Polymer base blend compositions containing destructurized starch

Abstract: A composition of matter capable of being formed into articles having substantial dimensional stability comprising a) destructurized starch, and b) at least one compound selected from the group consisting of styrene sulfonic acid polymers, styrene sulfonic acid copolymers, and salts thereof; said compound being present in an amount effective to enhance the physical properties of said articles. The composition may contain further conventional additives as well as hydrophobic, substantially water-insoluble polymers.

Description: The present invention relates to polymer compositions capable of being formed by heat and pressure into articles having dimensional stability and enhanced physical properties, and to pre-mixes useful for preparing these compositions. These compositions and pre-mixes comprise destructurized starch and other polymers as described herein. It is known that natural starch which is found in vegetable products and which contains a defined amount of water can be treated at an elevated temperature and in a closed volume, thereby at elevated pressures, to form a melt. The process is conveniently carried out in an injection molding machine or extruder. The starch is fed through the hopper onto a rotating, reciprocating screw. The feed material moves along the screw towards the tip. During this process, its temperature is increased by means of external heaters around the outside of the barrel and by the shearing action of the screw. Starting in the feed zone and continuing in the compression zone, the particulate feed becomes gradually molten. It is then conveyed through the metering zone, where homogenization of the melt occurs, to the end of the screw. The molten material at the tip can then be treated further by injection molding or extrusion or any other known technique to treat thermoplastic melts, to obtain shaped articles. This treatment, which is described in the European Patent Application No. 84 300 940.8 (Publication No. 118 240), which patent is incorporated herein by reference, yields an substantiallydestructurized starch. As described in the above mentioned patent, the reason for this is that the starch is heated above the glass transition and the melting temperatures of its components. As a consequence, a melting and disordering of the molecular structure of the starch granules takes place, so that a substantially destructurized starch is obtained. The expression "destructurized starch" defines starch obtained by such thermoplastic melt formation. Reference is also made to European Patent Applications No. 88810455.1 (Publication No. 298,920), No. 88810548.3 (Publication No. 304,401) and No. 89810046.6 (Publication No. 326,517), which further describe destructurized starch, methods for making it, and uses of it. These applications are also incorporated herein by reference. It is preferred that the destructurized starch used in the present invention has been heated to a high enough temperature and for a time long enough so that the specific endothermic transition analysis as represented by a differential scanning calometry (DSC) indicates that a specific relatively narrow peak just prior to oxidative and thermal degradation has disappeared, as described in the above-mentioned European Patent Application No. 89810046.6 (Publication No. 326,517). Destructurized starch is a new and useful material for many applications. An important property is its biodegradability. In humid air, however, destructurized starch takes up water from the air, thereby increasing its moisture content. As a consequence, a shaped article made from destructurized starch may under such conditions lose its dimensional stability. On the other hand such an article may dry out in low humidity and become brittle. Thermoplastic starch has a unique set of properties and while these are very useful, they may limit its utility in cases where a softer, more resilient or harder, tougher polymer is desired. Thermoplastic starch as mentioned can be extruded and molded into numerous useful shapes and profiles. However, the processing parameters such as water content, temperature, and pressure are generally critical and must be narrowly controlled to achieve reproducible quality products. This is a further disadvantage for many applications. To overcome these potential limitations, it would be useful to increase the dimensional stability over a wide humidity range; to increase the toughness (measured as break energy); to increase the elasticity (measured as elongation); to decrease polymer stiffness (measured as Young's modulus) and increase the hardness. Broadening processing latitude increases the variety of shapes and composites and decreases the need for close controls. It would therefore also be useful to improve the control of the melt strength, e.g. increasing the processing latitude for extruding, injection molding, film blowing or fiber drawing and to control the surface tack and adhesion to other substrates. Conventional thermoplastic materials are hydrophobic, substantially water-insoluble polymers which are conventionally processed in the absence of water and volatile materials. Starch to the contrary forms a melt in the presence of water but decomposes at elevated temperature, i.e. around 240°C. It was therefore expected that such a starch melt could not be used as a thermoplastic component together with hydrophobic, essentially water-insoluble polymeric materials not only because starch forms a melt in the presence of water as described above, but also because of its chemical structure and hydrophilic nature. EP-A-0 118 240 as mentioned above refers to destructurized starch and method of producing the same. GB-A-2 190 093 refers to moldable starch compositions comprising destructurized starch. The teaching refers to particulate, free-flowing starch-based formulations. The addition of a hydrophobic, substantially water-insoluble thermoplastic polymer is not mentioned; neither dos this document mentioned the addition of sulfonated polystyrenes. EP-A-0 327 505 was filed prior to the filing date of the present patent application but published on August 9,1989. EP-A-0 327 505 discloses compositions comprising a water-containing destructurized starch and at least one essentially water-insoluble synthetic thermoplastic polymer. None of these references refers to compositions comprising the three components a), b) and c) as defined in the present patent application. It has now been found that starch, when heated in a closed volume at proper moisture and temperature conditions as described above to form a melt of destructurized starch, is substantially compatible in its processing with melts formed by hydrophobic substantially water insoluble thermoplastic polymers and that the two types of molten materials show an interesting combination of properties, especially after the melt has solidified. One very important aspect is the surprisingly improved dimensional stability of such destructurized starch blended with such hydrophobic