Note: Descriptions are shown in the official language in which they were submitted.
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POLYMERIC FILM FOR AGRICULTURAL PRODUCT STORAGE,
CONTAINERS MADE THEREFROM AND RELATED METHODS OF
AGRICULTURAL PRODUCT STORAGE
Inventor: Rachel Dove
FIELD OF THE INVENTION
[00001] The present invention relates to polymeric laminate materials and
more
particularly to polymeric laminate materials exhibiting functional properties.
The present
invention further relates to barrier and cushioning films, in particular,
barrier and
cushioning films exhibiting functional properties proving advantageous for the
management of adverse conditions, pertaining particularly, but not limited to,
food
storage The present invention further relates to cushioning films in which the
chambers
contain active ingredients to be deployed on contact. The present invention
further relates
to the lamination of the cushioning film for increased functional properties.
BACKGROUND OF THE INVENTION
[00002] Polymeric laminates exhibiting functional properties have a wide
variety
of applications in multiple industries ranging from healthcare to modified
atmosphere
packaging to construction and others. For the purposes of the present
invention, more
specifically, food storage, recent technological advancements in flexible
packaging and
barrier films provide stored product and end user benefits such as moisture
absorbency,
odor absorbency, odor blocking, oxygen transmission and water vapor
transmission
management, all of which contribute to maintaining freshness and resisting
contamination.
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[00003] Post harvest practices have significant outcomes in human and
animal
health as well as agribusiness and the economic sustenance of farmers and
overall food
security. Poor handling, poor storage, insect infestations, mold, bacteria,
fungus and or
other contaminants pose significant health risks when contained within
foodstuffs
intended for human or animal consumption. Post harvest losses resulting in
such
infestations significantly hinder income generation, more specifically for
small-scale
farmers in Sub-Saharan Africa. "In Tanzania, maize losses of up to 35% may
occur due
to Prostephanus truncatus (Larger Grain Borer) within 5 to 6 months if
improperly stored
(Mallya, 1992) and up to 60% losses may occur after 9 months of storage (Keil,
1988), a
situation which may result in serious famine" according to the FAO's Paper on
Insect
Damage, Post Harvest Compendium. In Kenyan highlands, total losses due to
pests in
maize were estimated at 57% with insects being more important than disease
(Grisley,
1997). In Zimbabwe, grain damage of 92% in stored maize was reported due to
insect
pests, treatment with malthion reduced damage by only 10% (Matrio, et al.
1992).
Infestations of stored cowpeas can be as high as 90% in markets and in village
stores
(Alabeek, 1996). A wide variety of food stuffs are affected by insects, mold
and fungi
infestation is not limited to maize grains and pulses. Insect pests, in
addition to fungal
diseases, are responsible for 50% damage in cassava (Maninek, 1994). Losses of
up to
70% in dried cassava roots after 4 months of storage were reportedly due to P.
truncatus.
(Hodges, et al., 1985).
[00004] Insect pests inflict their damage on stored products mainly by
direct
feeding. Some species feed on the endosperm, causing loss of weight and
quality, while
other species feed on the germ, resulting in poor seed germination and less
viability
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(Malek & Parveen, 1989; Santus, et al. 1990). In addition to direct
consumption of the
product, insect pests contaminate their feeding media through excretion,
molting, dead
bodies and their own existence in the product, which is not commercially
desirable.
Damage done by insect pests encourages infection with bacteria and fungal
disease
through transmission of their spores (Cravedi & Quaroni, 1982; E. Kundayo,
1988;
Dunkel, 1980). The presence of insects also raises the stored product
temperature, due to
their feeding activity, resulting in hot spots (Appert, 1987; Mills, 1989).
These "hot
spots" can lead to condensation and excessive moisture, resulting in the
growth of mold
or fungi. Insects' activity can have profound effects on the spread of fungal
diseases
through transmitting the spores and increasing the surface area susceptible to
fungal
infection, which eventually increases production of mycotoxins (Dunkel, 1988).
1000051 Despite
the physical damage of insect pests, infestations resulting from
poor post-harvest storage can have economically devastating effects on
farmers,
communities, and the economies of several countries and ultimately
international food
security, depending on exportation of maize, wheat and other food stuffs. For
example,
P. truncatus cost Tanzania roughly US $91 million annually in lost maize
intended for
consumption or export (Bionet International & Global Invasion Species
Program).
Farmers in sub-Sharan Africa are frequently forced to sell stored produce
prematurely
because of the deterioration due to insect damage that occurs if storage
periods are
extended (Global, et al. 1996, Brice et al. 1996, Marsland & Golob 1996,
Donaldson, et
al., 1996). Inability to store and protect post-harvest leads to significant
income
reduction as farmers do not have the flexibility to wait for the higher price
as the market
fluctuates. The combined difficulties of on-farm food storage and the economic
burden
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of post-harvest loss are devastating for farmers in developing countries,
particularly due
to the lack of available resources for building insect and rodent proof
storage units, the
lack of information regarding insecticide/pesticide use, as well as lack of
affordability for
materials which can mitigate external environmental and climatic conditions.
[00006] On-farm storage difficulties and post-harvest losses occur mainly
as a
result of temperature, moisture, respiration of stored contents, infestation
of insects,
infestation of rodents and fumonisins, mycotxins and aflatoxins resulting from
mold and
fungi growth, due to lack of oxygen transmission and water vapor transmission
of storage
containers presently employed. Whether intended for human consumption, or used
as
animal food stock, stored product contamination poses serious health risks.
Aflatoxin
consumed by dairy cattle, though altered in their body, still remains toxic
and shows up
in the milk (Christensen & Meronuck, 1986, Gwinner, et al., 1996). A.
fumagatis is
report to result in high levels of abortion in cattle feeding on contaminated
food; also
infects human lungs (Darwish, et al., 1991; Pandey & Prasad 1993; Abud, et
al., 1995).
[00007] The use of plastic sacks, bag storage, prefabricated iron halls and
flexible
plastic silos are increasingly gaining ground among farmers for short term
storage
(Peterson & Simila, 1990; Compton, et al., 1993; Bartali, 1994). However, none
of the
current storage mechanisms effectively manage the comprehensive set of factors
including moisture management, barrier to or effective transmission of oxygen,
and
contact release mechanisms for active ingredients, which more specifically,
when
properly released, promote desired effects such as but not limited to insect
and or rodent
repellency and or moisture management and or bacteriostatic or fungicidal
properties..
[00008] Accordingly, there remains a need for improved polymeric materials
for
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maintaining acceptable and FAO recommended moisture levels for stored product
and
on-farm storage of dry foodstuffs to obtain optimal storage conditions for the
prevention
and reduction of post harvest losses.
[00009] In addition, there remains a need for effective dosing of
insecticides or
pesticides within a laminate structure, such as that used in a food container.
[000010] Polymeric laminates which have raised portions, membrane
structures, air
pockets, gaps, quilting, pillowing, three dimensional raised, conical, round,
honeycomb
membranes and different shapes, dimensions, and interconnected air pathways
contained
within the laminates have a wide variety of uses and was patented in July,
1968, US
Patent Number 3,142,599, Method for Making Laminated Cushioning Material,
becoming trademarked and commonly known as "Bubble Wrap," from which the
product
line has expanded to include films exhibiting functional properties such as
anti-static and
anti-flammability.
