# Patent

## Title
Direct melt processing of resins

## Abstract

The present invention relates to an animal chew including a resin and a method of direct injection molding the animal chew using a modified screw. The screw may incorporate, for example, additional flights or a larger transition zone. The formed resin may exhibit voids of about 1-100 μm in diameter.

## Background
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/251,261, filed Oct. 14, 2005, which is a continuation-in-part of U.S. application Ser. No. 11/198,881 filed Aug. 5, 2005.


FIELD OF INVENTION
The present invention relates to the formation of an animal chew composition. More particularly, the present invention is directed at direct injection molding of resins using a modified screw design to provide a ductile animal chew.
BACKGROUND
Numerous disclosures exist pertaining to the development of edible dog chews that are digestible and/or nutritious along with a texture that can be individually adjusted to suit a wide variety of a dog's preferences or needs. Attention is therefore directed to the following exemplary disclosures: U.S. Pat. No. 6,180,161 “Heat Modifiable Edible Dog Chew”; U.S. Pat. No. 6,159,516 “Method of Molding Edible Starch”; U.S. Pat. No. 6,126,978 “Edible Dog Chew”; U.S. Pat. No. 6,110,521 “Wheat and Casein Dog Chew with Modifiable Texture”; U.S. Pat. No. 6,093,441 “Heat Modifiable Peanut Dog Chew”; U.S. Pat. No. 6,093,427 “Vegetable Based Dog Chew”; U.S. Pat. No. 6,086,940 “High Starch Content Dog Chew”; U.S. Pat. No. 6,067,941 “Animal Chew”; U.S. Pat. No. 6,056,991 “Turkey and Rice Dog Chew With Modifiable Texture”; U.S. Pat. No. 5,941,197 “Carrot Based Dog Chew”; U.S. Pat. No. 5,827,565 “Process for Making an Edible Dog Chew”; U.S. Pat. No. 5,339,771 “Animal Chew Toy Containing Animal Meal”; U.S. Pat. No. 5,240,720 “Dog Chew with Modifiable Texture”; U.S. Pat. No. 5,200,212 “Dog Chew with Modifiable Texture.” Attention is also directed to U.S. Pat. No. 6,165,474 entitled “Application for Patent for Nutriceutical Toy” and U.S. Pat. No. 5,419,283 entitled “Animal Chew Toy of Starch Material and Degradable Ethylene Copolymer”. These disclosures provide non-limiting examples of starch based molding compositions and molding methods.
SUMMARY
In a first exemplary embodiment, the present invention relates to a method for providing a chew by direct injection molding of an edible resin comprising introducing edible resin into an injection molding machine including a screw, wherein the edible resin contains between 1-60% (wt) moisture. This may then be followed by directly injection molding the edible resin utilizing the screw wherein the screw includes a transition zone having a first length L1 and a feed zone having a second length L2, wherein L1>0.5*L2 and forming the edible resin into an animal chew wherein the formed edible resin exhibits a plurality of voids of about 1-100 μm in diameter.
In a second exemplary embodiment, the present invention relates to a method for providing a pet chew by direct injection molding comprising introducing an edible resin and water into an injection molding machine including a screw, wherein the screw includes a first flight and a second barrier flight. This may be followed by directly injection molding the edible resin wherein the edible resin and the water are plasticated with the screw and forming the edible resin into an animal chew, wherein the formed edible resin exhibits a plurality of voids of about 1-100 μm in diameter.



BRIEF DESCRIPTION OF DRAWINGS
Features and advantages of the present invention are set forth herein by description of embodiments consistent with the present invention, which description should be considered in conjunction with the accompanying drawings, wherein:
FIG. 1 is an exemplary embodiment of an injection molding machine.
FIG. 2 is an exemplary embodiment of a screw.
FIG. 3 is an exemplary embodiment of a portion of a screw including an additional flight.
FIG. 4 is perspective view of an exemplary test specimen.
FIGS. 5 a and b illustrate the dimensions of the testing specimens.
FIG. 6 is a scanning electron image of a sample produced by the unmodified screw at 20× magnification and an accelerating voltage of 10 keV.
FIG. 7 is a scanning electron image of a sample produced by the unmodified screw at 50× magnification and an accelerating voltage of 10 keV.
FIG. 8 is a scanning electron image of a sample produced by the unmodified screw at 200× magnification and an accelerating voltage of 10 keV.
FIG. 9 is a scanning electron image of a sample produced by the unmodified screw at 1000× magnification and an accelerating voltage of 10 keV.
FIG. 10 is a scanning electron image of a sample produced by the modified screw at 20× magnification and an accelerating voltage of 10 keV.
FIG. 11 is a scanning electron image of a sample produced by the modified screw at 50× magnification and an accelerating voltage of 10 keV.
FIG. 12 is a scanning electron image of a sample produced by the modified screw at 200× magnification and an accelerating voltage of 10 keV.
FIG. 13 is a scanning electron image of a sample produced by the modified screw at 1000× magnification and an accelerating voltage of 10 keV.



