Hemp and PBAT Biopolymer Substrate

Abstract

Provided is a hemp and PBAT based biopolymer substrate as a replacement composition to various synthetic, or synthetic containing compounds, plastics. The substrate requires no specialized knowledge as known in the art, utilizes existing manufacturing equipment and methods of processing and contains no synthetic polymers. The substrate is biodegradable and compostable, and produces no micro plastic waste when discarded or by degradation. By selectively adjusting the ranges of the biopolymer substrate, various products with attributes of a myriad of plastic products can be manufactured according to their existing methods. The substrate is comprised of compounds from renewable resources and contributes zero greenhouse gas emissions at the end of a products useful life.

Claims

1. A hemp and PBAT based biopolymer substrate comprising of hemp from approximately fifteen to thirty five percent (15% to 35%) by weight, approximately three to thirty percent (3 to 30%) PLA (Polylactic Acid) by weight, PCL (Polycaprolactone) of approximately ten to twenty five percent (10% to 25%) by weight, approximately ten to forty percent (10 to 40%) PBAT (Polybutylene Adipate Terephthalate) by weight, approximately ten to thirty percent (10-30%) of Calcium Carbonate (CaC03) in a 1 to 3 (one to three) micron size, a biodegradation additive of approximately three fourths to two percent (0.75 to 2%) by weight.

2. A biodegradable and compostable biopolymer substrate formed by thermodynamically combining hemp from approximately fifteen to thirty five percent (15% to 35%) by weight, approximately three to thirty percent (3-30%) PLA (Polylactic Acid) by weight, approximately ten to forty percent (10-40%) PBAT (Polybutylene Adipate Terephthalate) by weight, approximately ten to thirty five percent (10-30%) of Calcium Carbonate (CaC03) in a one to three (1 to 3) micron size, a biodegradation additive from approximately three fourths of a percent to two percent (0.75-2.0%) by weight.

3. A composition for the use in manufacturing various plastic items comprised of no synthetic polymers or plastic polymer blends utilizing various existing manufacturing equipment and processes and in which no micro plastic particles remain after its useful life whether degraded or discarded.

4. The composition of claim 1 wherein the compound is biodegradable.

5. The composition of claim 1 wherein the compound is compostable.

6. The composition of claim 1 wherein the compound contains no synthetic polymers.

7. The composition of claim 1 wherein the degraded or discarded compound leaves no micro plastic particles.

8. The composition of claim 1 wherein existing manufacturing machinery and methods are utilized to produce various plastics.

9. The composition of claim 1 where the compound can be utilized as a replacement for various synthetic polymer plastics or blends as a replacement to various plastics.

10. The composition of claim 1 wherein the compound has attributes similar to plastic products without synthetic polymers.

11. The composition of claim 1 wherein the composition in various embodiments can be produced to exhibit the properties of PP, HDPE and other plastic based materials and products without the inclusion of synthetic polymers.

12. The composition of claim 2 wherein existing manufacturing machinery and methods are utilized to produce various plastics.

13. The composition of claim 2 wherein the degraded or discarded compound leaves no micro plastic particles.

14. The composition of claim 2 wherein the compound contains no synthetic polymer plastics.

15. The composition of claim 2 where the compound can be utilized as a replacement for various synthetic polymer plastics or blends as a replacement to various plastics.

16. The composition of claim 2 wherein the compound has attributes similar to plastic products without synthetic polymers.

17. The composition of claim 2 wherein the composition in various embodiments can be produced to exhibit the properties of PP, HDPE and other plastic based materials and products without the inclusion of synthetic polymers.

18. The composition of claim 3 wherein the compound is biodegradable.

19. The composition of claim 3 wherein the compound is compostable.

20. The composition of claim 3 wherein the compound that can be manufactured to create various plastic products and objects in various manufacturing processes utilizing existing equipment.

21. The composition of claim 3 where the compound can be utilized as a replacement for various synthetic polymer plastics or blends as a replacement to various plastics.

22. The composition of claim 3 wherein the composition in various embodiments can be produced to exhibit the properties of PP, HDPE and other plastic based materials and products without the inclusion of synthetic polymers.

Description

DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] In one exemplary embodiment which has properties suitable for malleable plastic parts such as a light switch plate cover comprises of approximately: (A) 25-35% Calcium Carbonate (Caco3); (B) 15-22.5% Hemp from seeds (oil, powder or alternative aggregated form representing a biodegradable hemp resin), (C) 1% -2% biodegradable Eco-Pure additive, (D) 15-25% EcoFlex PBAT, (E) 20-30% PLA as a Bio-Polymer (F) 20-25% hemp.

[0036] In another exemplary embodiment which has properties suitable for rigid plastic parts, in this example specifically compounding the substrate for a Yoyo, the embodiment is comprised of the following approximate compounds: (A) 30-40% hemp from seeds, (B) 15-25% Limestone (CaCO3), (C) 20-30% PLA as a Biopolymer (D) 15-40% PBAT, and (E) 1-2% biodegradable additive.

[0037] And, in an exemplary embodiment as a sheet for thermoplastic forming such as is used to manufacture food service trays, the substrate comprises of approximately: (A) 25-40% PBAT, (B) 25-30% Limestone, (C) 0.05-1% Ecopure, and (D) 15-30% PLA.