[000011] Patents exist for the encapsulation of Holiday confetti and
graffiti,
associated holiday prints, as described in US Pat. No. 20100143614 "Holiday
and Event
Bubble Wrap" and holiday-inspired or event-themed scents for bubble wrap as
seen in
Patent No. 806255 filed on 02/21/1997, "Scented Bubble Wrap" as well as
multiple
patents detailing differences in pocket structure, load strength and wall
thickness of the
air pocket, bubble dimension and shape and interconnectedness of air pockets,
air
pathways, structural design and incorporation into other containment units and
free
standing containment units.
[000012] The foregoing patents are hereby incorporated herein by reference.
[000013] However, there exists no prior art which uses the air pocket as a
contact
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release mechanism for releasing substances to include but not limited to
active
ingredients in whatsoever state such as vapors, liquids, oils, pheromones,
gels, hydrogels,
gases or gaseous components, solids, waxes, powders or particulates of
whatsoever size,
admixtures and combinations of either chemical, inorganic, and or organic
materials and
or derivatives of natural or synthetic materials whatsoever for the purposes
of managing
adversities related to stored product conditions.
[000014] Such laminates which exhibit contact release mechanisms, with or
without
a barrier layer or alternative laminate substrate, may be used for the storage
of
agricultural products and the like, such as harvested grain, maize, cowpeas
and silage,
whereby such laminates function as mechanical barriers to pests, rodents and
insects
while mitigating the effects of temperature and humidity variations, stored
product
transpiration and moisture management as a result of contact pressure which
enables the
release of the food-safe active ingredient contained within the air cushioned
membrane.
[000015] There are several concomitant problems attendant to on-farm
storage of
dry foodstuffs (e.g., grain and maize), such as water ingress and the
subsequent moisture
accumulation in the surface layer of the grain adjacent the innermost layer of
the
container and the effects of external temperature and humidity on internal
stored product
atmosphere, creating conditions for mold, fungus, and bacteria contamination
and the
resulting toxins such as aflatoxin, mycotoxins and fumosins.
[000016] Free-standing storage units for bagged agricultural commodities
are prone
to both insect and rodent infestation. Insect infestation may exacerbate the
proliferation
of mold and fungal growth due to the insect's respiration, excretions, and
transmission
and further distribution of the mold, fungal, and bacterial spores while
migrating through
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the stored product. Accordingly, it is beneficial to provide on-farm storage
containers that
prevent or reduce both infestation and manage moisture transmission to prevent
fungal
growth. To reduce fungal growth, the containers should maintain some degree of
oxygen
permeability in a manner which permits complementary moisture vapor diffusion
or a
form of hermetic storage with use of the novel substrate detailed herein as a
component
of a hermetic approach whereby the polymeric layer either retains moisture or
functions
to achieve acceptable levels of difference between external and internal
temperatures and
relative humidity to prevent moisture accumulation and its related effects
such as hot
spots and areas of decomposing foodstuff due to centralized moisture.
[000017] In the preparation of polymeric materials of this type for these
purposes,
there has been a deficiency in the prior art to attempt to manage the adverse
effects of
combined infestations of insects of differing speciation and or rodent
populations as well
as fungal, bacterial and mold proliferations for stored products observing the
storage
condition parameters recommended by the FAO for foodstuffs intended for human
or
animal consumption with relation to moisture content at time of storage.
[000018] In the preparation of polymeric material of the air cushioned,
chambered,
quilted, raised, textured or three dimensional type whatsoever, there has been
a
deficiency in the prior art to encapsulate an active ingredient for the
purposes of
promoting a desired effect as a result of penetrating the bubble or raised
portion for the
controlled-by-contact release of the active ingredient, ingredients, or
combinations
thereof, more specifically for the controlled release of active ingredients
which, when
employed, have a desired effect to promote optimal conditions for the
protection of stored
products, more specifically, dry foodstuffs.
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SUMMARY OF THE INVENTION
[000019] It is therefore an object of the present invention to provide a
new
polymeric laminate incorporating, encapsulating or otherwise containing active
ingredients released on contact so as to bring about the intended effect of
the active
ingredient at the time of, during, or as a result of its release via
penetrative contact.
[000020] The present invention features the use of air cushioned film
encapsulating
or otherwise containing active ingredients or bioactive substances or
components thereof
specifically for the purpose of a release by penetration either used
singularly, as an insert,
and or in combination with polymeric films incorporated, coated, laminated,
infused,
coextruded or somehow containing active ingredients to provide one of the
following or a
combination of the following for the distinct purpose of promoting or
contributing to the
promotion of a desired effect; moisture management, oxygen transmission, water
vapor
transmission, fungal, bacterial and mold growth inhibitors or scavengers of
whatsoever
nature, and insecticides of whatsoever nature and class or family, whether
natural or
synthetic, to include but not limited to, insect sterilization, excito-toxins,
dessicants,
pheromones, attractants, scents, and rodent repellents of whatsoever nature as
well as
additives contributing or pertaining to material properties such as UV
blockers or
stabilizers, colors, or additives of whatsoever nature.
[000021] The present invention includes multilayer structures, laminates,
co-
extruded films or substrates and or air cushioning films and or three
dimensional films
having raised, quilted or pocketed structures or texturized substrates of
whatsoever
nature, encapsulating active ingredients which are released on contact by
penetration of
the raised portion, such laminates may be employed for use as films
singularly, as liners,
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inserts, special placement strips, or additional components to existing
storage
mechanisms, as multi-dimensional laminates combining one or more polymer
layer, or
manufactured as containers comprising the same for the storage of agricultural
products
and the like either for human or animal consumption such as harvested grain,
maize,
silage and feedstock as well as methods of storing foodstuffs for a period of
time to
permit on-farm storage and ultimately to promote the subsequent economic
benefits
related to timely market approach.
[000022] In another aspect of the present invention, there is provided a
polymeric
laminate comprising adapted to contact an insect of a given dimensional shape
with a
dose of an insecticide: an innermost layer comprising a bubble plastic
thermoplastic
polymeric material layer comprising bubbles containing at least one
insecticide, the
bubbles having a shape and an inter-bubble distance adapted to resist the
movement of
the insect thereabout. The bubbles may face inward or outward, and may also be
incorporated as a double layer.
[000023] In this regard, it has been found that the shape, size and/or
inter-bubble
distance can be chosen so as to resist the movement of the insect about the
bubbles, so as
to relatively increase the resident time the insect spends within a gnawing
distance from
the bubble(s). Because many boring insects will continue to gnaw or bore into
nearby
material, it is desirable to tune these parameters based upon the physical
dimensions of
the target insect(s) to make the spatial environment more difficult for the
insect(s) to
navigate.
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[000024] In a preferred embodiment, the insecticide is in powder form, and
preferably comprises a material selected from the group consisting of
diatomaceous earth
and cuticle desiccants.
[000025] It is also preferred that the burst strength of the thermoplastic
bubbles of
the bubble plastic thermoplastic polymeric material allows the insect to burst
the
thermoplastic bubbles so as to expose the insect to the at least one
insecticide. Although
the bubble layer may be made of any suitable polymeric material designed to
allow the
insect to gnaw, bore or otherwise pierce, preferably the bubble plastic
thermoplastic
polymeric material comprises a polymer selected from the group consisting of
LDPE,
LLDPE, VLDPE and may include one or more of the other thermoplastic group of
polymers.
