E. Khashoggi Industries, LLC

Shaode Ong

Simon K Hodson

Per Just Andersen

Bruce J Christensen

Bruce J Christiansen

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.

Compositions and methods for manufacturing starch-based sheets

Compositions and methods for manufacturing starch-based compositions

Compositions and methods for manufacturing sheets having a starch-bound matrix, optionally 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, a cellulosic ether, optionally 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 cellulosic ether 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 cellulosic ether 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.

Sheets having a starch-based binding matrix

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, a cellulosic ether, 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 cellulosic ether 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 cellulosic ether 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.

Compositions for manufacturing sheets having a high starch content

Methods for manufacturing molded sheets having a high starch content

Compositions and methods for the deposition of ettringite (3CaO-Al.sub.2 O.sub.3 .multidot.3Ca(SO.sub.4).multidot.30-32H.sub.2 O) onto the surfaces of fibers, aggregates, and other fillers. The ettringite is produced in situ within an aqueous suspension while in proximity to the fibers, aggregates, or other fillers to form a mineralized composite material comprising ettringite coated fibers, aggregates or other fillers. Ettringite treated fibers, aggregates, or other fillers are formed by adding chemical reactants such as calcium oxide and aluminum sulfate, which react together in the presence of water to form ettringite, which then precipitates onto the surface of the fibers or other substrates being treated. The ettringite treated fibers, aggregates or other fillers can be added to hydraulically settable materials to improve the chemical and mechanical bond between the fibers or other substrates within the resulting hardened hydraulically settable composite material, particularly a cementitious or concrete material.

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Goleta, CA, United States of America

Shaode Ong