Compositions for manufacturing fiber-reinforced, starch-bound articles having a foamed cellular matrix

Abstract

Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a fiber-reinforced, starch-bound cellular matrix. Suitable mixtures used to form the articles are prepared by first preparing a viscous preblended mixture comprising water, a gelatinized starch-based binder, and fibers having an average length greater than about 2 mm. The highly viscous preblended mixture effectively transfers the shearing forces of the mixer to the fibers. The final moldable mixture is then prepared by mixing into the preblended mixture the remaining starch-based binder, water, and other desired admixtures, e.g., mold-releasing agents, inorganic filler rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The moldable mixtures are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled foamed structural matrix. 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-based materials and have especial utility in the mass-production of containers, particularly food and beverage containers.

1. A starch-based composition for molding into an article having a starch-bound cellular matrix, the starch-based composition comprising water, a starch-based binder in a concentration greater than about 20% by weight of the starch-based composition, and a fibrous material having an average fiber length greater than about 2 mm and an aspect ratio greater than about 10:1, wherein the fibers are substantially homogeneously dispersed throughout the starch-based compositions, wherein the starch-based binder includes a substantially ungelatinized component comprising unmodified starch granules in an amount in a range from about 50% to about 90% by weight of the starch-based binder and a substantially gelatinized component comprising gelatinized starch in an amount in a range from about 10% to about 50% by weight of the starch-based binder prior to molding the composition into the article. 
     
     
       2. A composition as defined in  claim 1 , wherein the starch-based binder includes a potato starch or a waxy corn starch. 
     
     
       3. A composition as defined in  claim 1 , wherein the starch-based binder includes a plurality of different kinds of starches. 
     
     
       4. A composition as defined in  claim 1 , wherein the starch-based binder is included in an mount in a range from about 20% to about 80% by weight of total solids. 
     
     
       5. A composition 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 the total solids. 
     
     
       6. A composition as defined in  claim 1 , wherein the fibrous material is selected from the group consisting of natural cellulose fibers, glass fibers, synthetic polymer fibers, and mixtures thereof. 
     
     
       7. A composition as defined in  claim 1 , wherein the fibers have an average diameter in a range from about 10 μm to about 50 μm. 
     
     
       8. A composition as defined in  claim 1 , wherein the fibrous material is included in an amount in a range from about 1% to about 20% by weight of total solids. 
     
     
       9. A composition as defined in  claim 1 , further including an inorganic aggregate selected from the group consisting of calcium carbonate, perlite, zeolites, vermiculite, sandstone, glass beads, aerogel, mica, clay, kaolin, gravel, exfoliated rock, derivatives thereof, and mixtures thereof. 
     
     
       10. A composition as defined in  claim 9 , wherein the inorganic aggregate is included in an mount in a range from about 20% to about 80% by weight of the starch-based composition. 
     
     
       11. A composition as defined in  claim 9 , wherein the inorganic aggregate includes individual particles having a plurality of different sizes. 
     
     
       12. A composition as defined in  claim 11 , wherein the sizes of the individual particles are selected to maximize the natural packing density of the inorganic aggregate within the starch-based composition. 
     
     
       13. A composition as defined in  claim 12 , wherein the sizes of the individual particles are selected so that the natural packing density of the inorganic aggregate is in a range from about 0.5 to about 0.9. 
     
     
       14. A composition as defined in  claim 9 , wherein the inorganic aggregate has a specific surface area in a range from about 0.1 m 2 /g to about 50 m 2 /g. 
     
     
       15. A composition ad defined in  claim 9 , wherein the inorganic aggregate has a specific surface area in a range from about 0.2 m 2 /g to about 2 m 2 /g. 
     
     
       16. A composition as defined in  claim 9 , wherein the inorganic aggregate is included in an amount sufficient to yield an article having a specific heat in a range from about 0.1 J/g·K to about 400 J/g·K at 20° C. 
     
     
       17. A composition as defined in  claim 1 , wherein the water has a concentration in a range from about 15% to about 80% by weight. 
     
     
       18. A composition as defined in  claim 1 , having a viscosity greater than about 10 Pa·s measured at a shear rate of 1 s −1 . 
     
