Injection molded article and method of making the same

Abstract

A method of manufacturing an injection molded article, the method comprising: providing a flowable melt composition comprising cellulose diacetate, a viscosity-reducing additive, and a chemical blowing agent; introducing the flowable melt composition into a mold cavity of an injection molding machine; molding the flowable melt composition in the mold cavity at a pressure P, a temperature T, and a cycle time C to form the injection molded article having a length L and a density D in a range of 0.9 to 1.6 g / cc, wherein the method exhibits at least one of: a reduced pressure P, a reduced temperature T, a shortened cycle time C, when compared to an injection molded article using a melt composition identical to the flowable melt composition of the present application but not containing the chemical blowing agent.

Description

Technical Field

[0001] The embodiments herein disclose a method for manufacturing injection-molded articles formed from biodegradable and / or compostable cellulose ester formulations, and said injection-molded articles. Background Technology

[0002] Many plastic products (such as rigid cutlery and foam food packaging) are single-use items intended to be disposed of after use. However, many commonly used plastics (such as polystyrene) are neither compostable nor biodegradable. Furthermore, some cities, states, and countries have enacted or are considering bans on the use of polystyrene-based materials. Therefore, there is a desire to find alternative materials for plastic products, as well as feasible compositions, methods, and systems for producing such products. Summary of the Invention

[0003] In some embodiments herein, a method for manufacturing an injection-molded article is provided, the method comprising: providing a flowable melt composition comprising cellulose diacetate, a viscosity-reducing additive, and a chemical foaming agent decomposable to form carbon dioxide, water, or nitrogen; introducing the flowable melt composition into a mold cavity of an injection molding machine; and molding the flowable melt composition in the mold cavity at a pressure P, a temperature T, and a cycle time C to form the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 g / cc. The method is described as follows: psi, temperature T is 400 to 560 degrees Fahrenheit, and cycle time C is 8 to 30 seconds; wherein the method exhibits at least one of the following: pressure P is reduced by 5% to 40% compared to the injection molding pressure P2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the chemical foaming agent; temperature T is reduced by 1% to 15% compared to the injection molding temperature T2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the chemical foaming agent; and cycle time C is reduced by 2% to 30% compared to the injection molding cycle time C2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the chemical foaming agent.

[0004] In other embodiments of this document, a method for manufacturing an injection-molded article is provided, the method comprising: providing a flowable melt composition comprising cellulose diacetate, a viscosity-reducing additive, and a physical foaming agent; introducing the flowable melt composition into a mold cavity of an injection molding machine; and molding the flowable melt composition in the mold cavity at a pressure P, a temperature T, and a cycle time C to form the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 g / cc. The method is described as follows: psi, temperature T is 400 to 560 degrees Fahrenheit, and cycle time C is 8 to 30 seconds; wherein the method exhibits at least one of the following: pressure P is reduced by 5% to 40% compared to the injection molding pressure P2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the physical foaming agent; temperature T is reduced by 1% to 15% compared to the injection molding temperature T2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the physical foaming agent; and cycle time C is reduced by 2% to 30% compared to the injection molding cycle time C2 required to form an injection-molded article using a melt composition with the same formulation as the flowable melt composition but without the physical foaming agent.

[0005] In a further embodiment of this document, an injection-molded article is provided, the article being formed from a flowable melt composition comprising: cellulose diacetate, a viscosity-reducing additive, and a foaming agent, wherein the flowable melt composition is configured to be injected into a mold cavity of an injection molding machine, wherein when the flowable melt composition is injected into the mold cavity of the injection molding machine under pressure P, temperature T, and cycle time C, the flowable melt composition forms the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 psi, the temperature T is 400 to 560 degrees Fahrenheit, and the cycle time C is 8 to 30 seconds; wherein the injection-molded article exhibits a density D2 that is reduced by 0.5% to 20% compared to an injection-molded article formed under the same conditions using a melt composition with the same formulation as the flowable melt composition but without the foaming agent.

[0006] In one or more embodiments herein, the chemical foaming agent is selected from sodium bicarbonate, monosodium citrate, zinc stearate, aliphatic polyester, poly(butylene succinate-co-butylene adipate), caprolactone, and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

[0007] In one or more embodiments herein, the physical blowing agent is selected from hydrocarbons, chlorofluorocarbons, nitrogen, carbon dioxide, alcohols, ketones, methyl esters, and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

[0008] In one or more embodiments herein, the cellulose diacetate is present in an amount of 50 to 80% by weight of the flowable melt composition.

[0009] In one or more embodiments herein, the cellulose diacetate exhibits one or more of the following properties: a degree of acetyl substituent substitution (DSAC) of 2.2 to 2.8 per dehydrated glucose unit (AGU); a metal to sulfur molar ratio (M / S) of 1.35 to 5.0; or a number-average molecular weight (Mn) of 10,000 g / mol to 100,000 g / mol according to ASTM D6474.

[0010] In one or more embodiments herein, the viscosity-reducing additive is present in an amount of 2 to 40% by weight of the flowable melt composition.

[0011] In one or more embodiments herein, the viscosity-reducing additive is selected from triacetin, diacetin, dibutyl terephthalate, dimethyl phthalate, diethyl phthalate, polyethylene glycol with a molecular weight of 200 to 600 g / mol, triethylene glycol dipropionate, 1,2-epoxypropylphenyl glycol, 1,2-epoxypropyl(m-tolyl)ethylene glycol, 1,2-epoxypropyl(o-tolyl)ethylene glycol, β-oxyethyl cyclohexenecarboxylate, di(cyclohexyl)diethylene glycol, triethyl citrate, polyethylene glycol, propylene glycol, polysorbate, sucrose octaacetate, acetylated triethyl citrate, acetylated tributyl citrate, triglyceride tripropionate, poloxamer copolymer, polyethylene glycol succinate, diisobutyl adipate, polyvinylpyrrolidone, and tribenzoic acid glycol ester, triethyl citrate, triethyl phthalate ... Ethyl acetate, triethyl acetylglucanate, polyethylene glycol, poly(alkyl succinate) such as poly(butyl succinate), polyethersulfone, adipate-based viscosity reducing additives, soybean oil epoxide, sucrose-based viscosity reducing additives, dibutyl sebacate, glyceryl tribanoate, glyceryl tripropionate, sucrose isobutyrate, Resolflex™ series viscosity reducing additives, triphenyl phosphate, glycolate, methoxy polyethylene glycol, 2,2,4-trimethylpentane-1,3-dimethylbis(2-methylpropionate), and polycaprolactone, and combinations of two or more thereof.

[0012] In one or more embodiments herein, the flowable melt composition is biodegradable and / or compostable.

[0013] In one or more embodiments herein, the flowable melt composition further comprises an alkaline filler present in an amount of 0.1 to 20% by weight of the flowable melt composition and / or a neutralizing agent present in an amount of 0.1 to 5% by weight of the flowable melt composition, the neutralizing agent being suitable for neutralizing free alkali in the flowable melt composition. Attached Figure Description

[0014] Figure 1 This is a schematic diagram illustrating another biodegradable article formation process according to an embodiment of the invention, which is specifically configured to form a rigid article; Figure 2 This describes an embodiment of the invention that can be used... Figure 3 A schematic diagram of the extrusion section in the process of forming hard articles; and Figure 3 It is a graph illustrating the injection flow length of various molten resins injected at various injection molding temperatures.

[0015] Figure 4 This is a graphic illustration of the thermal degradation of molded parts when subjected to various injection molding temperatures. Detailed Implementation

[0016] The embodiments generally relate to methods, systems, and compositions for forming biodegradable particulate materials (e.g., granules) and rigid articles. Exemplary processes including methods, systems, and compositions are described in... Figures 1 to 4 The description is presented in the text and will be further detailed below. Hard articles can include articles of various sizes and shapes, but in some embodiments, they include single-use cutlery such as knives, spoons, forks, etc.

[0017] Methods and Systems like Figure 1 and Figure 2 As shown, raw materials can be introduced into a biodegradable polymer production process, which produces biodegradable polymer materials. In one embodiment, or in combination with any other embodiment mentioned herein, the biodegradable polymer material comprises one or more cellulose esters. The one or more cellulose esters may include cellulose acetate. In such embodiments, the raw materials may include pulp, such as wood pulp and / or cotton pulp. The pulp may be a dissolving grade pulp and / or a paper grade pulp. The cellulose in the pulp may be esterified, for example, with acetate to form a biodegradable cellulose ester polymer, such as a cellulose acetate polymer.

[0018] The biodegradable polymer material can then be introduced into the compounding process, where it can be mixed with viscosity-reducing additives and optionally one or more other additives (e.g., stabilizers) to form a compound containing the viscosity-reducing biodegradable polymer. Other additives can also be mixed with the polymer and the viscosity-reducing additive. For example, such as... Figure 1 and Figure 2 As shown, other materials (additives) may include, but are not limited to, stabilizers, (multiple) physical foaming agents, (multiple) chemical foaming agents (and / or precursors), (multiple) nucleating agents, (multiple) pigments, (multiple) fillers and / or (multiple) other additives. Mixing can be accomplished by any known mixing technique, including but not limited to rolling in a cylindrical container, top stirring, sigma blade mixing and tumbling.

[0019] The compounding process may include a micronization process. A micronization process typically includes mixing a biodegradable polymer material, a viscosity-reducing additive, and (a variety of) other additives to form a compound composition and forming microparticles from said composition. In particular, the micronization process may include a granulation process, and the microparticles may include a quantity of granules. The term “compounded CE material” refers to a cellulose ester material formed during the compounding process, which may include a mixture of cellulose esters, viscosity-reducing additives, and other additives. Furthermore, such compounded CE materials may be in the form of microparticles (e.g., granules, powders, particles, fibers, etc.). It should be understood that, as used herein, the phrase “micronization” or “micronization process” may be synonymous with “granulation” or “granulation process”, or may at least include “granulation” or “granulation process”. In some embodiments, the micronization process may include granulation in a water bath, granulation on an air-cooled zone, underwater granulation, solvent compounding, etc.

