Patent Number: 6,168,857

Title: Compositions and methods for manufacturing starch-based compositions

Abstract: Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, an auxiliary water-dispersible organic polymer, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the auxiliary polymer to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation. The starch and auxiliary polymer form the binding matrix of the sheets with the fibers and optional inorganic filler dispersed throughout the binding matrix. The starch-bound sheets can be cut, rolled, pressed, scored, perforated, folded, and glued to fashion articles from the sheets much like paper or paperboard. The sheets are particularly useful in the mass production of containers, such as food and beverage containers.

Inventors: Andersen; Per Just (Santa Barbara, CA), Ong; Shaode (Goleta, CA), Christensen; Bruce J. (Goleta, CA), Hodson; Simon K. (Santa Barbara, CA)

Assignee: E. Khashoggi Industries, LLC

International Classification: B29C 43/22 (20060101); B29C 43/00 (20060101); B29C 43/24 (20060101); B29C 43/02 (20060101); B29C 51/00 (20060101); B29C 55/18 (20060101); B32B 23/00 (20060101); B32B 23/12 (20060101); B29C 49/00 (20060101); B32B 13/02 (20060101); B29C 67/24 (20060101); B32B 13/00 (20060101); B32B 27/20 (20060101); B32B 27/04 (20060101); B05B 11/00 (20060101); B32B 5/02 (20060101); B29C 71/00 (20060101); B65D 43/16 (20060101); B28B 11/00 (20060101); B28B 1/52 (20060101); B28B 3/12 (20060101); B28B 3/20 (20060101); B28B 3/00 (20060101); B28B 23/00 (20060101); B28B 1/00 (20060101); C04B 26/00 (20060101); C04B 26/28 (20060101); C08J 5/18 (20060101); C08L 3/00 (20060101); C08L 3/02 (20060101); B32B 005/02 (); B32B 023/12 ()

Expiration Date: 01/02/2018