     
       19. A composition as defined in  claim 1 , having a viscosity in a range from about 50 to about 100 Pa·s measured at a shear rate of 1 s −1 . 
     
     
       20. A composition as defined in  claim 1 , having a viscosity in a range from about 200 to about 500 Pa·s measured at a shear rate of 1 s −1 .  
     
     
       21. A composition as defined in  claim 1 , wherein the average fiber length is greater than about 4 mm. 
     
     
       22. A composition as defined in  claim 1 , wherein the average fiber length is greater than about 8 mm. 
     
     
       23. An inorganically filled starch-based composition for molding into an article, the composition comprising:
 (a) a starch-based binder in a concentration greater than about 20% by weight of the starch-based composition, the starch-based binder including a substantially ungelatinized component comprising unmodified starch granules in an amount in a range from about 50% to about 90% by weight of the starch-based binder and a substantially gelatinized component comprising gelatinized starch in an amount in a range from about 10% to about 50% by weight of the starch-based binder prior to molding the composition into the article;    (b) fibers in a concentration greater than about 1% by weight of the starch-based composition and having an average fiber length greater than about 2 mm and an aspect ratio greater than about 10:1, wherein the fibers are substantially homogeneously dispersed throughout the starch-based composition; and    (c) an inorganic aggregate in a concentration greater than about 5% by weight of the starch-based composition.    
     
     
       24. An inorganically filled starch-based composition as defined in  claim 23 , wherein the fibers have a concentration greater than about 5% by weight of the starch-based composition. 
     
     
       25. An inorganically filled starch-based composition as defined in  claim 23 , wherein the fibers have a concentration greater than about 10% by weight of the starch-based composition. 
     
     
       26. An inorganically filled starch-based composition as defined in  claim 23 , wherein the average fiber length is greater than about 4 mm. 
     
     
       27. An inorganically filled starch-based composition as defined in  claim 23 , wherein the average fiber length is greater than about 8 mm. 
     
     
       28. An inorganically filled starch-based composition as defined in  claim 23 , wherein the inorganic aggregate is included in an amount greater than about 15% by weight of the starch-based composition. 
     
     
       29. An inorganically filled starch-based composition as defined in  claim 23 , wherein the inorganic aggregate is included in an amount greater than about 30% by weight of the starch-based composition. 
     
     
       30. A starch-based composition for forming an article of manufacture having a foamed structural matrix, the composition comprising:
 (a) a starch-based binder having a concentration of about 20% to about 80% by weight of solids within the starch-based composition;    (b) an inorganic aggregate having a concentration of about 0% to about 80% by weight of solids within the starch-based composition;    (c) a fibrous material having a concentration of about 2% to about 50% by weight of solids within the starch-based composition, said fibrous material having an average fiber length greater than about 2 mm and being substantially uniformly dispersed throughout the starch-based composition; and    (d) water having a concentration of about 15% to about 80% by weight of the starch-based composition;    wherein the starch-based binder includes a gelatinized component comprising gelatinized starch in an amount from about 5% to about 70% by weight of the starch-based binder, and wherein the balance of the starch-based binder comprises an ungelatinized component comprising ungelatinized, unmodified starch granules prior to forming the composition into an article, wherein said gelatinized component aids in the dispersion of the fibrous material throughout the starch-based composition during mixing.    
     
     
       31. A starch-based moldable mixture for forming an article of manufacture, the moldable mixture comprising water, a starch-based binder in a concentration greater than about 20% by weight, and a fibrous material having an average fiber length greater than about 2 mm, and an aspect ratio of at least about 10:1, wherein the moldable mixture has a viscosity greater than about 10 Pa·s, wherein the starch-based binder includes gelatinized component comprising gelatinized starch in an amount from about 5% to about 70% by weight of the starch-based binder, and wherein the balance of the starch-based binder comprises an ungelatinized component comprising ungelatinized, unmodified starch granules prior to forming the composition into an article, wherein said gelatinized component aids in the dispersion of the fibrous material throughout the starch-based composition during mixing. 
     
