A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. In a first step, dense pellets or granules are formed from starch and a plasticizing agent such as polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water and using a dwell time. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.
C08L 3/02 - Starch; Degradation products thereof, e.g. dextrin
B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
B29C 48/08 - Flat, e.g. panels flexible, e.g. films
B29C 48/345 - Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
B29C 48/40 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws, e.g. twin screw extruders
B65D 81/09 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using flowable discrete elements of shock-absorbing material, e.g. pellets or popcorn
2.
STARCH-BASED PACKAGING MATERIAL, APPARATUS AND METHOD FOR MAKING SAME
Starch-based packaging material and methods for making the material are described. The starch-based packaging material can comprise layers of expanded starch with a cellulosic web disposed between the layers. The expanded starch can be formed by extruding starch with water which acts as an expanding agent and causes the starch to expand resulting in an extrudate having a density of no more than about 5 lbs/ft3. An apparatus and methods for post-processing the expanded starch are described wherein the expanded starch is extruded as a tube that enters a funnel and is advanced forward by forced air. The tube passes over a blade where the tube is slit and subsequently opened up into a sheet by a second supply of forced air. The sheet then exits the funnel and can be calendered as well as stacked with subsequent lamination.
B65D 65/40 - Applications of laminates for particular packaging purposes
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 29/00 - Layered products essentially comprising paper or cardboard
B32B 3/28 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a layer with cavities or internal voids characterised by a layer comprising a deformed thin sheet, e.g. corrugated, crumpled
B32B 37/00 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
B29C 48/08 - Flat, e.g. panels flexible, e.g. films
B29C 48/32 - Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
3.
Starch pellets for sheet extrusion and methods for forming the pellets
A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. Generally, two processing steps for forming materials are involved. In a first step, dense pellets or granules are formed from starch and a plasticizing agent, such as a plasticizing polymer, for example, polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water as the expansion agent in which the dwell time in the extruder is short. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.
C08L 3/02 - Starch; Degradation products thereof, e.g. dextrin
B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
B29C 48/08 - Flat, e.g. panels flexible, e.g. films
B29C 48/40 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws, e.g. twin screw extruders
B65D 81/09 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using flowable discrete elements of shock-absorbing material, e.g. pellets or popcorn
B29C 48/345 - Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
4.
SHEETS OF STARCH BASED PACKING MATERIAL, STARCH PELLETS FOR SHEET EXTRUSION AND METHODS FOR FORMING THE PELLETS AND SHEETS
A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. Generally, two processing steps for forming materials are involved. In a first step, dense pellets or granules are formed from starch and a plasticizing agent, such as a plasticizing polymer, for example, polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs/cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water as the expansion agent in which the dwell time in the extruder is short. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.
A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. Generally, two processing steps for forming materials are involved. In a first step, dense pellets or granules are formed from starch and a plasticizing agent, such as a plasticizing polymer, for example, polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water as the expansion agent in which the dwell time in the extruder is short. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.
C08L 3/02 - Starch; Degradation products thereof, e.g. dextrin
B65D 81/09 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using flowable discrete elements of shock-absorbing material, e.g. pellets or popcorn
B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
B29C 48/08 - Flat, e.g. panels flexible, e.g. films
B29C 48/40 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws, e.g. twin screw extruders
B29C 48/345 - Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising