Molded starch-bound containers and other articles having natural and/or synthetic polymer coatings

• US 6,030,673 A
• Filed: 02/08/1999
• Issued: 02/29/2000
• Est. Priority Date: 11/25/1992
• Status: Expired due to Fees

• Current Assignee: Earthshell Spe, LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Andersen, Per Just, Hodson, Simon K.
• Primary Examiner(s): COPENHEAVER, BLAINE R
• Application Number:
  US09/246,163
• Time in Patent Office: 386 Days
• Field of Search: 428/310.5, 428/317.3, 428/317.9, 428/318.8, 428/319.1, 428/319.3, 428/319.7, 428/319.9, 428/36.4, 428/36.5, 428/913, 206/524.3, 206/524.7, 156/78, 427/316, 427/399
• 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: B05B 11/0037 Containers for several components B05B11/0078
• CPC Class Codes: B05B 11/0038 Inner container disposed in an outer shell or outer casing
• CPC Class Codes: B05B 11/10 Pump arrangements for transferring the contents from the container to a pump chamber by a sucking effect and forcing the contents out through the dispensing nozzle
• 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 2043/5841 : for accommodating variation in mould spacing or cavity volume during moulding
• 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 43/34 : 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 48/0011 : combined with compression moulding
• CPC Class Codes: B29C 48/0017 : combined with blow-moulding or thermoforming
• CPC Class Codes: B29C 48/03 : characterised by the shape of the extruded material at extrusion
• CPC Class Codes: B29C 48/15 : incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• 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 1/00 : Layered products having a non-planar shape
• CPC Class Codes: B32B 13/02 : with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2305/08 : Reinforcements
• CPC Class Codes: B32B 2305/30 : Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2305/70 : Scrap or recycled material
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2317/20 : Starch
• CPC Class Codes: B32B 2439/70 : Food packaging
• 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 7/02 : Portland cement
• 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 2999/00 : Subject-matter not otherwise provided for in this subclass
• CPC Class Codes: Y02A 40/90 : in food processing or handling, e.g. food conservation
• 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: Y10S 428/913 : Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/1348 : Cellular material derived from plant or animal source [e.g., wood, cotton, wool, leather, etc.]
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/1376 : Foam or porous material containing
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249961 : With gradual property change within a component
• CPC Class Codes: Y10T 428/249983 : As outermost component
• 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 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic

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.

Claims

1. An article of manufacture comprising:

a starch-bound cellular matrix formed by gelatinizing a starch-based binder in water and then causing the starch-based binder to substantially harden by removing a substantial portion of the water by evaporation to thereby form the starch-bound cellular matrix, wherein the starch-bound 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, the starch-bound cellular matrix further including optional components dispersed therein; and

a coating applied to at least a portion of the outer skin portion of the starch-bound cellular matrix selected from the group consisting of edible oils, drying oils, melamine, phenolic resins, polyester resins, epoxy resins, terpene resins, urea-formaldehyde reins, styrene polymers, polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, polyacrylates, polyamides, hydroxypropylmethylcellulose, methocel, polyethylene glycol, acrylics, acrylic copolymers, polyurethane, polylactic acid, polyhydroxybutyrate-hydroxyvalerate copolymers, starches, soybean protein, waxes, and mixtures thereof.

2. An article of manufacture as defined in claim 1, wherein the starch-based binder comprises a starch selected from the group consisting of potato starch, corn starch, waxy corn starch, rice starch, wheat starch, starches derived from cereals, tubers, and roots, and mixtures thereof.

3. An article of manufacture as defined in claim 1, wherein the starch-based binder is included in an amount in a range from about 10% to about 80% by weight of total solids in the starch-bound cellular matrix.

4. An article of manufacture as defined in claim 1, wherein the starch-based binder is included in an amount in a range from about 30% to about 70% by weight of total solids in the starch-bound cellular matrix.

5. An article of manufacture as defined in claim 1, wherein the starch-based binder is included in an amount in a range from about 40% to about 60% by weight of total solids in the starch-bound cellular matrix.

