WO2015059685A1 - A method of producing biodegradable composite - Google Patents

A method of producing biodegradable composite Download PDF

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Publication number
WO2015059685A1
WO2015059685A1 PCT/ID2014/000008 ID2014000008W WO2015059685A1 WO 2015059685 A1 WO2015059685 A1 WO 2015059685A1 ID 2014000008 W ID2014000008 W ID 2014000008W WO 2015059685 A1 WO2015059685 A1 WO 2015059685A1
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Prior art keywords
producing
biodegradable composite
starch
mixture
ground
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PCT/ID2014/000008
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French (fr)
Inventor
Herman MOELIANA
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Moeliana Herman
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Publication of WO2015059685A1 publication Critical patent/WO2015059685A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00Making granules
    • B29B9/02Making granules by dividing preformed material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00Mixing; Kneading
    • B29B7/002Methods
    • B29B7/007Methods for continuous mixing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00Mixing; Kneading
    • B29B7/30Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58Component parts, details or accessories; Auxiliary operations
    • B29B7/72Measuring, controlling or regulating
    • B29B7/726Measuring properties of mixture, e.g. temperature or density
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00Making granules
    • B29B9/12Making granules characterised by structure or composition
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00Processes of treating or compounding macromolecular substances
    • C08J3/20Compounding polymers with additives, e.g. colouring
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L29/00Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
    • C08L29/02Homopolymers or copolymers of unsaturated alcohols
    • C08L29/04Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00Mixing; Kneading
    • B29B7/30Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/34Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
    • B29B7/38Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00Making granules
    • B29B9/02Making granules by dividing preformed material
    • B29B9/06Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00Making granules
    • B29B9/16Auxiliary treatment of granules
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04Particle-shaped
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2003/00Use of starch or derivatives as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04PVOH, i.e. polyvinyl alcohol
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0088Blends of polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037Other properties
    • B29K2995/0059Degradable
    • B29K2995/006Bio-degradable, e.g. bioabsorbable, bioresorbable or bioerodible
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2329/00Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
    • C08J2329/02Homopolymers or copolymers of unsaturated alcohols
    • C08J2329/04Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2403/00Characterised by the use of starch, amylose or amylopectin or of their derivatives or degradation products
    • C08J2403/02Starch; Degradation products thereof, e.g. dextrin
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00Processes of treating or compounding macromolecular substances
    • C08J3/12Powdering or granulating