thermoplastic materials. Such polymer compositions are described in copending European Patent Application No. 89810078.9 (Publication No. 327,505) which is incorporated herein by reference. Although articles made from such compositions possess better dimensional stability than those made from destructurized starch alone, the physical properties of the therein-described compositions are not as good as might be desired for some end uses. In particular, it is important that articles made from destructurized starch compositions retain sufficient strength and dimensional stability to perform their desired function while still being biodegradable after disposal. It has now been found that articles made from such destructurized starch blended with specific hydrophobic thermoplastic materials as described herein show a surprising increase in all or a part of their physical properties and behaviour of their melts as to overcome the limitations as explained above. Moreover it was surprisingly found that many of the blends described herein show a significantly improved dimensional stability in humid air compared with non-blended destructurized starch whilst retaining a surprisingly high degree of disintegration in contact with liquid water which in consequence leads to a high degree of biodegradability. In order to achieve such properties, it has been found useful to make polymer compositions comprising: a) destructurized starch, b) at least one compound selected from the group consisting of styrene sulfonic acid polymers, styrene sulfonic acid copolymers, and salts thereof (referred to herein as "component b)"), and optionally c) a substantially water-insoluble polymer different from those defined as component b). In one aspect, the present invention relates to a composition comprising destructurized starch and component b). This composition is useful itself for making finished articles, but it is primarily useful as a "pre-mix" for combining with the substantially water-insoluble polymer. In a second aspect, the invention comprises the ternary composition of destructurized starch, component b), and at least one substantially water-insoluble polymer (component c)). These compositions may be in the form of powdery mixtures of the components, melts, or solid forms. The invention also includes methods for making and using both above - described compositions and shaped articles made therefrom. Specifically the present invention refers to a composition consisting of a) destructurized starch produced by heating a starch having a water content of 5 to 40% by weight based on the starch/water component, in a closed volume under shear; and at a temperature of 130°C to 190°C above the glass transition and the melting points of its components and at a pressure of up to 150 x 10⁵ N/m² to form a melt whereby the pressure corresponds at a minimum to the vapour pressure of water at the temperature used and heating the melt for a time long enough to obtain a melting of the molecular structure of the starch granules and a homogenization of the melt; b) at least one styrene sulfonic acid polymer or one sulfonic acid copolymer, or a salt thereof with an average molecular weight of between 2′000 and 1′500′000 and a degree of sulfonation between 5% and 50%; c) a thermoplastic polymer which undergoes melt formation at a set processing temperature within the range of 95°C to 190°C and is selected from (i) the group consisting of polyolefines, vinyl polymers, polyacrylonitriles, polyacrylates, polymethacrylates, polyacetals, polyamides, thermoplastic polyesters, thermoplastic polyurethanes, polycarbonates, polyarylethers, (ii) alkylene/vinyl ester-copolymers, ethylene vinyl acetate copolymers, ethylene/vinyl alcohol copolymers, ethylene/ethyl acrylate copolymers, ethylene/methacrylate copolymers, styrene/acrylonitrile copolymers, and mixtures thereof; d) optionally one or more materials selected from the group consisting of fillers, lubricants, mold release agents, plasticizers, foaming agents, stabilizers, flow accelerators, coloring agents, pigments and mixtures thereof; wherein the ratio of the destructurized starch to component b) varies from 99:1 to 80:20 and wherein the sum of the components b) and c) constitutes at least 50% and up to 80% by weight of the total composition. The present invention includes said polymer compositions in the form of powdery mixtures of their components, in the form of melts, or in solidified form. Component b) is chosen as described herein to be substantially compatible with the starch and also to promote the compatibility of component c) with the combination of starch and component b). The present invention further refers to a method of producing said polymer compositions in the molten or solid form as well as a method of producing shaped articles from said polymer compositions, and to the resulting shaped articles made therefrom. The polymer compositions of the present invention are prepared by admixing destructurized starch, component b) and optionally component c), and any further additives. This mixture is then be heated in a closed volume to elevated temperatures until a homogeneous melt is obtained, and shaped articles can be formed therefrom. An alternate method of producing the polymer compositions of the present invention comprises: Heating starch which is in a condition to be destructurized, in a closed volume to elevated temperatures and at elevated pressures for a time sufficient to destructurize the starch and form a melt; adding component b) as well as other polymer or polymers and/or additives before, during or after such starch destructurization; and continuing to heat the mixture until a homogenous melt is obtained. It is preferred that component b) and, if desired, component c), as well as other additives be combined with the starch and the combination formed into a melt. The starch in this combination may be already wholly or partially destructurized or the destructurization may take place during melt formation. The present invention further refers to the process of working said polymer composition under controlled water content, temperatures and pressure conditions as a thermoplastic melt wherein said working process is any known process, such as, for example injection molding, blow molding, extrusion, coextrusion, compression molding, vacuum forming, thermoforming or foaming. All of these processes are collectively referred to herein as "forming". The term "starch" as used herein includes chemically substantially non-modified starches as for example carbohydrates of natural, vegetable origin, composed mainly of amylose and/or amylopectin. They can be extracted from various plants, examples being potatoes, rice, tapioca, corn (maize), pea, and cereals such as rye, oats and wheat. Preferred is starch made from potatoes, corn, wheat or rice. Mixtures of starches obtained from these sources are contemplated. It further includes physically modified starches such as gelatinized or cooked starches. It further includes pre-extruded starches, as described in the above-referenced