Compositions and methods for manufacturing starch-based compositions

• US 6,168,857 B1
• Filed: 10/30/1998
• Issued: 01/02/2001
• Est. Priority Date: 04/09/1996
• Status: Expired due to Fees

• Current Assignee: E. Khashoggi Industries, LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Christensen, Bruce J., Ong, Shaode, Andersen, Per Just, Hodson, Simon K.
• Primary Examiner(s): COPENHEAVER, BLAINE R
• Application Number:
  US09/183,895
• Time in Patent Office: 795 Days
• Field of Search: 428/36.4, 428/36.5, 428/36.92, 428/43, 428/152, 428/182, 428/297.4, 428/532, 428/906, 428/220, 428/292.1, 428/300.7
• US Class Current: 428/292.1
• CPC Class Codes: B05B 1/34 designed to influence the nature of flow of the liquid or other fluent material, e.g. to produce swirl designed to control volume of flow B05B1/30
• CPC Class Codes: B05B 11/0037 Containers for several components B05B11/0078
• 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 23/0081 Embedding aggregates to obtain particular properties
• 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: 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 43/22 of articles of indefinite length
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/24 Calendering
• 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 51/002 characterised by the choice of material
• CPC Class Codes: B29C 55/18 by squeezing between surfaces, e.g. rollers
• 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 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: B32B 13/02 : with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 23/12 : next to a particulate 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 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 9/00 : Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
• 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: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00948 : for the fabrication of containers
• CPC Class Codes: C04B 24/14 : Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/26 : obtained by reactions only involving carbon-to-carbon unsaturated bonds 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 26/28 : Polysaccharides or derivatives thereof
• CPC Class Codes: C04B 40/0071 : making use of a rise in pressure
• CPC Class Codes: C04B 40/0082 : making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: C04B 40/0092 : Temporary binders, mortars or concrete, i.e. materials intended to be destroyed or removed after hardening, e.g. by acid dissolution
• CPC Class Codes: C08J 2303/02 : Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C08J 2323/02 : not modified by chemical after treatment
• CPC Class Codes: C08J 5/18 : Manufacture of films or sheets
• CPC Class Codes: C08L 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 3/02 : Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: Y02W 90/10 : Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics
• CPC Class Codes: Y10S 428/906 : Roll or coil
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate

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, an auxiliary water-dispersible organic polymer, 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 auxiliary polymer 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 auxiliary polymer 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.

Claims

1. A starch-bound sheet having a thickness less than about 1 cm and a density greater than about 0.5 g/cm³ and comprising:

(a) a binding matrix including starch and an auxiliary water-dispersible organic polymer, wherein the starch has a concentration greater than about 5% by weight of total solids in the sheet;

(b) fibers substantially homogeneously dispersed throughout the starch-bound sheet; and

(c) an inorganic mineral filler included in a range from 0% to about 90% by weight of total solids in the sheet.

2. A sheet as defined in claim 1, wherein the starch has a concentration in a range from about 15% to about 75% by weight of total solids in the sheet.

3. A sheet as defined in claim 1, wherein the starch has a concentration in a range from about 30% to about 70% by weight of total solids in the sheet.

4. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer has a concentration less than about 70% by weight of solids in the sheet.

5. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer has a concentration in a range from about 0.1% to about 50% by weight of total solids in the sheet.

6. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer has a concentration in a range from about 0.5% to about 30% by weight of total solids in the sheet.

7. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer has a concentration in a range from about 1% to about 10% by weight of total solids in the sheet.

8. A sheet as defined in claim 1, wherein the starch has a gelation temperature and wherein the auxiliary water-dispersible organic polymer has a thermal precipitation temperature such that the gelation temperature of the starch is greater than the thermal precipitation temperature of the auxiliary water-dispersible organic polymer.

9. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer comprises a cellulose-based material.