[0020] In one embodiment, or in combination with any other embodiment mentioned herein, viscosity-reducing additives and (multiple) other additives can be blended with cellulose esters using conventional melt compounding techniques. These techniques involve combining the cellulose esters with the viscosity-reducing additives and optionally other additives at appropriate temperature and pressure in a twin-screw extruder with suitable mixing elements to obtain a molten, homogeneous mixture of cellulose esters as the material exits the extruder. The molten compounded cellulose ester mixture can then be extruded through a die having an orifice with a diameter of about 2 to 6 mm to extrude a filament. This filament can then be cooled with water (e.g., by underwater granulation) or air and cut at regular intervals to provide a uniform and desired size and shape, referred to as “granules” or “particles.” Although methods for forming granules are described herein, it will be understood that, according to some embodiments, the compound fed into the injection molding production process can be in any physical form (e.g., granules, powder, particles, fibers).

[0021] As described above, the compounded CE material (which may contain granules of a biodegradable polymer with reduced viscosity) can then be introduced into the production process of rigid articles, such as... Figure 1 and Figure 2 As shown. The rigid articles production area may include one or more steps / areas for preparing rigid articles (e.g., single-use tableware).

[0022] Hard products Rigid articles can be formed using injection molding from the flowable melt composition described herein. Certain cellulose ester-based polymers are difficult to injection mold due to their poor flow properties. Embodiments of the present invention have been found to improve the flow properties of the flowable melt composition used in the injection molding process by adding one or more foaming agents (BAs), such as chemical foaming agents (CBAs) or physical foaming agents (PBAs), for example, such as... Figure 2 As shown.

[0023] This flowable melt composition may have good flow properties, making it more suitable for manufacturing rigid articles by injection molding. For example, a flowable melt composition containing cellulose ester, viscosity-reducing additive, and BA can be injected into a mold using an injection molding machine at a lower pressure than required for injecting a basic melt composition containing the same cellulose ester and viscosity-reducing additive but without BA. For example, the mold may have a cavity (e.g., a cavity 0.5 inches wide and 0.3 inches thick). The flowable melt composition containing cellulose ester, viscosity-reducing additive, and BA can be injected into the mold using an injection molding machine at a first injection molding pressure P and injection molding temperature T for a cycle time C, such that the flowable melt composition forms a first article having a length L and a density of 0.9 to 1.6 g / cc. Similarly, a basic melt composition containing cellulose ester, viscosity-reducing additive, and without BA can be injected into the mold using an injection molding machine at a second injection molding pressure P2 and injection molding temperature T2 for a cycle time C2, such that the melt composition forms a second article having a length L and a density of 0.9 to 1.6 g / cc. It should be noted that a melt composition can be equivalent to a flowable melt composition containing BA, the difference being that the melt composition does not contain BA.

[0024] It is worth noting that the injection molding pressure P required to inject a flowable melt composition containing BA into a mold to form a given length L is 5% to 40%, 10% to 35%, 20% to 30%, and / or about 5% to 40% lower than the injection molding pressure P2 required to inject a basic CBA molten resin without BA into a mold to form a given length L. For example, if the standard injection molding pressure (i.e., P2) required to inject a BA-free melt composition is 17,000 to 67,000 psi, then the reduced injection molding pressure P required to inject a flowable melt composition containing BA may be 10,000 to 40,000 psi. Without being bound by theory, it can be assumed that the reduction in required pressure is likely due to the use of BA, which appears to improve the flowability of the flowable melt composition by at least partially and / or temporarily foaming the resin.

[0025] This enhanced flowability may also facilitate a reduction in the temperature required during injection molding. For example, a flowable melt composition comprising cellulose esters, viscosity-reducing additives, and BA can be injected into a mold using an injection molding machine at a first injection molding temperature T and an injection molding pressure P over a cycle time C, such that the flowable melt composition forms a first article having a length L and a density of 0.9 to 1.6 g / cc. Similarly, a melt composition comprising cellulose esters, viscosity-reducing additives, and BA-free can be injected into a mold using an injection molding machine at a second injection molding temperature T2 and an injection molding pressure P2, such that the melt composition forms a second article having a length L and a density of 0.9 to 1.6 g / cc.

[0026] It is worth noting that the injection molding temperature T required to inject a BA-containing flowable melt composition into a mold to form a given length L is 1% to 15%, 2% to 8%, 3% to 6%, and / or about 5% lower than the injection molding temperature T2 required to inject a BA-free basic BA molten resin into a mold to a given length L. For example, if the standard injection molding temperature (i.e., T2) required to inject a BA-free melt composition is 470 to 660 degrees Fahrenheit, then the reduced injection molding temperature T required to inject a BA-containing flowable melt composition may be 5 to 100 degrees Fahrenheit lower than T2. Figure 3 The figure illustrates the beneficial flow properties of a flowable melt composition containing BA (i.e., CBA) compared to a melt composition without BA. The graph plots the flow length (y-axis) of molten resin injected into a mold via an injection molding machine at various temperatures (x-axis). Comparative composition A resin comprises a BA-free melt composition, while composition 1 of the present invention resin comprises the same melt composition as comparative composition A, except that it also contains 2% by weight of BA. Figure 3 As shown, for each injection molding temperature between 440°F and 480°F, the flow length of the flowable melt composition containing BA (i.e., composition 1 of the present invention) is longer than that of the melt composition without BA (i.e., comparative composition A). Accordingly, a given flow length can be achieved at a lower injection molding temperature.

[0027] Without being limited by theory, it can also be considered that the use of BA in flowable melt compositions may help increase density and / or reduce shrinkage of rigid articles injection molded from flowable melt compositions. For example, a flowable melt composition containing cellulose ester, viscosity-reducing additive, and BA can be injected into a mold with a cavity (e.g., a cavity 5 inches long, 0.5 inches wide, and 0.3 inches thick) using an injection molding machine. When the flowable melt composition containing cellulose ester, viscosity-reducing additive, and BA is injected into the mold to completely fill the cavity, the flowable melt composition will form with a density of 0.9 g / cm³. 3 Up to 1.60 g / cm 3 The first article has a density D and a length L. Conversely, when a melt composition containing cellulose esters, viscosity-reducing additives, and BA is injected into a mold to completely fill the mold cavity, the flowable melt composition will form a second article having a density D2 and a length L2. Notably, the density D of the first article is 0.5% to 20% lower than the density D2 of the second article. In some specific embodiments, the density D of the first article is 1% to 15%, 2% to 10%, 3% to 7%, 4% to 6%, and / or about 5% lower than the density D2 of the second article. Additionally, the length L of the first article may be 0.01% to 0.08% greater than the length L2 of the second article. In some specific embodiments, the length L of the first article is 0.02% to 0.04% and / or about 0.03% greater than the length L2 of the second article.

[0028] Compared to BA-free melt compositions, the increased density and / or reduced shrinkage (as indicated by increased length) of BA-containing flowable melt compositions can effectively reduce the cycle time required to manufacture rigid articles from flowable melt compositions by injection molding. Cycle time is known to be the amount of time required for (1) injecting resin into a mold, (2) allowing the resin to cool within the mold to form the article, (3) opening the mold to eject the article, and (4) resetting the mold for the next cycle. It will generally be understood that the second step, involving cooling the resin within the mold, is the most time-consuming. Advantageously, it has been found that because BA-containing flowable melt compositions have increased density and / or reduced shrinkage compared to BA-free melt compositions, they provide more contact with the inner surfaces of the mold, which enhances the cooling of the flowable melt composition and thus reduces the cooling time required during each injection molding cycle. In some embodiments herein, the process exhibits a 2% to 30% reduction in cycle time C compared to the injection molding cycle time C2 required to form an injection-molded article using a melt composition formulated with the same flowable melt composition but without a chemical foaming agent. All individual values ​​and subranges are disclosed and included herein. For example, in some embodiments, the process exhibits a reduction in cycle time C within the range of 2%, 3%, 5%, 7%, or 10% to 30%, 28%, 25%, 23%, 20%, or 18% compared to the injection molding cycle time C2 required to form an injection-molded article using a melt composition formulated with the same flowable melt composition but without a chemical foaming agent.

[0029] More specifically, a flowable melt composition comprising cellulose ester, viscosity-reducing additive, and BA can be injected through an injection molding machine using cycle time C to form a first article having a length of, for example, 5 inches, a width of, for example, 0.5 inches, and a thickness of, for example, 0.3 inches. Similarly, a melt composition comprising cellulose ester, viscosity-reducing additive, and BA-free can be injected through an injection molding machine using cycle time C2 to form a second article having a length of 5 inches, a width of, and a thickness of 0.3 inches. For example, if the cycle time C2 required for injection molding an article from a BA-free melt composition is 12 to 42 seconds (or 12 to 15 seconds), the cycle time C required for injection molding an article from a BA-containing flowable melt composition may be as low as 0.2 to 13 seconds.

[0030] Flowable melt composition The above process may include preparing and extruding a flowable melt composition that can be downstream processed to form useful articles. For example, in one embodiment or in combination with any other embodiment mentioned herein, the extrusion feed material may comprise a particulate material comprising a biodegradable polymer, a viscosity-reducing additive, a foaming agent, and optionally one or more additives, such as those described herein. In one embodiment or in combination with any other embodiment mentioned herein, the feed material may be combined with one or more additives (such as those described herein) to provide a mixed composition comprising a biodegradable polymer, a viscosity-reducing additive, and one or more additives. In one embodiment or in combination with any other embodiment mentioned herein, the biodegradable polymer comprises a cellulose ester. Further details of the composition components, including the biodegradable polymer (e.g., a cellulose ester), the viscosity-reducing additive, and other additives, are provided below.