European Patent Application No. 89810046.6 (Publication No. 326,517). As described above, it has been found that starches, e.g. with a water content within the range of about 5 to about 40 % by weight based on the weight of the composition, undergo a specific narrow endothermic transition on heating to elevated temperatures and in a closed volume just prior to the endotherm change characteristic of oxidative and thermal degradation. The specific endothermic transition can be determined by differential scanning calorimetric analysis (DSC) and is indicated on the DSC-diagram by a specific relatively narrow peak just prior to the endotherm characteristic of oxidative and thermal degradation. The peak disappears as soon as the mentioned specific endothermic transition has been undergone. The term "starch" includes also treated starches wherein said specific endothermic transition has been undergone. Such starch is described in the EP 89810046.6 (Publication No. 326,517). Although at the current time, destructurization of starch requires the presence of water in ranges disclosed herein, the present inventive compositions also contemplate the use of destructurized starch prepared by other methods, e.g. without the use of water. The water content of such a starch/water composition is preferably about 5 to about 40 % water by weight of the starch/water component and preferably about 5 to about 30 %. However, in order to work with the material near its equilibrium water content to which it gets when it is finally exposed to the free atmosphere, a water content of 10 to about 22 %, preferably of about 14 to about 18 % by weight calculated based on the starch/water component should be used in processing and is preferred. The compounds of component b) are selected from the group consisting of styrene sulfonic acid polymers, styrene sulfonic acid copolymers and salts thereof. Poly(styrene sulfonic acid) compounds, styrene sulfonic acid copolymers, both with different degrees of sulfonation, their corresponding sulfonates (salts) as well as the method for their production are known and described, e.g. in Encyclopedia of Polymer and Engineering, John Wiley & Sons, 1987. Poly(styrene sulfonic acid), i.e. styrene sulfonic acid polymers useful according to this invention have a molecular weight generally from about 2000 to about 1′500′000, preferably from about 4000 to about 1′200′000. Styrene sulfonic acid copolymers are known and can be described as copolymers of different unsaturated monomers with styrene sulfonic acid, resp. their sulfonate. As a special interest within the scope of this invention are block copolymers of sulfonated styrene with unsaturated monomers such as ethylene, propylene, butylene, isobutylene, butadiene, isoprene, and/or styrene. Preferred salts thereof, resp. the corresponding sulfonates are their salts with metal ions or the ammonium ion, preferably an alkali metal ion, magnesium or zinc and NH₄⁺, preferably sodium, potassium or zinc, preferably the sodium salt. Preferred are polystyrene sulfonic acids and polystyrene sulfonate sodium salt preferably with an average molecular weight of 10′000 to 400′000. The degree of sulfonation is between about 5 % and about 100 % preferably between about 10 % and about 50 %. As mentioned above, the polymer composition comprising the components a) and b) optionally contains one or more substantially water-insoluble hydrophobic polymers (component c), as well as further additives. The component c) is an substantially water-insoluble polymer or a mixture of such substantially water-insoluble polymers. Component c) is preferably present in an amount effective to enhance the physical properties of articles made from the composition of the invention (which amount is sometimes referred to herein as an "effective amount" of component c)), for example increase of dimensional stability of final products made therefrom or adjust the degree of biodegradability. As used herein a "substantially water-insoluble thermoplastic polymer" is a polymer which preferably absorbs less than 10 %, preferably less than 5 % of water per 100 grams of the polymer at room temperature and preferably at a rate of less than 2 % per 100 grams of the polymer at room temperature. Examples of substantially water-insoluble thermoplastic materials are polyolefines, such as polyethylene (PE), polyisobutylenes, polypropylenes; vinyl polymers such as poly(vinyl acetates); polyacrylonitriles (PAN); substantially water-insoluble polyacrylates or polymethacrylates; polyacetals; thermoplastic polycondensates such as polyamides (PA), polyesters, polyurethanes, polycarbonates, poly(alkylene terephthalates); polyarylethers. Further included are substantially water-insoluble thermoplastic copolymers known such as alkylene/vinyl ester-copolymers preferably ethylene/vinyl acetate-copolymers (EVA); ethylene/vinyl alcohol-copolymers (EVAL); alkylene/acrylates or methacrylate copolymers preferably ethylene/ethyl acrylate-copolymers (EEA); ethylene/methyl acrylate-copolymers (EMA); styrene/acrylonitrile-copolymers (SAN); as well as mixtures thereof. Preferred from these are those which undergo melt formation at a set processing temperature preferably within the range of 95°C to 190°C. Also preferred are those polymers containing polar groups such as ether, amide, or urethane groups. Such polymers include e.g. copolymers of ethylene, propylene or isobutylene with vinyl compounds such as, ethylene/vinyl alcohol-copolymers (EVAL), styrene/acrylonitrile-copolymers (SAN); as well as their mixtures. Such substantially water-insoluble thermoplastic polymers may be added in any desired amount as described herein. Such polymers may be used in any known form. Their molecular weight is also generally known in the art. It is also possible to use such polymers of relatively low molecular weight (oligomers). The choice of a particular molecular weight range is a matter of optimization and routine experimentation known to the one skilled in the art. In the composition according to this invention, the two components a) and b) or the three components a), b) and c) always add up to 100 % and the values of the components given in percent hereinbelow refer to the sum of 100 %. The ratio of destructurized starch to component b) may vary from about 99 : 1 to 80 : 20. The ratio of destructurized starch to the sum of components b) and c) can be 1 : 99 to 99 : 1. It is however preferred that the destructurized starch contributes noticeably to the properties of the final material. Therefore, it is preferred that the destructurized starch is present in an amount of at least about 20 %, more preferably about 50 % by weight of the entire composition. That is, the sum of the components b) and c) are present in amounts of about 80 % or less, more preferably less than or equal to about 50 % by weight of the entire composition. Component b) is a relatively polar material. When it functions in the present compositions in combination with component c), it is able to mix more readily with a more polar component c) than with a