[000026] It is a further object of the present invention to provide a new
polymeric
laminate which has the capacity to exhibit multifunctional properties while
providing an
effective barrier to pests and insects indiscriminate to the type of insect
and food product
stored, as a result of having taken into account varying speciation and or
diverse
infestations and or erratic insect behavior resulting in the discovery of a
variety of novel
and interconnected parameters directly contributing to the effectiveness of
the film's
mechanical barrier to include but not limited to; the depth and width of the
depressed
channels in between the raised air pockets of the film in relation to the
thoracic
dimensions, mandible positioning and or mode of feeding, mandible strength and
mouthpart construction, leg span, thrusting capacity, mobility, flexibility
and
maneuverability, tenacity, and overall interaction of the insect with the
textured substrate
such as scratching, burrowing, as well as the impacts of penetration to
include but not
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limited to, the rate of penetration of the raised portion upon differing
techniques and
methods of penetration and the subsequent rate of active ingredient release
and volume in
relation to the insect body dimensions, the differences in penetrability of
different shapes
due to mandible positioning and insect dimensions and thus manueverability,
and other
mechanical properties distinct to the construction and properties described
herein which
act as the initial barrier before the active ingredient release.
[000027] It is a further object of one variation of the present invention
to provide a
method of entrapment and or reactions whatsoever which alter and or impede the
maneuverability of the insect, immediately prior to, upon, during or shortly
thereafter the
release of the active ingredient, especially on insects whose mode of
infestation are
tenacious and persistent whereby the innate behavior of such insects will
cause their
entrapment, exposure to a laminate-incorporate insecticide or pesticide, and
ultimate
suffocation within the singular celled air pockets.
[000028] It is yet another object of another variation of the present
invention to
allow, in some embodiments, the encapsulation of a variety of one or more
active
ingredients to be released on contact by penetration and this may or may not,
depending
on the climactic and existing storage conditions and insect speciation present
in the
environment in which the film is to be deployed, require the dosing of
multiple active
ingredients in one air pocket, or singular air pockets containing singular
active
ingredients yet located in close proximity or adjacent to air pockets which
may contain an
alternative singular active ingredient or a combination of different active
ingredients so
that one film may contain either multiple air pockets encapsulating singular
active
ingredients, or selected air pockets may contain multiple active ingredients,
while other
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air pockets may contain no active ingredients.
[000029] It is yet another object of still another embodiment of the
invention to
provide insect-specific shape, volume, height, and strategic positioning of
the air pockets
within an array so that interconnectedness of air pathways can, if desired,
distribute
active ingredients in a pre-determined manner or in exact locations for
increased
effectiveness upon release.
[000030] It is yet another object of the invention to provide for a mix-on-
release
capacity whereby the air pockets containing one active ingredient and air
pockets
containing alternative ingredients can be, if such outcome is desired,
interconnected via
air pathways to allow for simultaneous penetration whereby the separate active
ingredients are mixed upon release.
[000031] Films of the present invention and those of slight variation
described
herein may also find beneficial use in building applications, such as in grain
storage
facilities, such as in grain or food storage warehouse floor applications,
ceiling or
easement coverings, or for use within residential construction to mitigate
infestation
while providing insulation,.
[000032] A related embodiment of the present invention may also include a
polymeric film used as a wrap deployed around tree trunks as barriers to
burrowing wood
pests and other forest diseases with the alternative active ingredients or
combinations of
active ingredients exhibiting properties including to but not limited to
repellency,
sterilization, growth regulation, contact killer, cuticle dessicant, propigate
or other type of
active ingredient or any mixtures or combinations whatsoever whether natural
or
synthetic or mechanically or chemically manipulated, for specific
applicability and
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effectiveness with consideration to the vector strain, speciation, insect
behavior,
resistance, reproduction, mode of action, etc as well as the modifications
required for
material properties to withstand environmental conditions and application
requirements.
[000033] Another related embodiment of the present invention may be
polymeric
film substrates dosed with active ingredients for contact release to include
but not limited
to fertilizers, agricultural inputs, pesticides, herbicides, and or other
active ingredients
whereby direct release of active ingredients enhances or somehow imparts
desired results
to include but not limited to soil quality, enriches plant nutrient uptake, or
other
beneficial properties on contact release, such films may be used underneath
the soil as a
catchment unit or as a protective covering.
[000034] The polymeric substrate and combinations thereof of the present
invention
may be produced by coextrusion, coextrusion blown film, double bubble blown
film,
texturized geomembrane film extrusion, profile extrusion, thermoforming,
vaccuum
forming, void fill forming, film extrusion, film lamination, coating by
stenter, saturation,
spray, powder dusting, hot roll pressing, or other means of incorporation,
impregnation,
or infusion whereby the laminate substrates can, if desired for increased end
product
effectiveness, undergo further manufacturing process to include but not
limited to heat
fusingõ bonding of all types to include thermal point bonding, sheet bonding,
electrostatic
bonding through coating mechanisms known to those skilled in the art and or
other
coating mechanisms intended to adhere substrates, and or thermal seaming,
thermal
embossing, calendarization, or stenter fixation, and or bonding methods known
and used
in the art not mentioned herein.
[000035] Separate laminates may be used in accordance with environmental
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conditions, and further bonding or lamination may be done in view of such
environmental
or cost considerations.
[000036] An alternate product which may utilize alternative fixation
methods may
include the use of adherents, glues, or other epoxies, resins, or mixtures
thereof or other
materials adequate to form a seal and intended to affix either portions and or
sheets of
whatsoever dimension of one laminate substrate to another may be included.
Such
locations of placement for adherents, glues, epoxies, and or resins or other
materials
intended to affix substrates not mentioned herein may be placed at the edges
during
manufacture for later use as a method of post-manufacture, consumer assembly
of a bag-
like structure or containment unit.
[000037] The method employed for dosing active ingredients within the air
pockets
may be dependent upon the composition, viscosity, heat index and other
properties of the
active ingredient whether it be in powder, liquid, gel, or any other substance
whatsoever
such as respective flow rates and other physical and chemical properties, and
such dosing
of active ingredients preferably should take place at the crucial phase in
film
manufacturing where the hot melt plastic sheet has conformed the desired
depressions
and dimensions after coming off the perforated roller with sufficient cooling
at a
temperature adequate so as not to entirely embed the active ingredient in the
hot plastic
but before moving onto the process whereby the second sheet second is to be
laid so as to
suspend the active ingredient between the raised portion and the flat
laminate, thus
enclosing, encapsulating, or otherwise containing the active ingredient in a
manner
sufficient so as to be released from the raised portion upon penetration.
[000038] Dispensing mechanisms appropriate for this technology may range
from
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simple to complex, based on the desired accuracy of the dosage of active
ingredient and
or precision of placement and affordability for the end product. Automated
overhead
mounted gravimetric dispensing units which precisely and accurately dose
active
ingredients, such as those commonly used in the pharmaceutical industry, as
well as in-
line spray coating, wet or dry powder coating and other dispensing units of
high precision
are examples of effective manufacturing apparatus for some variations of this
invention,
most preferably used when active ingredients are in liquid, gel, or format
other than dry
powder or particulate, although such high precision fill mechanisms may not be
the most
effective method of manufacture for providing affordable solutions for
mitigating post
harvest losses in developing economies.