[0031] Cellulose esters The cellulose esters used as described herein can be any known in the art. Cellulose esters that can be used in the embodiments described herein typically comprise repeating units of the following structures:

[0032] Where R 1 R 2 and R 3 The substitution level of cellulose esters is independently selected from hydrogen, acetyl, propyl, or butyl. The degree of substitution in cellulose esters is typically expressed as the degree of substitution (DS), which is the average number of non-OH substituents in each adipose glucose unit (AGU). Generally, conventional cellulose contains three substituted hydroxyl groups in each AGU unit; therefore, DS values ​​can range from zero to three. Natural cellulose is a large polysaccharide with a degree of polymerization of 250–5,000 even after pulping and purification, and therefore the assumption of a maximum DS of 3.0 is roughly correct. Since DS is a statistical average, a value of 1 does not guarantee that each AGU has a single substituent. In some cases, unsubstituted adipose glucose units may be present, some with two substituents and some with three, and typically, the values ​​will be non-integer. Total DS is defined as the average number of all substituents in each adipose glucose unit. The degree of substitution per AGU can also refer to a specific substituent, such as, for example, hydroxyl or acetyl. In one implementation or in combination with any other implementation, n is an integer in the range of 25 to 250, or 25 to 200, or 25 to 150, or 25 to 100, or 25 to 75.

[0033] In one embodiment or in combination with any other embodiment, the cellulose ester has at least two dehydrated glucose rings and may have between at least 50 and up to 5,000 dehydrated glucose rings, or at least 50 and less than 150 dehydrated glucose rings. The number of dehydrated glucose units per molecule is defined as the degree of polymerization (DP) of the cellulose ester. In one embodiment or in combination with any other embodiment, the cellulose ester may have a specific logarithmic viscosity (IV) of about 0.2 to about 3.0 dL / g, or about 0.5 to about 1.8, or about 1 to about 1.5, as measured at 25°C for a 0.25 g sample in a 60 / 40 weight solution of phenol / tetrachloroethane. In one embodiment or in combination with any other embodiment, the cellulose esters available herein may have a DS / AGU of about 1 to about 3.0, about 2.2 to about 2.8, or 1 to less than 2.2, or 1 to less than 1.5, and the substituted ester is acetyl.

[0034] Cellulose esters can be produced by any method known in the art. Examples of methods for producing cellulose esters are taught in Kirk-Othmer, Encyclopedia of Chemical Technology, 5th Edition, Volume 5, Wiley-Interscience, New York (2004), pp. 394-444. Cellulose is the starting material used for the production of cellulose esters and can be obtained from various grades and sources, such as from cotton linters, softwood pulp, hardwood pulp, corn fiber and other agricultural sources, as well as bacterial cellulose.

[0035] One method for producing cellulose esters involves esterifying cellulose by mixing it with a suitable organic acid, anhydride, and catalyst. The cellulose is then converted into cellulose triesters. Ester hydrolysis is then carried out by adding a water-acid mixture to the cellulose triesters, followed by filtration to remove any gel particles or fibers. Water is then added to the mixture to precipitate the cellulose esters. The cellulose esters can then be washed with water to remove reaction byproducts, followed by dehydration and drying.

[0036] The cellulose triesters to be hydrolyzed may have three acetyl substituents. These cellulose esters can be prepared by many methods known to those skilled in the art. For example, cellulose esters can be prepared by reacting them with a catalyst (such as H2SO4). 4) Cellulose triesters are prepared by heterogeneous acylation of cellulose in a mixture of carboxylic acids and acid anhydrides in the presence of cellulose. Cellulose triesters can also be prepared by homogeneous acylation of cellulose dissolved in a suitable solvent (such as acetic acid, acetic anhydride and an acid catalyst, or alternatively, LiCl / DMAc or LiCl / NMP).

[0037] Those skilled in the art will understand that the commercial term cellulose triester also encompasses cellulose esters that are not fully acyl-substituted. For example, cellulose triacetate, commercially available from Eastman Chemical Company, Kingsport, TN, USA, typically has a DS of about 2.85 to about 2.99.

[0038] After esterification of cellulose to a trimer, some acyl substituents can be removed by hydrolysis or alcoholysis to obtain secondary cellulose esters. As mentioned earlier, the distribution of acyl substituents can be random or non-random, depending on the specific method employed. Secondary cellulose esters can also be prepared directly without hydrolysis using a limited amount of acylating agent. This method is particularly useful when the reaction is carried out in a solvent in which cellulose is dissolved. All these methods yield cellulose esters suitable for use in this invention.

[0039] In one embodiment or in combination with any of the mentioned embodiments, cellulose acetate is cellulose diacetate having a polystyrene equivalent number-average molecular weight (Mn) of about 10,000 to about 100,000, said number-average molecular weight being measured by gel permeation chromatography (GPC) using NMP as a solvent and polystyrene equivalent Mn according to ASTM D6474. In one embodiment or in combination with any other embodiment, the flowable melt composition comprises cellulose diacetate having a concentration of 10,000 to 90,000; or 10,000 to 80,000; or 10,000 to 70,000; or 10,000 to 60,000; or 10,000 to less than 60,000; or 10,000 to less than 55,000; or 10,000 to 50,000; or 10,000 to less than 50,000; or 10,000 to less than 45,000; or 10,000 to 40,000; or 10,000 to 30,000; or 20,000 to less than 60,000; or 20,000 to less than 55,000; or 20,000 to The number-average molecular weight (Mn) of polystyrene equivalents is 50,000; or 20,000 to less than 50,000; or 20,000 to less than 45,000; or 20,000 to 40,000; or 20,000 to 35,000; or 20,000 to 30,000; or 30,000 to less than 60,000; or 30,000 to less than 55,000; or 30,000 to 50,000; or 30,000 to less than 50,000; or 30,000 to less than 45,000; or 30,000 to 40,000; or 30,000 to 35,000; said number-average molecular weight is measured by gel permeation chromatography (GPC) using NMP as solvent and according to ASTM D6474.

[0040] The most common commercial secondary cellulose esters are prepared by initial acid-catalyzed heterogeneous acylation of cellulose to form cellulose triesters. After obtaining a homogeneous solution of the cellulose triester in the corresponding carboxylic acid, the cellulose triester is then subjected to hydrolysis until the desired degree of substitution is achieved. Upon separation, atactic secondary cellulose esters are obtained. That is, the relative degree of substitution (RDS) of each hydroxyl group is approximately equal.

[0041] The cellulose esters used in this invention can be prepared using techniques known in the art and can be selected from various types of cellulose esters, such as those available, for example, from Eastman Chemical Company, Kingsport, TN, USA. Therefore, the cellulose esters used in embodiments of this invention can include cellulose acetate (“CA”), cellulose acetate propionate (“CAP”), cellulose acetate butyrate (“CAB”), or combinations thereof. Such mixed cellulose esters can contain various proportions of acetyl, propyl, and butyryl groups; types; viscosity; and hydroxyl content.

[0042] In one embodiment or in combination with any other embodiment, cellulose esters can be prepared by converting cellulose into cellulose esters using reactants obtained from recycled materials (e.g., a syngas source from recycled plastic contents). In one embodiment or in combination with any other embodiment, such reactants can be cellulose reactants that include organic acids and / or anhydrides used in the esterification or acylation of cellulose, such as those discussed herein.

[0043] In one embodiment of the invention, or in combination with any of the mentioned embodiments, a flowable melt composition comprising at least one recycled cellulose ester is provided, wherein the cellulose ester has at least one substituent on a dehydrated glucose unit (AU) derived from recycled contents material (e.g., recycled plastic contents syngas).

[0044] In one embodiment or in combination with any other embodiment, the flowable melt composition comprises 50 to 99 wt%, or 60 to 99 wt%, or 70 to 99 wt%, or 80 to 99 wt%, or 90 to 99 wt%, or 50 to 90 wt%, or 60 to 90 wt%, or 70 to 90 wt%, or 80 to 90 wt%, or 90 to 99 wt%, or 50 to 80 wt%, or 60 to 80 wt%, or 70 to 80 wt%, or 50 to 70 wt%, or 60 to 70 wt%, or 50 to 60 wt%, all based on the total weight of the flowable melt composition. In some embodiments, the cellulose esters used herein may comprise a combination, blend, or mixture of two or more different types of cellulose esters. For example, in some embodiments, the cellulose esters used herein may consist of a blend of two or more cellulose esters with different DSACs; however, the blend may have a total DSAC between 2.2 and 2.8.

[0045] In some embodiments, the cellulose esters used herein have a preferred molar ratio (M / S) of metal to sulfur. For example, the molar ratio (M / S) of metal to sulfur in the cellulose ester (forming a virgin or recycled cellulose ester polymer) may be at least 1.35, or 1.35 to 10.0, or 1.35 to 8.0, or 1.35 to 6.0, or 1.35 to 5.0, or 1.4 to 10.0, or 1.4 to 8.0, or 1.4 to 6.0, or 1.4 to 5.0, or 1.45 to 10.0, or 1.45 to 8.0, or 1.45 to 6.0, or 1.45 to 5.0, or 1.5 to 10.0, or 1.5 to 8.0, or 1.5 to 6.0, or 1.5 to 5.0, where M is the total molar amount of metals selected from calcium, magnesium, potassium, sodium, and combinations thereof, and S is the number of moles of sulfur. It has been found that materials formed from such cellulose esters can produce resins and resulting articles with reduced polymer degradation. Therefore, the cellulose esters used herein (such as those from various cellulose ester feedstocks) may include at least some recycled cellulose ester material.