DETAILED DESCRIPTION
The present invention relates to providing an animal chew exhibiting increased ductility and less rigidity. In particular, the animal chew may be provided utilizing a modified screw design in the direct injection molding of the animal chew resins. The modified screw design may be provided to increase shear and melt mixing of the resin. Such increase in shear and melt mixing may therefore obviate the need to first extrude the starch into pellet form. The resin may be an edible resin, such as starch and/or wheat gluten. The resin may be of a controlled particle size, and may have a controlled level of moisture, so that the resin may be formed, upon exposure to one cycle of heat, into a desired shape. In addition, the resin may exhibit an elongation at break of at least 6% and a tensile modulus of less than 160 MPa.
The resin may have a particle size distribution wherein all or a portion of the particles are less than about 2.0 millimeters (mm), or 2000 microns, including all ranges of particle size that may be below 2000 microns. For example, the resin particle size may be less than about 500 microns and any value or range between 500 microns and 1 micron, including less than 250 microns, less than 149 microns, less than 44 microns, etc. In one embodiment, approximately greater than 95% of the particles are less than 149 microns and approximately greater than 60% of the particles are less than 44 microns. In another embodiment, approximately greater than 97% of the particles are less than 250 microns, and approximately greater than 75% of the particles are less than 149 microns. The resin may also have a bulk density of between 30-50 lb/cubic foot, including all increments and values therebetween such as between 40-45 lb/cubic foot, 38-40 lb/cubic foot, 35-38 lb/cubic foot, etc.
The resin may include any starch or carbohydrate of natural or vegetable origin. The starch may include amylose and/or amylopectin and may be extracted from plants, including but not limited to potatoes, rice, tapioca, corn and cereals such as rye, wheat, and oats. The starch may also be extracted from fruits, nuts and rhizomes, or arrowroot, guar gum, locust bean, arracacha, buckwheat, banana, barley, cassaya, konjac, kudzu, oca, sago, sorghum, sweet potato, taro, yams, fava beans, lentils and peas. The starch may be present in the resin composition between about 30-99% including all increments and values therebetween such as levels above about 50%, 85%, etc.
The starch employed herein may be raw starch, which may be understood as starch that has not seen a prior thermal molding history, such as extrusion or other type of melt processing step where the resin is shaped in the presence of heat. The starch therefore may be non-crosslinked. The raw starch itself may also be native, which may be understood as unmodified starch recovered in the original form by extraction and not physically or chemically modified. The raw starch may also be in powder form of varying particle size, as described above, which may be understood as milled and/or pre-sifted. It should be understood that the raw starch may also have varying degrees of moisture present. In one embodiment moisture may be present in the raw starch between 1-60% (wt), including all increments and values therebetween such as 40%, 20%, 10%, etc. Accordingly, it should be appreciated that the term “direct” as used herein with respect to injection molding refers to the molding of resin (e.g. starch or gluten such as wheat gluten) without exposing the resin to prior thermal molding histories before injection molding. For example, the resin herein is not molded with heat into a desired shape prior to being directly injection molded. However, the resin (e.g. starch) herein may, e.g., be heated for drying purposes, which would not amount to a prior thermal molding history.
