Nut Waste Sheet Composites for Biodegradable Plastic Replacement

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Solution Overview

Problem

Plastic products contribute significantly to environmental pollution due to their non-biodegradability, and nut wastes, such as shells and hulls, are often discarded or incinerated instead of being utilized, representing a wasted resource and environmental burden.

Innovation Solution

Cured nut waste sheet composites are created by processing nut shells and hulls with binders like polyhydroxybutyrate, polylactic acid, and natural rubber latex, which are extruded into sheet form, offering a biodegradable and durable alternative to traditional plastics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plastic products are used, then durability and functionality are improved, but environmental pollution and non-biodegradability worsen

Engineering Contradiction:

ImprovedurabilityVSAvoidenvironmental pollution

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material composition parameters by replacing traditional petroleum-based plastics with bio-based polymers (PLA, PHA, starch) and natural fibers (cellulose, lignin). This substitution maintains the functional durability needed for single-use applications while fundamentally altering the biodegradability parameter to enable environmental breakdown, thus resolving the contradiction between durability and pollution.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates composite materials combining biodegradable polymers with natural fibers from agricultural waste. These composites integrate the structural properties needed for durability with the biodegradable characteristics of natural materials, achieving both strength and environmental compatibility that neither component could provide alone.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If nut wastes are discarded or incinerated, then waste management is simplified, but resource utilization and environmental friendliness worsen

Engineering Contradiction:

Improvewaste managementVSAvoidresource utilization

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent converts the harmful waste problem into a beneficial resource by using nut shells and hulls as feedstock for biodegradable plastic production. Instead of discarding or incinerating these materials, they are processed into valuable eco-friendly products, transforming an environmental burden into a sustainable resource stream.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention enables nut waste to serve its own purpose by using the waste material itself as the primary input for creating biodegradable packaging. The system is self-sufficient, converting its own waste output into useful products, thereby eliminating the need for external waste management infrastructure.

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If biodegradable materials are used to replace plastics, then environmental friendliness is improved, but product durability and functionality may worsen

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidproduct durability

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent develops composite materials that combine biodegradable polymers with natural fibers to achieve both environmental compatibility and mechanical durability. The fiber reinforcement provides structural strength while the biodegradable matrix ensures environmental breakdown, resolving the contradiction between eco-friendliness and product performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention applies different material properties to different functional requirements within the same product. The biodegradable polymer matrix provides environmental compatibility, while embedded natural fibers provide localized structural reinforcement, allowing each component to excel at its specific function.

Inventive Principle:

Principle #3Local quality

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 resulting composites are environmentally friendly, biodegradable, and cost-effective, providing a sustainable solution for various applications while reducing plastic waste and pollution.

Implementation Method 1

contacting about 5 wt% to 40 wt% of the nut waste component from step (c) with 60.0 to 95.0 wt% one or binder selected from a group consisting of polyhydroxybutyrate (PHB), polyhydroxyalkanoate (PHA), polylactic acid (PLA), guayule, natural rubber latex, bentonite, an anionic starch, hyaluronic acid, triethyl citrate, and combinations thereof

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

heating the mixture to a temperature from about 80° C. to about 180° C. for about 5 minutes

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

extruding the heated mixture into a sheet form

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 4

cooling the sheet

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11434373B2Formulations and products to replace single-use plastics and polystyrene with bio-benign materials such as agricultural wastes

Publication Date: 2022.09.06 NUTJOBS INC

AI summary

The present invention provides methods for preparing the nut waste sheet composites from a nut waste component and one or more binders.