[0046] viscosity reducing additives In one embodiment or in combination with any other embodiment, the flowable melt composition described herein may contain at least one viscosity-reducing additive. The viscosity-reducing additive lowers the melt temperature (i.e., Tg) and / or melt viscosity of the cellulose ester. Viscosity-reducing additives for cellulose esters may include triacetin, diacetin, dibutyl terephthalate, dimethyl phthalate, diethyl phthalate, or poly(ethylene glycol) with a molecular weight of 200 to 600. (e.g., PEG400 or polyethylene glycol 400), dibutyl tartrate, di-2-methoxyethyl phthalate, ethyl benzoylbenzoate, triethylene glycol dipropionate, 1,2-epoxypropylphenyl glycol, 1,2-epoxypropyl(m-tolyl)ethylene glycol, 1,2-epoxypropyl(o-tolyl)ethylene glycol, β-oxyethyl cyclohexenecarboxylate, bis(cyclohexyl)diethylene glycol, triethyl citrate, polyethylene glycol, propylene glycol, polysorbate, sucrose octaacetate, acetylated triethyl citrate, acetylated tributyl citrate, Admex, glyceryl tripropionate, Scandiflex, poloxamer copolymer, polyethylene glycol succinate, diisobutyl adipate, polyvinylpyrrolidone, and tribenzoate glycol esters, viscosity-reducing additives containing benzoate esters. Additives (such as the Benzoflex™ series), poly(alkyl succinates) such as poly(butyl succinate), polyethersulfone, o-cresol p-toluenesulfonate, n-ethyltoluenesulfonamide, adipate-based viscosity-reducing additives, soybean oil epoxides (such as the Paraplex™ series), sucrose-based viscosity-reducing additives, dibutyl sebacate, glyceryl tribocate, sucrose isobutyrate, Resoflex™ series, triphenyl phosphate (TPP), triethyl phosphate (TEP), glycolates (e.g., ethyl phthaloyl ethyl glycolate "EPEG" and methyl phthaloyl ethyl glycolate "MPEG"), methoxy polyethylene glycol, 2,2,4-trimethylpentane-1,3-dimethylbis(2-methylpropionate), and polycaprolactone. In some embodiments, the viscosity-reducing additives used herein may comprise a combination or mixture of two or more different types of viscosity-reducing additives.

[0047] In one or in combination with any other implementation, the viscosity-reducing additive is food compliant. Food compliant means that it complies with applicable food additive and / or food contact regulations, i.e., the viscosity-reducing additive is approved for use or deemed safe by at least one (national or regional) food safety regulatory agency (or organization), such as being listed in the 21 CFR Food Additives Regulation or being generally considered safe (GRAS) by the U.S. FDA. In one or in combination with any other implementation, the food-compliant viscosity-reducing additive is triacetate or polyethylene glycol (PEG) with a molecular weight of about 200 to about 600. Examples of food-compliant viscosity-reducing additives that may be considered in one or in combination with any other implementation may include triacetate, triethyl citrate, polyethylene glycol, Benzoflex, propylene glycol, polysorbate, sucrose octaacetate, acetylated triethyl citrate, acetylated tributyl citrate, Admex, triglycerides, Scandiflex, poloxamer copolymer, polyethylene glycol succinate, diisobutyl adipate, polyvinylpyrrolidone, and tribenzoic acid glycol ester.

[0048] In one embodiment or in combination with any other embodiment, the presence of a viscosity-reducing additive may be sufficient to allow the flowable melt composition to be melt-processed (or thermoformed) into useful articles, such as single-use plastic articles, in conventional melt processing equipment. In one embodiment or in combination with any other embodiment, the presence of a viscosity-reducing additive, based on the weight of the flowable melt composition, is 1 to 40 wt% for most thermoplastic processing; or 5 to 25 wt%, or 10 to 25 wt%, or 12 to 20 wt%. In one embodiment or in combination with any other embodiment, based on the weight of the flowable melt composition, viscosity-reducing additive levels in the range of 10 to 30 wt%, or 12 to 25 wt%, or 15 to 20 wt%, or 10 to 25 wt% can be used to complete profile extrusion, sheet extrusion, thermoforming, and injection molding.

[0049] In one embodiment or in combination with any other embodiment, the viscosity-reducing additive is a biodegradable viscosity-reducing additive. Some examples of biodegradable viscosity-reducing additives include triacetin, triethyl citrate, acetyl triethyl citrate, polyethylene glycol, benzoate-containing viscosity-reducing additives (such as the Benzoflex™ series), poly(alkyl succinates) such as poly(butyl succinate), polyethersulfone, adipate-based viscosity-reducing additives, soybean oil epoxides (such as the Paraplex™ series), sucrose-based viscosity-reducing additives, dibutyl sebacate, glyceryl tribote, Resoflex™ series, triphenyl phosphate, glycolates, polyethylene glycol, 2,2,4-trimethylpentane-1,3-dimethylbis(2-methylpropionate), and polycaprolactone.

[0050] In one embodiment or in combination with any other embodiment, the flowable melt composition may contain a viscosity-reducing additive selected from PEG and MPEG (methoxy PEG). The polyethylene glycol or methoxy polyethylene glycol composition has an average molecular weight of 200 Daltons to 600 Daltons, and said composition is melt-processable, biodegradable, and disintegrable.

[0051] In one embodiment or in combination with any other embodiment, the composition comprises polyethylene glycol or methoxy PEG with an average molecular weight of 300 to 550 Daltons.

[0052] In one embodiment or in combination with any other embodiment, the composition comprises polyethylene glycol with an average molecular weight of 300 to 500 Daltons.

[0053] In one embodiment or in combination with any other embodiment, the flowable melt composition comprises at least one viscosity-reducing additive (as described herein) in an amount of 1 to 40% by weight, or 5 to 40% by weight, or 10 to 40% by weight, or 12 to 40% by weight, or 13 to 40% by weight, or 15 to 40% by weight, or greater than 15 to 40% by weight, or 17 to 40% by weight, or 20 to 40% by weight, or 25 to 40% by weight, or 5 to 35% by weight, or 10 to 35% by weight, or 13 to 35% by weight, or 15 to 35% by weight, or greater than 15 to 35% by weight, or 17 to 35% by weight, or 20 to 35% by weight, or 5 to 30% by weight, or 10 to 30% by weight, or 13 to 30% by weight, or 15 to 30% by weight. Or greater than 15 to 30% by weight, or 17 to 30% by weight, or 5 to 25% by weight, or 10 to 25% by weight, or 13 to 25% by weight, or 15 to 25% by weight, or greater than 15 to 25% by weight, or 17 to 25% by weight, or 5 to 20% by weight, or 10 to 20% by weight, or 13 to 20% by weight, or 15 to 20% by weight, or greater than 15 to 20% by weight, or 17 to 20% by weight, or 5 to 17% by weight, or 10 to 17% by weight, or 13 to 17% by weight, or 15 to 17% by weight, or greater than 15 to 17% by weight, or 5 to less than 17% by weight, or 10 to less than 17% by weight, or 13 to less than 17% by weight, or 15 to less than 17% by weight, all amounts being based on the total weight of the flowable melt composition.

[0054] In one embodiment or in combination with any other embodiment, the at least one viscosity-reducing additive comprises, or is a food-compliant or FDA-approved viscosity-reducing additive. In one embodiment or in combination with any other embodiment, the food-compliant or FDA-approved viscosity-reducing additive comprises, or is triacetin or PEG MW 300 to 500.

[0055] Biodegradable polymers In one embodiment or in combination with any other embodiment, the flowable melt composition described herein comprises a biodegradable cellulose ester (BCE) component, said BCE component comprising: at least one BCE, which may include one or more of the cellulose esters described herein; and a biodegradable polymer component, which comprises at least one other biodegradable polymer (not a BCE). In one embodiment or in combination with any other embodiment, said other biodegradable polymer may be selected from polyhydroxyalkanoates (PHA and PHB), polylactic acid (PLA), polycaprolactone polymer (PCL), polybutylene terephthalate (PBAT), polyethylene glycol succinate (PES), polyvinyl acetate (PVA), polybutylene succinate (PBS) and copolymers (such as polybutylene succinate-co-adipate (PBSA)), cellulose esters, cellulose ethers, starch, proteins, derivatives thereof, and combinations thereof. In one embodiment or in combination with any other embodiment, the flowable melt composition comprises two or more biodegradable polymers. In one embodiment or in combination with any other embodiment, the flowable melt composition contains a biodegradable polymer (not BCE) in an amount of 0.1 to less than 50% by weight, or 1 to 40% by weight, or 1 to 30% by weight, or 1 to 25% by weight, or 1 to 20% by weight, based on the total amount of BCE and the biodegradable polymer. In one embodiment or in combination with any other embodiment, the at least one biodegradable polymer comprises a weight-average molecular weight (Mw) of 10,000 to 1,000,000, or 50,000 to 1,000,000, or 100,000 to 1,000,000, or 250,000 to 1,000,000, or 500,000 to 1,000,000, or 600,000 to 1,000,000. The weight-average molecular weight of the PHA is in the range of 0, or 600,000 to 900,000, or 700,000 to 800,000, or 10,000 to 500,000, or 10,000 to 250,000, or 10,000 to 100,000, or 10,000 to 50,000, measured using gel permeation chromatography (GPC) with a refractive index detector and polystyrene standards using methylene chlorosol. In one embodiment or in combination with any other embodiment, the PHA may comprise polyhydroxybutyrate-co-hydroxyhexanoate.

[0056] foaming agent A foaming agent is a physical or chemical material (or combination of materials) used to expand nucleation sites. Foaming agents can include chemical foaming agents, physical foaming agents, combinations thereof, or several types of chemical and physical foaming agents. The function of a foaming agent is to reduce the density of a material by expanding the cells formed in the molten formulation at nucleation sites. Foaming agents can be added to flowable melt compositions in an extruder. It has been surprisingly found that the hygroscopic properties of biodegradable particulate natural fillers allow them to absorb moisture and carry the absorbed water into the molten resin mixture, where water can act as a physical foaming agent.