less polar one. Accordingly, with more polar components c), relatively less of component b) will be required than with less polar ones. The skilled worker will be able to select appropriate ratios of components b) and c) to obtain a substantially homogenous melt composition. If the destructurized starch contains water, the percentage of this destructurized starch component is meant to be the destructurized starch/water component, i.e. including the weight of water. The starch may be mixed prior to destructurization with additives as named hereinbelow to yield a free flowing powder useful for continuous processing and is destructurized and granulated before it is mixed with the components b) and c) or the other optionally added components. The other components to be added are preferably granulated to a granular size equal to that of the granulated destructurized starch. However, it is possible to process native starch or pre-extruded and/or destructurized granulated or powdered starch together with powdered or granulated additives and/or the polymeric material in any desired mixture or sequence. Thus, it is preferred that components a), b) and c) as well as other conventional additives be mixed in a standard mixer. This mixture can then be passed through an extruder to produce granulates or pellets as one form of shaped articles which are also useful as starting material for processing into other articles. However, it is possible to avoid granulating and to process the obtained melt directly using down-stream equipment to produce films, blown films included, sheets, profiles, pipes, tubes, foams or other shaped articles. The sheets can be used for thermoforming. It is preferred that fillers, lubricants and/or plasticizers be added to the starch before destructurization. However, the the addition of the coloring agents as well as of components b), c) and additives other than the aforementioned can be added before, during or after destructurization. The substantially destructurized starch/water component or granules have a preferred water content in the range of 10 to 22 % by weight of the starch/water component, more preferably 12 to 19 % and most preferably 14 to 18 % by weight of the starch/water component. The water content described above refers to the percentage of water relative to the weight of the starch/water component within the total composition and not to the weight of the total composition itself, which would include also the weight of any added substantially water-insoluble thermoplastic polymer. In order to destructurize the starch and/or to form a melt of the new polymeric composition according to this invention, it is suitably heated in a screw and barrel of an extruder for a time long enough to effectuate destructurization and melt formation. The temperature is preferably within the range of 130°C to 190°C depending on the type of starch used. For this destructurization and melt formation, the composition is heated in a closed volume. A closed volume can be a closed vessel or the volume created by the sealing action of the unmolten feed material as happens in the screw and barrel of injection molding or extrusion equipment. In this sense the screw and barrel of an injection molding machine or an extruder is to be understood as being a closed vessel. Pressures created in a closed vessel correspond to the vapour pressure of water at the used temperature but of course additional pressure may be applied and/or generated as normally occurs in a screw and barrel. The preferred applied and/or generated pressures are in the range of pressures which occur in extrusion and are known per se , e.g. from 5 to 150 x 10⁵ N/m² preferably from 5 to 75 x 10⁵ N/m² and most particularly from 5 to 50 x 10⁵ N/m². If the thus-obtained composition is comprised only of destructurized starch, it may be granulated and ready to be mixed with the further components according to a chosen mixing and processing procedure to obtain the granular mixture of the destructurized starch/polymer starting material to be fed to the screw barrel. However, the obtained melt in the screw and barrel may be injection molded directly into a suitable mold, i.e. directly further processed to a final product if all necessary components are already present. Within the screw, the granular mixture obtained as described above is heated to a temperature which is generally within the range of 130°C to about 190°C. Preferably, such mixture is heated to a sufficiently high temperature and for a time long enough until the endothermic transition analysis (DSC) indicates that the specific relatively narrow peak just prior to the endotherm characteristic of oxidative and thermal degradation of starch has disappeared. The minimum pressures under which the melts are formed correspond to the water vapour pressures produced at said temperatures. The process is carried out in a closed volume as explained above, i.e. in the range of the pressures which occur in extrusion or molding processes and known per se, e.g. from zero to 150 x 10⁵ N/m² preferably from zero to 75 x 10⁵ N/m² and most particularly from zero to 50 x 10⁵ N/m². When forming a shaped article by extrusion the pressures are preferably as mentioned above. If the melt according to this invention is, e.g., injection molded, the normal range of injection pressures used in injection molding is applied, e.g. from 300 x 10⁵ N/m² to 3000 x 10⁵ N/m² and preferably from 700 x 10⁵ to 2200 x 10⁵ N/m². Accordingly the present invention provides a thermoplastic destructurized starch product formed by the process comprising: 1) providing a mixture consisting of: a starch composed mainly of amylose and /or amylopectin and having a water content of from 5% to 40% by weight; at least one polymer as defined herein above as component b); a thermoplastic polymer as defined herein above as component c); wherein the ratio of the destructurized starch to component b) varies from 99:1 to 80:20 and wherein the sum of the components b) and c) constitutes at least 50% and up to 80% by weight of the total composition; 2) heating said mixture in the screw and barrel of an injection molding machine or an extruder at a temperature of 130°C to 190°C and at a pressure of up to 150 x 10⁵ N/m² to form a melt and heating the melt for a time long enough to obtain a destructurization of the starch and a homogenization of the melt; 3) shaping the melt into an article; and 4) allowing the shaped article to cool to solidified dimensionally stable article. Various hydrophilic polymers may be used as additives. These include water-soluble and water-swellable polymers. As such it includes animal gelatin; vegetable gelatins; proteins such as sunflower protein, soybean proteins, cotton seed proteins, peanut proteins, rape seed proteins, acrylated proteins; water-soluble polysaccharides, alkyl celluloses, hydroxyalkyl celluloses and hydroxyalkylalkyl celluloses, such as methyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethylmethyl cellulose, hydroxpropylmethyl cellulose, hydroxybutylmethyl cellulose, cellulose esters