Corn Gluten Resin Molded at Low Pressure
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Solution Overview
Problem
Biopolymers derived from renewable resources face challenges in competing with traditional plastics on performance and cost, particularly in forming solid articles that require high pressures and energy-intensive processing.
Innovation Solution
A resin composition comprising 70% to 99% corn gluten meal, 1% to 18% non-toxic organic acid, and optional solvents, which can be molded into solid articles at low pressures using vacuum forming or stamping, leveraging the cross-linking properties of specific organic acids like lactic acid and sorbic acid to enhance flexural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional plastics are used to make solid articles, then manufacturing efficiency and structural integrity are high, but environmental friendliness and biodegradability are poor
Solution Approach 1:
The patent uses composite materials by combining corn gluten meal (biopolymer) with specific additives including organic acids (sorbic acid, lactic acid), crosslinking agents (glycerol, pentaerythritol), and processing aids. This composite approach maintains structural integrity while achieving biodegradability, resolving the contradiction between environmental friendliness and strength. The organic acids serve multiple functions as both curing agents and strength enhancers.
Solution Approach 2:
The patent applies parameter changes by controlling the molecular weight distribution, protein content (60-90%), and moisture content (10-30%) of corn gluten meal. By optimizing these parameters and using specific ratios of additives (e.g., 0.1-5% organic acid by weight), the material achieves both environmental benefits and mechanical strength suitable for solid articles.
2Object-affected harmful factors
If biopolymers are used to make solid articles, then environmental friendliness and biodegradability are improved, but manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent replaces high-energy mechanical processing with a chemical curing system. Instead of requiring high-pressure injection molding or extrusion typical of biopolymer processing, the invention uses organic acids to initiate crosslinking reactions at lower pressures and temperatures. This substitution of chemical mechanisms for mechanical ones significantly reduces energy consumption while maintaining biodegradability.
Solution Approach 2:
The patent utilizes phase transitions during the curing process where the organic acids undergo chemical transformation to form crosslinked networks. This phase change from liquid additives to integrated crosslinked structures enables the material to set and harden without requiring continuous high-energy input, reducing overall energy consumption during manufacturing.
3Strength
If high pressure processing is applied to biopolymers, then article density and structural integrity are improved, but manufacturing cost and energy consumption increase
Solution Approach 1:
The patent introduces organic acids (sorbic acid, lactic acid) and crosslinking agents as intermediaries that facilitate density and structural integrity development without requiring high pressure. These intermediaries mediate the crosslinking process, enabling the biopolymer to achieve high density through chemical bonding rather than mechanical compression, thereby reducing manufacturing costs and energy requirements.
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
The method allows for the production of biodegradable, compostable articles with improved flexural strength and reduced energy consumption, suitable for disposable utensils and other applications, while maintaining eco-friendly attributes.
Implementation Method 1
leveraging the cross-linking properties of specific organic acids like lactic acid and sorbic acid to enhance flexural strength
Data Source
AI summary
Disclosed are fast-curing, inexpensive corn-gluten resin compositions, methods for making them, methods for forming them into solid articles. In some embodiments, the resin composition includes corn meal gluten and a non-toxic organic acid.