[0057] In some embodiments, the BA comprises an endothermic CBA. In some embodiments, the CBA is biodegradable. For example, in some embodiments, the CBA comprises citric acid and / or sodium bicarbonate. In some specific embodiments, the CBA comprises a combination of citric acid, sodium bicarbonate, and a carrier. When CBA is biodegradable, the carrier may comprise polybutylene succinate (i.e., PBSA or poly(butylene succinate-co-butylene adipate)) and / or polycaprolactone (i.e., caprolactone). In embodiments where CBA is non-biodegradable, the carrier may comprise polystyrene. In other embodiments, BA may comprise PBA, such as water. In any case, BA (i.e., CBA or PBA) may be present in the flowable melt composition in amounts of 0.1 to 5.0 wt%, 0.1 to 4.0 wt%, 0.1 to 3.0 wt%, 0.1 to 2.0 wt%, 0.25 to 2.0 wt%, 0.5 to 1.5 wt%, 0.75 to 1.25 wt%, or about 1.0 wt%. For example, when BA is a biodegradable CBA, CBA may be present at 0.1 to 5.0 wt%. When BA is a non-biodegradable CBA, CBA may be present at 0.1 to 2.0 wt%.

[0058] Examples of physical blowing agents include H2O, N2, CO2, alkanes, alkenes, ethers, ketones, argon, helium, air, or mixtures thereof. Additionally, it has been surprisingly found that the hygroscopic properties of biodegradable particulate natural fillers allow them to absorb moisture and carry the absorbed water into the molten resin mixture, where water can act as a physical blowing agent. Hygroscopic biodegradable natural fillers can be formulated into compositions that allow the absorption of moisture prior to the injection molding process, and then release the water during injection molding to act as a physical blowing agent. Advantageously, water can also be used as a plasticizer for cellulose ester resins. Furthermore, in some embodiments, the physical blowing agent may include hydrocarbons such as pentane / isopentane or butane / isobutane. Other hydrocarbons may include propane, ethane, methane, hexane, cyclohexane, cyclopentane, cyclobutene, etc.

[0059] Chemical blowing agents are materials that degrade or react to produce gases (e.g., CO2 or N2). Chemical blowing agents can be endothermic or exothermic. They typically degrade at specific temperatures to decompose and release gases. Examples of chemical blowing agents include azodicarbonamide, acids (e.g., citric acid), and carbonates such as sodium bicarbonate, sodium carbonate, ammonium bicarbonate, ammonium carbonate, zinc carbonate, and combinations thereof.

[0060] In one embodiment or in combination with any embodiment mentioned herein, the foaming agent is present at 0.3 to 1.5% by weight, or 0.3 to 2.0% by weight, or 0.3 to 2.5% by weight, or 0.3 to 3.0% by weight, or 0.3 to 3.5% by weight, or 0.3 to 4.0% by weight, or 0.3 to 8%, or 1.3 to 1.5% by weight, or 1.3 to 2.0% by weight, or 1.3 to 2.5% by weight, or 1.3 to 3.0% by weight, or 1%. 3 to 3.5% by weight, or 1.3 to 4.0% by weight, or 1.3 to 4.5% by weight, or 1.3 to 5.0% by weight, or 1.3 to 5.5% by weight, or 1.5 to 3.0% by weight, or 1.5 to 4.0% by weight, or 1.5 to 5.0% by weight, or 1.5 to 6.0% by weight, or 2.0 to 3.0% by weight, or 2.0 to 4.0% by weight, or 2.0 to 5.0% by weight, or 2.0 to 6.0% by weight, or 2.5 to 3% by weight. 0.0% by weight, or 2.5 to 4.0% by weight, or 2.5 to 5.0% by weight, or 2.5 to 6.0% by weight, or 3.0 to 4.0% by weight, or 3.0 to 5.0% by weight, or 3.0 to 6.0% by weight, or 0.0 to 9.0% by weight, or 0.5 to 9.0% by weight, or 1.0 to 9.0% by weight, or 1.5 to 9.0% by weight, or 2.0 to 9.0% by weight, or 2.5 to 9.0% by weight, or 3.0 to 9.0% by weight. The following amounts are present: % by weight, or 3.5 to 9.0% by weight, or 4.0 to 9.0% by weight, or 4.5 to 9.0% by weight, or 5.0 to 9.0% by weight, or 5.5 to 9.0% by weight, or 6.0 to 9.0% by weight, or 6.5 to 9.0% by weight, or 7.0 to 9.0% by weight, or 7.5 to 9.0% by weight, or 8.0 to 9.0% by weight, or 8.5 to 9.0% by weight, all based on the total weight of the flowable melt composition. In some embodiments, the blowing agent used herein may comprise a combination or mixture of two or more different types of blowing agents, such as two or more chemical blowing agents, two or more physical blowing agents, and / or a combination of chemical and physical blowing agents. In any case, in some embodiments, the blowing agent used may be biodegradable, such as a biodegradable chemical blowing agent, citric acid, and / or sodium bicarbonate. In some embodiments, biodegradable chemical foaming agents, citric acid, and / or sodium bicarbonate may be dispersed in a biodegradable carrier, such as polybutylene succinate, polycaprolactone, or a combination thereof.

[0061] alkaline filler The alkaline filler suitable for use in this invention is at least one selected from metal oxides, metal hydroxides, metal carbonates, and mixtures thereof. Blends of alkaline fillers can be used in flowable melt compositions. In one embodiment or in combination with any other embodiment, the alkaline filler is at least one selected from alkaline earth metal oxides, alkaline earth metal hydroxides, and alkaline earth carbonates.

[0062] Alkaline fillers possess specific physical properties. For suitability in application, the water solubility of alkaline fillers at 20-25°C is only effective within a specific range. If the water solubility is too high, the moisture in the melt-processed product will prematurely trigger a chemical reaction leading to disintegration. If the water solubility is too low, the alkaline ions (OH-) will... -1 or CO3 -2 It cannot be released from the filler. Furthermore, the pH of a 1% by weight solution or suspension of the alkaline filler should be pH 8 or higher, which is related to water solubility. If the pH is not 8 or higher, the conditions are not suitable for promoting the chemical reactions that promote disintegration. In one embodiment or in combination with any other embodiment, the pH of a 1% by weight solution or suspension of the alkaline filler is pH 8.5 or higher. In one embodiment or in combination with any other embodiment, the pH range of a 1% by weight solution or suspension of the alkaline filler can be about 8 to about 12, about 8 to about 11.5, about 8 to about 11, about 8 to about 10.5, about 8 to about 10; 8.5 to about 12, about 8.5 to about 11.5, about 8.5 to about 11, about 8.5 to about 10.5, about 8.5 to about 10, about 9 to about 12, about 9 to about 11.5, about 9 to about 11, and about 9 to about 10.5. Not all metal oxides, hydroxides, and carbonates are suitable in this invention. For example, aluminum oxide (Al2O3) and titanium dioxide (TiO2) are insoluble in water and do not react with water to form the corresponding hydroxides that alter the pH of the water.

[0063] "Alkalinity efficiency" is defined as the number of moles of base divided by the number of kilograms of alkaline filler. The alkalinity efficiency of an alkaline filler also determines its ability to promote disintegration through chemical action. Alkalinity efficiency is the number of moles of alkaline ions associated with a given mass of filler in the presence of water. For example, CaO and MgO react with water and form two moles of hydroxide ions (OH⁻). In formulations, alkaline fillers with higher alkalinity efficiency can promote the chemical reaction that leads to disintegration at lower filler loadings (in weight percent). Alkaline-catalyzed hydrolysis of esters requires a stoichiometric amount of alkaline catalyst because the resulting acid neutralizes and deactivates the alkaline catalyst.

[0064] For applicability in applications, the water solubility of alkaline fillers at 20 to 25°C should be greater than 1 ppm but less than 1,000 ppm.In other embodiments of the invention, the water solubility of the alkaline filler at 20 to 25°C is approximately 2 ppm to 1,000 ppm, approximately 2 ppm to 950 ppm, approximately 2 ppm to 900 ppm, approximately 2 ppm to 850 ppm, approximately 2 ppm to 800 ppm, approximately 2 ppm to 750 ppm, approximately 2 ppm to 700 ppm, approximately 2 ppm to 650 ppm, approximately 2 ppm to 600 ppm, approximately 2 ppm to 550 ppm, approximately 2 ppm to 500 ppm, approximately 2 ppm to 450 ppm, approximately 2 ppm to 400 ppm, approximately 2 ppm to 350 ppm, approximately 2 ppm to 300 ppm, approximately 3 ppm to 1,000 ppm, approximately 3 ppm to 950 ppm, approximately 3 ppm to 900 ppm, approximately 3 ppm to 850 ppm, approximately 3 ppm to 800 ppm, approximately 3 ppm to 800 ppm, approximately 3 ppm to 1,000 ppm, approximately 3 ppm to 950 ppm, approximately 3 ppm to 900 ppm, approximately 3 ppm to 85 ... ppm to about 750 ppm, about 3 ppm to about 700 ppm, about 3 ppm to about 650 ppm, about 3 ppm to about 600 ppm, about 3 ppm to about 550 ppm, about 3 ppm to about 500 ppm, about 3 ppm to about 450 ppm, about 3 ppm to about 400 ppm, about 3 ppm to about 350 ppm, about 3 ppm to about 300 ppm, 4 ppm to about 1,000 ppm, about 4 ppm to about 950 ppm, about 4 ppm to about 900 ppm, about 4 ppm to about 850 ppm, about 4 ppm to about 800 ppm, about 4 ppm to about 750 ppm, about 4 ppm to about 700 ppm, about 4 ppm to about 650 ppm, about 4 ppm to about 600 ppm, about 4 ppm to about 550 ppm, about 4 ppm to about 500 ppm, about 4 ppm to about 450 ppm, about 4 ppm to about 400 ppm, about 4 ppm to about 350 ppm, about 4 ppm to about 300 ppm, 5 ppm to about 1,000 ppm, about 5 ppm to about 950 ppm, about 5 ppm to about 900 ppm, about 5 ppm to about 850 ppm, about 5 ppm to about 800 ppm, about 5 ppm to about 750 ppm, about 5 ppm to about 700 ppm, about 5 ppm to about 650 ppm, about 5 ppm to about 600 ppm, about 5 ppm to about 550 ppm, about 5 ppm to about 500 ppm, about 5 ppm to about 450 ppm, about 5 ppm to about 400 ppm, about 5 ppm to about 350 ppm, and about 5 ppm to about 300 ppm.

