Process and apparatus for manufacturing biodegradable products

• US 6,251,318 B1
• Filed: 12/09/1997
• Issued: 06/26/2001
• Est. Priority Date: 03/31/1995
• Status: Expired due to Term

• Current Assignee: Vertis BV (Sopra Steria Group SA)
• Original Assignee: Vertis BV (Sopra Steria Group SA)
• Inventors: Arentsen, Johan Hendrik, Huisman, Jan Wietze
• Primary Examiner(s): Kuhns, Allan R.
• Application Number:
  US08/930,890
• Time in Patent Office: 1,295 Days
• Field of Search: 425/547, 425/461, 425/4.R, 425/549, 425/550, 425/4.C, 425/325, 425/463, 264/51, 264/53, 264/45.5
• US Class Current: 264/45.5
• 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: B29K 2003/00 Use of starch or derivatives as moulding material

Abstract

A method for manufacturing biodegradable products with a blown foamy structure, wherein a mass comprising at least natural polymers such as starch is passed under pressure into or through a mould and the mass is heated in the mould in a manner such as to give rise to at least cross-linking of natural polymers, while the mass prior to the introduction into the mould has a temperature which is below the gelatinization temperature and in the mould is brought at least to the baking temperature.

Claims

1. A method for manufacturing biodegradable products with a blown, foam structure, wherein a mass including natural polymers is passed under pressure into or through a mold and the mass is heated in the mold in a manner such as to give rise to at least cross-linking of natural polymers to form a dense outside layer of a relatively thin rigid skin having closed, small cells, and a relatively thick foam inside core with open, larger cells, wherein the mass, prior to the introduction into the mold, is kept at a temperature whereby ungelatinized natural polymers in the mass are not gelatinized prior to introduction of the mass into the mold, whereby the mass which is below the gelatinization temperature is brought in the mold to at least the baking temperature to bake the product in the mold and form said relatively rigid skin, and wherein a relatively hard biodegradable product is formed with a blown, foam structure.

2. The method according to claim 1, wherein said larger cells of the product substantially form a wall of natural polymers cross-linked during heating, and wherein the cell size of said larger cells across the wall thickness of each product decreases in an outward direction.

3. The method according to claim 1, wherein each product is formed with a number of sheet, bar or dish-shaped parts, each having in at least one direction a dimension that is relatively small with respect to the total dimension of the product.

4. The method according to claim 1, wherein the mass is introduced into the mold in a relatively dry condition.

5. The method according to claim 4, characterized in that the mass, prior to the introduction into the mold, is slightly prefoamed without this giving rise to gelatinization.

6. The method of claim 4 wherein the mass is in granulate form.

7. The method according to claim 1, wherein a blowing agent, is included in the mass.

8. The method of claim 7 wherein the blowing agent includes water.

9. The method according to claim 1, wherein the mold is an injection mould.

10. The method according to claim 1, characterized in that the mold is an extrusion die.

11. The method of claim 1 wherein the natural polymers are starches.

12. A method for manufacturing biodegradable products with a blown, foam structure, wherein a mass including natural polymers is passed under pressure into or through a mold and the mass is heated in the mold in a manner such as to give rise to at least cross-linking of natural polymers, wherein the mass is a liquid batter comprising a suspension or solution of at least the natural polymers in a liquid and, prior to the introduction into the mold, the mass is kept at a temperature whereby ungelatinized natural polymers in the mass are not gelatinized prior to introduction of the mass into the mold, whereby the mass which is below the gelatinization temperature is brought in the mold to at least the baking temperature, and wherein a biodegradable product is formed with a blown, foam structure.

13. The method according to claim 12, wherein a batter is used which consists substantially entirely of biodegradable constituents.

14. The method of claim 12 wherein the natural polymers are starches.

15. A method for manufacturing biodegradable products with a blown, foam structure, wherein a mass including natural polymers is passed under pressure into or through a mold, wherein the mass is a batter of at least water and starch, and wherein the mold is heated to a temperature of more than 130°

C., and wherein the mass is heated in the mold in a manner such as to give rise to at least cross-linking of natural polymers, and, prior to the introduction into the mold, the mass is kept at a temperature whereby ungelatinized natural polymers in the mass are not gelatinized prior to introduction of the mass into the mold, whereby the mass which is below the gelatinization temperature is brought in the mold to at least the baking temperature, and wherein a biodegradable product is formed with a blown, foam structure.

16. The method according to claim 15, wherein the mold is heated to a temperature between 150°

C. and 200°

C.

17. An apparatus for manufacturing biodegradable products from a mass, comprising:

a) a mold which contains at least one mold cavity;

b) a mass supply means for feeding said mass under pressure into the at least one mold cavity;

c) a mold heating means for baking said mass into a relatively hard product by heating said mold and said mass to a baking temperature;

d) a cooling means for keeping said supply means relatively cool with respect to said mold and for maintaining said mass disposed therein at least below the gelatinization temperature of said mass while said mold is at least said baking temperature of said mass; and

e) means for thermally separating said mold and said supply means to maintain said mass in said supply means below said gelatinization temperature while said mold is maintained at least said baking temperature of said mass.

18. The apparatus according to claim 17, wherein the supply means include pumping means.

19. The apparatus according to claim 17, wherein the heating means include channels in the mold or die for passing therethrough a heated fluid.

20. The apparatus of claim 19 wherein the heated fluid is at least one of steam and oil.

21. The apparatus according to claim 17, wherein the heating means comprise electric heating elements.

22. The apparatus of claim 21 wherein the heating means are at least one of heating coils and induction heating means.

23. An apparatus for manufacturing biodegradable products from a mass, comprising:

a) an extrusion die which comprises at least one extrusion orifice;

b) a mass supply means for feeding said mass under pressure into and through the at least one extrusion orifice;

c) a mold heating means for heating the die and baking said mass to form a product with a dense outside layer having a relatively thin rigid skin with closed, small cells, and a relatively thick foam inner core with open, larger cells; and

d) a cooling means for keeping the supply means relatively cool with respect to the die and for maintaining said mass disposed therein at least below the gelatinization temperature while said extrusion die is maintained at least said baking temperature of said mass.

24. The apparatus of claim 23 further comprising means for thermally separating the extrusion die and the supply means.