10. A sheet as defined in claim 9, wherein the cellulose-based material comprises a cellulosic ether.

11. A sheet as defined in claim 10, wherein the cellulosic ether is selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethylpropylcellulose, hydroxypropylcellulose, and mixtures or derivatives thereof.

12. A sheet as defined in claim 9, wherein the cellulose-based material comprises a cellulose ester.

13. A sheet as defined in claim 12, wherein the cellulose ester is selected from the group consisting of cellulose formate, cellulose acetate, cellulose diacetate, cellulose propionate, cellulose dipropionate, cellulose butyrate, cellulose dibutyrate, cellulose valerate, esters of fatty acids and cellulose, cellulose sulfonate, cellulose benzoate, and mixtures or derivatives thereof.

14. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer comprises a polysaccharide material.

15. A sheet as defined in claim 14, wherein the polysaccharide material is selected from the group consisting of alginic acid, alginates, phycocolloids, agar, gum arabic, acacia gum, guar gum, carrageenan gum, furcellaran gum, locust bean gum, ghatti gum, psyllium gum, gum karaya, xanthan gum, quince gum, tamarind gum, okra derivatives, gum tragacanth, and mixtures or derivatives thereof.

16. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer comprises a protein-based material.

17. A sheet as defined in claim 16, wherein the protein-based material is selected from the group consisting of prolamines, collagen, casein, grafted proteins, and mixtures or derivatives thereof.

18. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer comprises a synthetic organic polymer.

19. A sheet as defined in claim 18, wherein the synthetic organic polymer is selected from the group consisting of polyvinyl acrylic acids, polyvinyl acrylic acid salts, polyvinylalcohol, polyvinylpyrrolidone, polyacrylamide, polyacrylic acids, polyacrylic acid salts, ethylene oxide polymers, polylactic acid, water-dispersible latexes, polyalkoxyalkylmethacrylates, polyvinylmethyl ether, polyvinylmethylether:

maleic anhydride, polyether polyols, and mixtures and derivatives thereof.

20. A sheet as defined in claim 18, wherein the synthetic organic polymer is selected from the group consisting of poly(ethylene oxide)akylphenyl ethers, polyethylene oxidelauryl, cetyl ethers, oleyl ethers, polyethylene oxide laurate, poly (ethylene oxide) oleate, sorbitan oleate, ethylene oxide/propylene oxide block copolymers, organic phosphate esters, and mixtures and derivatives thereof.

21. A sheet as defined in claim 18, wherein the synthetic organic polymer is selected from the group consisting of polydiethylene glycol methyl ether, polyproplyene glycol N-propyl ether, polydiproplyene glycol methyl ether, polyproplyene glycol methyl ether, polytriproplyene glycol methyl ether, polydiethylene glycol N-butyl ether, polyethylene glycol N-butyl ether, polydiproplyene glycol N-propylether, polyglycoldiether, and mixtures or derivatives thereof.

22. A sheet as defined in claim 1, wherein the auxiliary water-dispersible organic polymer comprises a starch derivative.

23. A sheet as defined in claim 22, wherein the starch derivative comprises a copolymer of starch and a synthetic polymer.

24. A sheet as defined in claim 1, wherein the inorganic mineral filler has a concentration in a range from about 10% to about 80% by weight of total solids in the sheet.

25. A sheet as defined in claim 1, wherein the inorganic mineral filler has a concentration in a range from about 20% to about 70% by weight of total solids in the sheet.

26. A sheet as defined in claim 1, wherein the inorganic mineral filler has a concentration in a range from about 30% to about 60% by weight of total solids in the sheet.

27. A sheet as defined in claim 1, wherein the inorganic mineral filler has a particle packing density in a range from about 0.65 to about 0.90.

28. A sheet as defined in claim 1, wherein the fibers have a concentration in a range from about 1% to about 50% by weight of total solids in the sheet.

29. A sheet as defined in claim 1, wherein the fibers have a concentration in a range from about 3% to about 30% by weight of total solids in the sheet.