The resin compositions herein may be sourced from Manildra Group USA, under the following tradenames: “GEMSTAR 100,” which is a refined food grade wheat starch; “GEMSTAR100+,” which is a refined food grade wheat starch; “GEM OF THE WEST VITAL WHEAT GLUTEN,” which is a powder product produced by low temperature drying of gluten extracted from wheat flour; “ORGANIC GEM OF THE WEST VITAL WHEAT GLUTEN,” which is a powder product produced by low temperature drying of gluten extracted from organic wheat flour; “ORGANIC GEMSTAR 100,” which is a wheat starch extracted from organic wheat flour; and/or “ORGANIC GEMGEL 100,” which is a pregelatinized organic wheat starch. In addition, the resin composition may be sourced from ADM under the trade names “EDIGEL 100,” which is a wheat resin composition and “AYTEX P,” which is a unmodified food grade wheat starch.
Other resins may be contemplated as well. For example, the resin may be a thermoplastic or rubber material, such as nylon, polyurethane, polyesteramide, natural rubber, isoprene, neoprene, thermoplastic elastomers, etc. Other resin materials may be contemplated that may be derived from animal sources such as casein, denatured or hydrolyzed casein, collagen, denatured or hydrolyzed collagen, rawhide, gelatin, other animal protein products, such as animal meal, etc. The resin material may also be derived from plant matter such as gluten, vegetable matter, nuts, such as nut flour, paste or bits, fruit matter, etc. Gluten may be understood as water-insoluble protein complex extracted from cereal grains such as maize or corn and wheat. The gluten may be present at levels between about 5-95% (wt), including all values and increments therein.
The resin may include cellulose. The cellulose may be, for example, a long-chain polymer of polysaccharide carbohydrate. The cellulose may also be derived or extracted from plants. The cellulose may be incorporated into the resin composition between about 1-15% by weight of the resin composition and any increment or value therebetween including 4%, 10%, 11%, etc.
Emulsifiers or surfactants may also be incorporated into the resin composition. The emulsifier may be present between about 1-10% by weight of the resin composition and all increments or values therebetween including 3%, 4%, etc. The emulsifier may include, for example, lecithin, which may be extracted or derived from, for example, egg yolk or soy beans.
The resin composition may also include a plasticizer. The plasticizer may include for example, glycerin. The plasticizer may be incorporated between about 15-30% by weight, including all increments and values therebetween such as levels greater than 15%, 21%, 27% etc.
A humectant may also be incorporated into the resin composition. The humectant may include, for example, oat fiber. The humectant may be incorporated between about 0.1-5% by weight of the resin composition including all intervals and values therebetween, including 1%, 25%, etc. A humectant may be understood to be any additive that may absorb water in the material.
The resin composition may also include water. The water may be introduced into the composition between about 1-40% by weight of the resin composition and any increment or value therebetween, including 4%, 20-40%, 10-20%, etc. After the product has been formed, the water may be present between 1-20% by weight of the resin composition including all increments or values therebetween, such as, below 20%, 4%, 5-10%, etc.
The resin composition may include a nutraceutical. The nutraceutical may be fermented soya. Fermented soya nutraceuticals are available from Bio Food, Ltd., Pine Brook, N.J. and sold under the general trade name Soynatto®. The fermented soya is present between about 1-40% by weight of the resin composition, including all increments and values therebetween, including 10%, 20%, etc. The Soynatto® product is more specifically described to contain the following as compared to other available compositions:













Constituents*











Made With

Soy
Soy














Units per
Foods*
protein
milk as
Tofu,















Nutrient
100 g
IEFS
Soynatto ®
Tempeh
Miso Paste
isolate
fluid
regular










Proximates















Protein
g
37.00
37.00
18.54
11.81
80.69
2.75
8.08


Total lipid
g
7.50
7.50
10.80
6.07
3.39
1.91
4.78


Carbohydrate
g
40.00
40.00
9.39
27.96
7.36
1.81
1.88


Fiber, total dietary
g
12.02
12.02

5.40
5.60
1.30
0.30







Minerals















Calcium
mg
151.50
151.50
111.00
66.00
178.00
4.00
350.00


Iron
mg
5.21
5.21
2.70
2.74
14.50
0.58
5.36


Magnesium
mg
191.25
191.25
81.00
42.00
39.00
19.00
30.00


Phosphorus
mg
608.25
608.25
266.00
153.00
776.00
49.00
97.00


Potassium
mg
1957.50
1957.50
412.00
164.00
81.00
141.00
121.00


Sodium
mg
18.30
18.30
9.00
3647.00
1005.00
12.00
7.00


Zinc
mg
3.84
3.84
1.14
3.32
4.03
0.23
0.80


Copper
mg
3.93
3.93
0.56
0.44
1.60
0.12
0.19


Manganese
mg
2.40
2.40
1.30
0.86
1.49
0.17
0.61


Selenium
mcg
27.98
27.98
0.02
1.60
0.80
1.30
8.90


Lithium
mcg
60.00
60.00
tr
tr
tr
tr
tr


Molybdenum
mcg
6.00
6.00
tr
tr
tr
tr
tr


Nickel
mcg
30.00
30.00
tr
tr
tr
tr
tr


Tin
mcg
12.00
12.00
tr
tr
tr
tr
tr







Lipids















Fatty acids, saturated
g
1.22
1.22
2.22
0.88
0.42
0.21
0.69


Fatty acids,
g
1.70
1.70
3.00
1.34
0.65
0.33
1.06


monounsaturated


Fatty acids,
g
4.14
4.14
3.83
3.43
1.65
0.83
2.70


polyunsaturated


Omega-6 Fatty Acid
g
3.57
3.57
3.59
3.02
1.45
0.74
2.38


Omega-3 Fatty Acid
g
0.55
0.55
0.22
0.41
0.20
0.10
0.32







Vitamins















Thiamin
mg
1.79
1.79
0.08
0.10
0.18
0.16
0.08


Riboflavin
mg
1.04
1.04
0.36
0.25
0.10
0.07
0.05


Niacin
mg
7.62
7.62
2.64
0.86
1.44
0.15
0.20


Pantothenic acid
mg
2.34
2.34
0.28
0.26
0.06
0.05
0.07


Vitamin B-6
mg
0.99
0.99
0.22
0.22
0.10
0.04
0.05


Folic
mcg
532.50
532.50
23.90
33.00
176.10
1.50
15.00


Vitamin A
IU
30.00
30.00
0.00
87.00
0.00
32.00
85.00


Vitamin E
mg_ATE
0.15
0.15
tr
0.01
0.00
0.01
tr


Biotin
mg
0.02
0.02
tr
tr
tr
tr
tr


Choline
mg
60.00
60.00
tr
tr
tr
tr
tr


Inositol
mg
72.00
72.00
tr
tr
tr
tr
tr


PABA
mg
6.00
6.00
tr
tr
tr
tr
tr







Special Nutrients















Isoflavones
mg
4000.00
200.00
43.52
42.55
97.43
9.65
23.61


Glycogen
g
1.10
1.10
tr
tr
tr
tr
tr


Beta Glucans
g
0.50
0.50
tr
tr
tr
tr
tr


Glutathione
mg
60.00
60.00
tr
tr
tr
tr
tr


SOD
unit
1650.00
1650.00
tr
tr
tr
tr
tr


RNA/DNA
g
1.05
1.05





An Empty Cell indicates a value is un-known;


“tr” indicates a value is probably a trace or none.






