Patent Description:
Many different types of modeling compositions for creating figures or sculptures have been introduced over time, particularly for use as craft products by children, and for general artistic purposes. patents which relate to moldable compositions include <CIT> to Li, <CIT> to Mariano et al. , <CIT>, <CIT>, and <CIT>,.

Some moldable compositions utilize "polymer clay technology," whereby particles of polyvinyl chloride (PVC) are plasticized with typical plasticizers (e.g., phthalates, diesters, triesters, etc), and heating these compositions in the oven melts the PVC particles to form a hardened article. A drawback of this technology is that polymer clay must be hardened in an oven at an elevated temperature, and there is a risk of thermal degradation of the PVC which releases hazardous HCl. Also, polymer clay requires kneading or other physical manipulation to make it soft and pliable for use.

<CIT> illustrates for example a moldable composition comprising a polar polymeric resin, present in an amount ranging from <NUM>-<NUM>% by weight, a filler, present in an amount up to <NUM>% by weight, a thickening agent, present in an amount ranging from <NUM>-<NUM>% by weight, a humectant, present in an amount up to <NUM>% by weight, and water, present in an amount ranging from <NUM>-<NUM>% by weight. The document also discloses a method of making the composition as described.

There remains a need for moldable compositions that overcome these drawbacks by having the ability to harden at ambient temperature (i.e., by air-drying), that are already soft so that they require no kneading prior to use, and that do not release HCl or easily thermally degrade.

The invention provides a moldable composition as set forth in claim <NUM> and a method of making the moldable composition as set forth in claim <NUM>. Embodiments of the invention are set forth in the dependent sub-claims.

An embodiment of the present invention provides a moldable composition comprising, consisting essentially of, or consisting of water, at least one polar polymeric resin (e.g., polyvinyl alcohol), at least one thickening agent (e.g., boric acid, borate salt, or hydrate of a borate salt), at least one humectant (e.g., glycerin, propylene glycol, etc.), at least one filler (e.g., corn starch), optionally at least one releasing agent (e.g., mineral oil) and optionally at least one additive (e.g., selected from the group consisting of pH adjusters, defoamers, dispersants, fungicides, pesticides, antimicrobial agents, colorants and scents).

Another embodiment of the present invention provides a method of using the moldable composition comprising molding the moldable composition into a desired shape, and drying the moldable composition so that it forms a hardened composition.

Embodiments of the present invention relate to moldable compositions that can harden at ambient temperature (i.e., by air-drying), that are already soft so that they require no kneading prior to use, and that do not release HCl or easily thermally degrade. Air drying of the moldable compositions, while taking longer than oven drying, is a safety factor which will broaden the appeal and utility of the product to young children, as the risk of burning occurring with the use of an oven is not present.

According to particular embodiments, moldable compositions of the present invention include polyvinyl alcohol (PVOH) that has been thickened by a borate compound (e.g., a borate salt). Preferably, the borate does not cure or harden the composition, but merely serves to stiffen the polymer into a gel. Preferably, there is no chemical bond between the polymer chains, (i.e. negligible crosslinking or no actual crosslinking), but rather a strong association between polymer chains within the system, whereby the structure demonstrates superior pliability compared to conventional water-based starch doughs because of the presence of a network of intermolecular attractions, instead of crosslinked chemical bonds. According to preferred embodiments, crosslinking is kept to a minimum (preferably to a negligible amount, and most preferably, none).

The compositions have a hardening characteristic, which means that they are initially moldable but are capable of drying and hardening if left in open air at room temperature for a period of time (i.e., left outside of any enclosure, such as a container, that would substantially prevent moisture from evaporating off of the composition), so that they maintain the achieved shape.

According to particular embodiments, the moldable composition of the present invention comprises water, at least one polar polymeric resin (e.g., polyvinyl alcohol), at least one thickening agent (e.g., boric acid, borate salt, or hydrate of a borate salt), at least one humectant (e.g., glycerin, propylene glycol, etc.), at least one filler (e.g., corn starch), optionally at least one releasing agent (e.g., mineral oil) and optionally at least one additive (e.g., selected from the group consisting of pH adjusters, defoamers, dispersants, fungicides, pesticides, antimicrobial agents, colorants and scents).