and hydroxyalkyl cellulose esters such as cellulose acetylphtalate (CAP), hydroxypropylmethyl cellulose (HPMCP); analogous known polymers made from starch; water-soluble or water-swellable synthetic polymers such as: polyacrylates, polymethacrylates, polyvinyl alcohols, shellac and other similar polymers. Preferred are synthetic polymers, most preferably polyacrylates, polymethacrylates, polyvinyl alcohols. Such hydrophilic polymers may optionally be added up to 50 % based on the starch/water component, preferably up to 30 % and most preferably between 5 % and 20 % based on the starch/water component. If any hydrophilic polymer is added, its mass should be considered along with the starch in determining the appropriate amount of water in the composition. Other useful additives may be e.g. adjuvants, fillers, lubricants, mold release agents, plasticizers, foaming agents, stabilizers, coloring agents, pigments, extenders, chemical modifiers, flow accelerators, and mixtures thereof. Examples for fillers are inorganic fillers, such as the oxides of magnesium, aluminum, silicon, titanium, preferably in a concentration in the range of 0.02 to 50 % by weight preferably 0.20 to 20 % based on the total weight of all the components. Examples for lubricants are stearates of aluminum, calcium, magnesium and tin as well as talc, silicones, etc. which may be present in concentrations of 0.1 to 5 % preferably at 0.1 to 3 % based upon the weight of the total composition. Examples of plasticizers include low molecular poly(alkylene oxides), such as poly(ethylene glycols), poly(propylene glycols), poly(ethylene-propylene glycols); organic plasticizers of low molar masses, such as glycerol, pentaerythritol, glycerol monoacetate, diacetate or triacetate; propylene glycol, sorbitol, sodium diethylsulfosuccinate, etc., added in concentrations ranging from 0.5 to 15 %, preferably ranging from 0.5 to 5 % based on the total weight of all the components. Examples of colouring agents include known azo dyes, organic or inorganic pigments, or colouring agents of natural origin. Inorganic pigments are preferred, such as the oxides of iron or titanium, these oxides, known per se, being added in concentrations ranging from 0.001 to 10 %, preferably 0.5 to 3 %, based on the weight of all the components. There may further be added compounds to improve the flow properties of the starch material such as animal or vegetable fats, preferably in their hydrogenated form, especially those which are solid at room temperature. These fats have preferably a melting point of 50°C or higher. Preferred are triglycerides of C₁₂ -, C₁₄ -, C₁₆-, and C₁₈ - fatty acids. These fats can be added alone without adding extenders or plasticizers. These fats can advantageously be added alone or together with mono- and/or diglycerides or phosphatides, especially lecithin. The mono- and diglycerides are preferably derived from the types of fats described above, i.e. from C₁₂ -, C₁₄ -, C₁₆ -, and C₁₈ - fatty acids. The total amount of fats, mono-, diglycerides and/or lecithins used are up to 5 % and preferably within the range of 0.5 to 2 % by weight of the total weight of starch and any added hydrophilic polymer. The materials may further contain stabilizers, such as antioxydants, e.g. thiobisphenols, alkylidenbisphenols secondary aromatic amines; light stabilizers such as UV-absorbers and UV-quenchers; hydroperoxide decomposer; free-radical scavengers; stabilizers against microorganisms. The compositions of the invention form thermoplastic melts on heating and in a closed volume, i.e. under conditions of controlled water-content and pressure. Such melts can be processed just like conventional thermoplastic materials, using, for example, conventional apparatus for injection molding, blow molding, extrusion and coextrusion (rod, pipe and film extrusion), compression molding, foaming, to produce known articles. The articles include bottles, sheets, films, packaging materials, pipes, rods, laminated films, sacks, bags, pharmaceutical capsules, granules, powders or foams. For example, these compositions may be used to prepare low density packaging materials (e.g. foams) by well-known methods. Conventional blowing agents may be utilized if desired or, for certain compositions, the water itself may act as the blowing agent. Open cell and closed cell foams may be produced as desired by varying the composition and processing condtions. These foams produced from the present compositions will demonstrate improved properties (e.g., dimensional stability, moisture resistance when compared with foams made of starch without incorporation of the components b) and c) according to this invention. These compositions may be used as carrier materials for active substances, and may be mixed with active ingredients such as pharmaceuticals and/or agriculturally active compounds such as insecticides or pesticides for subsequent release applications of these ingredients. The resulting extruded materials can be granulated or worked to fine powders. The following examples are provided to further explain and exemplify the invention but not to limit the scope thereof, which scope is defined by the appended claims. Example 1 (a) 9500 g of potato starch containing 15.1 % water are placed in a high speed mixer and 425 g of poly(styrene sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc; 80.75 g of hydrogenated fat (lubricant release agent) sold as Boeson VP by Boehringer Ingelheim, 40.37 g of a melt flow accelerator (lecithin) sold as Metarin P by Lucas Meyer are added under stirring. The water content of the final mixture is 14.43 %. (b) 10,000 g of the mixture prepared under (a) are fed through a hopper into a Werner & Pfleiderer co-rotating twin screw extruder (model Continua 37). The temperature profile of the four sections of the barrel is respectively 20°C/ 180°C/ 180°C/ 80°C. Extrusion is carried out with a mixture output of 8.4 kg/hr (screw speed 200 rpm). Water is added at the inlet with a flow rate of 2.1 kg/hr. The water content of the material during extrusion is therefore 32.2 %. In the last section of the extruder 300 mbar reduced pressure is applied to remove part of the water as water vapour. The water content of the granulates is 17.15 % as measured after they have equilibrated at room temperature. (c) The granulates of the pre-blended mixture as obtained under (b) (H₂O content: 17.5 %) are fed through a hopper to an injection molding machine Arburg 329-210-750 for the production of tensile test pieces. The temperature profile of the barrel is: 90°C/165°C/ 165°C/ 165°C. The shot weight is 8g, the residence time 450 sec., the injection pressure 1760 bar, the back pressure 80 bar, the screw speed 180 rpm. The tensile test pieces thus produced are conditioned in a climatic cabinet at 50 % R.H. for five days as an arbitrary standard condition. The test pieces are of standard DIN design (DIN No. 53455). (d) The conditioned tensile test pieces are then tested for their stress/strain behaviour on a Zwick tensile test apparatus. The samples are measured at room temperature