Patent Application
20220106507
Disclosed are natural based biodegradable adhesives. By being biodegradable, the these adhesives allow the materials with which they are used to be recyclable, repulpable and/or compostable, which can substantially increase the value of such materials once used, as well as provide a more green and more environmentally sustainable repurposing of the used materials.
A biodegradable adhesive for use in at least one chosen from glue lap, case and carton seal, slower speed carton seal and bookbinding, includes at least one chosen from:
The first basic adhesive is a natural gelatin (gelatine) based biodegradable adhesive as a substitute or replacement for non-biodegradable synthetic resin emulsion-based adhesives (aka, “cold glues”).
Various aspects of the various adhesives and applications described below can be combined in different manners to create different embodiments.
I. First Basic Adhesive
The first basic adhesive can include water, pure or various blends of gelatins, glycerin, Epsom salt, defoamer, and preservative. The gelatins can include blends of amber and opaque colored inedible porcine, bovine, and bone extracted collagen based gelatins, and can also include pharmaceutical and edible gelatins as well. The gelatins can be presented in various forms, including as granulated, noodles, dust, natural colored hard shell pharmaceutical capsule gelatin tailings, ground multi-colored hard shell pharmaceutical capsule gelatin tailings, and various pharmaceutical soft gelatin encapsulation web netting encapsulation waste gelatin tailings blends.
The glycerin can include 99.7% USP Kosher Grade, as well as lesser quality and lower priced grades, including 96.0% technical grade and 88% crude grade. The defoamer can be Solvay USA defoamer. The preservative prevents mold. Vanilla extract can be added to the first basic adhesive to provide a pleasant odor. All of the components can be provided in edible form to make an entirely edible product.
One basic formula for the first basic adhesive includes:
The specific percentages of components can be adjusted as necessary depending on a specific use and desired characteristic. All values and ranges within the given ranges are intended to be part of the invention.
One specific formula for the first basic adhesive (as represented by an adhesive sold under the name of Cooler-Melt 999™) includes:
This specific formula for the first basic adhesive provides an adhesive with the following properties:
Alternatives to this specific formula can be provided as follows:
Other alternatives can also be provided by varying the percentages of components.
The first basic adhesive can be gently gravity filtered through a twin 200-micron & 55-micron filter bag system.
This adhesive can be produced in food processing hemispherical bottom mixing kettles (super-mix, no mix dead spots), which provide superior mixing as compared to conventional adhesive production kettles having cone shaped or flat bottoms.
Application equipment involving applications 1-3 below may need to be modified to be non-corrosive in the presence of water (i.e., use of stainless steel, coated and/or other non-corrosive types of pumps, screws, modified lids for water drip-down evaporation, valves, heads and nozzles, etc. Also, the glycerin in the composition lubricates adhesive supply unit components, including O-rings. This first basic adhesive has shown an increased heat tolerance.
Applications
1. Glue Lap
A first specific application of the first basic adhesive is as a glue lap for glue lap seam corrugated and solid paperboard Folding Cartons/Boxes converter gluing/finishing to manufacture corrugated boxes and folding solid paperboard Cartons and/Boxes. Cold glues are predominately used today as glue lap adhesives and are not biodegradable.
In this application, the first basic adhesive can be applied by Roller/wheel, various forms of spraying, extruded dots, stitches, beads, etc. This can include hot melt tank units, heated hoses, and heated glue extrusion heads (beads, stitches, dots, etc.). In some cases, heated open glue pots with glue application wheels/rollers can be used to apply the first basic adhesive to the corrugated inner lap seam. Valco/Melton of Cincinnati is a market leader in corrugated adhesives application equipment, and has tested and approved the first basic adhesive in their adhesive application equipment.
The adhesive sticks corrugated and solid paperboard by losing water into the substrates and cooling (loss of temperature, applied at approximately 140° F./60° C. This is compared to conventional cold glues that are applied at room temperature and bond to corrugated and solid paperboard by losing water into the substrates.
As advantages in this glue lap application, the first basic adhesive is biodegradable and is freeze/thaw stable. That is, the adhesive can go through freeze/thaw cycles without substantive degradation. This means that the adhesive does not need to be shipped by heated trucks during winter conditions, a substantial cost savings, and/or, can be shipped year-round, and not just during warmer months. In addition, the adhesive has easy clean-up properties with hot (approximately) 160° F. water. No solvents or caustic chemical cleaners are required.