The moldable composition may comprise, consist essentially of, or consist of between <NUM> wt% to <NUM> wt% water, between <NUM> wt% to <NUM> wt% humectant(s) (e.g., glycerin, propylene glycol, etc.), between <NUM> wt% to <NUM> wt% polyvinyl alcohol, between <NUM> wt% to <NUM> wt% thickening agent(s) (e.g., borate compound), between <NUM> wt% to <NUM> wt% filler(s) (e.g., corn starch), optionally between <NUM> wt% to <NUM> wt% releasing agent(s) (e.g., mineral oil), and optionally between <NUM> wt% to <NUM> wt% additives (e.g., selected from the group consisting of pH adjusters, defoamers, dispersants, fungicides, pesticides, antimicrobial agents, colorants and scents).

Alternatively, the moldable composition may comprise, consist essentially of, or consist of between <NUM> wt% to <NUM> wt% water, between <NUM> wt% to <NUM> wt% humectant(s) (e.g., glycerin), between <NUM> wt% to <NUM> wt% polyvinyl alcohol, between <NUM> wt% to <NUM> wt% thickening agent(s) (e.g., borate compound), between <NUM> wt% to <NUM> wt% filler(s) (e.g., corn starch), optionally between <NUM> wt% to <NUM> wt% releasing agent(s) (e.g., mineral oil), and optionally between <NUM> wt% to <NUM> wt% additives (e.g., selected from the group consisting of pH adjusters, defoamers, dispersants, fungicides, pesticides, antimicrobial agents, colorants and scents).

The compositions of the present invention include a sufficient amount of water to act as a solvent for the other components, but preferably not so much water that the compositions shrink substantially after the water evaporates. The compositions preferably maintain a high dry strength upon hardening. In particular embodiments, compositions of the present invention comprise between <NUM> wt% to <NUM> wt% water, or between <NUM> wt% to <NUM> wt% water, or between <NUM> wt% to <NUM> wt% water. The amount of water in the composition may decrease over time as the composition is left in open air and the water evaporates.

The compositions of the present invention include a polar polymeric resin as a binder. According to particular embodiments, the polar polymeric resin is polyvinyl alcohol (PVOH). However, other polar polymeric resins known by those skilled in the art may also be used. In certain embodiments, compositions of the present invention comprise between <NUM> wt% to <NUM> wt% polar polymeric resin, or between <NUM> wt% to <NUM> wt% polar polymeric resin, or between <NUM> wt% to <NUM> wt% polar polymeric resin.

PVOH is made by the hydrolysis of poly(vinyl acetate) and, when commercially purchased, may be partially or fully hydrolyzed. PVOH varies in molecular weight according to the length of the resin chain. In a particular embodiment, the composition includes PVOH which is partially hydrolyzed ( <NUM>% to <NUM>%, or <NUM>% to <NUM>%, or <NUM>% to <NUM>% hydrolyzed). A particularly preferred type of PVOH is Celvol® <NUM>.

The compositions of the present invention include one or more thickening agents. The one or more thickening agents preferably comprise a boric compound, such as boric acid, a borate salt, or a hydrate of a borate salt (e.g., ammonium borate, zinc borate, sodium borate, sodium aluminate, ammonium pentaborate tetrahydrate, etc.). The compositions of the present invention may also include thickening agents such as guar gum and/or xanthan gum, which may interact with boric compounds to provide a thickening function with slight or minimal cross-linking. Non-limiting examples of other thickening agents include titanates, vanadates and zincates (e.g., those commercially available under the Tyzor® tradename), dialdehydes such as glutaraldehyde, polyfunctional acids such as adipic and citric acids, polyfunctional acid anhydrides such as trimellitic anhydride, non-monovalent cations such as Ca<NUM>+, Fe<NUM>+, etc. In certain embodiments, compositions of the present invention comprise between <NUM> wt% to <NUM> wt% thickening agent(s), or between <NUM> wt% to <NUM> wt% thickening agent(s), or between <NUM> wt% to <NUM> wt% thickening agent(s).

