Biodegradable masterbatch, its manufacturing and processing method and its products

Abstract

This invention provides a biodegradable masterbatch, its manufacturing process, and its products. The masterbatch comprises 20 wt% to 85 wt% biodegradable material, 0 wt% to 70 wt% inorganic powder, and 2 wt% to 50 wt% plant fiber. The process involves mixing the aforementioned materials, batch melt-blending, and then extruding to produce the masterbatch. By incorporating inorganic powder and plant fiber, this invention enhances the overall physical properties of the masterbatch and its products, improving strength, toughness, and decomposition speed. Furthermore, by utilizing the effects of charge, polar forces, Van der Waals forces, and surface bridging, and employing mechanical grinding and chemical methods, the aim is to break down hard agglomerates and prevent re-agglomeration. The surface of the powder material particles is chemically or physically modified, altering their surface properties and making them easier to disperse in another phase of a specific interphase. The batch melt mixing and extrusion process creates masterbatches that allow inorganic powders and plant fibers to be evenly distributed within biodegradable materials, ensuring the quality of both the masterbatches themselves and the finished products. These masterbatches can then be extruded, injected, vacuum-formed, or blow-formed into various products such as containers, tableware, packaging materials, kitchen and bathroom supplies, and household goods. They are also suitable for disposable products. The resulting products meet composting standards, and the raw materials and products decompose into water (H2O), carbon dioxide (CO2), and organic and inorganic nutrients, achieving a biological cycle. When buried in the soil, the products are decomposed by microorganisms into organic carbon nutrients that plants can absorb. This process provides excellent environmental benefits and helps reduce the use of plastic products, thereby reducing plastic pollution and environmental harm, ultimately achieving environmental protection and carbon reduction goals.

Description

Technical Field

[0001] This invention provides a biodegradable masterbatch, its manufacturing and processing method, and its products. In particular, it refers to a product that can be molded into various products through the production of biodegradable masterbatch, and can be quickly decomposed through household composting, thereby replacing and reducing the use of plastic products to achieve the goal and appeal of environmental protection. Prior Technology

[0002] Note that plastic granules are raw materials used to manufacture various plastic products. They are usually in granular form and are mainly made of polymer resins (such as PE, PP, PVC, etc.) and additives. The type and formulation of masterbatch will vary according to the needs of the final product. For example, color masterbatch can be added to give a specific color, or plasticizers can be added to improve flexibility. The main uses of plastic masterbatch cover the production of various plastic products such as household goods, building materials, packaging, and automotive parts.

[0003] However, plastic is difficult to decompose naturally, so improper handling or indiscriminate disposal will lead to environmental pollution. Even worse, it can endanger the lives of animals if ingested. In addition, in the marine environment, plastic can combine with persistent organic pollutants such as dioxins and polychlorinated biphenyls (PCBs), which may accumulate in organisms and be transferred through the food chain, causing significant health impacts on environmental organisms and humans. Although plastic can be recycled, plastic waste is diverse and extremely difficult to effectively collect and sort for recycling. It must be washed with clean water before it can be reused, which consumes water resources. Moreover, the cost of plastic recycling is high, all of which make it difficult to implement recycling effectively. Therefore, some governments are considering policies to completely ban plastic cups in order to reduce the pollution and harm of plastic products to the environment.

[0004] To address the lack of processing options for plastic materials and to comply with various countries' policies on limiting plastic use and environmental protection, companies have invested in the research and development of biodegradable materials in recent years. These materials have the characteristic of being decomposed by environmental microorganisms under specific conditions. However, due to their relatively high manufacturing costs, and the fact that most of them require extremely strict temperature and humidity conditions for decomposition, they cannot be decomposed at room temperature and normal humidity, nor can they be composted at home. Therefore, their applicability remains limited, and their processing costs are relatively high, making it difficult to effectively promote and apply their products.

[0005] In view of this, we, the inventors, devoted ourselves to further research on the manufacture of biodegradable masterbatches to facilitate the production of various products, and began research and development and improvement in order to solve the above problems with a better invention. After continuous experimentation and modification, this invention came into being. Summary of the Invention

[0006] Therefore, the purpose of this invention is to solve the aforementioned problems. To achieve the above objective, we, the inventors, provide a biodegradable masterbatch, characterized in that: the masterbatch is in granular form and contains the following raw materials in weight percentages: 20 wt% to 85 wt% of biodegradable materials, 0 wt% to 70 wt% of inorganic powder, and 2 wt% to 50 wt% of plant fiber.

