Biodegradable Molding Mass Composition for Residue-Free Demolding

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Solution Overview

Problem

Current biodegradable packaging materials face challenges in industrial manufacturing due to issues such as mold residues, irregular portioning, and non-uniform void distribution, which affect the quality and cohesion of molded articles, and are not environmentally neutral upon disposal.

Innovation Solution

A specific composition of water, starch, and fibers with a select mold release agent, formulated into a non-fluid, plastic-elastic molding mass, enabling residue-free release and controlled void generation, and post-thermal processing methods for producing biodegradable and compostable articles with improved mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional release agents are used during molding, then demolding is facilitated, but mold residues are generated that deteriorate mold surface quality and require periodic cleaning

Engineering Contradiction:

ImprovedemoldingVSAvoidmold surface quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The invention extracts and removes the harmful residues from the molding mass composition by selecting specific biodegradable materials that do not leave residues on the mold surface, eliminating the need for release agents that cause contamination

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the chemical composition parameters of the molding mass to use biodegradable materials with specific properties that prevent residue formation, transforming the material characteristics to achieve residue-free demolding

Inventive Principle:

Principle #35Parameter changes

2Shape

If thermal processing is applied to molding masses, then shaping and solidification are achieved, but steam generation causes non-uniform void distribution and compromises internal cohesion

Engineering Contradiction:

Improvemolded article formationVSAvoidinternal cohesion

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The invention changes the liquid content parameter to a specific range (57-65 wt.%) that controls steam generation during thermal processing, optimizing the balance between shaping capability and internal cohesion maintenance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite material system combining starch, fibers, and liquid components with specific ratios, where each component contributes to controlling void formation and maintaining internal cohesion during thermal processing

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If biodegradable materials are used to replace non-biodegradable packaging, then environmental impact is reduced, but manufacturing reliability and article quality are compromised

Engineering Contradiction:

Improveenvironmental impactVSAvoidmanufacturing reliability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention creates a composite biodegradable material system combining starch, fibers, and liquid components with optimized ratios, achieving both environmental sustainability and manufacturing reliability through synergistic material interactions

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention optimizes critical parameters including liquid content (57-65 wt.%), starch/fiber ratio, and granule size distribution to ensure consistent manufacturing performance and high-quality article production using biodegradable materials

Inventive Principle:

Principle #35Parameter changes

4Loss of substance

If lightweight materials are used for disposable containers, then material consumption is reduced, but environmental costs increase due to increased production volumes

Engineering Contradiction:

Improvematerial consumptionVSAvoidproduction volume

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The invention optimizes the density and structural parameters of the biodegradable molding mass to achieve lightweight articles with sufficient strength, reducing material consumption while maintaining production efficiency through controlled void distribution

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables large-scale industrial production of biodegradable and compostable articles with enhanced strength, stability, and environmental neutrality, reducing waste and environmental impact.

Implementation Method 1

The molding mass is heated to a temperature sufficient to gelatinize the starch component

Methodology Applied

Scientific EffectGelatinization:

Implementation Method 2

thermal processing of the molding mass into a molded biodegradable and compostable article

Methodology Applied

Scientific EffectThermal processing: Heating

Implementation Method 3

thermal processing of molding masses including fluid or semi-liquid batters or pastes, as taught in the current art, generate a lot of steam

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20220325078A1Biodegradable, compostable molding mass compositions, molded articles and methods of manufacture

Publication Date: 2022.10.13 EPS GLOBAL MARKETING LTD

AI summary

The invention features biodegradable, compostable molding mass compositions, molding masses, molded articles, coating solutions, and systems and methods for the manufacture of same.