Definitions

  • This invention relates toa method of producing biodegradable composite under controlled rheology and processing conditionfrom natural or modified starch, with addition of polyvinyl alcohol, polyhydric alcohol, and other additives.
  • plastics do not biodegrade regardless of environmental conditions, while some do so but in a time-consuming way by exposing to air, water and light. Due to high concerns on environmental issues these days, someplastics have been engineered to become biodegradable, and waysto accelerate biodegradation of the plastics are also being studied in the polymer industries.
  • Biodegradable plastics can be broken down by microorganism into water, carbon dioxide and some other organic matter that can be utilized by living organism.
  • the biodegradable plastics are mainly produced from plants which make the plastic biodegradable, thus replacing the conventional petroleum-based plastics.
  • composition comprises poly(lactic acid) (PLA) polymer and components of natural origin, includingstarch and protein material.
  • PLA poly(lactic acid)
  • the composition provides improved mechanical properties obtainable by providing PLA, starch and protein material according to the ratio, mixing to afford a homogeneous mixture, subjecting the mixture to extrusion compounding, drying and conditioning the extruded polymeric product.
  • a biodegradable plastic resin made from corn starch, tapioca, stearic acid, talc, glycerol, sorbitol, ethylene acrylic acid copolymer and completely biodegradable materials, which replaces the consumption of oil resources.
  • the raw materials are mixed proportionally, and extruded by a modified twin screw extruder to produce a pellet.
  • Film article made of the plastic resins has quick decomposition rate.
  • Plastic extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. Control parameters during extrusion process therefore are vital to produce quality plastic resins with better mechanical and degradation behaviour. Moisture content in the plastic resins would affect the biodegradation rate too. According to Sina Ebnesajjad in Handbook of Biopolymers and Biodegradable Plastics: Properties, Processing and Applications, biodegradation proceeded faster in the compost prepared with a moisture content of 65% than in the compost prepared with a moisture content of 45 and 55%. Therefore, a method to produce a controlled rheology and processing condition is needed in the art.
  • the present invention relates to a method of producing a biodegradable composite, characterised by the steps of: grinding starch into fine particles; grinding polyvinyl alcohol into fine particles; blending the ground starch in the range of 0-60% by total weight and ground polyvinyl alcohol in the range of 30-80% by total weight, with addition of additives to form a mixture; stabilizingthe mixture for a time period; subjecting the mixture to acontinuous kneadingprocess under various pressure and temperature to form non-porous material;extruding and cutting the non-porous material into pellet form; and stabilizingthe pellet for a time period to produce a biodegradable composite having controlled moisture content and rheology for further processing.
  • Fig. 1 is a flow chart of a method of producing a biodegradable composite in accordance to the present invention.
  • the present invention relates to a method of producing biodegradable composite with controlled rheology fromstarchsuch as tapioca starch, corn starch, natural starch or modified starch.
  • the method of producing a biodegradable composite characterised by the steps of:
  • ground starch in a range of 0-60% by total weight and ground polyvinyl alcohol in a range of 30-80% by total weight, with addition of additives to form a mixture;
  • the starch is tapioca starch, corn starch, natural starch, or modified starch. In a preferred embodiment of the method of producing a biodegradable composite, the starch is ground to particle size of 25 - 40 microns.
  • the polyvinyl alcohol is ground to particle size of 75 - 150 micrcons.
  • the additives comprise of water, urea, anti-blocking agent, organic plasticizer, anti-freezing agent, buffer, amide compatibiliser, acrylic modifier, elastomer, and proprietary additives.
  • the ground starch and ground polyvinyl alcohol are blended with addition of additives at temperature of 60-80°C.
  • the ground starch and ground polyvinyl alcohol are blended with addition of additives for 30 - 60 minutes.
  • the blended mixture is cooled to a temperature of 40-50°C before being stabilized.
  • the mixture is stabilized in atmospheric condition to let the additives befuily absorbed in the mixturefor a time period of 24-48 hours.
  • the continuous kneading process comprises the steps of intensive mixing and compressing the mixture to form non-porous material, followed by extruding and cutting into pellet form.
  • the continuous kneadingprocess is performed at a temperature in a range of 60°C to 170°C.
  • the continuous kneading process is performed under high pressure between 3000 - 15000 kilopascals (kPa) to control moisture content of the mixture.
  • the pellet is stabilized for a time period of minimum one dayin atmospheric condition to obtain biodegradable composite in pelletform which eliminatesshrinkage property and possesses goodflow processablity when being processed by blow, injection, and extrusion machinesinto finished product.
  • starch is obtained and ground to break the particles into fine particles with particle size of 25 - 40 microns.
  • Polyvinyl alcohol is obtained in solid form and ground to break the particles to a particle size of 75 - 150 microns.
  • the ground starch and ground polyvinyl alcohol is then blended in a high shear mixer, wherein 0-60% by total weight of ground starch and 30-80% by total weight of ground polyvinyl alcohol are mixed.
  • the mixer for blending the particles of ground starch and ground polyvinyl alcohol is not limited to a high shear mixer, but any other blending tools may be used to obtain the desired mixing result.
  • Additives including water, urea, anti-blocking agent, organic plasticizer, anti-freezing agent, buffer, amide compatibiliser, acrylic modifier, elastomer, and proprietary additives are added to the ground starch and ground polyvinyl alcohol while blending in the high shear mixer to form a mixture.
  • the organic plasticiser is preferablypolyhydric alcoholincluding glycerine,glycol, or esters.
  • the anti-blocking agent is preferably silica.
  • the anti-freezing agent is preferably but not limited to glycol and glycerine.
  • the buffer used in the present invention is preferably borax.
  • the amide compatibiliser is preferably formamide.
  • the acrylic modifier and elastomer is preferably ethylene maleat butyl acrylate.
  • the elastomer is preferably ethylene vinyl acetate (EVA).
  • the step of blending the ground starch and ground polyvinyl alcohol with addition of additives is carried out at a temperature range of 60-80°C for 30-60 minutes.
  • the blended mixture is then cooled to a temperature of 40-50°C.
  • the continuous kneading process comprises the steps of intensive mixing in a continuous kneaderand compressing the mixture under controlled condition.
  • the continuous kneading process involves cooking the mixture at a temperature in a range of 60°C to 170°C, under high pressure in the range of 3000-15000 kPa to control moisture content of the mixture during mixing and compressing.
  • the continuous kneading process at a high temperature, the water does not evaporate and turn into steam due to the high pressure control in the continuous kneader, therefore the water content in the mixture can be controlled.
  • the continuous kneader comprises a specially design screws, wherein during kneading, the screws turn to knead and squeeze the particles to form homogenous non-porous material.
  • the non-porous material is fed into an extruder and further cut into pellet form by a pelletizer and stabilizedfor a time period of minimum one day to obtain the biodegradable composite.
  • the stabilizedbiodegradable composite is subjected to further processing into finished goods by blowing process, extrusion process, injection process, etc.
  • Tapioca starch was ground into particle size of 25 - 40 microns and polyvinyl alcohol was ground into particle size of 75 - 150 micrcons separately.
  • the ground starch and polyvinyl alcohol was blended in a mixer at 60-80°C for 30-60 minutes, with addition ofadditives including water, urea, silica, glycol, glycerine, borax, formamide, ethylene maleat butyl acrylate, ethylene vinyl acetate (EVA), and proprietary additives.
  • the mixture was cooled to 40-50°Cand left for stabilizationfor 24-48 hours. Then, the mixture was undergone continuous kneading process at 60-170°C under high pressure between 3000-15000 kPato control moisture content of the mixture.
  • the continuos kneading process included intensive mixingand compressing the mixture in a continuous kneaderto form non-porous material. Then, the non-porous material was fed into an extruder and furthercut into pellet form in a pelletizer and stabilizedfor one day to obtain the biodegradable composite with 4-15%moisture content.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)