PROCESS FOR FORMULATION

[0038] Akin to creating a relevant mixture for a 2 foot concrete retaining wall versus a 10 foot concrete retaining wall wherein formulation attributes are all critical to the function, longevity and structural strength of any particular item, each has their own mechanical density, strength, and elasticity end product requirements to fulfill their role as a useful item. The ultimate composition and properties of the disclosed invention is dependent on its end use is related to the process of mixing dry compounds so as to be cohesively mixed first, then any remaining liquid compounds separately mixed also in cohesion with each other which is the first key to a successful compound.

[0039] Following, powder and liquid compounded materials are then mixed in the process below as to create ultimate even dispersion and cohesion of a final compound ready for manufacturing.

[0040] First, the composition of the substrate requires the application of CaC03 to be evenly dispersed throughout the resin blend in various amounts ranging from 30% to 50% by weight and with other powdered compounds. Whether the CaC03 is treated or untreated but in a powered state and 90%+ pure in sizes ranging from 1-3 microns, it is then sifted into other powdered compounds to achieve an evenly distributed powder mix. The amount of other powders is in the ratio of 2-20% by weight. Powdered compounds must be blended in a dry and powdered state. Any additional dry compounds are mixed in the percentage ranges identified herein including those such as PBAT, PLA, PCL or hemp granules.

[0041] Second, the compounding process then requires all liquids such as hemp oil from seeds, Biopolymers or other additive liquids to be consistently blended as a separate batch, independent of the first, and heated to a range of between 150 and 300 degrees Fahrenheit, processed and mixed in a heated agitation for a period of time between 2-4 hours for a consistently dispersed and blended integration of the inclusive liquid compounds prior to any powdered compound batch introductions. Processing temperature ranges may vary depending on formulation, manufacturing process and properties desired of a final product.

[0042] In the final stage of compounding, the process requires a merging meld of the heated processed and agitated liquid batch, with the processed agitated powdered batch to create a slurry or roux wherein a mixture is created in a heated state where they can thermodynamically activate at temperatures in the 150-330 Fahrenheit range. It is in this range which there is cohesion between the two within this specific temperature value. The blend of Limestone or other dry compounds must be added in an even fill to the melted batch compounds mass ratio whereas by weight, the liquid batch is between 20-50% of the dry batch formulation. The two batches of compounds are added together and must be continuously agitated for a period of time between 2-5 hours to its desired consistency for any given manufacturing process requirement.

[0043] The resulting biopolymer composition is now ready and compatible for any given manufacturing process such as thermoforming, extrusion blow molding, molding or other methods and processing as known in the art.

[0044] There must be a short thermal process in correlation to the slurry agitation within specific time parameters prior to either the vacuum forming or an injection molding processes depending upon desired end product formation. There is an injection of air in the majority of end product processes that is directly relevant to the substrates native characteristic as applied to the end product and must be observed as a product specific time value.

[0045] The process as described produces the substrate in a balanced and even dispersion suitable for standard manufacturing production equipment and processes as described, but not necessarily limited to those as provided as examples herein.

[0046] During the early stages of production and development in identifying a successful composition as a replacement for synthetic polymer products, several challenges ensued including notably, working with non-synthetic compounds in order to achieve various attributes of various useful plastic replacement items. By identifying specialized and varying non synthetic polymers in various selective loads by weight and combining the compounds in the disclosed process, the hemp and PBAT biopolymer composition formed a strong cohesion to retain not only the best of the initial compounds' various unique structure and attributes, but that with a uniform compounded master batch. This technique led to a successful composition, regardless of varying thermal and other properties of each compound noted herein to create a highly efficient and durable biopolymer suited to traditional manufacturing processing as a replacement to traditional synthetic or mixed synthetic plastic products as a biodegradable and compostable replacement. It should be noted that in of themselves, each of the herein discussed individual compounds are challenged to create a meaningful use as a plastic replacement product for several reasons. For example tensile strength (enough durability or flexibility to be useful), manufacturing challenges (elongation or lack thereof wherein reaction to processing heat may compromise a material), and expected everyday functional uses serving a purposeful life for that individual product. This also includes microwavable and freezable products. Additionally, attributes such as elongation, stretch and flexibility to achieve certain product requirements or alternately stiffness, bending stiffness, bend modulus or rigidity are also generally challenged to produce meaningful products as intended for their useful life.

[0047] A hemp and PBAT composition that in certain embodiments can be customized for the use in blow film extrusion, extrusion blow molding, extrusion, thermoforming, rotational and vacuum forming, injection molding, blow molding, CNC machining, 3D printing or other such plastic processing methods as known in the art for the production of various materials as stated herein.

BACKGROUND

[0048] The various embodiments and aspects described herein relate to a composition that can be used as an alternative to producing various plastic products and objects. Various issues relating to synthetic polymer based plastics with harmful impact to the environment and end of life disposal challenges are commonly known. Accordingly, there is a need for an improved plastic alternative compound without reliance on fossil fuels, greenhouse gas contributions, manufacturing changes or specialized knowledge as practiced, and understood in the art.