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Thermoplastic starch compositions incorporating a particulate filler component
| Details |
Inventors: Andersen, Per Just; Hodson, Simon K.;
Assignee: E. Khashoggi Industries, LLC (Santa Barbara, CA)
Primary Examiner: Copenheaver; Blaine
Assistant Examiner:
Attorney, Agent or Firm: Workman, Nydegger & Seeley
Thermoplastic starch compositions that include a particulate filler, e.g. an inorganic filler component, and optional fibrous component The compositions include a thermoplastic phase comprising a thermoplastic starch melt that contains, at a minimum, starch blended with an appropriate plasticizing agent under conditions in order for the starch to form a thermoplastic melt. The thermoplastic phase may also include one or more additional thermoplastic polymers and other optional reactants, liquids or cross-linking agents to improve the water-resistance, strength, and/or other mechanical properties of the thermoplastic melt, particularly upon solidification. The inorganic filler component may affect the mechanical properties but will mainly be added to reduce the cost of the thermoplastic starch compositions by displacing a significant portion of the more expensive starch or starch/polymer melt. Fibers may optionally be included in order to improve the mechanical properties of the thermoplastic starch compositions. The thermoplastic starch compositions may be shaped into a wide variety of useful articles, such as sheets, films, containers, and packaging materials. Because the thermoplastic starch compositions will typically include a thermoplastic phase that is biodegradable, and because the other components will either constitute a naturally occurring mineral and optionally a natural fiber, the overall composition will typically be more environmentally friendly compared to conventional thermoplastic materials. |
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS I.
Introduction and General Definitions The present invention encompasses thermoplastic starch compositions that, at a minimum, include starch, a plasticizer, and an inorganic mineral filler.
Such compositions may also include fibers, synthetic polymers, and other admixtures in order to impart desired properties to the composition while in a melt stage as well as the final resolidified composition and articles manufactured therefrom.
The inorganically filled, thermoplastic starch compositions can be shaped into a wide variety of articles of manufacture much like conventional thermoplastic materials.
The thermoplastic starch compositions of the present invention can generally be described as comprising multi-component, multi-scale, micro-composites.
By carefully incorporating a variety of different materials capable of imparting discrete, yet synergistically related, properties, it is possible to create a unique class or range of micro-composites having remarkable properties of strength, toughness, environmental soundness, mass-producibility, and low cost.
The term "multi-component" refers to the fact that the thermoplastic starch compositions typically include two or more chemically or physically distinct materials or phases, such as the binding matrix comprising, at a minimum, a starch melt formed by plasticizing starch with a plasticizer, a particulate filler and optional admixtures, such as fibers for reinforcement auxiliary polymers for added strength and water-resistance and void spaces for lightweight and/or insulation properties.
Each of these broad categories of materials imparts one or more unique properties to the final thermoplastic starch compositions made therefrom, as well as to the sheets, films and other articles manufactured therefrom.
Within these broad categories it is possible to further include different components such as, for example, two or more types of inorganic fillers, fibers, and synthetic organic polymers, which can impart different yet complementary properties to the inventive thermoplastic starch compositions
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