Abstract

The present invention relates to a method of producing a biodegradable composite, characterised by the steps of grinding starch into fine particles; grinding polyvinyl alcohol into fine particles; blending the ground starch and ground polyvinyl alcohol with addition of additives to form a mixture; stabilizing the mixture for a time period;subjecting the mixture to a continuous kneading process to form non-porous material;extruding and cutting the non-porous material into pellet form; and stabilizing the pellet for a time period to produce a biodegradable composite having controlled moisture content and rheology.

Description

A METHOD OF PRODUCING BIODEGRADABLE COMPOSITE
Technical Field of the Invention
This invention relates toa method of producing biodegradable composite under controlled rheology and processing conditionfrom natural or modified starch, with addition of polyvinyl alcohol, polyhydric alcohol, and other additives.
Background of Invention
Conventionally, plastics do not biodegrade regardless of environmental conditions, while some do so but in a time-consuming way by exposing to air, water and light. Due to high concerns on environmental issues these days, someplastics have been engineered to become biodegradable, and waysto accelerate biodegradation of the plastics are also being studied in the polymer industries. Biodegradable plastics can be broken down by microorganism into water, carbon dioxide and some other organic matter that can be utilized by living organism. The biodegradable plastics are mainly produced from plants which make the plastic biodegradable, thus replacing the conventional petroleum-based plastics. Disclosed in prior art US 2007/0 29467 A1 is a bio-based biodegradable polymer, which composition comprises poly(lactic acid) (PLA) polymer and components of natural origin, includingstarch and protein material. The composition provides improved mechanical properties obtainable by providing PLA, starch and protein material according to the ratio, mixing to afford a homogeneous mixture, subjecting the mixture to extrusion compounding, drying and conditioning the extruded polymeric product.
Also disclosed in WO 2007/134492 A1 a biodegradable plastic resin made from corn starch, tapioca, stearic acid, talc, glycerol, sorbitol, ethylene acrylic acid copolymer and completely biodegradable materials, which replaces the consumption of oil resources. The raw materials are mixed proportionally, and extruded by a modified twin screw extruder to produce a pellet. Film article made of the plastic resins has quick decomposition rate.
Besides of using bio-composition for making plastic resins degrade at a higher rate, the method of producing the plastic resins is also playing an important role for higher decomposition rate whilst maintaining the quality of the plastic resins. There area variety of producing methods invented by researchers in the polymer industries. Disclosed in the earlier cited arts, US 2007/0129467 A1 and WO 2007/134492 A1 , wherein the process of producing the biodegradable polymer comprises mixing and extruding the raw materials to obtain the final product.
Plastic extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. Control parameters during extrusion process therefore are vital to produce quality plastic resins with better mechanical and degradation behaviour. Moisture content in the plastic resins would affect the biodegradation rate too. According to Sina Ebnesajjad in Handbook of Biopolymers and Biodegradable Plastics: Properties, Processing and Applications, biodegradation proceeded faster in the compost prepared with a moisture content of 65% than in the compost prepared with a moisture content of 45 and 55%. Therefore, a method to produce a controlled rheology and processing condition is needed in the art.
Disclosed in Patent Application with International Publication No. WO 2013/022851 A2 is methods and systems for controlling the moisture content of biodegradable and bioresorbable polymer resin during extrusion. During the extrusion, drying gas is passed through the polymer resin to remove moisture from the polymer resin, then, the moisture content of the polymer resin is maintained in a selected range. The method is specifically designed for making medical devices that are adapted to be implanted in a bodily lumen. Also, drying gas is used for controlling the moisture content. A simple yet cost effective method is thus needed as an alternative method to produce a biodegradable resin for replacing the existing method. Accordingly, it can be seen in the prior arts that there exists a need to provide a method of producing biodegradable resinswith higher degradable rate yet maintain themechanical properties of the resin. - References
• Sina Ebnesajjad, Biodegradability Testing of Compostable Polymer Materials, Handbook of Biopolymers and Biodegradable Plastics: Properties, Processing and Applications,2012. Summary of Invention
It is the objective of the present invention to provide a method of producing a biodegradable composite.
