Renewably-Sourced Biodegradable Polyolefin Packaging, Utensils, and Containers

Abstract

Renewably-sourced biodegradable polyolefin packaging, utensils, and containers include a renewably-sourced polyolefin (for example, polyethylene and polypropylene) and a biodegrading agent. The renewably-sourced biodegradable polyolefin packaging is made from plant materials typically by polymerizing olefins that are made from reducing alcohols created by fermenting plant materials. An example of a suitable plant material is sugarcane and its derivatives. The biodegrading agent accelerates the biodegradation of polyolefin packaging even in anaerobic and dark (i.e., absent of ultraviolet light) environments. Such a packaging is particularly useful for packaging frozen food that is to be microwaved in the packaging. The package is also particularly usable as packaging for frozen comestibles, which are often stored at dry-ice temperatures. Ultimately, the renewably-sourced biodegradable polyolefin packaging provides a start-to-finish green packaging that meets the requirements of being renewably sourced, biodegradable in landfills, and having similar performance as traditional polyolefin packaging.

Claims

1. A renewably-sourced biodegradable polyolefin utensil, comprising: a resin being made from a polymerized mixture of a renewably-sourced polyolefin and a biodegrading agent.

2. The renewably-sourced biodegradable polyolefin utensil according to claim 1, further comprising: a tool for contacting food; a handle for a user to grip, said handle being connected to said tool; and at least one of said tool and said handle including said resin.

3. The renewably-sourced biodegradable polyolefin utensil according to claim 2, wherein: said tool includes said resin; and said tool further includes a knife blade.

4. The renewably-sourced biodegradable polyolefin utensil according to claim 2, wherein: said tool includes said resin; and said tool further includes fork having a root and two tines.

5. The renewably-sourced biodegradable polyolefin utensil according to claim 2, wherein: said tool includes said resin; and said tool further includes a spoon having a bowl.

6. The renewably-sourced biodegradable polyolefin utensil according to claim 2, wherein: said tool includes said resin; and said tool includes a spork having a bowl and two tines, each of said two tines being connected to said bowl.

7. The renewably-sourced biodegradable polyolefin utensil according to claim 2, wherein: said tool includes said resin; and said tool includes a stick for contacting food.

8. A renewably-sourced biodegradable polyolefin container, comprising: a vessel for holding food, said vessel including a resin being made from a polymerized mixture of a renewably-sourced polyolefin and a biodegrading agent.

9. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a plate having a well surface for supporting food and a base for contacting a tabletop.

10. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a bowl having a concave wall for supporting food and a base for contacting a tabletop.

11. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a tray having a top for supporting a further container, a base for contacting a tabletop, and a rim around said top for containing spills on said top.

12. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a pitcher including a bowl for storing a liquid, a spout for pouring the liquid from said bowl, and a handle connected to said bowl for lifting and tilting said bowl.

13. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a cup including a bowl for storing a liquid and a base for contacting a tabletop.

14. The renewably-sourced biodegradable polyolefin container according to claim 8, wherein said vessel is a bottle having a bowl for storing a liquid and a neck with a mouth, said neck being connected to said bowl and being narrower than said bowl, and said mouth allowing liquids to be added to said bowl or removed from said bowl.

15. The renewably-sourced biodegradable polyolefin container according to claim 14, further comprising a cap being removable connected to said neck and closing said mouth.

16. The renewably-sourced biodegradable polyolefin container according to claim 15, wherein: said bowl is flexible; and said cap has a nozzle for ejecting the liquid therethrough when said bowl is squeezed.

17. A method for forming a renewably-sourced biodegradable polyolefin utensil, which comprises: melting a mixture of renewably-sourced polyolefin and biodegrading agent to form a molten resin; and molding said molten resin to a shape of a utensil.

18. The method according to claim 17, which further comprises: mixing pelletized renewably-sourced polyolefin and pelletized biodegrading agent to form said mixture.

