Compositions having a high ungelatinized starch content and sheets molded therefrom
First Claim
1. A starch-bound sheet comprising:
- (a) a binding matrix including starch and a cellulosic ether, the starch having a concentration in a range from about 5% to about 90% by weight of solids in the sheet, the cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of solids in the sheet;
(b) fibers substantially homogeneously dispersed throughout the binding matrix and having a concentration in a range from about 3% to about 40% by weight of solids in the sheet; and
(c) an inorganic mineral filler included in a range from about 0% to about 90% by weight of solids in the sheet, the starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm3.
2 Assignments
0 Petitions
Accused Products
Abstract
Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, a cellulosic ether, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the cellulosic ether to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation. The starch and cellulosic ether form the binding matrix of the sheets with the fibers and optional inorganic filler dispersed throughout the binding matrix. The starch-bound sheets can be cut, rolled, pressed, scored, perforated, folded, and glued to fashion articles from the sheets much like paper or paperboard. The sheets are particularly useful in the mass production of containers, such as food and beverage containers.
332 Citations
86 Claims
-
1. A starch-bound sheet comprising:
-
(a) a binding matrix including starch and a cellulosic ether, the starch having a concentration in a range from about 5% to about 90% by weight of solids in the sheet, the cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of solids in the sheet; (b) fibers substantially homogeneously dispersed throughout the binding matrix and having a concentration in a range from about 3% to about 40% by weight of solids in the sheet; and (c) an inorganic mineral filler included in a range from about 0% to about 90% by weight of solids in the sheet, the starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm3. - 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. An inorganically filled starch-bound sheet comprising:
-
(a) a binding matrix including starch and a cellulosic ether, the starch having a concentration in a range from about 5% to about 75% weight of solids in the sheet, the cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of solids in the sheet; (b) fibers substantially homogeneously dispersed throughout the binding matrix and having a concentration in a range from about 3% to about 40% by weight of solids in the sheet; and (c) an inorganic mineral filler included in a range from about 20% to about 90% by weight of solids in the sheet, the starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm3. - View Dependent Claims (52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72)
-
-
73. A starch-bound sheet formed by passing a starch-based composition between at least one set of heated rollers, the starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm3, the starch-based mixture comprising:
-
(a) water; (b) ungelatinized starch granules having a concentration in a range from about 5% to about 90% by weight of total solids in the starch-based composition; (c) a cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of total solids in the starch-based composition; (d) an inorganic mineral filler having a concentration in a range from about 0% to about 90% by weight of solids in the starch-based composition; and (e) fibers having a concentration in a range from about 3% to about 40% by weight of total solids in the starch-based composition. - View Dependent Claims (74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85)
-
-
86. An inorganically filled starch-bound sheet formed by passing a starch-based composition between at least one set of heated rollers, the starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm3, the starch-based mixture comprising:
-
(a) water; (b) ungelatinized starch granules having a concentration in a range from about 5% to about 75% by weight of total solids in the starch-based composition; (c) a cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of total solids in the starch-based composition; (d) an inorganic mineral filler having a concentration in a range from about 20% to about 90% by weight of solids in the starch-based composition; and (e) fibers having a concentration in a range from about 3% to about 40% by weight of total solids in the starch-based composition.
-
Specification