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AssigneeE. Khashoggi Industries
InventorsPer Just Andersen, Simon K. Hodson
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Compositions, methods, and systems for manufacturing articles, particularlycontainers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix are disclosed. Suitable inorganically filled mixtures are prepared by mixing together a starch-based binder, a solvent, inorganic aggregates, and optimal admixtures, e.g., fibers, mold-releasing agents, rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The inorganically filled mixtures have a predetermined viscosity and are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled cellular, structural matrix. The molded articles may be placed in a high humidity chamber to obtain the necessary flexibility for their intended use. 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 materials. They have especial utility in the mass-production of containers, particularly food and beverage containers.
An inorganically filled starch-based mixture for forming an article of manufacture having an inorganically filled starch-bound cellular matrix, the mixture comprising substantially ungelatinized unmodified starch granules included in an amount in a range from about 10% to about 80% by weight of solids within the starch-based mixture, water included in a quantity sufficient to substantially gelatinize the unmodified starch granules upon heating the starch-based mixture to above the gelation temperature of the starch granules, and an inorganic aggregate filler included in an amount in a range from about 20% to about 90% by weight of solids within the starch-based mixture.
An inorganically filled starch-based mixture for forming an article of manufacture having an inorganically filled starch-bound cellular matrix reinforced with fibers, the mixture comprising substantially ungelatinized unmodified starch granules, water, an inorganic aggregate filler included in an amount in a range from about 20% to about 90% by weight of solids within the starch-based mixture, and fibers dispersed throughout the starch-based composition in an amount in a range from about 2% to about 40% by volume of solids within the starch-based mixture.
An inorganically filled starch-based mixture for forming an article of manufacture having an inorganically filled starch-bound cellular matrix reinforced with fibers, the mixture comprising water, substantially ungelatinized unmodified starch granules included in an amount in a range from about 30% to about 70% by weight of solids within the starch-based mixture, an inorganic aggregate filler included in an amount in a range from about 30% to about 70% by weight of solids within the starch-based mixture, organic fibers dispersed throughout the starch-based composition in an amount in a range from about 5% to about 20% by volume of solids within the starch-based mixture, and a mold release agent.
An inorganically filled starch-based mixture for forming an article of manufacture, the mixture comprising substantially ungelatinized, unmodified starch granules included in an amount in a range from about 20% to about 80% by weight of solids within the starch-based mixture, water, and an inorganic aggregate filler included in an amount in a range from about 20% to about 80% by weight of solids within the starch-based mixture.
An inorganically filled starch-filled starch-based mixture for forming an article of manufacture, the mixture comprising substantially ungelatinized, unmodified starch granules included in an amount sufficient to act as a binder in the mixture upon gelation of the starch granules, water included in an amount in a range from about 20% to about 70% by weight of the starch-based mixture, and an inorganic aggregate filler included in an amount in a range from about 20% to about 90% by weight solids within the starch-based mixture.
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