[0007] According to the above-described biodegradable masterbatch, the biodegradable material comprises at least one of polybutylene succinate (PBS), polybutylene adipate succinate (PBSA), polybutylene terephthalate (PBAT), polyhydroxyalkanoate (PHA), thermoplastic starch (TPS), or polycaprolactone (PCL).

[0008] According to the above-mentioned biodegradable masterbatch, the inorganic powder is at least one of calcium carbonate, magnesium carbonate, kaolin, stearic acid, zinc stearate, zinc oxide, antimony trioxide, silicon dioxide, talc, mica powder, barium sulfate, calcium silicate, or quartz powder.

[0009] According to the above-mentioned biodegradable masterbatch, the plant fiber is photosynthesized, converting carbon dioxide + water into oxygen + glucose. Most of the carbon converted into glucose is stored in the cell wall phloem and leaves of trees as (1) cellulose, hemicellulose, lignin (in polysaccharide form), or (2) starch (in polysaccharide form) in the seeds, roots, stems, and fruit fibers, at least one of them.

[0010] The biodegradable masterbatch described above has a particle size between 0.05 cm and 0.5 cm.

[0011] The present invention also provides a method for manufacturing a biodegradable masterbatch, the steps of which include: stirring and mixing a mixture comprising 20 wt% to 85 wt% of biodegradable material, 0 wt% to 70 wt% of inorganic powder, and 2 wt% to 50 wt% of plant fiber; batch melting and kneading the stirred and mixed mixture at a temperature of 120 to 170°C; and extruding it at a temperature of 120 to 170°C to form granules, thereby forming the masterbatch.

[0012] According to the above-described method for manufacturing biodegradable masterbatch, the particle size of the inorganic powder is between 0.01 and 100 μm.

[0013] According to the above-described method for manufacturing biodegradable masterbatch, the particle size of the plant fiber is between 0.1 and 1,000 μm.

[0014] According to the above-described method for manufacturing biodegradable masterbatch, the particle size of the masterbatch is between 0.05 cm and 0.5 cm.

[0015] The present invention also provides an article of biodegradable masterbatch, which is formed by extrusion, injection, thermoforming or blow molding of the masterbatch produced by the method of manufacturing biodegradable masterbatch as claimed in claim 8.

[0016] As can be seen from the above description and setup, the present invention mainly has the following advantages and effects, which are detailed below:

[0017] 1. This invention improves the overall strength and toughness of the masterbatch and its products by using a high proportion of inorganic powder in the formulation. Furthermore, by using batch melt mixing and extrusion to form the masterbatch, the inorganic powder can be evenly distributed in the biodegradable material, thus ensuring the quality of the masterbatch itself and the finished products.

[0018] 2. The masterbatch of this invention can be formed into various products through extrusion, injection, thermoforming, or blow molding, such as containers, tableware, packaging materials, kitchen and bathroom supplies, household products, etc., and can be applied to disposable products. The products obtained by this invention after subsequent processing have the effects of household composting and decomposition and excellent product quality, and have a lower cost. This can help reduce the use of plastic products, thereby reducing plastic pollution and harm to the environment, and thus achieving the goals of environmental protection and carbon reduction.

[0019] 3. The masterbatch of this invention can be rapidly decomposed by environmental microorganisms both before and after the manufacture of the product. It only needs to be buried in soil at room temperature for about four to six months to decompose. After decomposition, only water, carbon dioxide and inorganic filler powder remain. Therefore, it will not cause burden or harm to the environment. It can help reduce the amount of plastic used and reduce plastic pollution, thus helping to maintain the health and safety of the environment, organisms and humans. Simple Explanation of the Diagram

[0020] Figure 1 is a flowchart of the present invention. Implementation

[0021] Regarding the technical means employed by us inventors, several preferred embodiments are described in detail below with accompanying drawings, so that you may gain a deeper understanding and acceptance of the present invention.