19. A method for forming a renewably-sourced biodegradable polyolefin container, which comprises: melting a mixture of renewably-sourced polyolefin and biodegrading agent to form a molten resin; and molding said molten resin to a shape of a container.

20. The method according to claim 19, which further comprises: mixing pelletized renewably-sourced polyolefin and pelletized biodegrading agent to form said mixture.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0056] FIG. 1 is a sectional view of a laminate according to the invention.

[0057] FIG. 2 is a perspective view of an ice-cream container according to the invention.

[0058] FIG. 3 is a perspective view of a steaming tray according to the invention.

[0059] FIG. 4 is a perspective view of a gelato tray according to the invention.

[0060] FIG. 5 is a perspective view of the gelato tray shown in FIG. 4.

[0061] FIG. 6 is a top elevational view of a fork according to the invention.

[0062] FIG. 7 is a top elevational view of a spoon according to the invention.

[0063] FIG. 8 is a top elevational view of a knife according to the invention.

[0064] FIG. 9 is a top elevational view of a spork according to the invention.

[0065] FIG. 10 is a side elevational view of a pair of chopsticks according to the invention.

[0066] FIG. 11 is a top perspective view of a plate according to the invention.

[0067] FIG. 12 is a top perspective view of a bowl according to the invention.

[0068] FIG. 13 is a top perspective view of a tray according to the invention.

[0069] FIG. 14 is a top left perspective view of a pitcher according to the invention.

[0070] FIG. 15 is a top perspective view of a pitcher according to the invention.

[0071] FIG. 16 is a top perspective view of a bottle according to the invention.

[0072] FIG. 17 is a side elevational view of a sport bottle according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0073] Embodiments of the invention are described below and are shown in the figures of the drawing.

[0074] Renewably-Sourced Biodegradable Polyethylene Packaging

[0075] A preferred embodiment of the invention is renewably-sourced biodegradable polyethylene packaging. The packaging is formed with a mixture of ninety-eight to ninety-nine-and-five-tenths percent (98-99.5%) by weight of renewably-sourced polyethylene and five-tenths to two percent (0.5-2%) by weight of biodegrading agent. The renewably-sourced polyethylene is produced by polymerizing ethylene, where the ethylene is produced by reducing light alcohols sourced from fermented sugarcane. The preferred biodegrading agent is the biodegrading agent sold under the trademark BIOSPHERE® PLASTIC ADDITIVE.

[0076] Laminate

[0077] FIG. 1 is a first preferred embodiment of a laminate 1 for making food containers. The laminate 1 includes a base layer 10 and a coating 11. The base layer 10 is made from a renewable or sustainable material. The coating 11 is adhered to a surface 100 of the base layer 10 that will be facing the interior of the container when folded into the container. The base layer 10 has a thickness of 0.050 cm.

[0078] FIG. 1 also shows a second preferred embodiment of a laminate 1 for making packaging. The laminate 1 includes a base layer 10 and a coating 11. The base layer 10 is made from a renewable or sustainable material. Examples of renewable or sustainable materials include paper, cardboard, polylactic acid, and bamboo-sourced stock. The coating 11 is adhered to a surface 100 of the base layer 10 that will be facing the interior of the container when folded into the container. The base layer 10 has a thickness of 0.050 cm. The coating 11 is made from a film of renewably-sourced biodegradable polyolefin.

[0079] FIG. 2 shows a preferred embodiment of a container 2. In this embodiment, the container 2 is intended to be used to hold food and used once (i.e., single use). The container 2 is made from the laminate 1. The container 2 includes a carton 20 and a lid 21. The carton 20 has a wall 202 that is folded onto itself to form a seam 201. The carton 20 has a rim 204. The inside surface 203 of the wall 202 is covered with the coating 11. The lid 21 is made of the laminate 1 and has a wall 210 and a top 211.