It is also the objective of the present invention to provide a method of producing & biodegradable composite under controlled rheology of the composite, thus enabling further processability ofthe pellets into finished productsby blowing, injection, and extrusion process.
Accordingly, these objectives may be achieved by following the method of the present invention. The present invention relates to a method of producing a biodegradable composite, characterised by the steps of: grinding starch into fine particles; grinding polyvinyl alcohol into fine particles; blending the ground starch in the range of 0-60% by total weight and ground polyvinyl alcohol in the range of 30-80% by total weight, with addition of additives to form a mixture; stabilizingthe mixture for a time period; subjecting the mixture to acontinuous kneadingprocess under various pressure and temperature to form non-porous material;extruding and cutting the non-porous material into pellet form; and stabilizingthe pellet for a time period to produce a biodegradable composite having controlled moisture content and rheology for further processing.
Brief Description of the Drawings The features of the invention will be more readily understood and appreciated from the following detailed description when read in conjunction with the accompanying drawings of the preferred embodiment of the present invention, in which: Fig. 1 is a flow chart ofa method of producing a biodegradable composite in accordance to the present invention.
Detailed Description of the Invention
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for claims. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words "include," "including," and "includes" mean including, but not limited to. Further, the words "a" or "an" mean "at least one" and the word "plurality" means one or more, unless otherwise mentioned. Where the abbreviations or technical terms are used, these indicate the commonly accepted meanings as known in the technical field. For ease of reference, common reference numerals will be used throughout the figures when referring to the same or similar features common to the figures. The present invention will now be described with reference to Fig. 1.
The present invention relates toa method of producing biodegradable composite with controlled rheology fromstarchsuch as tapioca starch, corn starch, natural starch or modified starch. The method of producing a biodegradable compositecharacterised by the steps of:
grinding starch into fine particles; grinding polyvinyl alcohol into fine particles;
blending the ground starch in a range of 0-60% by total weight and ground polyvinyl alcohol in a range of 30-80% by total weight, with addition of additives to form a mixture;
stabilizingthe mixture for a time period;
subjecting the mixture to acontinuous kneading process to form non-porous material;
extruding and cuttingthe non-porous material into pellet form; and stabilizingthe pellet for a time period to produce a biodegradable composite having controlled moisture content and rheology for further processing.
In a preferred embodiment of the method of producing a biodegradable composite, the starch is tapioca starch, corn starch, natural starch, or modified starch. In a preferred embodiment of the method of producing a biodegradable composite, the starch is ground to particle size of 25 - 40 microns.
In a preferred embodiment of the method of producing a biodegradable composite, the polyvinyl alcohol is ground to particle size of 75 - 150 micrcons.
In a preferred embodiment of the method of producing a biodegradable composite, the additives comprise of water, urea, anti-blocking agent, organic plasticizer, anti-freezing agent, buffer, amide compatibiliser, acrylic modifier, elastomer, and proprietary additives.
In a preferred embodiment of the method of producing a biodegradable composite, the ground starch and ground polyvinyl alcohol are blended with addition of additives at temperature of 60-80°C.
In a preferred embodiment of the method of producing a biodegradable composite, the ground starch and ground polyvinyl alcohol are blended with addition of additives for 30 - 60 minutes. In a preferred embodiment of the method of producing a biodegradable composite, the blended mixture is cooled to a temperature of 40-50°C before being stabilized. In a preferred embodiment of the method of producing a biodegradable composite, the mixture is stabilized in atmospheric condition to let the additives befuily absorbed in the mixturefor a time period of 24-48 hours.
In a preferred embodiment of the method of producing a biodegradable composite, the continuous kneading process comprises the steps of intensive mixing and compressing the mixture to form non-porous material, followed by extruding and cutting into pellet form.
In a preferred embodiment of the method of producing a biodegradable composite, the continuous kneadingprocess is performed at a temperature in a range of 60°C to 170°C.
In a preferred embodiment of the method of producing a biodegradable composite, the continuous kneading process is performed under high pressure between 3000 - 15000 kilopascals (kPa) to control moisture content of the mixture.