using an extension rate of 10 mm per minute. Results are presented in Table 1 and compared with those of the tensile test pieces obtained from the same starch processed in a similar way but in absence of components b) and c). Example 2 Example 1 is repeated except that the ratio of the components is varied as given in Table 2. For comparison perspective, Example 1 is shown as Blend No. 1. The resulting injection molded polymers are tougher and more resistant to humid air than the unblended starch polymer. The toughness as judged by resistance to breaking upon bending increases from blend 9 to blend 2 in concert with the combined increase in poly(styrene sulfonic acid, sodium salt) content. While the resistance to softening in humid atmosphere is improved in all cases relative to unblended starch, the resistance of blends 1,4,5 and 6 are particularly good. These results illustrate the unexpected combinations as benefits in performance. Example 3 (a) 8900 g of potato starch containing 15 % water are placed in a high speed mixer and 765 g of poly(styrene sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc.; 170 g of polystyrene (component c) sold as Polystyrol 144-C by BASF, 340 g of polyethylene (component c) Lupolen 2410 T of BASF; 80 g of hydrogenated fat (lubricant release agent) sold as Boeson VP by Boehringer Ingelheim, 40 g of a melt flow accelerator (lecithin) sold as Metarin P by Lucas Meyer are added under stirring. The water content of the final mixture is 13 %. (b) 10,000g of the mixture prepared under (a) are fed through a hopper into a Werner & Pfleiderer co-rotating twin screw extruder (model Continua 37). The temperature profile of the four sections of the barrel is respectively 20°C/ 180°C/ 180°C/ 80°C. Extrusion is carried out with a mixture output of 8 kg/hr (screw speed 200 rpm). Water is added at the inlet with a flow rate of 2.1 kg/hr. The water content of the material during extrusion is therefore 32.7 %. In the last section of the extruder 500 mbar reduced pressure is applied to remove part of the water as water vapour. The water content of the granulates is 17.2 % as measured after they have equilibrated at room temperature. (c) The granulates of the pre-blended mixture as obtained under (b) (H₂O content: 17 %) are fed through a hopper to an injection molding machine Arburg 329-210-750 for the production of tensile test pieces. The temperature profile of the barrel is: 90°C/ 165°C/ 165°C/165°C. The shot weight is 7.9 g, the residence time 450 sec., the injection pressure 1650 bar, the back pressure 80 bar, the screw speed 180 rpm. The tensile test pieces thus produced are conditioned in a climatic cabinet at 50 % R.H. for five days as an arbitrary standard condition. The test pieces are of standard DIN design (DIN No. 53455). (d) The conditioned tensile test pieces are then tested for their stress/strain behaviour on a Zwick tensile test apparatus as given in Example 1. The results are presented in Table 1. Example 4 (a) 2100 g of potato starch containing 15.1 % water are placed in a high speed mixer and 765 g of poly(styrene, sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc., (component C) 4250 g of thermoplastic polyamide elastomer Pebax MA-4011 of Atochem, 1700 g of thermoplastic polyurethane elastomer (component c) Pellethane 2103-80-AEF of the Dow Chemical Company; 18 g of hydrogenated fat (lubricant/release agent) Boeson VP and 9 g of a melt flow accelerator (lecithin/Metarin P) are added under stirring. The water content of the final mixture is 3.6 %. (b) 8000 g of the mixture prepare under (a) are fed through a hopper into the same twin-screw co-rotating extruder described in Example 1. The extrusion of the mixture is carried out with the following temperature profile: 20°C/ 80°C/190°C/ 150°C. The other parameters of the extrusion experiment are the following: The water content of the granulates is 2 % as measured after they havequilibrated at room temperature. They are brought to a water content of 17 % by spraying water under stirring in a standard mixer. (c) The granulates obtained under (b) are processed using the same injection molding machine described in (c) of Example 1 The temperature profile of the barrel is 90°C/ 175°C/ 175°C/ 175°C. The other processing parameters are: shot weight: 6.8 g residence time: 450 sec. injection pressure; 2200 bar back pressure: 80 bar screw speed: 180 rpm The tensile test pieces thus produced are conditioned and tested on a Zwick tensile test apparatus as described in (d) of Example 1. Results are presented in Table 1. Example 5 (a) 8000 g of potato starch containing 15 % water are placed in a high speed mixer and 340 g of poly(styrene sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc., 680 g of thermoplastic polyamide-block-polyether elastomer (component c) sold as Pebax MA-4011 by Atochem, 680 g of thermoplastic polyurethane elastomer (component c) sold as Pellethane 2103-80-AEF by the Dow Chemical Company; 72 g of hydrogenated fat (lubricant/ release agent) Boeson VP; 36 g of a melt flow accelerator (lecithin) Metarin P are added under stirring. The water content of the final mixture is 12.2 %. (b) 9000 g of the mixture prepared under (a) are fed through a hopper into the same twin-screw co-rotating extruder described in Example 1. The extrusion of the mixture is carried out with the following processing parameters: The water content of the granulates is 17.1 % after they have equilibrated at room temperature. (c) The granulates of (b) are processed using the same injection molding machine of Example 1. The processing parameters are the following: temperature profile: 90°C/ 165°C/ 165°C/ 165°C shot weight: 7.8 g residence time; 450 sec injection molding: 1650 bar back pressure; 80 bar screw speed: 180 rpm The tensile test pieces thus produced are conditioned and tested on a Zwick tensile test apparatus described in (d) of Example 1. Results are presented in Table 1. Example 6 (a) 7000 g of potato starch containing 15.1 % water are placed in a high speed mixer and 1700 g of poly(styrene sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc.; 425 g of a thermoplastic polyamide elastomer (component c) sold as Pebax MA-4011 by Atochem; 424 g of a thermoplastic elastomer polyurethane block polyether (component c) sold as Pellethane 2103-80-AE by Dow Chemical Company; 60 g of hydrogenated fat (lubricant/ release agent) Boeson VP; 30 g of a melt flow accelerator (lecithin) Metarin P are added under stirring. The water content of the final mixture is 12.3 %. (b) 9000 g of the mixture prepared under (a) are fed through a hopper into the same twin-screw co-rotating extruder described in Example 1. The extrusion of the mixture is carried out with the following processing temperature: The water content of the granulates is 17.3 % after they have equilibrated at room temperature. (c) The granulates obtained under (b) are processed using the same injection molding machine described in (c) of Example 1. The processing parameters are the following: temperature profile: 90°C/ 175°C/ 175°C/ 175°C shot weight: 