[0065] In one embodiment or in combination with any other embodiment, the pH of a 1% by weight suspension of the alkaline filler should be 8 or higher, and the alkalinity efficiency should be at least 5. In one embodiment or in combination with any other embodiment, the alkalinity efficiency is at least 6, at least 7, at least 8, at least 9, or at least 10. The comparative properties of the selected alkaline fillers are shown below, where only some of the alkaline fillers meet all the criteria of this invention. Examples of alkaline fillers that meet the criteria include calcium carbonate (CaCO3), magnesium oxide (MgO), magnesium hydroxide (Mg(OH)2), magnesium carbonate (MgCO3), and barium carbonate (BaCO3). Effective and readily available alkaline fillers are calcium carbonate (CaCO3), magnesium oxide (MgO), magnesium hydroxide (Mg(OH)2), and magnesium carbonate (MgCO3). In addition, these alkaline fillers are particularly suitable for food contact applications.

[0066] In some embodiments herein, the basic filler is present in 1 to 25% by weight of the flowable melt composition. All individual values ​​and subranges are included herein and disclosed. For example, in some embodiments, the basic filler is present in a range from 1, 2, 5, 7, 10, 12, or 15% by weight of the flowable melt composition to 25, 23, 21, or 20% by weight.

[0067] In one embodiment or in combination with any other embodiment, the basic filler is a mixture of calcium carbonate and at least one of the following: magnesium oxide, magnesium hydroxide, or magnesium carbonate, wherein calcium carbonate is present in an amount of 1 to 25% by weight, and at least one of magnesium oxide, magnesium hydroxide, or magnesium carbonate is present in an amount of 1 to 20% by weight, all amounts based on the total weight of the flowable melt composition. In one embodiment or in combination with any other embodiment, the basic filler is a mixture of calcium carbonate and at least one of the following: magnesium oxide, magnesium hydroxide, or magnesium carbonate, wherein calcium carbonate is present in an amount of 5 to 15% by weight, and at least one of magnesium oxide, magnesium hydroxide, or magnesium carbonate is present in an amount of 1 to 20% by weight, all amounts based on the total weight of the flowable melt composition. In one embodiment or in combination with any other embodiment, the basic filler is a mixture of calcium carbonate and at least one of the following: magnesium oxide, magnesium hydroxide, or magnesium carbonate, wherein calcium carbonate is present in an amount of 5 to 10% by weight, and at least one of magnesium oxide, magnesium hydroxide, or magnesium carbonate is present in an amount of 1 to 20% by weight, all amounts based on the total weight of the flowable melt composition.

[0068] Basic fillers may undergo hydration. Blends of basic fillers can also be used to create basic conditions to promote disintegration. Basic fillers, hydrates, or blends can be natural or synthetic blends, compounds, or minerals. For example, magnesium carbonate can be mined from magnesite or prepared in the laboratory by reacting a soluble magnesium salt with sodium bicarbonate. Examples of hydrates and blends as minerals include basic magnesium carbonate (BMC, typically hydrated with 3 to 5 water molecules), hydromagnesite (4MgCO3·Mg(OH)2·3H2O), hydromagnesite (Mg5(CO3)4(OH)2·4H2O), spheroidal magnesite (4MgCO3·Mg(OH)2·5H2O), and dolomite (CaCO3·MgCO3). If soluble magnesium salts (e.g., magnesium chloride or magnesium sulfate) are treated with sodium carbonate or sodium bicarbonate, the resulting precipitate may include hydrated complexes of magnesium carbonate and / or magnesium hydroxide, such as [MgCO3·3H2O] or [4MgCO3·Mg(OH)2·4H2O], depending on the reaction temperature and CO2 partial pressure. Blends can also be formed by combining MgO, Mg(OH)2, and / or anhydrous or hydrated forms of MgCO3 with each other or with another mineral in the same water-soluble range (e.g., CaCO3 or BaCO3).

[0069] Neutralizing agent The melt-processable, flowable melt composition also contains at least one neutralizing agent. A neutralizing agent is also required in the formulation to manage basicity or free base as a color source. The neutralizing agent is a carboxylic acid with a first pKa in the range of about 2 to about 7 or about 2 to about 6. Examples of neutralizing agents include, but are not limited to, citric acid, malic acid, succinic acid, adipic acid, fumaric acid, formic acid, lactic acid, maleic acid, tartaric acid, malonic acid, glutamic acid, glutaric acid, gluconic acid, isophthalic acid, terephthalic acid, glycolic acid, itaconic acid, ferulic acid, mandelic acid, aconitic acid, benzoic acid, aspartic acid, and vanillic acid.

[0070] In one embodiment or in combination with any other embodiment, the neutralizing agent is selected from citric acid, malic acid, succinic acid, adipic acid, and fumaric acid, particularly suitable for flowable melt compositions in food contact applications. In one embodiment or in combination with any other embodiment, the neutralizing agent is selected from citric acid, adipic acid, or fumaric acid.

[0071] The minimum amount of neutralizing agent is sufficient to neutralize the free base in the flowable melt composition. However, an excess amount may be added. In one embodiment or in combination with any other embodiment, about 0.5% to about 5% by weight of neutralizing agent is added based on the weight of the flowable melt composition. In one embodiment or in combination with any other embodiment, the neutralizing agent is added at about 0.5% to about 5% by weight, or about 0.5% to about 4.5% by weight, or about 0.5% to about 4% by weight, or about 0.5% to about 3.5% by weight, or about 0.5% to about 3% by weight, or about 0.5% to about 2.5% by weight, or about 0.5% to about 2% by weight, or about 0.5% to about 1% by weight, or about 1.5% to about 5% by weight, or about 1.5% to about 4.5% by weight, or about 1% to about 5% by weight, or about 1% to about 4.5% by weight, or about 1% to about 4% by weight. The following amounts are present, or about 1 wt% to about 3.5 wt%, or about 1 wt% to about 3 wt%, or about 1 wt% to about 2.5 wt%, or about 1.5 wt% to about 5 wt%, or about 1.5 wt% to about 4.5 wt%, or about 1.5 wt% to about 4 wt%, or about 1.5 wt% to about 3.5 wt%, or about 1.5 wt% to about 3 wt%, or about 1.5 wt% to about 2.5 wt%, or about 2 wt% to about 5 wt%, or about 2 wt% to about 4.5 wt%, or about 2 wt% to about 4 wt%, or about 2 wt% to about 3.5 wt%, or about 2 wt% to about 3 wt%, respectively, based on the weight of the flowable melt composition. Products Rigid articles can be formed by injection molding from a flowable melt composition. This flowable melt composition may advantageously include one or more chemical foaming agents, as described below, which can improve the flowability of the resin during injection molding. Example articles include straws, cups, lids, trays, bowls, pots, cutlery (e.g., forks, knives, spoons, etc.). In some embodiments, the articles may be single-use items, such as cutlery (e.g., forks, knives, spoons, etc.). Alternatively, the articles may be multi-use items, such as cups, bowls, pots, etc. The articles may have one or more particularly advantageous properties. For example, the articles may be biodegradable, compostable, recyclable, and / or the articles may have excellent mechanical properties (e.g., strength, density, cell size, absorption, etc.).

[0072] In one embodiment or in combination with any embodiment described herein, the density of the rigid article can be greater than 0.90 g / cm³. 3 Greater than 1.0 g / cm 3 Greater than 1.10 g / cm 3 Greater than 1.20 g / cm3 Greater than 1.30 g / cm 3 Greater than 1.40 g / cm 3 Greater than 1.50 g / cm 3 and / or not exceeding 1.60 g / cm 3 Not exceeding 1.50 g / cm 3 Not exceeding 1.40 g / cm 3 Not exceeding 1.30 g / cm 3 Not exceeding 1.20 g / cm 3 Not exceeding 1.10 g / cm 3 Or not exceeding 1.0 g / cm 3 In some implementations, the rigid article will have a density of 0.90 g / cm³. 3 Up to 1.60 g / cm 3 1.00 g / cm 3 Up to 1.60 g / cm 3 1.10 g / cm 3 Up to 1.60 g / cm 3 1.20 g / cm 3 Up to 1.60 g / cm 3 1.30 g / cm 3 Up to 1.60 g / cm 3 1.40 g / cm 3 Up to 1.60 g / cm 3 1.50 g / cm 3 Up to 1.60 g / cm 3 0.90 g / cm 3 Up to 1.50 g / cm 3 1.00 g / cm 3 Up to 1.50 g / cm 3 1.10 g / cm 3 Up to 1.50 g / cm 3 1.20 g / cm 3 Up to 1.50 g / cm 3 1.30 g / cm 3 Up to 1.50 g / cm 3 1.40 g / cm 3 Up to 1.50 g / cm 3 0.90 g / cm 3 Up to 1.40 g / cm 3 1.00 g / cm 3 Up to 1.40 g / cm 3 1.10 g / cm 3Up to 1.40 g / cm 3 1.20 g / cm 3 Up to 1.40 g / cm 3 1.30 g / cm 3 Up to 1.40 g / cm 3 0.90 g / cm 3 Up to 1.30 g / cm 3 1.00g / cm 3 Up to 1.30 g / cm 3 1.10 g / cm 3 Up to 1.30 g / cm 3 1.20 g / cm 3 Up to 1.30 g / cm 3 0.90 g / cm 3 Up to 1.20 g / cm 3 1.00 g / cm 3 Up to 1.20 g / cm 3 1.10 g / cm 3 Up to 1.20 g / cm 3 0.90 g / cm 3 Up to 1.10 g / cm 3 1.00 g / cm 3 Up to 1.10 g / cm 3 and / or 0.90 g / cm 3 Up to 1.00 g / cm 3 The density.