30. A sheet as defined in claim 1, wherein the fibers have a concentration in a range from about 5% to about 20% by weight of total solids in the sheet.

31. A sheet as defined in claim 1, wherein the sheet has a thickness less than about 3 mm.

32. A sheet as defined in claim 1, wherein the sheet has a thickness less than about 1 mm.

33. A sheet as defined in claim 1, wherein the sheet comprises a film having a thickness less than about 0.1 mm.

34. A sheet as defined in claim 1, wherein the sheet has a density greater than about 1 g/cm³.

35. A sheet as defined in claim 1, wherein the sheet further includes a coating.

36. A sheet as defined in claim 1, wherein the sheet further includes at least one other sheet laminated thereto.

37. A sheet as defined in claim 1, wherein the sheet has been fashioned into a container.

38. A sheet as defined in claim 1, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.

39. A sheet as defined in claim 1, wherein the fibers have a length greater than about 1.5 mm and an aspect ratio greater than about 10:

1.

40. A sheet as defined in claim 1, wherein the fibers have a length in a range from about 0.3 mm to about about 1.5 mm and an aspect ratio greater than about 100:

1.

41. A sheet as defined in claim 1, further including a plasticizer.

42. A sheet as defined in claim 41, wherein the plasticizer is selected from the group consisting of polyethylene glycol, polypropylene glycol, glycerin, polyglycerine, sorbitol, mannitol, erythritol, xylitol, and mixtures thereof.

43. An inorganically filled starch-bound sheet having a thickness less than about 1 cm and comprising:

(a) a binding matrix including starch and an auxiliary water-dispersible organic polymer, wherein the starch has a concentration greater than about 5% by weight of solids in the sheet;

(b) fibers included in an amount in a range from about 1% to about 50% by weight of solids in the sheet, being substantially homogeneously dispersed throughout the binding matrix, having an average length greater than about 1.5 mm and having an average aspect ratio greater than about 10;

1; and

(c) an inorganic mineral filler included in an amount greater than about 10% by weight of solids in the sheet.

44. An inorganically filled starch-bound sheet having a thickness less than about 1 cm and comprising:

(a) a binding matrix including starch and an auxiliary water-dispersible organic polymer, wherein the binding matrix has a concentration of at least about 20% by weight of solids in the sheet;

(b) optionally fibers substantially homogeneously dispersed throughout the binding matrix and having an aspect ratio greater than about 10;

1; and

(c) an inorganic mineral filler included an amount greater than about 20% by weight of solids in the sheet.

45. A starch-bound sheet formed by passing a starch-based composition between at least one set of heated forming 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 composition comprising:

(a) water;

(b) substantially ungelatinized starch granules having a concentration greater than about 5% by weight of total solids in the starch-based composition, the starch granules having a gelation temperature;

(c) an auxiliary water-dispersible organic polymer having a thermal precipitation temperature that is less than the gelation temperature of the starch granules;

(d) an inorganic mineral filler having a concentration in a range from about 0% to about 90% by weight of total solids in the starch-based composition; and

(e) fibers substantially homogeneously dispersed throughout the starch-based composition.

46. A starch-bound sheet as defined in claim 45, wherein at least a portion of the ungelatinized starch granules in the starch-based composition become at least partially gelatinized upon formation of the starch-bound sheet.

47. A starch-bound sheet as defined in claim 45, wherein the auxiliary water-dispersible organic polymer reduces adhesion between the starch-based composition and the heated forming rollers during formation of the starch-bound sheet.

48. A starch-bound sheet as defined in claim 45, wherein the sheet has a thickness of less than about 3 mm.

49. A starch-bound sheet as defined in claim 45, wherein the sheet has a thickness of less than about 1 mm.

50. A starch-bound sheet as defined in claim 45, wherein the sheet comprises a film having a thickness of less than about 0.1 mm.

