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The present invention provides an improved method and materials for forming biodegradable containers that can hold food products in dry, damp or wet conditions and provides the biodegradable containers prepared according to the disclosed process. The containers are produced through the use of a pre-

The present invention provides an improved method and materials for forming biodegradable containers that can hold food products in dry, damp or wet conditions and provides the biodegradable containers prepared according to the disclosed process. The containers are produced through the use of a pre-gelled starch suspension that is unique in its ability to form hydrated gels and to maintain this gel structure in the presence of many other types of materials and at low temperatures.

대표청구항 ▼

1. A process for forming a biodegradable material by comprising:(a) forming a pre-gelled starch suspension, “the pre-gel,”produced from approximately 2.5-15% potato starch by weight of the pre-gel, and approximately 75-97% water by weight of the pre-gel such that the pre-gelled suspension is maintai

1. A process for forming a biodegradable material by comprising:(a) forming a pre-gelled starch suspension, “the pre-gel,”produced from approximately 2.5-15% potato starch by weight of the pre-gel, and approximately 75-97% water by weight of the pre-gel such that the pre-gelled suspension is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, a pre-gelled starch suspension produced from approximately 15% corn starch by weight of the pre-gel and approximately 85% water by weight of the pre-gel, and a native starch to form a homogeneous mixture; (c) adding to the pre-gelled starch suspension the homogeneous mixture to form a final homogenous moldable composition; and (d) molding the homogenous moldable composition with heat to form a biodegradable material. 2. The process of claim 1 wherein the native starch is corn starch.3. The process of claim 2 wherein approximately 50-70% by weight of the homogenous mixture of corn starch is added.4. The process of claim 2 wherein approximately 57-65% by weight of the homogenous mixture of corn starch is added.5. The process of claim 1 wherein the native starch is potato starch.6. The process of claim 5 wherein approximately 5-60% by weight of the homogenous mixture of potato starch is added.7. The process of claim 5 wherein approximately 15-30% by weight of the homogenous mixture of potato starch is added.8. A process for forming a biodegradable material comprising:(a) forming a pre-gelled paper starch suspension, the “pre-gel”, that is maintained at temperatures between 0-60° C.; (b) adding to the pre-gelled paper starch suspension a dry or damp, homogeneous mixture containing at least wood fiber, or wood flour having an aspect ratio between approximately 1:2 and 1:8 to form a homogeneous moldable composition; and (c) molding the homogeneous moldable composition with heat to form a biodegradable material. 9. The process of claim 8, further comprising adding a material selected from the following list to the wood fibers to form a homogeneous mixture:(i) waxes, fatty alcohols, phospholipids or glycerol; (ii) approximately 0.5-20% water by weight of the homogenous moldable composition; (iii) baking powder; (iv) natural earth fillers, glycerol, clay, bentonite, kaolin, amorphous raw products, gypsum or calcium sulfate, minerals, limestone, or man made inert fillers; and/or (v) cellulose-based materials. 10. The process of claim 9, wherein the cellulose-based material is methylcellulose.11. The process of claim 9, wherein the cellulose-based material is ethylcellulose.12. The process of claim 8, wherein the pregelled starch suspension is produced from approximately 2.5-15% starch by weight of the pre-gel, and from approximately 85-97.5% of water by weight of the homogenous moldable composition.13. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 2.5-5.5% starch and from approximately 94.5-97.5% water by weight of the homogenous moldable composition.14. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 2.5-10% potato starch, and 90 to 97.5% water by weight of the pre-gel.15. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 15% corn starch by weight of the pre-gel.16. The process of claim 8, wherein the pregelled paper starch solution is produced from approximately 5-10% paper pulp by weight of the pre-gel, approximately 5-15%, natural starch, and approximately 75-90% water by weight of the pre-gel.17. The process of claim 8, wherein the starch is corn starch or potato starch.18. The process of claim 17, wherein corn starch comprises approximately 4-18%, by weight of the homogenous moldable composition.19. The process of claim 8, wherein the starch is a mixture of potato starch and corn starch.20. The process of claim 8, wherein wood fibers or wood flour comprise approximately 11-24% of the homogenous moldable composition that contains the pregelled starch solution.21. The process of claim 8, wherein the wood fibers or flour comprise approximately 7-11% by weight of the homogenous moldable composition that contains the pregelled paper starch solution.22. The process of claim 8, wherein the wood fibers or wood flour have an aspect ratio, width to length of between approximately 1:2 and 1:4.23. The process of claim 8 that further comprises using pressure in combination or alternation with heat to mold the biodegradable material.24. The process of claim 23, wherein the pressure is between approximately 2-3 psi.25. The process of claim 4, wherein the heat used to mold the biodegradable materials is between approximately 150-250° C.26. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 5-10% of potato starch.27. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 7% of potato starch.28. The process of claim 8, wherein the pre-gelled starch suspension is approximately 8% of potato starch.29. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 5-10% of paper.30. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 7-10% of paper.31. The process of claims 8, wherein the pre-gelled starch suspension is produced from approximately 8% of paper.32. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 9% of paper.33. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 80-85% of water.34. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 83% of water.35. The process of claim 8, wherein the pre-gelled starch suspension is produced from approximately 84% of water.36. The process of claim 8, wherein approximately 10% of wood fibers are added.37. The process of claim 8, wherein approximately 7% of wood fibers are added.38. The process of claim 8, further comprising adding potato starch to the wood fibers.39. The process of claim 8, further comprising adding corn starch to the wood fibers.40. The process of claim 8, further comprising adding potato starch and corn starch to the wood fibers.41. The process of claim 8, wherein the pre-gelled starch suspension is maintained at temperatures between 0-40° C.42. A process for forming a biodegradable material comprising:(a) forming a pre-gelled paper starch suspension that is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, and a native starch to form a homogeneous mixture; (c) adding to the pre-gelled starch suspension the homogenous mixture to form a homogenous moldable composition; and (d) molding the homogenous moldable composition with heat to form a biodegradable material. 43. A process for forming a biodegradable material comprising:(a) forming a pre-gelled starch suspension produced from approximately 2-15% potato starch by weight of the pre-gel; approximately 5-10% paper pulp by weight of the pre-gel; and approximately 75-95% water by weight of the pre-gel such that the pre-gelled suspension is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, native corn starch and native potato starch to form a homogeneous mixture; (c) adding to the pre-gelled potato starch suspension the homogeneous mixture to form a homogenous moldable composition; and (d) molding the homogenous moldable composition with heat to form a biodegradable material. 44. The process of claim 43 wherein approximately at least 2.5 or at least 5% by weight of the homogenous mixture of potato starch is added.45. The process of claim 43 wherein approximately 6-8% of paper pulp is added.46. The process of claim 43 wherein the wood fibers have an aspect ratio between 1:2 and 1:4.47. A process comprising the steps of:(a) forming a pre-gelled starch suspension or paper starch suspension that is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, water and additional materials selected from the group comprising: (i) dry or damp starch; (ii) pre-gelled starch; (iii) wax, fatty alcohol, phospholipid and/or glycerol; (v) baking powder; and/or (vi) homogenous moldable composition of natural earth fillers, clays, bentonite, amorphous raw products, gypsum or calcium sulfate, minerals and man made materials to form a homogeneous mixture; (c) adding to the pre-gelled starch suspension the dry or damp, homogeneous mixture to form a homogenous moldable composition; and (d) molding the homogenous moldable composition with heat to form a biodegradable material. 48. The process of claim 47, wherein the mineral is limestone.49. The process of claim 47, wherein the man made material is fly ash.50. The process of claim 47, wherein the pregelled starch comprises about 30% potato starch by weight of the homogenous moldable composition.51. The process of claim 47, wherein the pregelled starch comprises about 60% potato starch by weight of the homogenous moldable composition.52. The process of claim 47, wherein the corn starch comprises about 30% by weight of the homogenous moldable composition.53. The process of claim 47, wherein the starch comprises about 60% corn starch by weight of the homogenous moldable composition.54. A biodegradable, compostable material made according to a process of ant one of claims 43 or 47.55. The material of claim 54 that disintegrates to component parts in less than one year.56. The material of claim 54 that disintegrates to component molecules in less than six months.57. The material of claim 54, that disintegrates in approximately 24 days.58. The material of claim 54 coated with a suitable liquid-resistant coating.59. The process of claim 58, wherein a vacuum is used to form a film around the molded article.60. The material the claim 58, wherein the coating is selected from the group consisting of: polylactic acid; poly hydroxyalkanoate; bacterial cellulose; chitosan based polymer; methylcellulose, ethylcellulose, polyvinylacetate, waxes and oil based coatings.61. The material of claim 58, wherein the coating is applied either as a thin film, sprayed or dipped.62. The material of claim 54 in the form of a cup.63. The material of claim 54 in the form of a tray.64. The material of claim 54 in the form of a bowl.65. The material of claim 54 in the form of a plate.66. The material of claim 54 in the form of a utensil.67. The material of claim 54 in the form of a coffee cup.68. The material of claim 54 in the form of a microwave dinner tray.69. The material of claim 54 in the form of a “TV” dinner tray.70. A process for creating a waterproof material comprising:(a) forming a first pre-gelled starch suspension that is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, and another material selected from the group consisting of waxes, fatty alcohols, phospholipids and glycerol; (c) adding to the first pre-gelled starch suspension the homogeneous mixture containing the wood fiber, or wood flour and another material; (d) molding the homogeneous composition with heat to form a biodegradable material; and (e) coating the material with a liquid-resistant coating. 71. The process of claim 70, wherein the coating is selected from the group consisting of; polylactic acid; poly hydroxyalkanoate; bacterial cellulose; chitosan based polymers; methylcellulose, ethylcellulose, polyvinylacetate or waxes and oil based coatings.72. A process is provided for creating an open cell foam material comprising:(a) forming a first pre-gelled paper starch suspension that is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour, having an aspect ratio between approximately 1:2 and 1:8, a second pre-gelled starch suspension to form a homogeneous composition, and a source of gas; (c) adding to the first pre-gelled starch suspension a dry or damp, homogeneous mixture containing the wood fibers or wood flour and second pre-gelled starch; and (d) molding the homogeneous composition with heat to form a biodegradable material. 73. A process for forming an open cell foam material comprising:(a) forming a pre-gelled paperstarch suspension produced from approximately 5-10% paper pulp, 5-15% native starch by weight of the pre-gel and approximately 75-90% water (by weight of the pre-gel) such that the pre-gelled suspension is maintained at temperatures between 0-60° C.; (b) mixing together wood fibers or wood flour having an aspect ratio between approximately 1:2 and 1:8, 16% corn starch, 17.5% potato starch and 5% wood fibers by weight of the second pre-gel and approximately 75-90% water by weight, and baking powder of 0.4-12% baking powder by weight of the homogeneous moldable composition to form a homogeneous mixture; (c) adding to the pre-gelled potato paper starch suspension a homogeneous mixture containing the wood fibers or wood flour corn starch and potato starch to form a homogeneous moldable composition; and (d) molding the homogeneous moldable composition with heat to form a biodegradable material.