[0073] definition It should be understood that the following is not intended to be an exhaustive list of the defined terms. Other definitions may be provided in the foregoing description, for example, when used in the context of a defined term.

[0074] As used herein, the terms “a / an” and “the” mean one or more species.

[0075] As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transitional terms used to transition from a subject listed before the term to one or more elements listed after the term, wherein the one or more elements listed after the transitional term are not necessarily the only elements constituting the subject.

[0076] To be considered “compostable,” a material must meet the following four criteria: (1) the material must pass the biodegradation requirement in a test at elevated temperature (58°C) under controlled composting conditions according to ISO 14855-1 (2012), which corresponds to 90% absolute biodegradation or 90% relative biodegradation compared to a control polymer; (2) the material must achieve 90% disintegration under aerobic composting conditions according to ISO 16929 (2013); (3) the tested material must meet all requirements for volatile solids, heavy metals, and fluorine as specified in ASTM D6400 (2012), EN 13432 (2000), and ISO 17088 (2012); and (4) the material should not have a negative impact on plant growth.

[0077] As used herein, the term "biodegradable" generally refers to the biotransformation and consumption of organic molecules. Biodegradability is an inherent property of a material, and materials can exhibit varying degrees of biodegradability depending on the specific conditions under which they are exposed. The term "disintegrable" refers to the tendency of a material to physically break down into smaller fragments when exposed to specific conditions. Disintegration depends on both the material itself and the physical size and structure of the article being tested. Ecotoxicity measures the effects of materials on plant life and determines the heavy metal content of the material according to procedures specified in standard testing methods.

[0078] According to French standard NF T 51-800 and Australian standard AS 5810, for a material to be considered "biodegradable" under home composting conditions, it must exhibit at least 90% total biodegradation (e.g., compared to the initial sample), or at least 90% of the maximum biodegradation of a suitable reference material after both the reference and test articles have reached a stabilization period. The maximum testing period for biodegradation under home composting conditions is one year.

[0079] According to ASTM D6400 and ISO 17088, to be considered "biodegradable" under industrial composting conditions, at least 90% of the organic carbon in the entire article (or for each component present in amounts exceeding 1% by dry mass) must be converted to carbon dioxide by the end of the test period, compared to a control or absolute value. According to European Standard ED 13432 (2000), the material must exhibit at least 90% total biodegradation, or at least 90% of the maximum biodegradation of a suitable reference material after both the reference and test articles have reached a stabilization period. The maximum test duration for biodegradability under industrial composting conditions is 180 days.

[0080] According to Vinçotte's OK biodegradable soil conformity mark and DIN CERTCO's DIN Geprüft soil biodegradability certification scheme, to be considered "biodegradable" under soil composting conditions, a material must exhibit at least 90% total biodegradation (e.g., compared to the initial sample), or at least 90% of the maximum degradation of a suitable reference material after both the reference and test articles have reached a stabilization period. The maximum testing period for biodegradability under soil composting conditions is 2 years.

[0081] In one embodiment or in combination with any embodiment mentioned herein, the biodegradable rigid article is industrially compostable or household compostable. In one subclass of this category, the rigid article is industrially compostable. In one sub-subclass of this category, the rigid article has a thickness of less than 6 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 3 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 1.1 mm. In one subclass of this category, the rigid article is household compostable. In one sub-subclass of this category, the rigid article has a thickness of less than 6 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 3 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 1.1 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 0.8 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 0.6 mm. In one sub-subclass of this category, the rigid article has a thickness of less than 0.4 mm.

[0082] In one embodiment or in combination with any of the embodiments mentioned herein, the thickness of the rigid article is 1 to 10 mm, 1 to 8 mm, 2 to 8 mm, 3 to 7 mm, 4 to 6 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, or about 8 mm. However, it should be noted that the rigid article may have other larger sizes. For example, in some embodiments, the rigid article may have a thickness of 0.5 to 24 inches, 1 to 15 inches, or 3 to 12 inches.

[0083] In one embodiment or in combination with any embodiment mentioned herein, as described in the specification, the rigid article exhibits greater than 90% disintegration after 12 weeks, according to the disintegration test protocol for membranes.

[0084] Compositions for preparing biodegradable rigid articles may contain other additives, such as fillers, stabilizers, odor modifiers, waxes, compatibilizers, biodegradation promoters, dyes, pigments, colorants, lubricants, antioxidants, viscosity modifiers, antifungal agents, heat stabilizers, antibacterial agents, softeners, release agents, UV absorbers, and combinations thereof. Each additional additive may be present in the cellulose ester-based material in an amount less than 10% by weight, less than 5% by weight, less than 4% by weight, less than 3% by weight, less than 2% by weight, or less than 1.0% by weight. It should be noted that compounds or materials of the same type may be identified or included in multiple component classes for flowable melt compositions. For example, polyethylene glycol (PEG) may act as a viscosity-reducing additive or as an additive that does not act as a viscosity-reducing additive, such as a hydrophilic polymer or a biodegradation promoter, for example, where lower molecular weight PEG has a plasticizing effect, while higher molecular weight PEG acts as a hydrophilic polymer but does not have a plasticizing effect.

[0085] In one embodiment or in combination with any other embodiment mentioned herein, the hard composition further comprises a photodegradation catalyst. In one category of this embodiment, the photodegradation catalyst is titanium dioxide or iron oxide. In a subcategory of this category, the photodegradation catalyst is titanium dioxide. In a subcategory of this category, the photodegradation catalyst is iron oxide.

[0086] In one embodiment or in combination with any other embodiment mentioned herein, the rigid composition further comprises a pigment. In one category of this embodiment, the pigment is titanium dioxide, carbon black, or iron oxide. In a subcategory of this category, the pigment is titanium dioxide. In a subcategory of this category, the pigment is carbon black. In a subcategory of this category, the pigment is iron oxide. In a subcategory of this category, the pigment is a biodegradable particulate natural filler.

[0087] Example Table 1 - Test Methods

[0088]

[0089] Table 2 – Materials

[0090] The components shown in Tables 2 and 3 (excluding the foaming agent) were blended and compounded together according to the weight percentages shown in Table 3. The ratio of calcium carbonate to magnesium in the total amount of alkaline filler was 3:1. These granules were then used together with the foaming agent in an injection molding machine to form injection-molded articles. A thick flexible rod mold was used, with the following dimensions: a double-cavity flexible rod mold, producing a flexible rod 0.125 inches thick, 0.50 inches wide, and 5.0 inches long. A cutlery mold was formed, characterized as follows: a double-cavity cutlery mold, producing cutlery 3 / 8 inch thick, 0.5 inches wide, and 6.5 inches long. An injection-molded plate was formed, with the following characteristics: a single-cavity plate mold, producing a plate 0.060 inches thick, 5.0 inches wide, and 5.0 inches long. The properties of the molds and plates are shown in Tables 3 through 7.

[0091] Table 3 - Compositions

[0092] As shown in Table 3, the compositions of the present invention exhibit a density reduction between 4 wt% and 15.0 wt% when compared with the comparative compositions.

[0093] Table 4 - Helical Flow at Various Temperatures

[0094] As shown in Table 4, the spiral flow length was measured at different temperatures. Flow length is an indicator of flowability / viscosity. The composition of this invention achieved a flow length of approximately 5.25 at about 467℉ (a relatively low temperature), which is roughly the same as the comparative composition. Improved flow can speed up the cycle time of injection molding machines and / or reduce operating temperatures. Figure 4 As shown, materials molded in a spiral flow mold exhibit different flow lengths. Increasing the barrel temperature leads to increased flow due to the shear-thinning behavior (viscosity reduction) of the polymer. Furthermore, the addition of CBA1 results in an increased flow length due to the plasticizing effect of CBA.

[0095] Table 5 - Thick Flexible Rod Mold

[0096] As shown in Table 5, compared with the comparative thick flexible rod mold, the thick flexible rod mold of the present invention shows a reduction in density, injection molding pressure, VPT pressure, and cycle time. Furthermore, Table 6 - Tableware Molds

[0097] As shown in Table 6, when compared with the comparative tableware mold, the tableware mold of the present invention shows a reduction in injection molding pressure and cycle time.

[0098] Table 7 - Injection Molded Plates

[0099] As shown in Table 7, the injection molding plate of the present invention exhibits a reduction in density and injection molding pressure compared to the comparative injection molding plate.

[0100] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​stated. Rather, unless otherwise specified, each such dimension is intended to represent the value and a range around which the value is functionally equivalent. For example, a dimension disclosed as “40 mm” is intended to represent “approximately 40 mm”.

[0101] Unless expressly excluded or otherwise limited, every reference cited herein (if any), including any cross-referenced or related patent or application and any patent application or patent claiming priority or benefit to this application, is hereby incorporated in its entirety by reference. Reference to any reference does not imply that it is prior art relating to any invention disclosed or claimed herein, or that it, alone or in any combination with any other reference, teaches, suggests, or discloses any such invention. Furthermore, where any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a referenced document, the meaning or definition given to the term in this document shall prevail.

