Biodegradable and compostable composition having improved physical and chemical properties
The present application is generally directed to novel compositions and methods used to produce a biodegradable, starch-based, water-resistant article of manufacture. The teachings include a composition comprising a biodegradable fiber component in an amount ranging from about 5% to about 40% on a dry weight basis, starch component in an amount ranging from about 40% to about 94.5% on a dry weight basis, and an additive component in an amount ranging from more than 0% to about 15% on a dry weight basis. The additive component can comprise an epoxidized vegetable oil, a hydrogenated triglyceride, poly(vinyl acetate), poly(vinyl acetate-ethylene) copolymer, poly(ethylene-vinyl acetate) copolymer, or a combination thereof.
1. A composition comprising
a biodegradable fiber component in an amount ranging from about 5% to about 40% on a dry weight basis;
a starch component in an amount ranging from about 40% to about 94.5% on a dry weight basis; and,
an additive component in an amount ranging from more than 3% to about 15% on a dry weight basis, wherein the additive component comprises 3% magnesium stearate, and a hydrogenated triglyceride;
wherein the composition is mixed to allow for shaping of the composition into a form that creates a biodegradable, disposable, and water-resistant article of manufacture when heated at a sufficient temperature and for a sufficient time.
2. The composition of claim 1 , wherein the biodegradable fiber component comprises a natural fiber, and the natural fiber comprises a woody fiber, a non-woody fiber, or an animal fiber.
3. The composition of claim 1 , wherein the biodegradable fiber component comprises a biodegradable synthetic fiber.
4. The composition of claim 1 , wherein the starch component comprises an organic filler material having a ratio of starch to filler that ranges from about 10:1 to about 1:1.
5. The composition of claim 4 , wherein the ratio of starch to filler is about 3:1.
6. The composition of claim 1 , wherein the additive is present in an amount ranging from about 3% to about 5%.
7. The composition of claim 1 , wherein the additive component is a hydrogenated triglyceride with a melting point of about 54 to 85° C.
8. The composition of claim 1 , wherein the additive component further comprises an epoxidized vegetable oil.
9. The composition of claim 1 , wherein the additive component further comprises a polymer selected from the group consisting of poly(vinyl acetate), poly(vinyl acetate-ethylene) copolymer, and poly(ethylene-vinyl acetate) copolymer.
10. An aqueous mixture comprising the composition of claim 1 , wherein the mixture contains water in a quantity sufficient to allow for shaping of the composition into a form that creates a biodegradable, disposable, and water-resistant article of manufacture when heated at a sufficient temperature and for a sufficient time.
11. The aqueous mixture of claim 10 comprising from about 40% to about 80% water.
12. The aqueous mixture of claim 10 , wherein the starch component comprises a combination of native starch and pre-gelatinized starch, and the ratio of the fiber to pre-gelatinized starch ranges from about 1.5:1 to about 3:1.
13. The aqueous mixture of claim 11 further comprising a wax, a cross-linking agent, or a combination thereof.
14. A method of creating a biodegradable, starch-based, water-resistant article of manufacture, wherein the method comprises:
adding the mixture of claim 13 to a mold apparatus having a cavity; and
heating the mixture in the mold apparatus at a sufficient temperature and for a sufficient time for the mixture to be a stable form having a skin formed on the outer surface of the mixture where the mixture contacts the surface of the cavity during the heating;
wherein, the mold apparatus comprises at least one gap such that vapor can exit the cavity of the mold though the gap without substantial loss of the mixture through the gap;
and wherein the material fills the mold cavity by in situ expansion during heating.
15. An article of manufacture comprising the composition of claim 1 , wherein the article of manufacture is biodegradable and water-resistant.
16. The article of manufacture of claim 15 , wherein the article of manufacture is compostable.
17. The article of manufacture of claim 15 , wherein the article of manufacture is a food service product, a packaging material, or a combination thereof.
18. The article of manufacture of claim 15 , wherein the article of manufacture is a food product that is edible.
19. The article of manufacture of claim 15 , wherein the additive component is a hydrogenated triglyceride with a melting point of about 54 to 85° C.
20. The article of manufacture of claim 15 , wherein the additive component further comprises an epoxidized vegetable oil.
21. The article of manufacture of claim 15 , wherein the additive component further comprises a polymer selected from the group consisting of poly(vinyl acetate), poly(vinyl acetate-ethylene) copolymer, and poly(ethylene-vinyl acetate) copolymer.
22. A method of creating a biodegradable, starch-based, water-resistant article of manufacture, wherein the method comprises:
preparing a mixture of a biodegradable fiber component and a starch component, wherein the biodegradable fiber component is in an amount ranging from about 5% to about 40% on a dry weight basis, and the starch component is in an amount ranging from about 40% to about 94.5% on a dry weight basis;
adding an additive component to the mixture in an amount ranging from more than 3% to about 15% on a dry weight basis, wherein the additive component comprises 3% magnesium stearate, and a hydrogenated triglyceride;
adding an aqueous component to the mixture to create an aqueous composition, wherein the aqueous component comprises water in a quantity sufficient to allow for shaping of the composition into a desired form; and,
heating the desired form at a sufficient temperature and for a sufficient time to create a biodegradable, disposable, and water-resistant article of manufacture from the composition.