In a preferred embodiment of the method of producing a biodegradable composite, the pellet is stabilized for a time period of minimum one dayin atmospheric condition to obtain biodegradable composite in pelletform which eliminatesshrinkage property and possesses goodflow processablity when being processed by blow, injection, and extrusion machinesinto finished product.
Firstly, starch is obtained and ground to break the particles into fine particles with particle size of 25 - 40 microns.Polyvinyl alcohol is obtained in solid form and ground to break the particles to a particle size of 75 - 150 microns.
The ground starch and ground polyvinyl alcohol is then blended in a high shear mixer, wherein 0-60% by total weight of ground starch and 30-80% by total weight of ground polyvinyl alcohol are mixed. The mixer for blending the particles of ground starch and ground polyvinyl alcohol is not limited to a high shear mixer, but any other blending tools may be used to obtain the desired mixing result. Additives including water, urea, anti-blocking agent, organic plasticizer, anti-freezing agent, buffer, amide compatibiliser, acrylic modifier, elastomer, and proprietary additives are added to the ground starch and ground polyvinyl alcohol while blending in the high shear mixer to form a mixture. The organic plasticiser is preferablypolyhydric alcoholincluding glycerine,glycol, or esters. The anti-blocking agent is preferably silica. The anti-freezing agent is preferably but not limited to glycol and glycerine. The buffer used in the present invention is preferably borax. The amide compatibiliser is preferably formamide. The acrylic modifier and elastomer is preferably ethylene maleat butyl acrylate. The elastomer is preferably ethylene vinyl acetate (EVA).
The step of blending the ground starch and ground polyvinyl alcohol with addition of additives is carried out at a temperature range of 60-80°C for 30-60 minutes. The blended mixture is then cooled to a temperature of 40-50°C.
After the mixture is cooled, the mixture is left for a time period of 24-48 hours for stabilizingprocess in atmospheric condition.
Thereafter, the stabilized mixture is subjected to a continuous kneading process to form the non-porous material. The continuous kneading process comprises the steps of intensive mixing in a continuous kneaderand compressing the mixture under controlled condition. The continuous kneading process involves cooking the mixture at a temperature in a range of 60°C to 170°C, under high pressure in the range of 3000-15000 kPa to control moisture content of the mixture during mixing and compressing. During the continuous kneading process at a high temperature, the water does not evaporate and turn into steam due to the high pressure control in the continuous kneader, therefore the water content in the mixture can be controlled.
The continuous kneadercomprises a specially design screws, wherein during kneading, the screws turn to knead and squeeze the particles to form homogenous non-porous material.
Next, the non-porous material is fed into an extruder and further cut into pellet form by a pelletizer and stabilizedfor a time period of minimum one day to obtain the biodegradable composite. The stabilizedbiodegradable compositeis subjected to further processing into finished goods by blowing process, extrusion process, injection process, etc.
Below is an example of a method of producing a biodegradable composite from which the advantages of the present invention may be more readily understood. It is to be understood that the following example is for illustrative purpose only and should not be construed to limit the present invention in any way.
- Examples
Tapioca starchwas ground into particle size of 25 - 40 microns and polyvinyl alcohol was ground into particle size of 75 - 150 micrcons separately. The ground starch and polyvinyl alcohol was blended in a mixer at 60-80°C for 30-60 minutes, with addition ofadditives including water, urea, silica, glycol, glycerine, borax, formamide, ethylene maleat butyl acrylate, ethylene vinyl acetate (EVA), and proprietary additives.The mixture Was cooled to 40-50°Cand left for stabilizationfor 24-48 hours. Then, the mixture was undergone continuous kneading process at 60-170°C under high pressure between 3000-15000 kPato control moisture content of the mixture. The continuos kneading process included intensive mixingand compressing the mixture in a continuous kneaderto form non-porous material. Then, the non-porous material was fed into an extruder and furthercut into pellet form in a pelletizer and stabilizedfor one day to obtain the biodegradable composite with 4-15%moisture content. Although the present invention has been described with reference to specific embodiments, also shown in the appended figures, it will be apparent for those skilled in the art that many variations and modifications can be done within the scope of the invention as described in the specification and defined in the following claims.