[000039] The preferred method to reduce manufacturing costs and thus end
product
cost for dispensing active ingredients within the air pockets of the bubble
film employs a
metal drum roller set, most preferably a non-stick metal which may have an
anti-static
coating or pre-treatment, and most preferably with perforations and or meshes,
whereby
such drum roller set is designed for use as a dispensing unit affixed to
braces welded to
the machine frame in a manner which allows interchangeability with other
roller sets,
most preferably located after the perforated vacuum suction roller and even
more
preferably located directly after a cooling unit positioned so as to
sufficiently cool the
raised portions before passing to the dispensing drum roller set, most
preferably
containing two drums, one outer and one inner, most preferably with an outer
metal drum
having perforations of a larger diameter, shape and dimension sufficient for
releasing the
powder and or particle size to be released, most preferably circular in shape,
whereby the
inner drum, acting as the distributor of active ingredient to the outer drum
is affixed yet
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rotating independently of and most preferably affixed in a manner to cause the
internal
drum to rotate opposite the outer drum, with the inner drum most preferably
having a
smaller mesh size so as to filter and allow for even mixture and distribution
of the
powders or particulates upon rotation.
[000040] Depending upon the powder or particulate sizes, dosing may come
from
an automatic, gravimetric and or pressurized pump unit attached to the inner
drum,
dispensing the active ingredient into the inner drum in metered doses through
a
perforated central pipe whereby the pressurization forces the powder and or
particulates
through the perforations releasing the active ingredient to the inner drum.
Through
alignment of holes and or mesh apertures between both drums during opposite
rotation,
the outer drum ultimately releases the active ingredient into the air pocket.
[000041] Alternative methods of manufacture for dispensing multiple active
ingredients may include multiple active ingredients dosed together through one
central
hopper and external feed unit, and or by a segregation mechanism whereby the
external
dispensing unit has a partitioned hopper which contains and distributes
multiple active
ingredients into separate and respective chambers, pumped through respective
hoses to
the segregated perforated pipe within the inner drum depositing the active
ingredients
into segregated chambers of the inner drum and through the alignment of the
holes and or
mesh between both drums during opposite rotation, the active ingredient is
released. For
larger industries producing wider width films, it is most preferable for the
even
distribution of active ingredient to have two separate external dispensing
units located on
either side of the drum for the purpose of reducing the distance of travel of
active
ingredient, economizing air supply and speed of manufacturing so as to reduce
the time
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of film under dosing process. Such dual location of external dispensing units
may also
provide for further differentiation and or multiplicity of active ingredients.
[000042] Alternative methods of manufacture to provide multiple active
ingredients
dosed in a segregated manner for cost conscious considerations may include a
mechanism
whereby the inner drum is segregated with a partition of the desired amount of
allocations, resulting in separated chambers to be fed manually.
[000043] Alternative methods of manufacture to provide multiple active
ingredients
dosed in a segregated manner may include the manual loading of active
ingredients
desired per chamber within the segregated inner drum.
[000044] Partitioning and segregating chambers of the drums may be done
either in
horizontal or vertical manner, containing and dosing any singular, and or
multiple, and or
mixtures of active ingredients to provide the intended pattern of active
ingredient dosing.
[000045] Portions of the polymer laminates and air cushioned laminates may
include different or combined active ingredients to impart different or
collective
properties to different portions of the laminate as the dosing environment
requires. This
may include design features to include but not limited to air pocket
dimensions,
structures, pocket or quilting shapes of different geometry and may include
interconnected air passages or aesthetics commonly used in various industries,
such as
colored film packaging, or other color and text associations such as printing
and
laminating for brand identification or pictographic representation or imagery
or design of
whatsoever nature whereby such printing of specific areas may be done with
inks, paints,
solvents, laminates, and/or adhesives containing active ingredients, so as to
provide a
combination of different active properties on one substrate.
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[000046] In a further preferred embodiment, the polymeric laminate
additionally
comprising a mesh material layer disposed adjacent the mesh material having
openings of
sufficient size to permit the partial passage of the insect through the mesh
material so as
to hold an insect of the dimensional shape. It is preferred that the inter-
layer distance
between the innermost layer and the mesh material layer is less than the
length of the
insect so as to permit only the partial passage of the insect through the mesh
material so
as to hold an insect of the dimensional shape between the innermost layer and
the mesh
material layer.
[000047] The polymeric laminate may incorporate any of the features and
layers
otherwise described herein not inconsistent with this aspect of the invention.
Optionally,
the polymeric laminate may additionally comprise an outermost layer comprising
a
thermoplastic polymeric material containing at least one ultraviolet blocking
material. It
may also include a bio-composite absorbent layer comprising super-absorbent
polymers,
and a bio-composite compatibilizer layer comprising activated [bamboo] carbon
and a
compatibilizer. Likewise, additionally comprising a rodent repellent
intermediate layer
comprising a thermoplastic polymeric material, a rodent repellent material and
ethyl vinyl
acetate. It may also incorporate an oxygen barrier intermediate layer
comprising ethylene
vinyl alcohol and EMMA inorganic/organic additives. For instance, the
polymeric
laminate may additionally include: (a) an outermost layer comprising a woven
thermoplastic polymeric material containing at least one rodent repellent
material and an
ultraviolet blocking material, and a layer comprising at least one pesticide
and/or
insecticide; and (b) an innermost layer comprising a food grade polymer and an
adhesive;
and, interposed between the outermost layer and innermost layers, the
following layers: a
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bio-composite layer comprising a thermoplastic yarn mesh containing at least
one super-
absorbent polymer and activated carbon. The bio-composite layer may be of an
HDPE
mesh containing at least one super-absorbent polymer, and a second layer
comprising an
HDPE mesh containing a biocomposite material and activated bamboo carbon. The
polymeric laminate may be incorporated into a multi-layer laminate comprising:
(a)an
outermost layer comprising a thermoplastic polymeric material containing at
least one
rodent repellent material; (b)=an innermost layer comprising a food grade
polymer and an
adhesive; and, interposed between the outermost layer and innermost layers,
the
following layers: (1) a woven thermoplastic polymeric material; (2) a bubble
plastic
thermoplastic polymeric material layer comprising bubbles containing at least
one
insecticide as described herein; and (3) a bio-composite layer comprising a
thermoplastic
yarn mesh containing at least one super-absorbent polymer and activated
carbon.
Polymeric Laminate ¨ Coextruded Version
[000048] In general terms, the invention includes a polymeric laminate
comprising:
(a) an outermost layer comprising a thermoplastic polymeric material
containing at least
one of the following and within a multilayer sheet or a substrate comprised of
multiple
layers, but most preferably the combination of rodent repellent material, at
least one
pesticide and/or insecticide and an ultraviolet blocking material; (b) an
innermost layer
comprising a food grade polymer and an adhesive; and, interposed without
respect to
order between the outermost layer and innermost layers, the following layers:
(c) an
oxygen barrier intermediate layer comprising a thermoplastic polymeric
material
containing at least one additive that functions as a desiccant, a free radical
scavenger or
an oxygen barrier; and (d) a bio-composite absorbent/compatibilizer layer
comprising a
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thermoplastic polymeric material containing at least one super-absorbent
polymer and
activated carbon, such as activated bamboo carbon charcoal or another
antifungal
additive (such as Triclosan). Examples are shown in Figures 1 ¨ le.
[000049] It is preferred that the outermost layer comprises a first layer
comprising a
polyolefin, a rodent repellent (as per environmental demand in areas of use)
and an
ultraviolet blocking material; and a second layer comprising a thermoplastic
polymeric
material and at least one insecticide or pesticide material. It is further
preferred that the
bio-composite absorbent/compatibilizer layer comprises a first layer
comprising at least
one super-absorbent polymer; and a second layer comprising an anti-fungal or
another
organic material or combination thereof exhibiting both moisture absorbency
and anti-
fungal properties such as activated bamboo carbon.