In particular embodiments, compositions of the present invention comprise one or more humectants. Humectants inhibit drying and increase the amount of time that the composition remains moldable prior to drying and becoming hardened. A wide variety of humectant materials may be employed; for example, the humectant may be selected from the group consisting of glycerin, propylene glycol, triglycerol, poly(ethylene glycol), diethylene glycol, and combinations thereof. In a particular embodiment, the composition includes glycerin and propylene glycol as humectants. The composition preferably includes between <NUM> wt% to <NUM> wt% humectant(s), or between <NUM> wt% to <NUM> wt% humectant(s), or between <NUM> wt% to <NUM> wt% humectant(s).

The compositions of the present invention include at least one filler. According to particular embodiments, fillers may be selected from the group consisting of starch (e.g., corn starch, arrowroot, or tapioca), calcium carbonate, cellulose fibers, talc, mica, clays (e.g., Bentonite clay), silicates, and mixtures thereof. In a preferred embodiment, the filler is corn starch. In another preferred embodiment, the filler includes arrowroot and/or tapioca. In a particular embodiment, the composition includes between <NUM> wt% to <NUM> wt% filler(s), or between <NUM> wt% to <NUM> wt% filler(s), or between <NUM> wt% to <NUM> wt% filler(s).

According to certain embodiments, compositions of the present invention include at least one releasing agent to reduce tackiness. Typical releasing agents include mineral oil, petrolatum, silicone wax, etc. In a preferred embodiment, the releasing agent is mineral oil. In a particular embodiment, the composition includes between <NUM> wt% to <NUM> wt% releasing agent(s), or between <NUM> wt% to <NUM> wt% releasing agent(s), or between <NUM> wt% to <NUM> wt% releasing agent(s).

According to certain embodiments, compositions of the present invention include one or more additional additives. These additives may include, but are not limited to, pH adjusters, defoamers, dispersing agents, scents, glitter, preservatives (e.g., fungicides, pesticides, antimicrobial agents, etc.), and/or colorants. The compositions may comprise less than <NUM>% additives, or less than <NUM>% additives, or less than <NUM>% additives. In particular embodiments, the compositions of the present invention comprise between <NUM>% to <NUM>% additives, or between <NUM>% to <NUM>% additives, or between <NUM>% to <NUM>% additives.

Such additives are readily available from numerous sources. Common pH adjusters include phosphoric acid and triethanolamine. Defoamers, such as Foamex® <NUM>, can be added to eliminate air bubbles upon mixing of the components. One or more preservatives, such as anti-microbial agents and fungicides, can be added to increase the shelf life of the composition. Some examples of preservatives include Fungitrol® <NUM>, Kathon® LX, Nuosept® <NUM>, Acticide® LA, and Polyphase® P100. One or more colorants, such as pigments or dyes, may optionally be used in the composition. A scent or fragrance may also be added to the composition.

According to certain embodiments, compositions of the present invention include agents that may function in more than one capacity. For example, arrowroot may function primarily as a filler in the compositions of the present invention, but can also provide some slight function as a thickening agent and/or a humectant.

According to one embodiment, the moldable composition comprises, consists essentially of, or consists of: water; glycerin; polyvinyl alcohol; propylene glycol; at least one filler selected from the group consisting of corn starch, tapioca, clay and a combination thereof; mineral oil; at least one borate compound (e.g., ammonium borate) and at least one additive selected from the group consisting of pH adjusters, defoamers, dispersants, preservatives (e.g., fungicides, pesticides, antimicrobial agents), colorants and scents.

Advantageously, there are ingredients in other commercially available moldable compositions which are not included in compositions of the present invention. In a particular embodiment, the composition does not include any cellulose gum or hydroxypropyl cellulose. In additional embodiments, the composition does not include any microspheres, as they are defined in <CIT>.