This adhesive can be used to internally and externally seal encapsulated pharmaceuticals and nutritional supplements folding cartons, and can use, essentially, waste gelatin capsules to safely seal the encapsulated products packaged in folding cartons.
2. Case and Carton Seal
A second specific application of the first basic adhesive is as an adhesive for corrugated box and solid paperboard folding carton and or box sealing, commonly referred to as a case-seal adhesive. Applications of such case-seal adhesives are in the sealing of tops and bottoms of cereal boxes, as well as the sealing of the tops and bottoms of the corrugated boxes that the cereal boxes get packed in. Hot melt adhesives are predominately used today as case-seal adhesives and are not biodegradable.
The first basic adhesive can be applied in this case-seal application in the same manner as in the glue lap application.
The adhesive sticks corrugated and solid paperboard by losing water into the substrates and cooling (loss of temperature, applied at approximately 140° F./60° C. This is compared to conventional hot melt adhesives that are applied at approximately 250-350° F. and bond by surrounding surface fibers and cooling (loss of temperature).
The first basic adhesive in this case-seal application provides the same advantages as discussed above with respect to the glue lap application. In addition, it also provides stronger, deeper, fiber-tearing bonds, and energy conservation, as the typical EVA-based case seal hot melt adhesives require approximately 50% more energy to apply versus application of the first basic adhesive in this case-seal application. Further, the lower temperature of application advances worker safety by curtailing serious skin burns and reducing lost-time accidents due to skin burns. Also, the first basic adhesive in this application provides improved adhesion in the presence of oil vapors, improved heat resistance bonds versus the EVA-based hot melt adhesives and is unconditionally repulpable.
3. Slower Speed Case Seal
A third specific application of the first basic adhesive is as an adhesive for replacement of non-biodegradable corrugated box sealing tapes, plastic corrugated banding materials, stretch wrap, and staples to seal the tops and bottoms of corrugated boxes.
The first basic adhesive can be applied in this case seal application in the same manner as in the glue lap application.
The adhesive sticks corrugated and solid paperboard by losing water into the substrates and cooling (loss of temperature, applied at approximately 140° F./60° C.
The first basic adhesive in this case seal application provides the same advantages as discussed above with respect to the glue lap application. In addition, it also provides stronger, deeper, fiber tearing bonds and problem resolution to widespread tape use related adhesion failure. It can replace pressure sensitive tapes which do not stick well below 30° F. It is unconditionally repulpable and saves money over the use of sealing tapes, plastic corrugated banding materials, stretch wrap, and staples.
Testing
The first basic adhesive (Cooler Melt 999™) has been tested for strength with respect to construction of a pork box. Below are the results of three tests using the noted adhesives, where Test 1 was directed to use of Cooler Melt 999™ only; Test 2 was directed to use of a conventional (plastic/petroleum) hot melt adhesive and Test 3 was directed to a mixture of the Cooler Melt 999™ and the conventional hot melt adhesive. In the tests, the “Compress” and “Deflect” measurements are an indicator of the ability of the box to protect contents, with a higher “Compress” value being better and a lower “Deflect” value being better. The mixture of Test 3 provides for high speed of the line but the material is not biodegradable because of the inclusion of the conventional hot melt adhesive. This mixture also shows the highest compression and lowest deflection combination of the 3 tests.
II. Second Basic Adhesive
The second basic adhesive can include water, pure or various blends of gelatins, glycerin, defoamer, and preservative. The gelatins can include blends of amber and opaque colored inedible porcine, bovine, and bone extracted collagen based gelatins, and can also include pharmaceutical and edible gelatins as well. The gelatins can be presented in various forms, including as granulated, noodles, dust, natural colored hard shell pharmaceutical capsule gelatin tailings, ground multi-colored hard shell pharmaceutical capsule gelatin tailings, and various pharmaceutical soft gelatin encapsulation web netting encapsulation waste gelatin tailings blends.