As can be seen from the above, the Soynatto® product may provide proteins, minerals, and vitamins, in a fermented soy form. The fermentation process may infuse the product with saccharomyces cerevisiae, commonly known as “bakers yeast” or “brewers yeast.” Saccharomyces cerevisiae is more traditionally known to ferment sugars present in flour or dough, yielding carbon dioxide and alcohol. Accordingly, it should be appreciated that a protein, one or more of a mineral, and one or more of a vitamin, along with saccharomyces cerevisiae may be present in the resin composition.
The fermented soy product herein may include increased concentrations of glycitein, daidzein and genistein, reportedly present at several hundred percent more than other more common soyfood sources. Glycitein, daidzein and genistein belong to the isoflavone class of flavanoids and may be classified as phytoestrogen, since they are plant derived nonsteriodal compounds that contain estrogen-like biological activity.
In the context of the present invention, the direct injection molding of the fermented soy product may offer advantages with respect to the activity of the soy product in a final molded shape. Specifically, the direct injection molding provides that the fermented soy product is not substantially degraded and the nutritional value of the fermented soy product remains substantially unchanged.
The resin composition may also include enzymes and/or co-enzymes which are similarly available through Bio Foods, Ltd., Pine Brook, N.J. and sold under the trade name of BT-CoQ10®. This reportedly is a biologically transformed (fermented) cell mitochondrial coenzyme and contains Coenzyme Q10, antioxidants, phytonutrients and cofactor mineral nutrients and other cell constituents. The enzymes and/or co-enzymes may be present between 0.1-10% by weight of the resin composition, including all increments and values therebetween such as 1%, 5%, etc.
Reportedly, the coenzyme Q10 is a fat-soluble compound primarily synthesized by the body and also consumed in the diet and is required for mitochondrial ATP synthesis. The fermented coenzyme also reportedly belongs to the family of compounds known as ubiquinones, which are either of two isomeric cyclic crystalline compounds C6H4O2 that are di-keto derivatives of dihydro-benzene. It may also function as an antioxidant in cell membranes and lipoproteins.
Other additives may be introduced into the composition as well. These additives may include vegetable matter, fruit matter, rawhide, nuts, nut bits or nut flour such as peanut flour, and animal or fish products, by-products, meal or digests, etc. These additives may be present individually or cumulatively between about 0.1-50% by weight of the resin composition and all increments and values therebetween including 0.1-5.0%, 15%, 25%, etc.
Additionally, flavorants, herbs, herbal extracts, vitamins, minerals, colorants, yeast products, soy products, attractants, etc., may be incorporated into the resin composition. Yeast products may include nutritional yeast or brewers yeast such as saccharomyces cerevisiae, dairy yeast such as kluyveromyce marxianus or wine yeast such as saccharomyces fermentati. The soy products may include fermented soy or other soy products, as listed in the table above. Attractants may include compounds listed herein, such as the animal or fish digests, or other compounds that may increase an animal's interest in the resin composition. These additives may be present individually or cumulatively between about 0.01-25% by weight of the resin composition and any increment or value therebetween including 0.01-0.5%, 10%, 20%, etc. The composition may also include calcium carbonate. The calcium carbonate may be present between about 5-10% by weight.
It should be appreciated, however, that the resins contemplated herein may consist essentially of the base resin, i.e. starch, wheat gluten, rawhide, etc., and water. Sufficient plastication may be experienced by the resin which may minimize the effect of processing enhancing additives, such as plasticizers, humectants, or emulsifiers, etc. In particular, the use of the modified screw discussed herein may generally lead to a more uniformly plasticated material.
The additives of the resin composition may be introduced directly into the barrel of an injection molding machine 100, illustrated in FIG. 1, through a hopper or other feeding device 102. Various feeding devices for introducing the additives into the injection molding barrel may be contemplated including loss-in weight gravimetric blenders/feeders, auger feeders, venturi loaders, etc. Those skilled in the art will appreciate that an injection molding machine 100 typically contains a barrel 104 including a feed section 106, a screw 108 and an output nozzle 110. The barrel 104 may include a plurality of temperature control zones 112, 114, 116, 118 in the barrel extending from the feed section 106 section to the nozzle 110. The injection molding machine may include a mold 120 having one or more cavities 122. The molding machine may also be vented, including a vented barrel and/or a vented mold.