[000050] The outermost layer and other layers within the multilayer
substrate may
comprise a polyolefin, polymer, thermoplastic or thermoset selected from the
group
consisting of polypropylene, HDPE, LDPE, LLDPE, VLDPE and copolymers and
homoploymers thereof or blends with other materials or varying ratios
thereof,including
recycled materials, or compatibilizers for ease of manufacturing to add
desired properties
providing further mechanical barrier to pests, additives determined by
humidity,
temperature, pest behavior, and pest penetration and migration methods per
environmental conditions and stored product conditions.
[000051] Active ingredients for pest control and insecticides may be
selected,
depending upon the pest behavior, from the group consisting of synthetic
pyrethroids,
such as permethrin and deltamethrin and/or organophosphorous compounds,
pirimiphos
methyl, chlorpiriphos methyl, fenitrothion, malathion and/or composition or
mixtures
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thereof and or from other pertinent and applicable insecticide families and/or
ethnobotanical mixtures, including without limitation to and in environments
whereby
organic methods are preferred neem plant or oil, sweet flag worm seed and
peppers,
geranium oil and menthol and its derivatives, and/or other plant-based or
naturally
derived materials with reported repellency or efficacy of pest control
exhibited and
known to those skilled in the art..
[000052] In another related variation of the present invention, the
polymeric
laminate comprises: (a) an outermost layer comprising a polyolefin, a rodent
repellent
and an ultraviolet blocking material; (b) an innermost layer comprising a food
grade
polymer and an adhesive; and, interposed without respect to order between the
outermost
layer and innermost layers, the following layers: (c) an insecticide/pesticide
intermediate
layer comprising a thermoplastic polymeric material and either an insecticide
or a
pesticide material; (d) an oxygen barrier intermediate layer comprising
ethylene vinyl
alcohol and preferably EMMA with inorganic/organic additives; (e) a bio-
composite
absorbent layer comprising super-absorbent polymers; and (f) a bio-composite
compatibilizer layer comprising a naturally occurring anti-fungal,and
absorbent such as
activated bamboo carbon kapok fibers or others.
[000053] The compatibilizer(s) used in accordance with the present
invention may
include any compatibilizer effective to render the additive compatible with
the
surrounding polymer, such as those selected from the group consisting of
chitin and citric
acid for compatibility with ethylene vinyl copolymers or naturally derived
components
such as granulated activated bamboo carbon
[000054] In still another variant of the present invention, the invention
includes a
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polymeric laminate comprising: (a) an outermost layer comprising a polyolefin,
an
insecticide/pesticide material, a cuticle desiccant and an ultraviolet
blocking material; (b)
an innermost layer comprising a food grade polymer and an adhesive; and, may
or not be
interposed, most preferrably included in high moisture areas, without respect
to order
between the outermost layer and innermost layers, the following layers: (c) an
rodent
repellent intermediate layer comprising a thermoplastic polymeric material, a
rodent
repellent material and ethyl vinyl acetate; (d) an oxygen barrier intermediate
layer
comprising ethylene vinyl alcohol and/or EMMA and at least one
inorganic/organic
additives, (e) a bio-composite absorbent layer comprising at least one super-
absorbent
polymer(s); and (f) a bio-composite compatibilizer layer comprising activated
bamboo
carbon charcoal or another antifungal additive, and a compatibilizer.
Polymeric Laminate ¨ Mesh Version
[000055] In still another variation of the present invention, the invention
includes a
polymeric laminate comprising, as shown for example in Figure 2: (a) an
outermost layer
comprising a woven thermoplastic polymeric material containing at least one
rodent
repellent material and an ultraviolet blocking material, and a layer
comprising at least one
pesticide; (b) an innermost layer comprising a food grade polymer and an
adhesive; and,
interposed without respect to order between the outermost layer and innermost
layers, the
following layers: and (c) a bio-composite layer comprising a thermoplastic
yarn mesh
containing at least one super-absorbent polymer and activated carbon, such as
an
activated bamboo carbon charcoal or another antifungal additive.
[000056] It is preferred that the bio-composite layer be of a mesh
structure
comprised of either a thermoplastic, polyester, or monofilament yarns of
either HDPE,
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PP, PE, PET or other mesh containing at least one super-absorbent polymer, and
a
second layer comprising a thermoplastic, more preferrably an HDPE mesh
containing a
biocomposite material and antifungal additive, such as activated bamboo
carbon.
[000057] Another variation of the present invention is a polymeric laminate
comprising (a) an outermost layer comprising a thermoplastic polymeric
material
containing at least one rodent repellent material; (b) an innermost layer
comprising a food
grade polymer and an adhesive; and, interposed without respect to order
between the
outermost layer and innermost layers, the following layers: (c) a woven
thermoplastic
polymeric material; (d) a thermoplastic polymer layer containing at least one
pesticide;
(e) a bio-composite layer comprising a thermoplastic yarn mesh containing at
least one
super-absorbent polymer and activated carbon.
[000058] In one variation, the bio-composite layer comprises a
thermoplastic mesh,
such as HDPE or polypropylene mesh containing at least one super-absorbent
polymer,
and a second layer comprising an HDPE or polypropylene mesh containing a
biocomposite material and activated bamboo carbon.
[000059] Still another variation of the invention is a polymeric laminate
comprising
(as exemplified in Figures 2b and 2c): (a) an outermost layer comprising a
woven
thermoplastic polymeric material containing at least one rodent repellent
material and an
ultraviolet blocking material, and a layer comprising at least one pesticide;
(b) an
innermost layer comprising a food grade polymer and an adhesive; and,
interposed
without respect to order between the outermost layer and innermost layers, the
following
layers: (c) a bio-composite layer comprising a thermoplastic yarn mesh
containing at least
one super-absorbent polymer and activated carbon such as activated bamboo
carbon
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charcoal or another antifungal additive.
[000060] A further variation is a polymeric laminate comprising (see Figure
3): (a)
an outermost layer comprising a woven thermoplastic polymeric material
containing at
least one ultraviolet blocking material as well as, optionally, the rodent
repellent and the
at least one pesticide; (b) an innermost layer comprising a food grade polymer
and an
adhesive; and, interposed without respect to order between the outermost layer
and
innermost layers, the following layers: (c) a first bubble plastic
thermoplastic polymeric
material layer comprising bubbles containing at least one rodent repellent
material; (d) a
second bubble plastic thermoplastic polymeric material layer comprising
bubbles
containing at least one pesticide; (e) a non-woven or other equivalent layer,
such as a
filter membrane, that encapsulates cellulosic or other naturally absorbent
materials and/or
superabsorbent polymers, and (f) an optional bio-composite layer comprising a
thermoplastic yarn mesh containing at least one super-absorbent polymer and
activated
carbon or other antifungal additive.
[000061] A variant of this embodiment additionally comprises a layer of a
thermoplastic polymeric material containing calcium carbonate or equivalent
material as
a filler/blocking agent, and disposed between the second bubble plastic
thermoplastic
polymeric material layer and the a non-woven or other equivalent layer or
within the
layers of the coextrudate film.