[0102] While specific embodiments of the invention have been described and illustrated, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, the appended claims are intended to cover all such changes and modifications that fall within the scope of the invention.

Claims

1. A method for manufacturing injection-molded articles, the method comprising: A flowable melt composition comprising cellulose diacetate, a viscosity-reducing additive, and a chemical foaming agent, wherein the chemical foaming agent is decomposable to form carbon dioxide, water, or nitrogen. The flowable melt composition is introduced into the mold cavity of the injection molding machine; The flowable melt composition is molded in the mold cavity under pressure P, temperature T, and cycle time C to form the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 psi, the temperature T is 400 to 560 degrees Fahrenheit, and the cycle time C is 8 to 30 seconds; The method described herein exhibits at least one of the following: When compared with the injection molding pressure P2 required to form an injection-molded article using a melt composition with the same formulation as the described flowable melt composition but without the described chemical foaming agent, the pressure P is reduced by 5% to 40%; When compared with the injection molding temperature T2 required to form an injection-molded article using a melt composition with the same formulation as the described flowable melt composition but without the described chemical foaming agent, the temperature T is reduced by 1% to 15%; When compared with the injection molding cycle time C2 required to form an injection molded article using a melt composition with the same formulation as the flowable melt composition but without the chemical foaming agent, the cycle time C is reduced by 2% to 30%.

2. A method for manufacturing injection-molded articles, the method comprising: A flowable melt composition comprising cellulose diacetate, viscosity-reducing additives, and a physical foaming agent is provided; The flowable melt composition is introduced into the mold cavity of the injection molding machine; The flowable melt composition is molded in the mold cavity under pressure P, temperature T, and cycle time C to form the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 psi, the temperature T is 400 to 560 degrees Fahrenheit, and the cycle time C is 8 to 30 seconds; The method described herein exhibits at least one of the following: When compared with the injection molding pressure P2 required to form an injection molded article using a melt composition with the same formulation as the described flowable melt composition but without the described physical foaming agent, the pressure P is reduced by 5% to 40%; When compared with the injection molding temperature T2 required to form an injection-molded article using a melt composition with the same formulation as the described flowable melt composition but without the described physical foaming agent, the temperature T is reduced by 1% to 15%; When compared with the injection molding cycle time C2 required to form an injection molded article using a melt composition with the same formulation as the described flowable melt composition but without the described physical foaming agent, the cycle time C is reduced by 2% to 30%.

3. The method according to claim 1, wherein the chemical foaming agent is selected from sodium bicarbonate, sodium citrate, zinc stearate, aliphatic polyester, poly(butylene succinate-co-butylene adipate), caprolactone, and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

4. The method of claim 2, wherein the physical foaming agent is selected from hydrocarbons, chlorofluorocarbons, nitrogen, carbon dioxide, alcohols, ketones, methyl esters and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

5. The method according to claims 1 to 4, wherein the cellulose diacetate is present in an amount of 50 to 80% by weight of the flowable melt composition.

6. The method according to claims 1 to 5, wherein the cellulose diacetate exhibits one or more of the following properties: a degree of acetyl substituent substitution (DSAC) of 2.2 to 2.8 per dehydrated glucose unit (AGU); a metal to sulfur molar ratio (M / S) of 1.35 to 5.0; or a number average molecular weight (Mn) of 10,000 g / mol to 100,000 g / mol according to ASTM D6474.

7. The method according to claims 1 to 6, wherein the viscosity-reducing additive is present in an amount of 2 to 40% by weight of the flowable melt composition.

8. The method according to claims 1 to 7, wherein the viscosity-reducing additive is selected from triacetin, diacetin, dibutyl terephthalate, dimethyl phthalate, diethyl phthalate, polyethylene glycol with a molecular weight of 200 to 600 g / mol, triethylene glycol dipropionate, 1,2-epoxypropylphenyl glycol, 1,2-epoxypropyl(m-tolyl)ethylene glycol, 1,2-epoxypropyl(o-tolyl)ethylene glycol, β-oxyethyl cyclohexenecarboxylate, bis(cyclohexyl)diethylene glycol, triethyl citrate, polyethylene glycol, propylene glycol, polysorbate, sucrose octaacetate, acetylated triethyl citrate, acetylated tributyl citrate, triglyceride tripropionate, poloxamer copolymer, polyethylene glycol succinate, diisobutyl adipate, polyvinylpyrrolidone, and tribenzoic acid glycol ester, triethyl citrate, triethyl phthalate ... Ethyl acetate, triethyl acetylglucanate, polyethylene glycol, poly(alkyl succinate) such as poly(butyl succinate), polyethersulfone, adipate-based viscosity reducing additives, soybean oil epoxide, sucrose-based viscosity reducing additives, dibutyl sebacate, glyceryl tribanoate, glyceryl tripropionate, sucrose isobutyrate, Resolflex™ series viscosity reducing additives, triphenyl phosphate, glycolate, methoxy polyethylene glycol, 2,2,4-trimethylpentane-1,3-dimethylbis(2-methylpropionate), and polycaprolactone, and combinations of two or more thereof.

9. The method according to claims 1 to 8, wherein the flowable melt composition is biodegradable and / or compostable.

10. The method according to claims 1 to 9, wherein the flowable melt composition further comprises an alkaline filler present in an amount of 1 to 25% by weight of the flowable melt composition and / or a neutralizing agent present in an amount of 0.1 to 5% by weight of the flowable melt composition, the neutralizing agent being suitable for neutralizing free alkali in the flowable melt composition.

11. An injection-molded article, said article being formed from a flowable melt composition, said flowable melt composition comprising: Cellulose diacetate, Viscosity-reducing additives, and foaming agent, The flowable melt composition is configured to be injected into the mold cavity of an injection molding machine. When the flowable melt composition is injected into the mold cavity of an injection molding machine under pressure P, temperature T, and cycle time C, the flowable melt composition forms the injection-molded article having a length L and a density D in the range of 0.9 to 1.6 g / cc, wherein the pressure P is 10,000 to 40,000 psi, the temperature T is 400 to 560 degrees Fahrenheit, and the cycle time C is 8 to 30 seconds; When compared with the density D2 of an injection-molded article formed under the same conditions using a melt composition with the same formulation as the flowable melt composition but without the foaming agent, the injection-molded article exhibits a density D decrease of 0.5% to 20%.

12. The injection-molded article according to claim 11, wherein the foaming agent is a chemical foaming agent selected from sodium bicarbonate, monosodium citrate, zinc stearate, aliphatic polyester, poly(butylene succinate-co-butylene adipate), caprolactone, and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

13. The injection-molded article of claim 11, wherein the foaming agent is a physical foaming agent selected from hydrocarbons, chlorofluorocarbons, nitrogen, carbon dioxide, alcohols, ketones, methyl esters and combinations thereof, and is present in an amount of 0.1 to 5.0% by weight of the flowable melt composition.

14. The injection-molded article according to claims 11 to 13, wherein the cellulose diacetate is present in an amount of 50 to 80% by weight of the flowable melt composition.

15. The injection-molded article according to claims 11 to 14, wherein the cellulose diacetate exhibits one or more of the following properties: a degree of acetyl substituent substitution (DSAC) of 2.2 to 2.8 per dehydrated glucose unit (AGU); a metal to sulfur molar ratio (M / S) of 1.35 to 5.0; or a number-average molecular weight (Mn) of 10,000 g / mol to 100,000 g / mol according to ASTM D6474.

16. The injection-molded article according to claims 11 to 15, wherein the viscosity-reducing additive is present in an amount of 2 to 40% by weight of the flowable melt composition.

17. The injection-molded article according to claims 11 to 16, wherein the viscosity-reducing additive is selected from triacetin, diacetin, dibutyl terephthalate, dimethyl phthalate, diethyl phthalate, and has a molecular weight of 200 to 600. g / mol of polyethylene glycol, triethylene glycol dipropionate, 1,2-epoxypropylphenyl glycol, 1,2-epoxypropyl(m-tolyl)ethylene glycol, 1,2-epoxypropyl(o-tolyl)ethylene glycol, β-oxyethyl cyclohexenecarboxylate, bis(cyclohexyl)diethylene glycol, triethyl citrate, polyethylene glycol, propylene glycol, polysorbate, sucrose octaacetate, acetylated triethyl citrate, acetylated tributyl citrate, triglyceride tripropionate, Scandiflex, poloxamer copolymer, polyethylene glycol succinate, diisobutyl adipate, polyvinylpyrrolidone, and tribenzoic acid glycol esters. Triethyl citrate, acetyl triethyl citrate, polyethylene glycol, poly(alkyl succinates) such as poly(butyl succinate), polyethersulfone, adipate-based viscosity reducing additives, soybean oil epoxides, sucrose-based viscosity reducing additives, dibutyl sebacate, glyceryl tribanoate, glyceryl tripropionate, sucrose isobutyrate, Resolflex™ series viscosity reducing additives, triphenyl phosphate, glycolates, methoxy polyethylene glycol, 2,2,4-trimethylpentane-1,3-dimethylbis(2-methylpropionate), and polycaprolactone, and combinations of two or more thereof.

18. The injection-molded article according to claims 11 to 17, wherein the flowable melt composition is biodegradable and / or compostable.

19. The injection-molded article according to claims 11 to 18, wherein the flowable melt composition further comprises an alkaline filler present in an amount of 1 to 25% by weight of the flowable melt composition and / or a neutralizing agent present in an amount of 0.1 to 5% by weight of the flowable melt composition, the neutralizing agent being suitable for neutralizing free alkali in the flowable melt composition.

20. The injection-molded article according to claims 11 to 19, wherein the article is used to manufacture tableware, utensils, cups, plates, bowls or trays for single or multiple use.

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