8 g residence time; 450 sec injection molding: 1670 bar back pressure; 80 bar screw speed: 180 rpm The tensile test pieces thus produced are conditioned and tested on a Zwick tensile test apparatus described in (d) of Example 1. Results are presented in Table 1. Example 7 (a) 8900 g of potato starch containing 15.1 % water are placed in a high speed mixer and 765 g of poly(styrene sulfonic acid, sodium salt) (component b) having a M w of 70,000 and sold by Monomer-Polymer and Dajac Laboratories Inc.; 170 g of high impact polystyrene (component c) sold as Polystyrol SB-432-B by BASF; 3400 g of polyethylene Lupolen 2410 T (component c) sold by BASF; 80 g of hydrogenated fat (lubricant/ release agent) Boeson VP; 40 g of a melt flow accelerator (lecithin) Metarin P are added under stirring. The water content of the final mixture is 13.8 %. (b) 9000 g of the mixture prepared under (a) are fed through a hopper into the same twin-screw co-rotating extruder described in Example 1. The extrusion of the mixture is carried out with the following processing parameters: The water content of the granulates is 13.5 % after they have equilibrated at room temperature. They are brought to a water content of 17 % by spraying water under stirring in a standard mixer. (c) The granulates obtained under (b) are processed using the same injection molding machine described in (c) of Example 1. The processing parameters were the following: temperature profile: 90°C/ 175°C/ 175°C/ 175°C shot weight: 7.9 g residence time; 450 sec injection molding: 1830 bar back pressure; 80 bar screw speed: 180 rpm The tensile test pieces thus produced are conditioned and tested on a Zwick tensile test apparatus described in (d) of Example 1. Results are presented in Table 1. Example 8 (a) 7000 g of potato starch containing 15.0 % water are placed in a high speed mixer and 30 g of poly(styrene sulfonic acid, sodium salt) (component b) of M w of 70,000 from Monomer-Polymer and Dajac Laboratories Inc.; 300 g of polystyrene Polystyrol 144-C from BASF; 59.5 g of hydrogenated fat (lubricant/ release agent) Boeson VP; 29.75 g of a melt flow accelerator (lecithin) Metarin P are added under stirring. The water content of the final mixture is 14.2 %. (b) 7000 g of the mixture prepared under (a) are fed through a hopper into a Leistritz twin-screw co-rotating extruder (Model LSM 34 GL). The extrusion of the mixture is carried out with the following processing parameters: The water content of the granulates is 17 % after they have equilibrated at room temperature. (c) The granulates obtained under (b) are processed using a Kloeckner-Ferromatic FM 60 injection molding machine. The processing parameters are the following: temperature profile: 90°C/ 165°C/ 165°C/ 165°C shot weight: 21 g residence time; 450 sec injection molding: 725 bar back pressure; 80 bar screw speed: 180 rpm The tensile test pieces thus produced of standard ISO design: ISO R 527 are conditioned and tested on a Zwick tensile test apparatus described in (d) of Example 1. Results are presented in Table 1. Example 9 (a) 10,000 g of potato starch containing 15.0 % water are placed in a high speed mixer and 85 g of poly(styrene sulfonic acid, sodium salt) (component b) of a M w of 70,0000 from Monomer-Polymer and Dajac Laboratories Inc.; 850 g of Polystyrene Polystyrol 144 C from BASF (component c)); 85 g of hydrogenated fat (lubricant/ release agent) Boeson VP; 42.5 g of a melt flow accelerator (lecithin) Metarin P are added under stirring. The water content of the final mixture is 13.6 %. (b) 9000 g of the mixture prepared under (a) are fed through a hopper into the same twin-screw co-rotating extruder described in Example 8. The extrusion of the mixture is carried out with the following processing parameters: The granulates are brought to a water content of 17 % by spraying water under stirring in a conventional mixer. (c) The granulates obtained under (b) are processed using the same injection molding machine described in (c) of Example 8. The processing parameters are the following: temperature profile: 90°C/ 155°C/ 155°C/ 155°C shot weight: 21.2 g residence time; 450 sec injection molding: 1600 bar back pressure; 80 bar screw speed: 180 rpm The tensile test pieces thus produced standard ISO design: ISO R 527 are conditioned and tested on a Zwick tensile test apparatus described in (d) of Example 1. Results are given in Table 1. Example 10 Example 9 is repeated, replacing component b) (poly(styrene sulfonic acid, sodium salt) by the sodium salt of a sulfonated diblock-copolymer made of polystyrene (block A), and polyethylene-co-propylene (block B). The sulfonation is carried out on the polystyrene block of Kraton G 1701 a commercial product sold by Shell in which block A contains 37 % by weight of styrene units and block B contains 63 % by weight of ethylene-propylene units. The sulfonation is made using acetyl sulfate as reagent which is prepared by stirring a mixture of 9.8 g concentrated sulfuric acid, 10.2 g acetic anhydride and 200 ml of dichloromethane for 30 minutes at room temperature. This mixture is then added slowly to a solution of 30 g Kraton G 1701 in 300 ml CH₂Cl₂. The color of the reaction mixture changes from red to dark brown after about 30 minutes during which time the polymer precipitates. The mixture is stirred another 4 hours to complete the reaction. Then 500 ml of water are added, the mixture is transferred to a separatory funnel and the organic solvent is removed. The aqueous phase which contains the polymer is neutralized with a 50 % NaOH-solution. The solid is collected by vacuum filtration, thoroughly washed with deionized water and dried over P₂O₅. 30.6 g are obtained (yield: 82 %). The material is characterized by its infra-red spectrum which shows a strong characteristic sulfonate band at 1200 cm⁻¹ and a medium characteristic sulfonate band at 1050 cm⁻¹. The resulting injection-molded polymer is tougher and more resistant to humid air than unblended starch polymer. Example 11 Example 1 (Sections a) and b)) is repeated except that the water content is adjusted to 22 %, and the cutter is removed from the die face. A continuous extrudate is obtained which is foamed as a result of the excess water evaporation. The foam is chopped into 30-40 mm lengths and is useful as a loose-fill, packaging insulation material. Example 12 During each of the injection molding operations in Examples 2 - 10 an experiment is performed to demonstrate the utility of making foams. The molten material is obtained as described in Example 1, Sections a), b) and c) in each case is extruded into the open atmosphere (Section c) instead of being injection molded into a closed mold. In every case the material is converted into a foamed extrudate useful for loose-fill in packaging applications. Example 13 The granulates from Example 1 are mixed with polystyrene in the proportion of 30 to 70 parts by weight and are treated according to Example 12. The resulting foamed extrudate contains a very fine and uniform cell structure suitable for a variety of uses including structural foam.