[000062] Preferably, the first bubble plastic layer comprises a polymer
selected
from the group consisting of LDPE, VLDPE, polypropylene or other suitable
polymeric
material, adhered to the outermost layer by an adhesive such as EVOH, and
wherein
second bubble plastic layer bubbles are provided with an insecticide in powder
form,
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such as diatomaceous earth or other cuticle desiccants or mixtures of
different
insecticides from different families to include but not limited to
pyrethroids,
organophosphates, or admixtures and varying insecticide cocktails to achieve
effective
results and avoid resistance with repeat contact.
[000063] Yet another embodiment of the present invention includes a
polymeric
laminate comprising: (a) an outermost layer comprising a thermoplastic
polymeric
material containing at least one ultraviolet blocking material as well as,
optionally, the
rodent repellent and at least one pesticide; (b) an innermost layer comprising
a food grade
polymer and an adhesive; and, interposed without respect to order between the
outermost
layer and innermost layers, the following layers: (c) a first bubble plastic
thermoplastic
polymeric material layer comprising bubbles containing at least one rodent
repellent
material; (d) a second bubble plastic thermoplastic polymeric material layer
comprising
bubbles containing at least one pesticide; (e) a bio-composite absorbent layer
comprising
at least one super-absorbent polymer(s); and (f) a bio-composite
compatibilizer layer
comprising activated carbon such as bamboo carbon, and a compatibilizer.
[000064] With respect to all of the embodiments of the present invention,
it will be
recognized that the layered substrates, or mixtures thereof may include
recycled material
in place of or in addition to biobased material in an amount of up to 100% of
the biobased
material. As used herein, "recycled" materials encompass post-consumer
recycled (PCR)
materials, post-industrial recycled (PIR) materials, and a mixture thereof.
A Polymeric Storage Container for Harvested Agricultural Products
[000065] The present invention also includes a polymeric storage container
for
harvested agricultural products, the container comprising a polymeric laminate
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to any of embodiments of the invention. These may be produced by any methods
and
through the use of machinery known and used in the art for creating polymeric
bags and
other containers made from or incorporating polymeric sheet or woven sheet
material and
may or may not be fit within or supported by a framed structure.
System for Storage of Harvested Agricultural Products
[000066] A system for storage of harvested agricultural products, the
system
involving the use of such laminates, sections or portions of the laminate to
be
strategically placed within existing storage containers to provide spatial
effectivenessor
containers made therefrom and/or bags for on-farm storage at a farm.
[000067] Laminates of the present invention may be used in a system and
method
for free-standing hermetic storage of bulk, boxed or bagged commodities, such
as that
described for instance in U.S. Patent No. 8,141,328, which is hereby
incorporated herein
by reference.
[000068] The present invention may also be considered an improvement upon
the
materials and methods described in Korean Patent Application No. KR10109267,
which
is hereby incorporated herein by reference.
[000069] The foregoing and other objects, features, and advantages of this
invention
will become more readily apparent from the following detailed description of a
preferred
embodiment which proceeds with reference to the accompanying drawings, wherein
the
preferred embodiment of the invention is shown and described, simply by way of
illustration of the best mode contemplated of carrying out the invention.
[000070] As will be realized, the invention is capable of other and
different
embodiments, and its several details are capable of modifications in various
obvious
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respects, all without departing from the invention. Accordingly, the drawings
and
description are to be regarded as illustrative in nature, and not as
restrictive. It will also
be appreciated that the detailed description represents the preferred
embodiment of the
invention, and that individual steps of the process of the invention may be
practiced
independently so as to achieve similar results; and likewise that variations
of the
described laminates and containers may be made by modifications in the design
or
manufacturing process to achieve similar results.
BRIEF DESCRIPTION OF THE DRAWINGS
[000071] Figure 1 is a schematic of a polymeric laminate in accordance with
one
embodiment of the present invention.
[000072] Figure 1 a is a schematic of a polymeric laminate in accordance
with an
alternative embodiment of the present invention.
[000073] Figure lb is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention.
[000074] Figure lc is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention.
[000075] Figure 2 is a schematic of a woven material laminate in accordance
with
one embodiment of the present invention.
[000076] Figure 2a is a schematic of a woven material laminate in
accordance with
an alternative embodiment of the present invention.
[000077] Figure 2b is a schematic of a woven material laminate in
accordance with
yet another alternative embodiment of the present invention.
[000078] Figure 2c is a schematic of a woven material laminate in
accordance with
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yet another alternative embodiment of the present invention.
[000079] Figure 3 is a schematic representation of the production of a
polymeric
laminate in accordance with one embodiment of the present invention.
[000080] Figure 3a is a schematic representation of the production of a
polymeric
laminate in accordance with one embodiment of the present invention.
[000081] Figure 4 is a schematic of a grain storage bag containing grain,
in
accordance with one embodiment of the present invention.
[000082] Figure 5 is a detailed perspective view of a thermoplastic bubble-
containing material containing active ingredients, in accordance with one
embodiment of
the present invention.
[000083] Figure 6 is a detailed perspective view of a double-layered
thermoplastic
bubble-containing material containing multiple active ingredients, in
accordance with one
embodiment of the present invention.
[000084] Figure 7 is a detailed longitudinal view of a metal drum unit that
may be
used to make the thermoplastic bubble-containing material containing multiple
active
ingredients, in accordance with one embodiment of the present invention.
[000085] Figure 8 is a partially sectioned view of a metal drum with powder
dispensing unit that may be used to create and fill the thermoplastic bubble-
containing
material containing multiple active ingredients, in accordance with one
embodiment of
the present invention.
[000086] Figure 9 is a partially sectioned view of a metal drum with powder
dispensing unit that may be used to create and fill the thermoplastic bubble-
containing
material containing multiple active ingredients, in accordance with one
embodiment of
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the present invention.
[000087] Figure
10 is a perspective view of a metal drum which may be used to
dose a single active ingredient into the thermoplastic bubble-containing
material, in
accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[000088] In
accordance with the foregoing summary, the following provides a
detailed description of the preferred embodiment, which is presently
considered to be the
best mode thereof. It is understood that multiple variations or combinations
of properties
desired differs according to environment and climatic conditions, types,
presence and life
cycle of insects, respiration rates and transpiration intensities of stored
product.
[000089] Features
and advantages of the invention will now be described with
occasional reference to specific embodiments. However, the invention may be
embodied
in different forms and should not be construed as limited to the embodiments
set forth
herein. Rather, these embodiments are provided so that this disclosure will be
thorough
and complete and will fully convey the scope of the invention to those skilled
in the art
[000090] As used
throughout this application, the term "polymer" refers to a
material which is the product of a polymerization or copolymerization reaction
of natural,
synthetic or combined natural and synthetic monomers and/or co-monomers and is
inclusive of homopolymers, copolymers, terpolymers, etc. In general, the
layers of
the multilayer film described in the present application may comprise a single
polymer, a
mixture of a single polymer and non-polymeric material, a combination of two
or more
polymers blended together, or a mixture of a blend of two or more polymers and
non-
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polymeric material. It will be noted that many polymers may be synthesized by
the
mutual reaction of complementary monomers. It will also be noted that some
polymers
are obtained by the chemical modification of other polymers such that the
structure of the
macromolecules that constitute the resulting polymer may be thought of as
having been
formed by the homopolymerization of a hypothetical monomer.
[000091] Polymers and thermoplastic raw materials may be selected for their
barrier
properties, mechanical properties, rheological properties, or other factors
influencing
barrier functions such as the climatic conditions, intended conditions of
stored product,
insects, pests, and or risk of fungal contamination.