The temperature adjustment may vary for each zone. For example, in one exemplary embodiment, the molding machine barrel may include 4 zones, zone 1 112 being the closest to the feed section 106 and zone 4 118 being the closest to the nozzle 110. Zone 1 112 may be set to less than about 150 degrees F., including any increment or value between about 35 to 150 degrees F. including between about 46 to 150 degrees F., 46 to 70 degrees F., etc. Similarly zone 2 114 may be set between about 70 to 150 degrees F. including any increment or value therebetween, zone 3 116 between about 50 to 300 degrees F. including any increment or value therebetween, and zone 4 118 between about 200 to 375 degrees F. including any increment or value therebetween. The nozzle 110 may be set between about 250 to 390 degrees F. including any increment or value therebetween. The bushing 124 inside of the mold 120 may be set between about 250 to 425 degrees F. including any increment or value therebetween and the mold 120 may also be set between about 35 to 65 degrees F. including any increment or value therebetween.
Once introduced into the barrel 104 of the molding machine 100 the resin and additives may be blended as the screw 108 conveys the material towards the mold 120 where the resin composition may be formed. The mold 120 may cool the resin composition. Once molded and venting takes place, the resin composition may include water between about 1-20% by weight of the resin composition, including all increments and values therebetween such as 10%, 15%, etc. The resin composition may be molded into any form capable of being produced in an injection molding cavity.
The design of the screw 108 may also be varied or modified to provide greater thermal and/or mechanical interaction with the resin composition. In particular, the screw may impart increased shear stress on the material. It should be appreciated that as referred to herein, an unmodified screw may include what is termed a general purpose screw design. As illustrated in FIG. 2a a modified screw 108 may include a number of zones which extend along the length L of the screw. For example, the screw may include a feed zone 210, a transition zone 212 and a metering zone 214. The feed zone 210 may be proximate to the hopper or other feeding device 102 in the barrel 104 and the metering zone may be proximate to the nozzle 110. The feed zone therefore may function to convey solid material away from the feed section 106.
The length of the feed zone 210, the transition zone 212 and the metering zone 214 may be adjusted while maintaining the overall length L of the screw at the same size. The length of the feed zone 210 may be decreased and the length of the transition zone and/or the metering zone 212, 214 may be increased. The screw therefore may include a transition zone having a first length L1 and a feed zone having a second length L2, wherein L1>f*L2. The metering zone may similarly have a length L3 wherein L3>f*L2. In the previous equations, the value of “f” may be 0.5 and greater, such 0.6, 0.7 up to 10.0, including all incremental values therebetween.
Solids conveying in the screw may be improved by increasing the surface roughness of the internal barrel surface or the root surface of the screw. The increased roughness may cause an increase in the coefficient of friction between the resin composition and the barrel wall. Increasing the roughness may be accomplished by coating the surface of the screw and/or barrel wall. The surface roughness may have an Ra value of greater than about 5 micro-inches, including all ranges and increments above such as 9, 30, 42 etc. The variable “Ra” is an arithmetic mean and represents the average of all peaks and valleys. Lower numbers indicate a smoother finish.
The modified screw 108 may also include one or more flights 216 wrapping helically around the axis α of the screw (shown in phantom) extending from the feed zone 210 to the metering zone 214. The flight 216 may define a plurality of channels 218. Referring to FIG. 2b, the screw 108 includes an outer diameter OD, defined by the surface of the flight and a root diameter RD defined by the channels forming the root of the screw. The channel depth CD is the distance between the top of a flight to the screw root. Either the outer diameter or the inner diameter may vary along the length of the screw. Stated another way, there may be a consistent reduction or increase in either the outer diameter OD or the root diameter RD of the screw. Alternatively, there may be random reductions and increases in either the outer diameter OD or root diameter RD along the screw length for purposes such as venting.
The modified screw may have a flighted length to diameter ratio of between 10:1 to 40:1. The flighted length of the screw FL is a general reference to the length of the screw incorporating a flight (or flights), illustrated in FIG. 2a. The diameter refers to the outer diameter of the screw OD (referring back to FIG. 2b). The flight may also have a helix angle φ of approximately 15.0-20.0 degrees, illustrated in FIG. 2b. 
The compression ratio of the screw may also be increased. The compression ratio is a reference to the difference in channel depth between the feed zone and metering zone of the screw. In one embodiment, the compression ratio may be greater than about 2:1, including all increments and values above such as 3.5:1, 4:1 etc.