[0022] Please refer to Figure 1 first. This invention relates to a biodegradable masterbatch, characterized by:

[0023] The masterbatch is in granular form with a particle size between approximately 0.05 cm and 0.5 cm. The masterbatch contains the following raw materials by weight percentage:

[0024] The composition comprises 20 wt% to 85 wt% biodegradable material, 0 wt% to 70 wt% inorganic powder, and 2 wt% to 50 wt% plant fiber; wherein the inorganic powder system may be selectively added, and in one embodiment, the inorganic powder system may be configured to be 1 wt% to 70 wt%, preferably 20 wt% to 70 wt%; however, this is merely illustrative and not intended to be limiting.

[0025] Firstly, regarding the formulation of biodegradable materials, they can be at least one of various existing biodegradable resins, such as: polybutylene succinate (PBS), polybutylene adipate succinate (PBSA), polybutylene terephthalate (PBAT), polyhydroxyalkanoates (PHA), thermoplastic starch (TPS), or polycaprolactone (PCL);

[0026] Regarding the configuration of inorganic powder, food-grade materials can be selected, and materials with different acid and alkali resistance can be selected according to the application requirements. Therefore, in a specific embodiment, the inorganic filler powder includes at least one of calcium carbonate, magnesium carbonate, kaolin, stearic acid, zinc stearate, zinc oxide, antimony trioxide, silicon dioxide, talc, mica powder, barium sulfate, calcium silicate, or quartz powder.

[0027] As for plant fiber, it can be the fibrous part of various plants. The plant fiber is photosynthetic, which converts carbon dioxide + water into oxygen + glucose. Most of the carbon converted into glucose is stored in the phloem and leaves of trees as (1) cellulose, hemicellulose, and lignin (in polysaccharide form), or (2) starch (in polysaccharide form) in the seeds, roots, stems, and fruit fibers. Such as: at least one of the following: seeds, bast, leaves, or fruit fibers of plants; plant fibers are mainly abundant, readily available, and environmentally friendly materials found in nature, and are naturally non-toxic, causing no negative impact on the environment or health. Common sources include agricultural waste such as rice straw, wheat straw, corn cobs, sugarcane bagasse, and coconut shells, which are considered byproducts after crop harvesting, are highly renewable, do not waste resources, and contribute to the circular economy; in addition, plant fibers can decompose naturally, quickly returning to organic matter, and are harmless to land and water, making them a good choice for reducing environmental pollution; furthermore, since plant fibers can be obtained from agricultural waste, they do not require additional planting, and collection costs are relatively low, aligning with the development trend of a green economy; in many countries and regions, these agricultural wastes, if not properly utilized, may be burned, wasting resources and releasing large amounts of greenhouse gases. Therefore, this invention uses plant fibers, which can be effectively processed and reused, increasing economic value and effectively reducing carbon emissions, in line with the concept of sustainable development, providing environmentally friendly and cost-effective solutions for various industries.

[0028] Regarding the specific manufacturing method of this invention, the steps include:

[0029] S001: A mixture comprising 20 wt% to 85 wt% biodegradable material, 0 wt% to 70 wt% inorganic powder, and 2 wt% to 50 wt% plant fiber is stirred and mixed.

[0030] Before mixing, the plant fibers can be sterilized by baking and then ground into powder. The plant fibers can be fibers from one or more plants that have been crushed and ground. In one embodiment, the particle size of the ground fibers can be between 0.1 and 1,000 μm. The inorganic powder is mainly used to improve the overall strength and toughness, and in order to enable it to adhere and solidify the plant fibers and enhance their strength, the particle size of the inorganic powder is preferably between 0.01 and 100 μm.

[0031] S002: The mixture after stirring is subjected to batch melt blending at a temperature of 120~170°C; this process is used to uniformly mix biodegradable materials, inorganic powders and plant fibers in a molten state. During this process, different additives, such as reinforcing agents, fillers, antioxidants or color masterbatches, can be added to give the final material specific properties, such as improved strength, heat resistance, flexibility or color change. However, this is only an example and is not intended to be limiting.