23. The method of claim 22 , wherein the article of manufacture is compostable.
24. The method of claim 22 , wherein the article of manufacture is a food service product, a packaging material, or a combination thereof.
25. The method of claim 22 , wherein the article of manufacture is an approved food product that is edible.
26. The method of claim 22 , wherein the biodegradable fiber component comprises a natural fiber, and the natural fiber comprises a woody fiber, a non-woody fiber, or an animal fiber.
27. The method of claim 22 , wherein the biodegradable fiber component comprises a biodegradable synthetic fiber.
28. The method of claim 22 , wherein the starch component comprises an organic filler material having a ratio of starch to filler that ranges from about 10:1 to about 1:1.
29. The method of claim 28 , wherein the ratio of starch to filler is about 3:1.
30. The method of claim 22 , wherein the additive component is present in an amount ranging from about 3% to about 5%.
31. The method of claim 22 , wherein the starch component comprises a combination of native starch and pre-gelatinized starch, and the ratio of the fiber to pre-gelatinized starch ranges from about 1.5:1 to about 3:1.
32. The method of claim 22 , further comprising a wax, a cross-linking agent, or a combination thereof.
33. The method of claim 22 , wherein the additive component is a hydrogenated triglyceride with a melting point of about 54 to 85° C.
34. The method of claim 22 , wherein the additive component further comprises an epoxidized vegetable oil.
35. The method of claim 22 , wherein the additive component further comprises a polymer selected from the group consisting of poly(vinyl acetate), poly(vinyl acetate-ethylene) copolymer, and poly(ethylene-vinyl acetate) copolymer.
36. A method of creating a biodegradable, starch-based, water-resistant article of manufacture having an improved strength, wherein the method comprises:
preparing a mixture comprising a biodegradable fiber component and a starch component, wherein the biodegradable fiber component is in an amount ranging from about 5% to about 40% on a dry weight basis, and the starch component is in an amount ranging from about 40% to about 94.5% on a dry weight basis;
adding an additive component to the mixture in an amount ranging from more than 3% to about 15% on a dry weight basis, wherein the additive component comprises 3% magnesium stearate, and a hydrogenated triglyceride;
adding an aqueous component to the mixture to create an aqueous composition, wherein the aqueous component comprises water in a quantity sufficient to allow for shaping of the composition into a desired form; and,
heating the desired form at a sufficient temperature and for a sufficient time to create a biodegradable, disposable, and water-resistant article of manufacture from the composition.
37. The method of claim 36 , wherein the article of manufacture is compostable.
38. The method of claim 36 , wherein the article of manufacture is a food service product, a packaging material, or a combination thereof.
39. The method of claim 36 , wherein the article of manufacture is a food product that is edible.
40. The method of claim 36 , wherein the biodegradable fiber component comprises a natural fiber, and the natural fiber comprises a woody fiber, a non-woody fiber, or an animal fiber.
41. The method of claim 36 , wherein the biodegradable fiber component comprises a biodegradable synthetic fiber.
42. The method of claim 36 , wherein the starch component comprises an organic filler material having a ratio of starch to filler that ranges from about 10:1 to about 1:1.
43. The method of claim 42 , wherein the ratio of starch to filler is about 3:1.
44. The method of claim 36 , wherein the additive component is present in an amount ranging from about 3% to about 5%.
45. The method of claim 36 , wherein the starch component comprises a combination of native starch and pre-gelatinized starch, and the ratio of the fiber to pre-gelatinized starch ranges from about 1.5:1 to about 3:1.
46. The method of claim 36 , further comprising a wax, a cross-linking agent, or a combination thereof.
47. The method of claim 36 , wherein the additive component is a hydrogenated triglyceride with a melting point of about 54 to 85° C.
48. The method of claim 36 , wherein the additive component further comprises an epoxidized vegetable oil.
49. The method of claim 36 , wherein the additive component further comprises a polymer selected from the group consisting of poly(vinyl acetate), poly(vinyl acetate-ethylene) copolymer, and poly(ethylene-vinyl acetate) copolymer.
50. The composition of claim 1 , wherein at least a portion of the starch component can be comprised of one or more water-resistant starches.
51. The composition of claim 50 , wherein the water-resistant starch component comprises a high-amylose starch.
52. The composition of claim 50 , wherein the water-resistant starch component comprises alkenyl succinic anhydride modified starch, acetic anhydride modified starch, vinyl acetate modified starch, acrolein modified starch, epichlorohydrin modified starch, phosphorus oxychloride modified starch, sodium trimetaphosphate modified starch, or propylene oxide modified starch or a combination thereof.
53. The composition of claim 1 , wherein the additive is present in an amount ranging from about 3% to about 7%.