Inorganically filled, starch-bound compositions for manufacturing containers and other articles having a thermodynamically controlled cellular matrix

An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:

• a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation;
• an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 20% to about 90% by weight of solids within the starch-bound cellular matrix;
• and
• fibers dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 2% to about 40% by volume of solids within the starch-bound cellular matrix,
• wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water.

An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:

• a starch binder selected from the group consisting of potato starch, corn starch, and waxy corn starch, the starch binder having been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation, the starch binder having a concentration in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix;
• an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix;
• and
• organic fibers dispersed throughout the starch-bound cellular matrix and included in an amount up to about 20% by volume of solids within the starch-bound cellular matrix,
• wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water.

An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate, the starch-bound cellular matrix comprising:

• a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation;
• and
• an inorganic aggregate dispersed throughout the starch-bound cellular matrix in a concentration in a range from about 20% to about 90% by weight of total solids within the starch-bound cellular matrix,
• wherein the starch-bound cellular matrix has a thickness less than about 1 cm and degrades after prolonged exposure to water, wherein the article includes a coating on at least a portion thereof.

An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:

• a starch-based binder that has been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation;
• an inorganic aggregate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 20% to about 90% by weight of solids within the starch-bound cellular matrix;
• and
• fibers dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 2% to about 40% by volume of solids within the starch-bound cellular matrix,
• wherein the starch-bound cellular matrix has a thickness less than about 6 mm, includes glycerin within a portion thereof, and degrades after prolonged exposure to water.

An article of manufacture comprising a starch-bound cellular matrix of starch and inorganic aggregate reinforced with fibers, the starch-bound cellular matrix comprising:

• a starch binder selected from the group consisting of potato starch, corn starch, and waxy corn starch, the starch binder having been substantially gelatinized by water and then hardened through the removal of a substantial quantity of the water by evaporation, the starch binder having a concentration in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix;
• calcium carbonate dispersed throughout the starch-bound cellular matrix and included in an amount in a range from about 30% to about 70% by weight of solids within the starch-bound cellular matrix;
• and
• organic fibers dispersed throughout the starch-bound cellular matrix and included in an amount up to about 20% by volume of solids within the starch-bound cellular matrix,
• wherein the starch-bound cellular matrix has a thickness less than about 6 mm and degrades after prolonged exposure to water, wherein the article includes a coating on at least a portion thereof.