6. An article of manufacture as defined in claim 1, further including an inorganic aggregate filler substantially homogeneously dispersed throughout the starch-bound cellular matrix.

7. An article of manufacture as defined in claim 6, wherein the inorganic aggregate filler comprises calcium carbonate.

8. An article of manufacture as defined in claim 6, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, sand, crushed sandstone, crushed limestone, glass beads, hollow glass spheres, mica, clay, kaolin, crushed rock, exfoliated rock, and mixtures thereof.

9. An article of manufacture as defined in claim 6, wherein the inorganic aggregate filler is included in an amount in a range from about 20% to about 90% by weight of total solids in the starch-bound cellular matrix.

10. An article of manufacture as defined in claim 6, wherein the inorganic aggregate filler is included in an amount in a range from about 30% to about 70% by weight of total solids in the starch-bound cellular matrix.

11. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes a mold-release agent.

12. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes fibers substantially homogeneously dispersed throughout the starch-bound cellular matrix.

13. An article of manufacture as defined in claim 12, wherein the fibers are selected from the group consisting of sisal, hemp, cotton, plant, leaf, abaca, bagasse, wood, graphite, silica, ceramic, and metal fibers, and mixtures thereof.

14. An article of manufacture as defined in claim 12, wherein a portion of the starch-based binder includes pregelatinized or modified starch.

15. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes a natural polymer selected from the group consisting of alginic acid, phycocolloids, agar, gum arabic, guar gum, locust bean gum, gum karaya, gum tragacanth, cellulose-based materials, protein-based materials, and mixtures thereof.

16. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes a synthetic polymer selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, polyacrylic acid, polylactic acid, and mixtures thereof.

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

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

19. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix is in the form of a container selected from the group consisting of cups, plates, clam-shell boxes, food trays, and bowls.

20. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix has a thickness up to about 10 cm.

21. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix has a thickness in a range from about 1 mm to about 1 cm.

22. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix has a thickness in a range from about 2 mm to about 5 mm.

23. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes a plasticizer.

24. An article of manufacture as defined in claim 23, wherein the plasticizer is selected from the group consisting of glycerin, monoglycerides, diglycerides, polyethylene glycol, sorbitol, and mixtures thereof.

25. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix further includes an organic particulate filler.

26. An article of manufacture as defined in claim 1, wherein the coating is applied to the outer skin portion of the starch-bound cellular as a liquid which subsequently hardens to form a liquid-tight barrier.

27. An article of manufacture as defined in claim 1, further including an additional coating applied to the outer skin portion of the starch-bound cellular matrix selected from the group consisting of other cellulosic ethers, cellulose acetate, other cellulose-based materials, polyethylene, mixtures of the foregoing, and derivatives of the foregoing.

28. An article of manufacture as defined in claim 1, wherein the coating further includes an inorganic coating material dispersed therein.

29. An article of manufacture as defined in claim 1, further including an inorganic coating material applied to the outer skin portion of the starch-bound cellular matrix selected from the group consisting of sodium silicate, calcium carbonate, aluminum oxide, silicon oxide, kaolin, clay, ceramics, and mixtures thereof.

30. An article of manufacture as defined in claim 1, wherein the coating is applied to the outer skin portion of the starch-bound cellular matrix as a laminating material.

31. An article of manufacture as defined in claim 30, wherein the laminating material is applied in the form of a substantially uniform film.

32. An article of manufacture as defined in claim 30, wherein the laminating material is applied in the form of a sheet.

33. An article of manufacture as defined in claim 30, wherein the laminating material is selected from the group consisting of polylactic acid, polyhydroxybutylate-hydroxyvalerate copolymer, other polyesters, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyamides, melamine, hydroxypropylmethylcellulose, methylcellulose, and mixtures of the foregoing.

34. An article of manufacture as defined in claim 1, wherein the coating is utilized as an adhesive.

35. An article of manufacture as defined in claim 1, wherein the starch-bound cellular matrix degrades after prolonged exposure to water.