[0080] FIG. 3 shows a preferred embodiment of packaging: a steaming tray 3. The steaming tray 3 includes a cover 30. The cover 30 has a rim 31 around its periphery. The cover 30 has perforations 32 formed therein. In a first preferred embodiment, the steaming tray 3 is made of the laminate 1 in which the base layer 10 is made from a renewable or sustainable material. In a second preferred embodiment, the steaming tray 3 is made of the laminate 1 in which the base layer 10 is made of a renewably-sourced biodegradable polyolefin. In a third preferred embodiment, the steaming tray 3 is made of renewably-sourced biodegradable polyolefin. Two suitable examples of the polyolefin are polyethylene and polypropylene. The third embodiment is made by injection molding the renewably-sourced biodegradable polyolefin into the shape of the steaming tray 3.

[0081] Preferred methods of using the steaming tray 3 include combinations of at least one of the following steps. One step is placing food within a container that includes the steaming tray 3. The next step is freezing the food by cooling the container that includes the steaming tray 3 to a temperature below freezing (i.e., <0° C.). If the food is to be blast frozen, then the next step is to freeze by cooling the food and the container that includes the steaming tray 3 to a temperature equal to or less than negative forty degrees Celsius (<−40° C.). If the food is to be stored and cooled with dry ice, then the next step is to freeze the food and the packaging that includes the steaming tray 3 to negative seventy-eight or lower degrees Celsius (<−78° C.). Once in its desired frozen state, the food and the container that includes the steaming tray 3 are stored, shipped, and distributed. In the next step, a retailer sells the food and the container that includes the steaming tray 3 at a temperature below freezing (<0° C.). The purchaser/consumer/end user keeps the frozen food held in the container that includes the steaming tray in a freezer at a temperature below freezing (<0° C.). When the food preparer or end user is ready to eat the frozen food, the container that holds the frozen food along with the steaming tray 3 is heated in a microwave. The steaming tray 3 is exposed to steam which is at the temperatures equal to the boiling point of water (i.e., 100° C.). The next is to uncover the now cooked food by removing the steaming tray 3.

[0082] FIGS. 4-5 shows a gelato tray 4. The gelato tray 4 includes a rounded cuboid container 40 an opening at a top of the rounded cuboid container 40 and a rim 41 extending peripherally from a top edge of the rounded cuboid container 40. While FIGS. 4-5 does not show a lid for the gelato tray 4, a lid can be added. The cuboid container 40 has a front wall 42, a right wall 43, a rear wall 44, a left wall 45, and a bottom 46.

[0083] The laminate 1 performs as packing for food in the temperature that range from negative-seventy-nine (i.e., dry ice) to two-hundred-four degrees Centigrade (−79-204° C.). The laminate 1 performs after sustained exposure in the ranges from −40° C. (I.e., blast freeze) to −18° C. (i.e., conventional freezer) and −18° C. to 104° C. (microwaving water=100° C.) and 4° C. (refrigerator) to 104° C. The laminate 1 performs as packaging during short exposure (i.e., two days or less, most likely less than one day) to −79° C. is possible.

[0084] In a first embodiment, the gelato tray 4 is made from the laminate 1 that has been molded to the shape. The coating 11 of the laminate 1 faces an interior of the rounded cuboid container 40. In the first preferred embodiment, the base layer 10 is made from polylactic acid (PLA), where the PLA is corn based.

[0085] In a second preferred embodiment of the gelato tray 4, the base layer 10 is made of cellulose acetate propionate (CAP). The CAP can be soy based, tree based, or grass based (e.g., bamboo).

[0086] The container 2, the steaming tray 3, and the gelato tray 4 are formed by thermoforming, compression molding, injection molding, extruding, additive manufacturing, and/or splitting, cutting, gluing, and coating sheets of the laminate 1.

[0087] A preferred embodiment of the composition is polypropylene. An alternate preferred embodiment is polyethylene. The resin is used to form the preferred embodiments of the utensils shown in FIGS. 6-10 and the containers shown in FIGS. 11-17.