[000092] As used throughout this application, the term "thermoplastic"
refers to a
polymer or polymer mixture that softens when exposed to heat and then returns
to its
original condition when cooled to room temperature. In general, thermoplastic
materials
may include natural or synthetic polymers.
[000093] Unless otherwise indicated, all numbers expressing quantities of
ingredients, properties such as molecular weight, reaction conditions, and so
forth as used
in the specification and claims are to be understood as being modified in all
instances by
the term "about." Accordingly, unless otherwise indicated, the numerical
properties set
forth in the specification and claims are approximations that may vary
depending on the
desired properties sought to be obtained in embodiments of the present
invention.
Notwithstanding that the numerical ranges and parameters setting forth the
broad scope
of the invention are approximations, the numerical values set forth in the
specific
examples are reported as precisely as possible. Any numerical values, however,
inherently contain certain errors necessarily resulting from error found in
their respective
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measurements
[000094] Figure 1 is a schematic of a polymeric laminate in accordance with
one
embodiment of the present invention which may be produced by co-extrusion and
film-
blowing, such as by using multilayer coextrusion blown film equipment
commercially
available from Kung Hsing of Taiwan. This may be made as a multi-layer
coextrusion
wherein the substrate and the different active ingredients used is not limited
to the
number or order of the layers.
[000095] The typical thickness range of the laminates used as singular
layers, or as
multilayers of the present invention made from coextrusion is from about 50
microns to
600 microns, although other thicknesses may be produced. The thicknesses of
the
individual layers may be determined to obtain overall laminate dimensions, but
typically
will be in the general range of 80 to 150 microns.
[000096] The outermost layer 1 may be produced of a thermoplastic material,
such
as a polyolefin selected from the group consisting of polypropylene, HDPE,
LDPE,
LLDPE, VLDPE and copolymers and homoploymers thereof. An example of the LLDPE
is PLEXAR 800 commercially available from Lyondell Basel.
[000097] The rodent repellent(s) that may be used in accordance with the
present
invention may include without limitation any synthetic or natural rodent
repellent
partially or wholly miscible with the polyolefin and/or thermoplastic base
layer, such as
denatonium benzoate, trinitrobenezene-aryl amine complexes, and tributyl tin
chloride.
Natural rodent repellents may include, without limitation, salicylic ester,
menthol, corn
mint oil, eucalyptus, camphor, terpene, peppermint oil, citronella oil,
rosemary oil, clove
oil, geranium oil, cayenne pepper, methyl nonyl ketone, or combinations
thereof.
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[000098] The ultraviolet blocking material(s) may be any material
effectively
miscible with the base polymer, and in an effective amount known in the art
such as, for
instance, from about 2% to about 5% percent by weight. An example of such a
material
is Optiblock 10 commercially available from Specialty Minerals, Inc. Other
materials
providing UV reflection or absorbency may be used such as carbon black or
titanium
dioxide of 18-150nm particle size or other UV stabilizers.
[000099] The pesticide intermediate layer 2 may comprise a thermoplastic
polymeric material or polyolefin, and at least one insecticide or pesticide
material that
may include any synthetic or natural insecticide or pesticide or combinations
partially or
wholly compatible or miscible with the polymeric material, provided in an
effective
amount to reduce or eliminate infestation. Examples include those selected
from the
group consisting of synthetic pyrethroids, such as permethrin, or
deltamethrin. Most
preferably, the insecticide is a combination of either synthetic or natural
compounds or
admixtures thereof to include but not limited to pirimiphos-methyl (sold
commercially
under the name Actellic Superdust), with permethrin at a concentration of 3%
by weight
and pirimiphos-methyl at 14% by weight, or other silicone dioxide plus
synthetic
pyrethroids or mixtures thereof, specifically to repel Prostephanus truncatus
and S.
zeamis in tropic and sub tropic zones, particularly for maize storage. It is
understood that
other admixtures of active ingredients may be used, to include but not limited
to;
malthion + permethrin, fenitrothion + deltamethrin, or either of such
compounds mixed
with alternatives of similar insecticide families
[0000100] The insecticide may also include a cuticle desiccant material, or
materials
that sterilize insects, inhibit their growth or retard their reproduction or
to cause excito-
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repellency, mortality, or to attract for migration and proprigation, or
combinations
thereof.
[0000101] The thermoplastic polymeric material may be selected from among
any
material that may be amenable to co-extrusion while being able to contain the
active
ingredients at an effective level. Examples may include ethyl vinyl acetate or
a
thermoplastic polymer mixed with natural starches so as to form a
biocomposite. An
example of such a starch-blended polyester is Ecoflex from BASF.
[0000102] The oxygen barrier intermediate layer 3 preferably may comprise
any
thermoplastic material, though it is preferred to use ethyl vinyl alcohol
(EVOH),
ethylene methyl acrylic co-polymer (EMMA) or ethylene-methacrylic acid (EMAA)
owing to their increased adhesion with the other layers. An example of such an
EMMA
material is PXL 164 commercially available from Lyondell Basel as PLEXAR. This
layer includes at least one oxygen barrier material, such as inorganic or
organic additives
or materials that function as desiccants, free radical scavengers or oxygen
barriers, and
provided in effective amount to inhibit oxygen ingress. This amount will vary
with the
foodstuff volume to laminate surface area ratio of the specific application,
but generally
will be in the range of from about 2% to 75% by weight. Such inorganic
additives may
include iron, ascorbic acid, calcium hydroxide, activated carbon, sodium
chloride,
potassium chloride, magnesium oxide, titanium oxide, aluminum oxides, chromium
oxide, calcium oxide, silica, bentonite, zeolites, montmorillonite, mullites,
wollastonites
and agalmatolite clay or admixtures thereof in either particle, powder, or
masterbatch
form.
[0000103] Organic additives may include such substances as are known in the
field,
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such as compatibilizers including but not limited to metal alcoholates and
alkoxysilanes.
Typical content of these materials will be in the range of from about 1% to
about 25%
percent by weight, or otherwise, depending upon the rate of adherence and or
miscibility
of the material to be incorporated into the polymeric structural layer.
[0000104] The bio-composite absorbent layer 4 comprises one or more super-
absorbent polymers, such as sodium polyacrylates commercially available from
Shanghai
Dinghan Chemical Co., Shanghai, PRC, or from Teijin Limited of Taiwan, and
provided
in an effective amount to absorb moisture respiring from the dry foodstuff to
be
contained or from the moisture diffusion caused by changes in relative
humidity and
temperature This amount may be determined by both the preference for placement
within the multilayer co-extrudate or within the layered structure and with
reference to
local climatic conditions and the amount of moisture to be generated through
transpiration of the stored product, such as in the context of contained corn
or maize
stored outdoors in tropical regions having different transpiration intensities
compared to
wheat or grain stored in bunkers in colder climates
[0000105] The bio-composite absorbent layer 4 may preferably be provided
with
micro perforations of a valve type, of angled, conical, or otherwise shaped
structure to
manage oxygen transmission and moisture vapor transmission, in accordance with
methods known in the art. Such valve perforations, when preferably placed at
approximately a 45 degree angle to the laminate surface, are effective to
permit moisture
migration from this layer to reach the outside of the laminate, yet
prohibitive of in-flow.
[0000106] The bio-composite compatibilizer layer 5 comprises a
thermoplastic
polymer material as the base material, with addition of antifungals preferably
activated
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bamboo carbon, and a compatibilizer, in an amount effective to such as chitin,
citric acid,
such as Ciroflex A4, commercially available from Vertellus. Typical content of
these
materials will be in the range of from about 1% to about 25% percent by
weight.