Furthermore, the modified screw may include barrier flights and other mixing heads or flights. A barrier zone 310 is a reference herein to a portion of the screw having more than one flight, such as a main flight 312 and a barrier flight 314, as illustrated in FIG. 3. The main flight and the barrier flight may wrap around the screw concurrently.
The barrier flight may have a varying pitch P or the pitch may be similar to the main flight. Pitch P is a general reference to the axial distance between two points on the flight separated by a full turn of the screw. For example, the pitch Pb of the barrier flight may be greater than the pitch of the main flight Pm, wherein Pb>d*Pm, where d is greater than or about 1.01, including any increment or value above, such as 1.1, 1.5 etc.
The barrier flight may be undercut and have a smaller outer diameter ODb than the main flight allowing polymer melt to pass from one channel to the other. The solids may not pass over the flight until they are small enough or have been completely melted. For example, the barrier flight ODb may be less than the diameter of the main flight OD. Accordingly, the ODb may be equal to x*OD wherein x is 0.5-0.99. Furthermore, the ODb may be equal to the OD of the main flight.
The channel depth CD of the barrier flight may also be the same as the main flight or may differ from the main flight. For example, the channel depth of the barrier flight may be greater than the channel depth of the main flight or the channel depth may increase or decrease along the length of the screw. The barrier zone may extend the entire flighted length (FL illustrated in FIG. 2) of the screw or may extend along a portion of the screw, such as along the length of one or two of the zones, or along only a portion of a single zone.
Mixing heads, zones or flights may include dispersive mixing elements and distributive mixing elements. Dispersive mixing elements may be used to decrease agglomerates or gels. The mixing element may be fluted or splined. The splines or flutes may be arranged parallel, perpendicular or at an angle to the longitudinal screw axis α. The element may also be in the form of a blister ring.
Distributive mixing elements may be used to disrupt the velocity profiles of the material in the barrel. Pins of various sizes and geometries or small lands may be arranged radially about the axis of the screw including pin mixing sections or pineapple mixing sections. Slotted channels or narrow channels may also be employed or a cavity transfer mixing section. These elements may be used alone or in combination to provide adequate mixing of the polymer composition prior to exiting the barrel and entering the mold.
The resulting resin composition and chew product produced by the modified screw may exhibit greater ductility and a lower modulus than the composition produced by the unmodified screw. Ductility may be understood as the amount of strain that a material can withstand before fracture. Thus the greater the ductility, the higher the amount of strain the material can withstand prior to fracture. Strain may be understood as the per unit change, due to force, in the size or shape of a body in reference to its original size and shape. Accordingly, the resulting chew composition produced with the modified screw may have a break strain, or an elongation at break of greater than 6%. It may also have a value between about 6-25% including all ranges and increments therein, such as 10%, 18%, etc.
Modulus may be understood as the ratio of stress to strain in a material that is elastically deformed. Accordingly, the higher the modulus, the more rigid the material is. The resulting chew composition produced with the modified screw may have a tensile modulus less than 160 MPa. The tensile modulus may also fall in the range of 50-160 MPa including all values and ranges therein, such as 150 MPa, etc.
In addition, the resin may exhibit voids and may be relatively devoid of crack discontinuities greater than about 100 μm in length. The voids may possess an aspect ratio, i.e. the ratio between the length “L” and width “W” of a void (L:W), between about 1:1 to about 10:1. In addition, the resin may appear less granular in nature than resin formed or produced by an unmodified screw, or a general purpose screw.
EXAMPLES
The examples provided herein are merely for illustrative purposes only and are not meant to be construed as limiting the scope of the presently described and claimed invention.
To determine the difference between the compositions provided by direct injection molding using the modified and unmodified screws a series of tensile tests and scanning electron microscope observations were made on samples produced via both the modified and unmodified screws. The samples were formed of about 63-65% by weight wheat starch, about 6-10% by weight cellulose, approximately 2-4% by weight lecithin, about 24-27% by weight glycerin, flavorants and colorants.
FIG. 4 illustrates a perspective view of an exemplary test specimen. FIGS. 5a and 5b illustrate the dimensions of the test specimens 10. The specimens had a neck width, NW, a neck thickness, NT, an overall length, L, and a shoulder diameter S. The averages and standard deviations of which are included in Table 1.