[0088] FIG. 6 shows a preferred embodiment of a fork 60. The fork 60 includes a handle 61 connected to a root 62. Four tines 63, 64, 65, 66 extend from the root 62.

[0089] FIG. 7 shows a preferred embodiment of a spoon 70. The spoon 70 includes a handle 71 connected to a bowl 72.

[0090] FIG. 8 shows a preferred embodiment of a knife 80. The knife 80 includes a handle 81 connected to a knife blade 82.

[0091] FIG. 9 shows a preferred embodiment of a spork 90. The spork 90 includes a handle 91 connected to a bowl 92. Four tines 93, 94, 95, and 66 extend from the bowl 92.

[0092] FIG. 10 shows a pair of chopsticks: i.e., chopstick 100A and chopstick 100B. Each chopstick 100A and 100B has a handle 101A and 101B, respectively. From each handle 101A and 101B, a stick 102A and 102B extends, respectively.

[0093] FIG. 11 shows a plate 110. The plate 110 has a well surface 111 for supporting food and a base 112 for contacting a tabletop.

[0094] FIG. 12 shows a bowl 120 having a concave wall 121 for holding food and a base 122 for contacting a tabletop.

[0095] FIG. 13 shows a tray 130. The tray 130 has a flat top 131 for supporting food or a further container. The tray 130 has a base, which is not shown, for contacting a tabletop. A rim 132 is disposed around and extends upward from the flat top 131. The rim 132 prevents spills from escaping the tray 130.

[0096] FIG. 14 shows a pitcher 140. The pitcher 140 includes a bowl 141 for storing a liquid. A user pours liquid from the bowl 141 with the spout 142. A handle connects to the bowl 141 and is used for lifting and tilting the bowl 141.

[0097] FIG. 15 shows a cup 150. The cup including a frustoconical bowl 151 for storing a liquid and a base 152 for contacting a tabletop or other surface.

[0098] FIG. 16 shows a bottle 160. The bottle 160 has a bowl 161 for storing a liquid and a neck 162 with a mouth, which is not visible in FIG. 16. The neck 162 is connected to the bowl 161 and is narrower than the bowl 161. The mouth allows liquids to be added to the bowl 161 or removed from the bowl 161.

[0099] FIG. 17 shows a bottle 160. The bottle 160 has a bowl 161 for storing, a liquid and a neck 162. In the embodiment shown in FIG. 17, the bowl 161 is flexible. The cap 163 has a nozzle 164 for ejecting the liquid therethrough when the bowl 161 is squeezed.

[0100] A preferred embodiment of a method for forming a renewably-sourced biodegradable polyolefin utensil, includes the following steps. [0101] Mixing pelletized renewably-sourced polyolefin and pelletized biodegrading agent to form a mixture. [0102] Melting the mixture of renewably-sourced polyolefin and biodegrading agent to form a molten resin by heating the mixture to 160° C. [0103] Injecting the molten resin into a mold with a cavity having a shape of a utensil to form a utensil. [0104] Opening the mold to release the utensil from the mold. [0105] Cooling the utensil to harden the molten resin in the shape of the utensil.

[0106] A preferred embodiment of a method for forming a renewably-sourced biodegradable polyolefin container, includes the following steps. [0107] Mixing pelletized renewably-sourced polyolefin and pelletized biodegrading agent to form a mixture. [0108] Melting the mixture of renewably-sourced polyolefin and biodegrading agent to form a molten resin by heating the mixture to 160° C. [0109] Injecting the molten resin into a mold with a cavity having a shape of a container to form a utensil. [0110] Opening the mold to release the container from the mold. [0111] Cooling the container to harden the molten resin in the shape of the container.

[0112] While the embodiments show examples of the invention, the scope of the invention should not be limited to those examples, but rather set by scope of the entire specification and claims.