The glycerin can include 99.7% USP Kosher Grade, as well as lesser quality and lower priced grades, including 96.0% technical grade and 88% crude grade. The defoamer can be Solvay USA defoamer. The preservative prevents mold. Vanilla extract can be added to the first basic adhesive to provide a pleasant odor.
One basic formula for the second basic adhesive includes:
The specific percentages of components can be adjusted as necessary depending on a specific use and desired characteristic. All values and ranges within the given ranges are intended to be part of the invention.
One specific formula for the second basic adhesive (as represented by an adhesive sold under the name of Bio-Bond 1230™) includes:
This specific formula for the second basic adhesive provides an adhesive with the following properties:
Alternatives to this specific formula can be provided as follows:
Other alternatives can also be provided by varying the percentages of components.
This adhesive can be gently gravity filtered through a twin 400-micron and 200-micron filter bag system.
Applications
4. Spine Glue
The second basic adhesive provides a replacement adhesive for non-biodegradable perfect binding hot melt spine adhesives, for use on perfect binding equipment and spine gluing equipment (wheel/roller application) involving ground wood paper stocks for crossword, puzzle, coloring and other types of books.
The second basic adhesive in this application can be applied via wheel and roller application using an open heated pot, such as used on Harris Perfect Binder Machine. Muller Martini, Kolbus, and other perfect binding and spine gluing equipment.
The second basic adhesive in this application is biodegradable and provides stronger, deeper, fiber-tearing bonds. It also provides energy conservation, as the typical EVA-based case seal hot melt adhesives require approximately 50% more energy to apply versus application of the first basic adhesive in this case-seal application. Further, the lower temperature of application advances worker safety by curtailing serious skin burns. Also, the first basic adhesive in this application provides improved adhesion in the presence of oil vapors, improved heat resistance bonds versus the EVA-based hot melt adhesives and is unconditionally repulpable. It provides doubled their waste paper value (versus hot melt adhesives contaminated paper). It saves money through these advantages. It also provides improved page pull & flex test results, as well as improved layflat (reader-friendly, diminished mousetrapping (when you open the book it snaps shut)) quality properties. It has been found that this adhesive doesn't rope off the application wheel, because of the inclusion of strong gelatin with added water content, and also because of the noted filtration.
Softcover books can be produced with a single application of the second basic adhesive at a viscosity of less than 5,000 cps. (Brookfield Viscometer Model RVT 20 RPM's at 70 C).
In one version of the second basic adhesive, high strength inedible pharma/edible waste gelatins can be blended with added water in conjunction with 99.7% USP Kosher grade glycerin at levels that exceed 20% (of the 100% total composition). Such a blend produces deeper book backbone fiber penetration, resulting in stronger bonds. This also produces improved lay flat easier-read book products with added film flexibility properties. This is a substantial improvement over current, plastic based non-biodegradable spine glues, which are stiff and cause mouse trapping.
With one or both of the first and second basic adhesives discussed above, the adhesives may require longer set-up times than typical wax/plastic adhesives. Where a typical wax/plastic adhesive may set up in 1-2 seconds, the first and second basic adhesives may need approximately 5 seconds to set up. This longer time may be accommodated by adding additional length of compression belts in a compression line to extend the time of compression to that necessary for set up. Alternatively, or in addition thereto, it has been found that using a slot die applicator, which extrudes a flat film of adhesive onto the material, without a roller, allows water from the adhesive to evaporate quicker to allow the adhesive to set up within the desired time, such as 2 seconds. Controlled fiberization swirl spray adhesive application can also be used.
It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present disclosure in any way. Thus, those skilled in the art will appreciate that other aspects of the disclosure can be obtained from a study of the drawings, the disclosure and the appended claims. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. Various features of the various embodiments disclosed herein can be combined in different combinations to create new embodiments within the scope of the present disclosure. Any ranges given herein include any and all specific values within the range and any and all ranges within the given range. To the extent that “about” or “substantively” is used to modify a value, that value is rendered as ±10% and ±2% of the value, respectively, unless otherwise stated.
This application claims priority to U.S. Provisional Patent Application No. 62/801,480 filed Feb. 5, 2019, which application is incorporated by reference herein in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2020/016718 | 2/5/2020 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62801480 | Feb 2019 | US |