     
       32. A composite composition comprising a first region that includes a fiber- reinforced starch - based composition and a second region adjacent to the first region that includes a coating composition, the composite composition formed by the process comprising the steps of:      providing an aqueous starch - based composition including water, a starch - based binder in a concentration greater than about  20   %  by weight, and a fibrous material having an aspect ratio of at least about  10 : 1 , wherein the intermediate composition has a viscosity greater than about  10  Pa·s, wherein the starch - based binder includes a gelatinized component comprising gelatinized starch in an amount from about  5   %  to about  70   %  by weight of the starch - based binder, and wherein the balance of the starch - based binder comprises an ungelatinized component comprising ungelatinized, unmodified starch granules, wherein the gelatinized component aids in the dispersion of the fibrous material throughout the intermediate aqueous starch - based composition during mixing in order for the fibrous material to strengthen the starch - based composition;        forming the first region of the starch - based composite composition by heating the aqueous starch - based composition so as to at least partially gelatinize the starch granules and so as to also remove at least a portion of the water by evaporation to thereby cause the starch - based binder to become at least partially solidified; and        forming the second region of the starch - based composite composition by positioning a coating composition that is resistant to moisture adjacent to the first region, wherein the coating composition is formed from at least one of an edible oil, a drying oil, melamine, an epoxy resin, a terpene resin, polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, a polyacrylate, hydroxypropylmethylcellulose, methocel, polyethylene glycol, an acrylic, an acrylic copolymer, polyurethane, polylactic acid, polyhydroxybutyrate - hydroxyvalerate copolymer, a biodegradable polyester resin, soybean protein, or a wax.     
     
     
       33. A composite composition as defined in  claim 32 , wherein the fibrous material includes fibers having a length less than about  25  mm. 
     
     
       34. A composite as defined in  claim 32 , wherein the fibrous material includes fibers having a length less than about  1 . 5  mm. 
     
     
       35. A composite composition as defined in  claim 32 , wherein the fibrous material includes fibers having an aspect ratio in a range from about  40 : 1  to about  2500 : 1 . 
     
     
       36. A composite composition as defined in  claim 32 , wherein the fibers are included in an amount in a range from about  2 %  to about  80   %  by weight of the aqueous starch - based composition.   
     
     
       37. A composite composition as defined in  claim 32 , wherein the aqueous starch- based composition further includes an inorganic filler included in an amount in a range from about  20   %  to about  90   %  by weight of the aqueous starch - based composition.   
     
     
       38. A composite composition as defined in  claim 32 , wherein the first region includes sufficient void spaces so as to have a density in a range from about  0 . 05  g/cm 3    to about  1  g/cm   3 . 
     
     
       39. A composite composition as defined in  claim 32 , wherein the first region includes sufficient void spaces so as to have a density in a range from about  0 . 1  g/cm 3    to about  0 . 5  g/cm   3 . 
     
     
       40. A composite composition as defined in  claim 32 , wherein the first region includes an exterior skin subregion having a density and an interior foam subregion adjacent to the exterior skin subregion having a density that is significantly lower than the density of the exterior skin subregion. 
     
     
       41. A composite composition as defined in  claim 32 , wherein the first region has a cross- sectional thickness in a range of about  0 . 5  mm to about  5  mm.   
     
     
       42. A composite composition as defined in  claim 32 , wherein the coating composition is initially in liquid form when positioned adjacent to the first region. 
     
     
       43. A composite composition as defined in  claim 32 , wherein the coating composition comprises a laminating material. 
     
     
       44. A composite composition as defined in  claim 32 , wherein the coating composition comprises a substantially uniform film. 
     
     
       45. A composite composition as defined in  claim 32 , wherein the starch- based binder includes at least one of native starch or a starch derivative.   
     