A method according to the present invention comprises combining all of the components of the compositions described above and thoroughly mixing them until they display a substantially uniform color, consistency, and texture. According to certain aspects of the present invention, a method for making a moldable composition comprises mixing the components of the compositions described above, namely, water, at least one polar polymeric resin, at least one thickening agent, at least one humectant, at least one filler, optionally at least one releasing agent, and optionally at least one additive (e.g., one or more pH adjusters, buffers, defoamers, dispersing agents, scents, preservatives, colorants, glitter or a combination thereof) in the weight percentages described above. According to particular embodiments, the mixing is carried out at room temperature (i.e., the method is free of any heating steps).

According to one embodiment, the method comprises mixing water, polyvinyl alcohol, glycerin, anti-foam agent(s), dispersant(s), preservative(s), and pH buffer (e.g., phosphoric acid), corn starch, mineral oil, water, and a borate salt (e.g., ammonium borate or "NH4 borate" as used herein) until a substantially homogeneous composition results. The order of mixing ingredients can vary. According to another embodiment, the method includes mixing this homogeneous composition with a further boric compound (e.g., ammonium pentaborate tetrahydrate), water, a further humectant (e.g., propylene glycol), a further pH buffer/adjuster (e.g., triethanolamine), a further filler (e.g., arrowroot and/or tapioca), a further thickening agent (e.g., guar gum and/or xanthan gum), and additional releasing agent (e.g., mineral oil). The order of mixing these ingredients with the homogeneous composition may also vary.

A method for using a moldable composition of the present invention comprises molding the moldable composition into a desired shape, and exposing the moldable composition to air (e.g., ambient air at room temperature, <NUM> - <NUM>, or in an oven that is heated to a temperature greater than room temperature), for a period of time sufficient for the moldable composition to become a hardened composition (i.e., exposing the composition to air comprises leaving the moldable composition outside of any enclosure, such as a container, that would substantially prevent moisture from evaporating off of the composition), wherein the moldable composition comprises any of the moldable compositions described herein.

According to alternative embodiments, additional modifications may be made to the composition after it has been molded into a desired shape. For example, the method may further comprise adding a decorative agent to the composition, either before or after it has hardened. The decorative agent may be selected from the group consisting of glaze, paint, glitter, shimmer, and a combination thereof. After the composition has hardened, the method may further comprise chiseling the hardened composition (e.g., to add texture), further sculpting the hardened composition, or piercing the hardened composition and threading it onto a string to use it as a bead.

As used herein, a percentage (%) refers to a weight percentage of the composition (with the "composition" referring to all of the components in the total composition, including any components that are premixed prior to being combined with the rest of the components), unless indicated otherwise.

The embodiments of the invention are described above using the term "comprising" and variations thereof. However, it is the intent of the inventors that the term "comprising" may be substituted in any of the embodiments described herein with "consisting of" and "consisting essentially of".

The following examples are provided to describe the invention in greater detail.

While exemplary compositions are set forth below, alternative compositions will be apparent to those skilled in the art. Such artisans will be able to modify the compositions with an eye toward the desired performance properties and intended use.

The moldable composition shown in Table <NUM> was made according to the following method. A mixture ("PVA Premix") comprising water, polyvinyl alcohol, glycerin, propylene glycol, defoamer, dispersant, preservatives (fungicide, pesticide), and phosphoric acid were added to a mixing vessel. Cornstarch (C+) and mineral oil were then added to the PVA Premix, followed by ammonium borate. This order of mixing can be modified, as needed. The mixture was kneaded for approximately <NUM>-<NUM> minutes until it became substantially homogeneous.

Additional exemplary moldable compositions are shown in Tables <NUM>,<NUM>, and <NUM> below. The compositions included the same "PVA Premix" described in Example <NUM>. The fillers used in the composition shown in Table <NUM> included tapioca and arrowroot starch, as well as Bentonite clay. "TEA" stands for triethanolamine. "AMPBTH" stands for ammonium pentaborate tetrahydrate.

Claim 1:
A moldable composition comprising water, at least one polar polymeric resin, at least one thickening agent comprising one and more of a borate salt or a hydrate of a borate salt selected from the group consisting of ammonium borate, zinc borate, sodium borate and ammonium pentaborate tetrahydrate further comprising guar gum and xanthan gum , at least one humectant, at least one filler, optionally at least one releasing agent and optionally at least one additive.