36. An article of manufacture comprising:

a starch-bound cellular matrix formed by gelatinizing a starch-based binder in water and then causing the starch-based binder to substantially harden by removing a substantial portion of the water by evaporation to thereby forming the starch-bound cellular matrix, wherein the starch-bound cellular matrix further includes optional components dispersed therein, has a thickness less than about 1 cm, and degrades after prolonged exposure to water; and

a coating applied to at least a portion of the starch-bound cellular matrix, wherein the coating comprises a biodegradable polymer selected from the group consisting of biodegradable polyamides, polyvinyl acetate, polyvinyl alcohol, starches, polylactic acid, polyhydroxybutyrate-hydroxyvalerate copolymer, other biodegradable polyesters, hydroxypropylmethylcellulose, methocel, soybean protein, and mixtures thereof.

37. An article of manufacture as defined in claim 36, wherein the starch-bound 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.

38. An article of manufacture as defined in claim 36, wherein the coating is applied to the starch-bound cellular as a liquid which subsequently hardens to form a substantially solidified coating.

39. An article of manufacture as defined in claim 36, wherein the coating is applied to the starch-bound cellular as a laminating material.

40. An article of manufacture as defined in claim 36, wherein the coating is applied to the starch-bound cellular as an adhesive.

41. An article of manufacture as defined in claim 36, further including an additional coating applied to the outer skin portion of the starch-bound cellular matrix selected from the group consisting of other cellulosic ethers, cellulose acetate, other biodegradable cellulose-based polymer materials, other biodegradable polymers, polyethylene, waxes, derivatives of the foregoing, and mixtures of the foregoing.

42. A method for manufacturing articles of manufacture having a starch-bound cellular matrix comprising:

heating an aqueous starch-based mixture including starch and water in order to first gelatinize the starch and then cause it to substantially solidify as a result of evaporation of water therefrom to thereby form the starch-bound cellular matrix in a desired shape of the article of manufacture; and

applying a laminate film coating to at least a portion of the starch-bound cellular matrix.

43. A method as defined in claim 42, wherein the laminate film coating is a film or sheet comprising a plastic or elastomer selected from the group consisting of polylactic acid, polyhydroxybutyrate-hydroxyvalerate copolymer, other biodegradable polyesters, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyamides, melamine, cellulosic others, cellulose acetate, other cellulosic polymers, starches, other biodegradable polymers, polyethylene, and mixtures of the foregoing.

44. A method as defined in claim 42, further including an inorganic filler dispersed within the laminating film.

45. A method as defined in claim 42, wherein the starch-based mixture further includes fibers dispersed therein.

46. A method as defined in claim 42, wherein the starch-based mixture further includes an inorganic filler dispersed therein.

47. A method as defined in claim 42, wherein the starch-bound cellular matrix has a thickness of less than about 5 mm.

48. A method as defined in claim 42, wherein the starch-bound cellular matrix includes an outer skin portion having a density and an interior foam portion having a density that is significantly less than the density of the outer skin portion.

49. A method for manufacturing articles of manufacture having a starch-bound cellular matrix comprising:

heating an aqueous starch-based mixture including starch and water in order to first gelatinize the starch and then cause it to substantially solidify as a result of evaporation of water therefrom to thereby form the starch-bound cellular matrix in a desired shape of the article of manufacture; and

applying a coating to at least a portion of the starch-bound cellular matrix selected from the group consisting of edible oils, drying oils, melamine, phenolic resins, polyester resins, epoxy resins, terpene resins, urea-formaldehyde resins, styrene polymers, polyethylene, polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, polyacrylates, polyamides, hydroxypropylmethylcellulose, methocel, poyethylene glycol, acrylics, acrylic copolymers, polyurethane, polylactic acid, polyhydroxybutyrate-hydroxyvalerate copolymers, starches, soybean protein, waxes, and mixtures thereof.

50. A method as defined in claim 49, wherein the coating further includes an inorganic filler dispersed therein.

51. A method as defined in claim 49, wherein the starch-based mixture further includes an inorganic filler.

52. A method as defined in claim 49, wherein the starch-based mixture further includes fibers dispersed therein.

53. A method as defined in claim 49, wherein the coating is applied as a laminate film.