     
       46. A composite composition comprising a first region that includes a fiber- reinforced starch - based composition and a second region adjacent to the first region that includes a laminating composition, the composite composition formed by the process comprising the steps of:      providing an aqueous starch - based composition including water, a starch - based binder in a concentration greater than about  20   %  by weight, and a fibrous material having an aspect ratio of at least about  10 : 1 , wherein the intermediate composition has a viscosity greater than about  10  Pa·s, wherein the starch - based binder includes a gelatinized component comprising gelatinized starch in an amount from about  5   %  to about  70   %  by weight of the starch - based binder, and wherein the balance of the starch - based binder comprises an ungelatinized component comprising ungelatinized, unmodified starch granules, wherein the gelatinized component aids in the dispersion of the fibrous material throughout the intermediate aqueous starch - based composition during mixing in order for the fibrous material to strengthen the starch - based composition;        forming the first region of the starch - based composite composition by heating the aqueous starch - based composition so as to at least partially gelatinize the starch granules and so as to also remove at least a portion of the water by evaporation to thereby cause the starch - based binder to become at least partially solidified; and        forming the second region of the starch - based composite composition by positioning a substantially solid laminating composition that is resistant to moisture adjacent to the first region after the starch - based binder has become at least partially solidified.     
     
     
       47. A composite composition as defined in  claim 46 , wherein the laminating composition is formed from a biodegradable polymer selected from the group consisting of cellulosic ethers, cellulose acetate, starches, biodegradable polyamides, polyvinyl alcohol, polyvinyl acetate, polylactic acid, polyhydroxybutyrate- hydroxyvalerate copolymer, other biodegradable polyester resins, soybean protein, and mixtures thereof.   
     
     
       48. A composite composition as defined in  claim 46 , wherein the laminating composition comprises a substantially uniform film. 
     
     
       49. A composite composition as defined in  claim 46 , wherein the first region includes an exterior skin subregion having a density and an interior foam subregion adjacent to the exterior skin subregion having a density that is significantly lower than the density of the exterior skin subregion. 
     
     
       50. A composite composition as defined in  claim 46 , wherein the starch- based binder includes at least one of native starch or a starch derivative.   
     
     
       51. A composite composition as defined in  claim 46 , wherein the fibrous material includes fibers having a length less than about  1 . 5  mm. 
     
     
       52. A composite composition comprising a first region that includes a fiber- reinforced starch - based composition and a second region adjacent to the first region that includes a biodegradable material, the composite composition formed by the process comprising the steps of:      providing an aqueous starch - based composition including water, a starch - based binder in a concentration greater than about  20   %  by weight, and a fibrous material having an aspect ratio of at least about  10 : 1 , wherein the intermediate composition has a viscosity greater than about  10  Pa·s, wherein the starch - based binder includes a gelatinized component comprising gelatinized starch in an amount from about  5   %  to about  70   %  by weight of the starch - based binder, and wherein the balance of the starch - based binder comprises an ungelatinized component comprising ungelatinized, unmodified starch granules, wherein the gelatinized component aids in the dispersion of the fibrous material throughout the intermediate aqueous starch - based composition during mixing in order for the fibrous material to strengthen the starch - based composition;        forming the first region of the starch - based composite composition by heating the aqueous starch - based composition so as to at least partially gelatinize the starch granules and so as to also remove at least a portion of the water by evaporation to thereby cause the starch - based binder to become at least partially solidified, wherein the first region includes an exterior skin subregion having a density and an interior foam subregion adjacent to the exterior skin subregion having a density that is significantly lower than the density of the exterior skin subregion; and        forming the second region of the starch - based composite composition by positioning a biodegradable material adjacent to the first region, the biodegradable material being formed from at least one of a biodegradable polyester resin, polyvinyl alcohol, polyvinyl acetate, polylactic acid, or a polyhydroxybutyrate - hydroxyvalerate copolymer.     
     
     
       53. A composite composition as defined in  claim 52 , wherein the starch- based binder includes at least one of native starch or a starch derivative.   
     
     
       54. A composite composition as defined in  claim 52 , wherein the biodegradable material is initially in liquid form when positioned adjacent to the first region. 
     
     
       55. A composite composition as defined in  claim 52 , wherein the coating composition comprises a laminating material. 
     
     
       56. A composite composition as defined in  claim 52 , wherein the biodegradable material is a substantially uniform film. 
     
     
       57. A composite composition as defined in  claim 52 , wherein the fibrous material includes fibers having a length less than about  1 . 5  mm.