Claims: A composition consisting of a) destructurized starch produced by heating a starch having a water content of 5 to 40% by weight based on the starch/water component, in a closed volume under shear; and at a temperature of 130°C to 190°C above the glass transition and the melting points of its components and at a pressure of up to 150 x 10⁵ N/m² to form a melt whereby the pressure corresponds at a minimum to the vapour pressure of water at the temperature used and heating the melt for a time long enough to obtain a melting of the molecular structure of the starch granules and a homogenization of the melt; b) at least one styrene sulfonic acid polymer or one styrene sulfonic acid copolymer, or a salt thereof with an average molecular weight of between 2′000 and 1′500′000 and a degree of sulfonation between 5% and 50%; c) a thermoplastic polymer which undergoes melt formation at a set processing temperature within the range of 95°C to 190°C and is selected from (i) the group consisting of polyolefines, vinyl polymers, polyacrylonitriles, polyacrylates, polymethacrylates, polyacetals, polyamides, thermoplastic polyesters, thermoplastic polyurethanes, polycarbonates, polyarylethers, (ii) alkylene/vinyl estercopolymers, ethylene vinyl acetate copolymers, ethylene/vinyl alcohol copolymers, ethylene/ethyl acrylate copolymers, ethylene/methacrylate copolymers, styrene/acrylonitrile copolymers, and mixtures thereof; d) optionally one or more materials selected from the group consisting of fillers, lubricants, mold release agents, plasticizers, foaming agents, stabilizers, flow accelerators, coloring agents, pigments and mixtures thereof; wherein the ratio of the destructurized starch to component b) varies from 99:1 to 80:20 and wherein the sum of the components b) and c) constitutes at least 50% and up to 80% by weight of the total composition. The composition according to claim 1 wherein component b) has a molecular weight between 10′000 and 400′000. The composition according to claim 1 wherein component b) has a degree of sulfonation between 10% and 50%. The composition according to any one of the claims 1 to 3 wherein component b) is a block-copolymer of sulfonated styrene with ethylene, butylene, isobutylene, propylene, butadiene, isoprene and/or styrene, or a salt thereof. The composition according to any one of the claims 1 to 3 wherein component b) is a sulfonated polystyrene. The composition according to any one of the claims 1 to 5 wherein the salt of component b) is a sodium, potassium, zinc or ammonium salt. The composition according to any one of the claims 1 to 6 wherein component c) is selected from (i) the group consisting of polyethylenes, polypropylenes, polyisobutylenes, poly(vinylchloride), poly(vinyl acetate), polyamides, thermoplastic polyesters, thermoplastic polyurethanes, polycarbonates, or (ii) the group consisting of ethylene vinyl acetate copolymers, ethylene/vinyl alcohol copolymers, ethylene/ethyl acrylate copolymers, ethylene/methacrylate and mixtures thereof. The composition according to any one of the claims 1 to 7 wherein the ratio of destructurized starch to component b) is from 95:5 to 90:10. The composition according to any one of the claims 1 to 8 wherein the polymer of component c) absorbs water at a rate of less than 10% per 100 grams of the polymer at room temperature. The composition according to any one of the claims 1 to 8 wherein the polymer of component c) absorbs water at a rate of less than 5% per 100 grams of the polymer at room temperature. The composition according to any one of the claims 1 to 10 wherein the water content is from 5% to 30% by weight of the starch/water component. The composition according to any one of the claims 1 to 10 wherein the water content is from 10% to 22% by weight of the starch/water component. The composition according to any one of the claims 1 to 12 in the form of a melt. The composition according to any one of the claims 1 to 12 in a solidified form. The composition according to claim 14 in particulate, granulated or pelletized form, The composition according to claim 14 in the form of a shaped article selected from the group consisting of containers, bottles, pipes, rods, packing materials, sheets, foams, films,sacks, bags and pharmaceutical capsules. The composition according to claim 15 further melted and processed to form a shaped article selected from the group consisting of containers, bottles, pipes, rods, packing materials, sheets, foams, films, sacks, bags and pharmaceutical capsules. The shaped articles according to claim 16 and claim 17 wherein the shaping process comprises foaming, filming, compression molding, injection molding, blow molding, extruding, co-extruding, vacuum forming, thermoforming and combinations thereof. A thermoplastic destructurized starch product formed by the process comprising: 1) providing a mixture consisting of: a starch composed mainly of amylose and /or amylopectin and having a water content of from 5% to 40% by weight; at least one polymer as defined in claim 1 as component b); a thermoplastic polymer as defined in claim 1 as component c); wherein the ratio of the destructurized starch to component b) varies from 99:1 to 80:20 and wherein the sum of the components b) and c) constitutes at least 50% and up to 80% by weight of the total composition. 2) heating said mixture in the screw and barrel of an injection molding machine or an extruder at a temperature of 130°C to 190°C and at a pressure of up to 150 x 10⁵ N/m² to form a melt and heating the melt for a time long enough to obtain a destructurization of the starch and a homogenization of the melt ; 3) shaping the melt into an article; and 4) allowing the shaped article to cool to a solidified dimensionally stable article. The product according to claim 19 in particulate, granulated or pelletized form. The product according to claim 19 in the form of a shaped article selected from the group consisting of containers, bottles, pipes, rods, packing materials, sheets, foams, films,sacks, bags and pharmaceutical capsules. The product according to claim 20 further melted and processed to form a shaped article selected from the group consisting of containers, bottles, pipes, rods, packing materials, sheets, foams, films, sacks, bags and pharmaceutical capsules.

Inventors: LENTZ DAVID JOHN, SACHETTO JEAN-PIERRE, SILBIGER JAKOB, LENTZ, DAVID JOHN, DR., SACHETTO, JEAN-PIERRE, DR., SILBIGER, JAKOB, DR.
Applicants: WARNER LAMBERT CO, WARNER-LAMBERT COMPANY
Application year: 1990
Main classification: C08L3
IPC codes: C08L79, C08L67, C08L69, C08L29, C08L75, C08L25, C08L33, C08J5, C08L23, C08L53, C08L3, C08L71, C08L1