, mica, clay, kaolin, synthetic clay, alumina, silica, fly ash, fused silica, tabular alumina, microspheres, calcium sulfate dihydrate, calcium aluminate, hydrated hydraulic cement particles, and unhydrated hydraulic cement particles.

72. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, hollow glass spheres, aerogels, xerogels, porous ceramic spheres, xonotlite, lightweight expanded clays, pumice, and exfoliated rock.

73. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

74. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a concentration in a range from about 40% to about 60% by weight of the cellular matrix.

75. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a specific surface area in a range from about 0.1 m² /g to about 400 m² /g.

76. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a specific surface area in a range from about 0.15 m² /g to about 50 m² /g.

77. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a specific surface area in a range from about 0.2 m² /g to about 2 m² /g.

78. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a natural packing density in a range from about 0.5 to about 0.9.

79. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the inorganic aggregate filler has a natural packing density in a range from about 0.6 to about 0.8.

80. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the cellular matrix further comprises a humectant.

81. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, further comprising a coating on a surface of the article.

82. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating renders the article more resistant to water.

83. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating renders the article more resistant to oils.

84. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises a wax.

85. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises polyethylene.

86. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises polylactic acid.

87. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises shellac.

88. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises ethyl cellulose.

89. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises polyvinyl alcohol.

90. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 81, wherein the coating comprises magnesium stearate.

91. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, the cellular matrix further comprising an integral sealing material.

92. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 91, wherein the internal sealing material comprises polyvinyl alcohol.

93. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article comprises a food or beverage container.

94. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article comprises a liquid tight container.

95. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a clam shell container.

96. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a carton.

97. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a box.

98. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a cup.

99. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a plate.

100. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a bowl.

101. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 1, wherein the article is in the shape of a tray.

102. An article of manufacture having a fiber-reinforced, inorganically filled, starch-bound cellular matrix of starch and inorganic aggregate, the cellular matrix comprising a starch-based binder, an inorganic aggregate filler having a concentration in a range from about 20% to about 80% by weight of the cellular matrix, and fibers substantially uniformly dispersed throughout the matrix, the fibers having an average fiber length in a range from about 2 mm to about 25 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by volume of the starch-bound cellular matrix, wherein the starch-bound cellular matrix has a thickness less than about 5 mm and degrades after prolonged exposure to water.

103. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 102, wherein the cellular matrix is formed without a separate conditioning step.

104. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 102, wherein the cellular matrix includes less than about 5% by weight of a synthetic polymer.

105. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 102, wherein the cellular matrix includes no synthetic polymer.

106. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 102, wherein the article comprises a food or beverage container.

107. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix comprising a starch-based binder and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average length greater than about 2 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by weight of the cellular matrix, the cellular matrix having a thickness less than about 1 cm and degrades after prolonged exposure to water.

108. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the cellular matrix has a density in a range from about 0.05 g/cm³ to about 1 g/cm³.

109. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the cellular matrix has a density in a range from about 0.1 g/cm³ to about 0.5 g/cm³.

110. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the cellular matrix includes an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

111. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder includes an unmodified starch that has been gelatinized during molding.

112. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder includes a potato starch or potato starch derivative that has been gelatinized during molding.

113. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder includes a waxy corn starch or waxy corn starch derivative that has been gelatinized during molding.

114. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder includes a modified starch.

115. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder has a concentration in a range from about 10% to about 80% by weight of the cellular matrix.

116. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the starch-based binder has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

117. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the fibers include naturally occurring organic fibers.

118. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the fibers have an aspect ratio of at least about 100:

1.

119. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the fibers have an aspect ratio of at least about 250:

1.

120. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the fibers have an average length of at least about 3.5 mm.

121. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, further comprising an inorganic aggregate filler.

122. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler includes calcium carbonate.

123. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler is selected from the group consisting of sand, gravel, rock, limestone, sandstone, glass beads, mica, clay, kaolin, synthetic clay, alumina, silica, fly ash, fused silica, tabular alumina, microspheres, calcium sulfate dihydrate, calcium aluminate, hydrated hydraulic cement particles, and unhydrated hydraulic cement particles.

124. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, hollow glass spheres, aerogels, xerogels, porous ceramic spheres, xonotlite, lightweight expanded clays, pumice, and exfoliated rock.

125. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler has a concentration in a range from about 20% to about 80% by weight of the cellular matrix.

126. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

127. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 121, wherein the inorganic aggregate filler has a concentration in a range from about 40% to about 60% by weight of the cellular matrix.

128. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the cellular matrix further comprises a humectant.

129. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, further comprising a coating on a surface of the article.

130. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the article comprises a food or beverage container.

131. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the article comprises a liquid tight container.

132. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the article is in the shape of a clam shell container.

133. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 107, wherein the cellular matrix has a thickness less than about 5 mm.

134. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix comprising a starch-based binder and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average length greater than about 2 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by weight of the cellular matrix, the cellular matrix including an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

135. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the cellular matrix has a density in a range from about 0.05 g/cm³ to about 1 g/cm³.

136. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the cellular matrix has a density in a range from about 0.1 g/cm³ to about 0.5 g/cm³.

137. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the cellular matrix has a thickness less than about 1 cm.

138. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, further comprising an inorganic aggregate filler.

139. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 138, wherein the inorganic aggregate filler includes calcium carbonate.

140. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 138, wherein the inorganic aggregate filler has a concentration in a range from about 20% to about 80% by weight of the cellular matrix.

141. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 138, wherein the inorganic aggregate filler has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

142. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, further comprising a coating on a surface of the article.

143. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder includes an unmodified starch that has been gelatinized during molding.

144. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder includes a potato starch or potato starch derivative that has been gelatinized during molding.

145. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder includes a waxy corn starch or waxy corn starch derivative that has been gelatinized during molding.

146. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder includes a modified starch.

147. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder has a concentration in a range from about 10% to about 80% by weight of the cellular matrix.

148. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the starch-based binder has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

149. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the fibers include naturally occurring organic fibers.

150. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the fibers include inorganic fibers.

151. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the fibers have an aspect ratio of at least about 100:

1.

152. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the fibers have an aspect ratio of at least about 250:

1.

153. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the fibers have an average length greater than about 3.5 mm.

154. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the cellular matrix further comprises a humectant.

155. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the article comprises a food or beverage container.

156. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the article comprises a liquid-tight container.

157. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 134, wherein the article is in the shape of a clam-shell container.

158. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix of starch and inorganic aggregate, the cellular matrix comprising a starch-based binder, and inorganic aggregate filler, and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average aspect ratio greater than about 25:

1, the inorganic aggregate filler having a concentration greater than about 20% by weight of the cellular matrix, the cellular matrix including an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

159. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the article comprises a food or beverage container.

160. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, further comprising a coating on a surface of the article.

161. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder includes an unmodified starch that has been gelatinized during molding.

162. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder includes a potato starch or potato starch derivative that has been gelatinized during molding.

163. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder includes a waxy cornstarch or waxy cornstarch derivative that has been gelatinized during molding.

164. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder includes a modified starch.

165. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder has a concentration in a range from about 10% to about 80% by weight of the cellular matrix.

166. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the starch-based binder has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

167. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the fibers include naturally occurring organic fibers.

168. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the fibers include inorganic fibers.

169. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the fibers have an aspect ratio of at least about 100:

1.

170. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the fibers have an aspect ratio of at least about 250:

1.

171. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the fibers have an average length greater than about 3.5 min.

172. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein said inorganic aggregate filler is homogeneously dispersed throughout the cellular matrix.

173. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic aggregate filler includes calcium carbonate.

174. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic aggregate filler is selected from the group consisting of sand, gravel, rock, limestone, sandstone, glass beads, mica, clay, kaolin, synthetic clay, alumina silica, fly ash, fused silica, tabular alumina, microspheres, calcium sulfate dihydrate, calcium aluminate, hydrated hydraulic cement particles, and unhydrated hydraulic cement particles.

175. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, hollow glass spheres, areogels, xerogels, porous ceramic spheres, xonotlite, lightweight expanded clays, pumice, and exfoliated rock.

176. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic aggregate filler has a concentration in a range from about 20% to about 80% by weight of the cellular matrix.

177. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic filler has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

178. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the inorganic aggregate filler has a concentration in a range from about 40% to about 60% by weight of the cellular matrix.

179. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the cellular matrix further comprises a humectant.

180. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the article comprises a liquid-tight container.

181. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 158, wherein the article is in the shape of a clam-shell container.

182. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix comprising a starch-based binder and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average length greater than about 2 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by weight of the cellular matrix, the cellular matrix having an average density less than about 0.25 g/cm³.

183. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 182, wherein the article comprises a food or beverage container.

184. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 182, further comprising a coating on a surface of the article.

185. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 182, further comprising an aggregate filler.

186. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic aggregate filler includes calcium carbonate.

187. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic aggregate filler is selected from the group consisting of sand, gravel, rock, limestone, sandstone, glass beads, mica, clay, kaolin, synthetic clay, alumina silica, fly ash, fused silica, tabular alumina, microspheres, calcium sulfate dihydrate, calcium aluminate, hydrated hydraulic cement particles, and unhydrated hydraulic cement particles.

188. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, hollow glass spheres, areogels, xerogels, porous ceramic spheres, xonotlite, lightweight expanded clays, pumice, and exfoliated rock.

189. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic aggregate filler has a concentration in a range from about 20% to about 80% by weight of the cellular matrix.

190. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic filler has a concentration in a range from about 30% to about 70% by weight of the cellular matrix.

191. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 185, wherein the inorganic aggregate filler has a concentration in a range from about 40% to about 60% by weight of the cellular matrix.

192. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix comprising a starch-based binder, an aggregate filler, and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average length greater than about 2 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by weight of the cellular matrix, the cellular matrix including an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

193. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 192, further comprising a coating on a surface of the article.

194. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 193, wherein the coating comprises a wax.

195. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 193, wherein the coating comprises a polymeric material.

196. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix comprising a starch-based binder, an inorganic aggregate filler, and fibers substantially uniformly dispersed throughout the starch-bound cellular matrix, the fibers having an average length greater than about 2 mm, an average aspect ratio greater than about 25:

1, and a concentration in a range from about 2% to about 80% by weight of the cellular matrix, the inorganic aggregate filler having a concentration greater than about 20% by weight of the cellular matrix, the cellular matrix including an outer skin portion having a density and an interior foam portion having a density that is significantly lower than the density of the outer skin portion.

197. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 196, further comprising a coating on a surface of the article.

198. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 197, wherein the coating comprises a wax.

199. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 197, wherein the coating comprises a polymeric material.

200. An article of manufacture having a fiber-reinforced, starch-bound cellular matrix as defined in claim 196, wherein the article comprises a food or beverage container.