Methods of increasing formability of a palm sheath material, methods of producing a palm sheath-based product, and palm sheath foodware produced thereby

Abstract

Methods of increasing formability of a palm sheath material, methods of producing a palm sheath-based product, and palm sheath foodware produced thereby. The formability of a palm sheath material is increased by treating the palm sheath material with a fluid substance that weakens bonds between cellulose fibers of the palm sheath material by partially eliminating lignin and hemicellulose of the palm sheath material. The treated palm sheath material can be used to form various products, such as foodware products by deforming the treated palm sheath material into a shape. Advantageously, the treated palm sheath material can typically be deformed by stretching or punching using dies to a height to diameter aspect ratio of greater than 0.2 and/or to a limit strain of the palm sheath material greater than 0.38.

1 . A method of increasing formability of a palm sheath material, the method comprising treating the palm sheath material with a fluid substance that weakens bonds between cellulose fibers of the palm sheath material by partially eliminating lignin and hemicellulose of the palm sheath material without inducing large-scale structural damage that promotes fracture. 
     
     
         2 . The method of  claim 1 , wherein the fluid substance is chosen from the group consisting of ethylene glycol, hot water or boiling water, and aqueous solutions containing one or more hydroxides and/or sulfites. 
     
     
         3 . The method of  claim 2 , wherein the fluid substance contains at least one of sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, and ammonium hydroxide. 
     
     
         4 . The method of  claim 1 , wherein the fluid substance is an aqueous solution. 
     
     
         5 . The method of  claim 1 , wherein the fluid substance is an aqueous sodium hydroxide solution. 
     
     
         6 . The method of  claim 5 , wherein the aqueous sodium hydroxide solution has a NaOH concentration of about 2% to less than 10%. 
     
     
         7 . The method of  claim 5 , wherein the aqueous sodium hydroxide solution has a NaOH concentration of about 5%. 
     
     
         8 . The method of  claim 5 , wherein the palm sheath material is treated with the aqueous sodium hydroxide solution for a duration of not greater than twelve hours. 
     
     
         9 . The method of  claim 5 , wherein the palm sheath material is treated with the aqueous sodium hydroxide solution for a duration of greater than one hour and up to about six hours. 
     
     
         10 . The method of  claim 5 , wherein the aqueous sodium hydroxide solution has a NaOH concentration of about 5% and the palm sheath material is treated with the aqueous sodium hydroxide solution for a duration of about one to about six hours. 
     
     
         11 . The method of  claim 5 , wherein the aqueous sodium hydroxide solution has a NaOH concentration of about 5% and the palm sheath material is treated with the aqueous sodium hydroxide solution for a duration of about two to about six hours. 
     
     
         12 . The method of  claim 5 , wherein the aqueous sodium hydroxide solution consists of sodium hydroxide and water. 
     
     
         13 . The method of  claim 2 , wherein the fluid substance contains at least one of potassium sulfite, calcium sulfite, magnesium sulfite, and ammonium sulfite. 
     
     
         14 . The method of  claim 1 , wherein the fluid substance contains at least one of methanol, formic acid, acetic acid, chlorite, and tetrahydrofuran. 
     
     
         15 . The method of  claim 1 , wherein the palm sheath material is an areca palm sheath. 
     
     
         16 . The method of  claim 1 , wherein the palm sheath material is in a raw condition when treated with the fluid substance. 
     
     
         17 . A method of producing a palm sheath-based product, the method comprising:
 performing the method of  claim 1  on the palm sheath material to produce a treated palm sheath material; and   deforming the treated palm sheath material into a shape to produce a product.   
     
     
         18 . The method of  claim 17 , wherein the deforming step is accomplished by mechanical pressing, stretching, twisting, bending, punching, rolling, piercing, cutting, or some combination thereof. 
     
     
         19 . The method of  claim 17 , wherein the deforming step forms a limit strain that exceeds 0.38. 
     
     
         20 . The method of  claim 17 , further comprising:
 heating the product to preserve the shape by removing excess moisture without causing structural damage to the treated palm sheath material.   
     
     
         21 . The method of  claim 17 , wherein the deforming step is performed on the treated palm sheath material with dies. 
     
     
         22 . The method of  claim 21 , wherein the dies are heated to heat the product. 
     
     
         23 . A palm sheath foodware comprising a product produced in accordance with the method of  claim 17 , wherein the product comprises at least one of a cup, a bowl, a plate, a utensil, a tumbler, and packaging. 
     
     
         24 . The palm sheath foodware of  claim 23 , wherein the product has a height to diameter aspect ratio of greater than 0.2 and a limit strain of the palm sheath material greater than 0.38.