51. A starch-bound sheet as defined in claim 45, wherein the sheet has a density greater than about 1 g/cm³.

52. A starch-bound sheet as defined in claim 45, wherein the sheet further includes a coating on at least a portion thereof.

53. A starch-bound sheet as defined in claim 45, wherein the sheet further includes at least one other sheet laminated thereto.

54. A starch-bound sheet as defined in claim 53, wherein the at least one other sheet is selected from the group consisting of starch-bound sheets, organic polymer sheets, metal foil sheets, ionomer sheets, elastomeric sheets, plastic sheets, fibrous sheets, mats, paper sheets, cellophane sheets, nylon sheets, wax sheets, hydraulically settable sheets, highly inorganically filled sheets, metallized film sheets and combinations thereof.

55. A starch-bound sheet as defined in claim 45, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.

56. A starch-bound sheet as defined in claim 45, wherein the fibers have a concentration in a range from about 1% to about 50% by weight of total solids in the starch-based composition.

57. An inorganically filled starch-bound sheet formed bypassing a starch-based composition between at least one set of heated rollers, the starch-bound sheet having a thickness less than about 1 cm, the starch-based composition comprising:

(a) water;

(b) substantially ungelatinized starch granules having a gelation temperature;

(c) an auxiliary water-dispersible organic polymer having a thermal precipitation temperature that is less than the gelation temperature of the substantially ungelatinized starch granules, wherein the substantially ungelatinized starch granules and auxiliary water-dispersible organic polymer have a combined concentration greater than about 20% by weight of total solids in the starch-based composition;

(d) an inorganic mineral filler having a concentration greater than about 20% by weight of total solids in the starch-based composition; and

(e) optionally fibers substantially homogeneously dispersed throughout the starch-based composition.

58. 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, the starch-based composition comprising:

(a) water;

(b) substantially ungelatinized starch granules having a concentration greater than about 5% by weight of total solids in the starch-based composition and having a gelation temperature;

(c) an auxiliary water-dispersible organic polymer having a thermal precipitation temperature that is less than the gelation temperature of the substantially ungelatinized starch granules;

(d) an inorganic mineral filler having a concentration greater than about 10% by weight of total solids in the starch-based composition; and

(e) fibers included in an amount in a range from about 1% to about 50% by weight of total solids in the starch-based composition, wherein the fibers are substantially homogeneously dispersed throughout the starch-based composition, have an average length greater than about 1.5 mm, and have an average aspect ratio greater than about 10;

1.

59. A starch-bound sheet formed by a process comprising the steps of:

(a) providing a starch-based mixture including water, substantially ungelatinized starch granules, fibers, optionally an inorganic mineral filler, and an auxiliary water-dispersible organic polymer that is capable of reducing adhesion between the starch-based mixture and heated forming rollers upon gelatinization of the starch granules;

(b) forming the starch-based mixture into an initial green sheet by passing the mixture between at least one set of heated forming rollers having a temperature such that a portion of the auxiliary water-dispersible organic polymer forms a layer of reduced adhesion on the outer surfaces of the initial green sheet in order to prevent substantially adhesion of the starch-based mixture to the forming rollers upon gelatinization of the starch granules;

(c) heating the initial green sheet to cause at least a portion of the starch granules to become substantially gelatinized in order to form an intermediate green sheet; and

(d) removing at least a portion of the water from the intermediate green sheet by evaporation so as to form a substantially hardened starch-bound sheet having a binding matrix that includes a mixture of substantially dried starch and auxiliary water-dispersible organic polymer, wherein the starch-bound sheet has a thickness less than about 1 cm and a density greater than about 0.5 g/cm³, wherein the substantially dried starch has a concentration greater than about 5% by weight of total solids in the starch-bound sheet wherein the fibers are substantially homogeneously dispersed throughout the starch-bound sheet, and wherein the inorganic mineral filler has a concentration in a range from about 0% to about 90% by weight of total solids in the sheet.