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Methods for manufacturing molded sheets having a high starch content

  • US 5,810,961 A
  • Filed: 04/09/1996
  • Issued: 09/22/1998
  • Est. Priority Date: 11/19/1993
  • Status: Expired due to Fees
First Claim
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1. A method for manufacturing a starch-bound sheet comprising the steps of:

  • (a) mixing together water, substantially ungelatinized starch granules, a cellulosic ether, a fibrous material, and optionally an inorganic aggregate filler to form a moldable mixture;

    (b) forming the moldable mixture into an initial green sheet by passing the mixture between at least one set of forming rollers having a temperature such that at least a portion of the cellulosic ether forms a skin on outer surfaces of the initial green sheet such that the initial green sheet does not substantially adhere to the forming rollers upon gelatinization of the starch granules;

    (c) passing the initial green sheet between at least one set of rollers having a temperature such that at least a portion of the starch granules become substantially gelatinized in order to form an intermediate green sheet; and

    (d) heating the intermediate green sheet in order to remove a substantial portion of the water from the intermediate green sheet so as to form a substantially hardened sheet having a binding matrix including substantially dried starch and cellulosic ether.

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