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US 6,878,199 B2Granted
Biodegradable or compostable containers
AssigneeNew Ice Limited
InventorsJoe A. Bowden, Christine C. Johnston
Life of this patent
Estimating the term…
Abstract
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.
Claims73
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 more elements
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.
1 more element
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.
2 more elements
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.
4 more elements
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.
7 more elements
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.
3 more elements
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.
2 more elements
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.
2 more elements
Dependencies are inferred from the claim text.