TABLE 1







Sample Dimensions










Modified Screw
Unmodified Screw














Neck Width (mm)
NW
 6.71 +/− 0.12
 6.48 +/− 0.07


Neck Thickness (mm)
NT
 7.32 +/− 0.06
 7.32 +/− 0.21


Length (mm)
NL
49.54 +/− 1.17
49.27 +/− 0.49


Shoulder (mm)
S
10.32 +/− 0.28
10.18 +/− 0.51









The samples were tensile tested in accordance with a modified version of ASTM D638 due to sample geometry. The crosshead speed of the testing machine was 2 in/min. The grip distance on the samples was 25.4 mm. The results of the tensile testing are illustrated in Table 2. It should be noted that all of the samples broke at the neck.







TABLE 2







Tensile Testing Results










Modified Screw
Unmodified Screw













Modulus (MPa)
114 +/− 38 
187 +/− 18 


Break Stress (MPa)
2.8 +/− 1.2
4.7 +/− 0.3


Elongation at Break (%)
14.27 +/− 3.52 
5.73 +/− 0.13









As can be seen from the above, the samples produced using the modified screw had an elongation at break that is greater than the elongation at break of the samples produced on the unmodified screw by a factor of approximately 2.5. In addition, the samples produced on the unmodified screw had higher modulus and break stress values by a factor of about 1.6 in both cases. It should be noted however that the samples produced on the unmodified screw did not yield, where as the samples on the modified screw demonstrated a yield point, wherein the yield stress was 4.8+/− 0.7 MPa and the elongation at yield was approximately 9.66%+/− 2.33.
Scanning Electron Microscope (SEM) images of the specimens were also taken of the samples produced on the modified and unmodified screws. The samples were cut and tested at an accelerating voltage of 10 keV at magnifications of 20×, 50×, 200×, and 1000×. FIGS. 6-9 illustrate the SEM images for the samples produced using the unmodified screw at 20×, 50× 200×, and 1000× respectively. FIGS. 10-13 illustrate the SEM images for the samples produced using the modified screw at 20×, 50× 200×, and 1000× respectively.
FIG. 6, a cross-flow direction SEM image of the resin produced by the unmodified screw at 20× magnification, illustrates a large number of relatively large scale crack discontinuities “a” which are present throughout the sample thickness. Cross-flow direction may be understood herein as a direction perpendicular to the flow of the polymer material during formation of the sample. As can be seen from the picture, the discontinuities may be as large as 100 μm and greater than 500 μm. On the other hand, relatively few voids, if any, have been formed in the sample.
FIG. 7 illustrates a close-up view of a portion of the sample of resin produced by the unmodified screw at 50× magnification. As can be seen from this view, the aspect ratio (length to width ratio) of the relatively large scale cracks “a” appears to be larger than 50:1. Also illustrated in FIG. 7, as well as FIG. 8, which is a SEM of a sample of resin produced by the unmodified screw at 200× magnification, is the relatively grainy texture of the sample.
FIG. 9 illustrates a SEM image of the sample of resin produced by the unmodified screw at 1000× magnification. As can be seen from this view, some short scale or micron size cracking “b” is present. The cracks appear to have an aspect ratio of around 10:1.
Without being bound to any particular theory, it appears that the samples produced with the unmodified screw may generally be characterized as crazing throughout the thickness of the sample, which may be due to lack a lack of plastication during processing. Accordingly, during forming or cooling, the resin may separate into a number of layers through its thickness leading to relatively large scale and micron cracking.
FIG. 10 illustrates a SEM image of a cross-flow direction view of a sample of resin produced by a modified screw at 20× magnification. Unlike the sample produced with the unmodified screw, this sample illustrates a number of voids “c” across the surface of the material. Furthermore, significantly less crack discontinuities of greater than about 100 μm are present.
FIG. 11 illustrates a cross-flow direction view of a sample at 50× magnification. The texture of the sample appears to be relatively less grainy than the sample produced by the unmodified screw. FIGS. 12 and 13 illustrate the voids at higher magnifications, 200× and 1000× respectively. As can be seen, it appears that the voids have an aspect ratio (length to width ratio) in the range of about 1:1 to 10:1, including all values and increments therein e.g. 1.5:1, 2:1, etc.
Once again, while not being bound to any particular theory, the samples produced with the modified screw did not exhibit the crack discontinuities and graininess seen in the samples produced by the unmodified screw. In addition, it appears that the resin formed a number of voids across the diameter/thickness of the sample. This may indicate that the resin may have experienced relatively higher degrees of plastication.
The foregoing description is provided to illustrate and explain the present invention. However, the description hereinabove should not be considered to limit the scope of the invention set forth in the claims appended here to.

## Claims

1. A method for providing a chew by injection molding of edible resin comprising:
introducing ingredients of a composition directly into an injection molding barrel of an injection molding machine, wherein said barrel houses a single screw comprising a single screw having a flight having a helix angle, said screw comprising a transition zone having a first length L1 and a feed zone having a second length L2, wherein L1>0.5*L2 and a helix angle between about 15 and 20 degrees extending from said feed zone through said transition zone;
wherein said ingredients comprise:
raw starch in an amount ranging from 30-99% by weight, wherein said raw starch:
comprises unmodified starch recovered by extraction and which has not been physically or chemically altered;
has not seen a prior thermal molding history including extrusion and any type of melt processing step;
has a particle size ranging from 1 micron to 500 microns; and
contains between 1 to 60 weight % moisture;


mixing said ingredients in said barrel, thereby producing said composition in said injection molding barrel; and
providing a mold having at least one cavity to form the chew in open communication with said composition in said injection molding barrel;
conveying said composition with said screw from said injection molding barrel into said at least one cavity of said mold; and
forming said composition into a formed raw starch animal chew in said mold, wherein said formed raw starch animal chew exhibits a plurality of voids of about 1-100 μ in diameter length and has an elongation at break of greater than 6% and a tensile modulus of less than 160 MPa.

2. The method of claim 1 wherein said voids have an aspect ratio (L:W) in the range of about 1:1 to 10:1.

3. The method of claim 1 wherein said formed raw starch animal chew is substantially devoid of crack discontinuities of greater than about 100 μm.

4. The method of claim 1 wherein said single screw further comprises a metering zone having a third length L3, wherein L3>0.5*L2.

5. The method of claim 4 wherein said feed zone has a first channel depth CD1 and said metering zone has a second channel depth CD2, wherein CD1>2.0*CD2.