Biodegradable plastic product made from coconut husk fiber powder

mixture

Abstract

Processed plant fine fibers such as those from the mesocarp of a coconut together are blended with a
biodegradable plastic to produce a biodegradable plastic product that can be further made into other
items. Plastics thus made from coconut husk fine fiber powder will return to the environment after disposal
much more rapidly than those without coconut husk fine fiber powder. In the process, a dry compressed
plant fine fiber powder is created from fine fibers of the coconut mesocarp. An example product created
from this raw material is composed of 10 to 40% by weight of dry coconut husk powder mixed with
environmentally degradable plastic. Environmentally non-degradable plastic may be added to the dry
powder as a biodegradation rate modulator to create a modified raw material with a modified
biodegradation rate. Plastic additives, standard in the industry, can be added to achieve additional
desired properties. For example, a surface active agent may be added in order to increase the degree of
processability; a colorant may be added to increase marketability; pesticides may be added as needed in
order to protect the product or the soil in which the product is disposed from insects; and/or
polymerization modifiers such as cross-linkers, monomer derivatives, heteromonomers, curing agents,
etc. may be utilized to vary the properties of the base plastic.

BACKGROUND OF THE INVENTION

The present invention relates to biodegradable plastics. More specifically, the present invention relates to
biodegradable plastics having an enhanced rate of biodegradability resulting from the presence of
compressed powdered plant fiber such as, for example, fine fiber from coconut mesocarp. In particular,
the present invention relates to an improvement in biodegradable plastics wherein the biodegradability is
made predictable by blending conventional polymers, biodegradable polymers and biodegradability
enhancing compressed plant fine fiber powder having moisture expansion characteristics capable of
generating structure disrupting internal mechanical forces upon prolonged exposure to the environment.
In other words, the present invention relates to plastics which decompose in the soil after use.

Because of environmental issues facing society, environmentally degradable plastics are increasing in
popularity. The biodegradable plastics currently developed are divisible into four categories that
somewhat overlap: a) the natural polymers which use polysaccharides such as starch and the like; b) the
microbial polyesters which use the biological activity of microorganisms; c) blends with accelerated
degradation properties which are regular plastics with degradation accelerator additives; and d) chemical
synthetics which include the aliphatic polyesters and the like.

Depending on the particular properties of the different materials, biodegradable plastics are used as raw
materials for disposable products and in products that generally do not have to carry heavy loads. Such
applications include: agricultural products such as films, sheets, bottles, pots, and bags; products for daily
use and tableware such as trays, cases, and straws; some medical equipment; and sports equipment.
Nonetheless, the use of biodegradable plastics is still limited and their effect on the general plastics
industry as a whole is limited.

A review of the "state of the art" for environmentally degradable polymers is found in: "Encyclopedia of
Chemical Technology" 4th edition, Vol. 19, Pages 968-1004, John Wiley & Sons Inc. (1996), the entirety
of which is incorporated herein by reference. Additionally, a review of manufacturing processes and
testing procedures in current use, in: "Encyclopedia of Chemical Technology" 4th edition, Vol. 19, Pages
290-347, John Wiley & Sons Inc. (1996), is incorporated herein, in its entirety, by reference.
Biodegradable plastic offers promise to solve the problem of the disposal of regular plastic. But there
have been several obstacles. Depending on the type and ratios of the components in the biodegradable
plastic and depending on the environment where the biodegradable plastic is disposed, the rate of
biodegradation may be less than desired. Another obstacle is that as the thickness of the product
containing biodegradable plastic increases, the biodegradability property is diminished. Furthermore, the
life span of the product containing biodegradable plastic might be detrimentally shortened as a result of
insects causing damage. A greater problem still is that many polymers are specifically formulated to serve
narrow optimized functions, or to display certain manufacturing process behaviors. Substitution with a
biodegradable plastic diminishes the effectiveness of these processes and generates an inferior final
product. It would therefore be highly advantageous to formulate a way to improve the biodegradability of
all plastics while maintaining each plastic's desirable features.

One possibility for achieving this goal would be through the use of an additive to the plastic, in place of
currently used common fillers, that increases the plastic's susceptibility to environmental degradation.
Additives to plastics are currently used to obtain desirable properties in the plastic. For example, additives
are used to impart such properties as strength, hardness, flexibility, color, etc. An extensive review of
properties, applications, and toxicologies of additives for plastics is found in: "Chemical Additives for the
Plastics Industry", prepared by Radian Corp., Noyes Data Corp, N.J. (1987), the entirety of which is
incorporated herein by reference. One possibility of a plastic additive to increase environmental
degradability may be a biomaterial such as plant fiber or wood powder.

Coconut husks as a substitute for synthetic fibers

Researching and developing ways of using fiber extracted from coconut husks to produce
higher-value products has turned into more than a growing business for Elisa Teipel, her
husband Blake Teipel and Matt Kirby. In addition to producing environmentally friendly products,
the three founders of Essentium Materials see their business venture as a means of lifting small
coconut farmers out of poverty.

As explained in a National Science Foundation profile, “Today their new company, the
College Station, Texas-based Essentium Materials, is turning out automotive trunk
liners, load floors (battery pack covers in electric cars), and living wall planters, among
other things, with technology they developed that produces a composite material made
of coconut husks combined with recycled plastics.”

The resulting coconut husk-based composite material, NSF highlights, “is greener and cost
neutral, as well as stronger and stiffer, than the traditional all-synthetic plastic fibers, and with
neutral anti-microbial properties due to a high lignin content.”

Another big benefit could be realized if coconut husk fibers were used instead of synthetic
polyester fibers: an annual reduction in petroleum consumption of 2 to 4 million barrels and an
associated reduction in carbon dioxide emissions of 450,000 tons each year.

As Teipel said, "The coolest part is seeing something that was once just waste become
a new resource ... Also, it is benefitting both the environment and the communities in
developing nations where the coconuts are grown."