Claims

Claims
I/We claim: . A method of producing a biodegradable composite, characterised by the steps of:
grinding starch into fine particles;
grinding polyvinyl alcohol into fine particles;
blending the ground starch in arange of 0 - 60% by total weight and ground polyvinyl alcoholinarange of 30 - 80% by total weight.with addition ofadditives to form a mixture;
stabilizingthe mixture for a time period;
subjecting the mixture to continuous kneading process to form non-porous material;
extruding and cutting the non-porous material into pellet form; and stabilizing the pellet for a time period to produce processable biodegradable composite.
2. A method of producing a biodegradable composite according to claim 1 , wherein the biodegradable composite comprises 4-15% moisture content.
3. A method of producing a biodegradable composite according to claim 1 , wherein the starch is tapioca starch, corn starch, natural starch, or modified starch.
4. A method of producing a biodegradable compositeaccording to claim 1 , wherein the starch is ground to particle size of 25 - 40 microns.
5. A method of producing a biodegradable composite according to claim 1 , wherein the polyvinyl alcohol is ground to particle size of 75 - 150 microns.
A method of producing a biodegradable composite according to claim 1 , wherein the additivescomprise ofwater, urea, anti-blocking agent, organic plasticizer, anti-freezing agent, buffer, amide compatibiliser, acrylic modifier, elastomer, and proprietary additives.
7. A method of producing a biodegradable composite according to claim 1 , wherein the ground starch and ground polyvinyl alcohol are blended with addition of additivesat temperature of 60-80°C.
8. A method of producing a biodegradable composite according to claim 1 , wherein the ground starch and ground polyvinyl alcohol are blended with addition of additivesfor 30 - 60minutes.
9. A method of producing a biodegradable composite according to claim 1 , wherein the blended mixture is cooled to a temperature of 40-50°Cbefore being stabilized.
10. A method of producing a biodegradable composite according to claim 1 , wherein the mixture is stabilizedfor a time period of 24-48 hours.
11. A method of producing a biodegradable composite according to claim 1 , wherein the continuous kneadingprocess comprises the steps of intensive mixing and compressing the mixture to form non-porous material.
12. A method of producing a biodegradable composite according to claim 1 , wherein the continuous kneadingprocess is performed at a temperature in a range of 60°C to 170°C.
13. A method of producing a biodegradable compositeaccording to claim 1 , wherein the continuous kneading process is performed under high pressurebetween 3000 - 15000kPato controlmoisture content of the mixture. A method of producing a biodegradable composite according to claim 1 , wherein the pellet is stablizedfor a time period of minimum one day in atmospheric condition to obtain the biodegradable composite.
PCT/ID2014/000008 2013-10-25 2014-08-21 A method of producing biodegradable composite WO2015059685A1 (en)

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CN114591582A (en) * 2022-03-18 2022-06-07 深圳市明星盛包装集团有限公司 Photo-biodegradable plastic film and preparation method thereof

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