[0032] It should be noted that if a twin-screw extrusion process is used, the inorganic powder will be unevenly distributed in the biodegradable material, resulting in defects in the quality of the subsequent processed products. Therefore, in this invention, melt mixing is used to ensure the uniformity of the mixing process, which can greatly improve the quality and strength of the subsequent processes.

[0033] S003: The batch melt-blended mixture is continuously extruded at a temperature of 120~170°C to form granules, thereby forming the masterbatch. The particle size of the masterbatch is approximately between 0.05 cm and 0.5 cm. The masterbatch can then be used as a raw material for subsequent processing and shaping. In terms of the characteristics of the masterbatch itself, since all the raw materials used in its manufacturing process do not contain any plastic, the entire invention is a material that can be rapidly decomposed by environmental microorganisms. Therefore, it only needs to be buried in soil at room temperature for about four to six months to decompose. After decomposition, only water, carbon dioxide and inorganic filler powder remain, so it will not cause any burden or harm to the environment. Therefore, it can help reduce the use of plastics and reduce plastic pollution, thereby protecting the health and safety of the environment, organisms and humans.

[0034] Furthermore, the present invention, through a higher proportion of inorganic powder, enables it to adhere to plant fibers and chelate with biodegradable materials, giving it higher overall strength and plasticity, thus preventing embrittlement during subsequent processing.

[0035] S004: Regarding the subsequent molding of the masterbatch into products, it can be formed through extrusion, injection molding, vacuum forming, or blow molding. As mentioned above, since the masterbatch itself can decompose naturally at room temperature by burying, the products made from it can also be rapidly decomposed by environmental microorganisms. It only needs to be buried in soil at room temperature for about four to six months to decompose. After decomposition, only water, carbon dioxide, and organic (inorganic) powder remain, which will not have any negative impact on the environment or health. Therefore, the masterbatch of the present invention can be made into various products, such as containers, tableware, packaging materials, kitchen and bathroom products, household products, etc. It can also be used for disposable products and has the effects of household composting and excellent product quality. When discarding, it can be naturally decomposed by household composting as mentioned above, so as to achieve the goals of energy saving, carbon reduction, and green environmental protection.

[0036] In conclusion, the technical means disclosed in this invention can effectively solve the problems of conventional inventions and achieve the expected purpose and effect. Moreover, it has not been published or publicly used before the application and has long-term progressiveness. It is indeed an invention as defined by the Patent Law. Therefore, this application is filed in accordance with the law. I humbly request Your Excellency to give a detailed review and grant me an invention patent. I am deeply grateful for Your Excellency's kindness.

[0037] However, the above descriptions are merely several preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of the patent application and the contents of the specification of the present invention should still fall within the scope of the patent of the present invention.

[0038] S001~S004: Steps

Claims

1. A method for manufacturing a biodegradable masterbatch, comprising the steps of: mixing 20 wt% to 85 wt% of biodegradable material, 1 wt% to 70 wt% of inorganic powder, and 2 wt% to 50 wt% of... A mixture of plant fibers in wt% is stirred and mixed; the particle size of the inorganic powder is between 0.01 and 100 μm; and the particle size of the plant fibers is between 0.1 and 1,000 μm; the biodegradable material includes at least one of polybutylene succinate (PBS), polybutylene adipate succinate (PBSA), polybutylene terephthalate (PBAT), polyhydroxyalkanoates (PHA), thermoplastic starch (TPS), and polycaprolactone (PCL); the inorganic powder is at least one of calcium carbonate, magnesium carbonate, kaolin, stearic acid, zinc stearate, zinc oxide, antimony trioxide, silicon dioxide, talc, mica powder, barium sulfate, calcium silicate, or quartz powder; and the plant fibers are at least one of the fibers of plant seeds, bast, leaves, or fruits. The mixture after stirring is batch melt-blended at a temperature of 120~170°C and then extruded into granules at a temperature of 120~170°C to form the masterbatch.

2. The method for manufacturing biodegradable masterbatch as described in claim 1, wherein, The particle size of the masterbatch is between 0.05 cm and 0.5 cm.

3. An article of biodegradable masterbatch, wherein the article is formed by extrusion, injection, thermoforming or blow molding of the masterbatch produced by the manufacturing method of biodegradable masterbatch as claimed in claim 1.

Images