[0000107] Any of the foregoing layers 3, 4 or 5 may contain a blocking
ingredient or
an additive which prohibits the migration of active ingredients such as
calcium carbonate,
silica or talc, that restrict the mobility of the pesticide or rodent
repellent ingredient to
prevent them reaching the contained dry foodstuff. A stabilizer may also be
contained
within, such as Uvinul 4050H which is FDA approved.
[0000108] The innermost layer 6 comprises preferably a food grade polymer
and an
adhesive adapted to affix this layer to the immediately adjacent intermediate
layer, such
as layer 5. Examples of food grade polymers may include Sabic 6135 NE.
[0000109] It will be understood that each of the individual layers shown
and
described may be combined and/or amalgamated along with the active ingredients
contained within or affixed to each such layer so as to produce a functional
laminate not
inconsistent with the integration of the constituent layers and the function
of the active
ingredients. Examples of such variation are described herein.
[0000110] Figure la is a schematic of a polymeric laminate in accordance
with an
alternative embodiment of the present invention. This embodiment is similar to
that of
Figure 1 except that the outermost layer contains the pesticide and the UV
blocker
ingredient, while the first intermediate layer contains the rodent repellency
ingredient(s).
[0000111] Figure lb is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention. This embodiment is
similar to
that of Figure 1 except that layers 1 and 2 have been effectively combined by
being
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coextruded as a single layer.
[0000112] Figure lc is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention. This embodiment is
similar to
that of Figure 1 except that arrangement of layers 4 and 5 has been reversed.
[0000113] Figure id is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention. This embodiment is
similar to
that of Figure 1 except that layers 4 and 5 have been effectively combined by
being
coextruded as a single layer.
[0000114] Figure le is a schematic of a polymeric laminate in accordance
with yet
another alternative embodiment of the present invention. This embodiment is
similar to
that of Figures 1 ¨ id except that layer 6 is produced as a single layer and
inserted as
liner when the film is converted to a bag through the use of such techniques
as horizontal
or vertical form, fill and seal, or manually.
[0000115] Figure 2 is a schematic of a woven material laminate in
accordance with
one embodiment of the present invention. This Figure shows outermost layer 1
which is
a tape-woven layer 7 of an HDPE (or polypropylene) flat yarn containing the
pesticide
and rodent repellent ingredients which is thermally laminated with a EMMA
thermoplastic layer 8 also containing a pesticide. It is preferred that the
pesticide in the
warp or weft of layer 7 be different from that of layer 8. Additionally, the
warp (or weft)
of layer 7 may contain the pesticide while the weft (or warp) of layer 7
contains the
rodent repellent. Additionally, the warp (or weft) of layer 7 may contain
different active
ingredients than the weft (or warp) of layer 7 so that two different active
ingredients and
the desired different properties may be contained on one substrate with
actives of one
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complementary to the adjacent active ingredient to produce a desired combined
effect, or
for one active ingredient to enhance or decrease the effect of the opposite
The HDPE (or
polypropylene) flat yarn may come from post-industrial or post-consumer
recycled
material and this recycled material may or may not contain active ingredients.
[0000116] Figure 2 also shows the HDPE monofilament yarn mesh layer 9 which
has
the superabsorbent polymer chemically incorporated into the yarn. Layer 10 is
a
biocomposite mesh prepared from a monofilament yarn of HDPE with activated
carbon
contained in the polymer. Layer 11 is a sheet of food grade polymer with an
adhesive to
bind it to the mesh layer 10. The laminate of Figure 2 is prepared by first
assembling
sub-laminates of layers 7 and 8 and 9 ¨ 11, respectively, followed by thermal
point
bonding the two sub-laminates together, as indicated by the series of X's in
Figure 2.
[0000117] Figure 2a is a schematic of a woven material laminate in
accordance with
an alternative embodiment of the present invention. This embodiment is similar
to that of
Figure 2 except that layers 1 and 2 have been effectively combined by being
coextruded
as a single layer.
[0000118] Figure 2a is a schematic of a woven material laminate in
accordance with
an alternative embodiment of the present invention. This embodiment is similar
to that of
Figure 2 except that the woven layer 13 contains no active ingredients while
additional
layer 12 laminated on the outside of the woven layer 13 contains a rodent
repellent and
layer 14 contains an insecticide. This embodiment also shows layers 15 and 16
that are
similar to layers 9 and 10 of Figure 2, and layer 17 that may be produced as a
single layer
and inserted as liner when the film is converted to a bag through the use of
such
techniques as horizontal or vertical form, fill and seal, or manually.
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[0000119] Figure 2b is a schematic of a woven material laminate in
accordance with
yet another alternative embodiment of the present invention. This embodiment
is similar
to that of Figure 2 with layers 18 and 19 similar to layers 7 and 8, and with
the exception
that layers 9 and 10 have been combined as a single layer 20, and layer 21
being
produced as a single layer and inserted as liner when the film is converted to
a bag
through the use of such techniques as horizontal or vertical form, fill and
seal, or
manually.
[0000120] Figure 2c is a schematic of a woven material laminate in
accordance with
yet another alternative embodiment of the present invention. This embodiment
is similar
to that of Figure 2b with layers 24 and 25 being coextruded as a single sub-
laminate prior
to thermal point bonding.
[0000121] Figure 3 is a schematic representation of the production of a
polymeric
laminate formed in accordance with yet another alternative embodiment of the
present
invention. Figure 3 shows outermost layer 30 which would be the same
construction as
layers 7 and 8 of Figure 2. Layer 31 is a bubble plastic layer of LDPE, VLDPE,
polypropylene or other suitable polymeric material, adhered to layer 30 by an
adhesive
such as EMMA, or EVOH, and wherein the bubbles are encapsulating an
insecticide in
powder, particulate or granular form, such as diatomaceous earth (such as is
sold under
the trade name Protect-It from Headley Technologies) or other cuticle
desiccants and
insecticide cocktails and may or may not include one or more of the synthetic
pyrethroids
or synthetic organophosphate insecticides or insecticide families exhibiting
preferred
properties which may or may not include sterilizing effect,s, growth regulator
effects,
repellency effects, propagation effects or other desired effects for pest and
insect control.
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Layer 32 is an opposing layer of bubble plastic (such as may be produced by
thermoforming in combination with layer 31) wherein the bubbles are provided
with a
rodent repellent such as those described herein. Layer 33 is a separate layer
of a
thermoplastic material containing a filler/blocking agent (such as calcium
carbonate)
provided so as to prevent any liberated rodent repellent and/or
insecticide/pesticide from
migrating toward the food grade layer.
[0000122] Layer 34 is a non-woven or other equivalent layer, such as a
filter
membrane or porous substrates, that encapsulate cellulosic or other naturally
absorbent
materials (such as bamboo fiber, kapok fiber, coconut husks, apricot pits, and
the like)
and/or synthetic absorbants such as superabsorbent polymers, to provide a
moisture
barrier while retainingand absorbing moisture diffusion from the contained
foodstuff,
such as that of transpiration of grain and the like and from changes in
relative humidity,
transpiration, respiration intensity and other conditions prone to moisture.
[0000123] Layer 35 is an adhesive layer, such as EVOH or other equivalent
materials, such as those described herein. Layer 36 is a food grade polymer
that is
attached to layer 34 by adhesive layer 35. Layers 34/35/36 may then thermal
point
bonded to layers 30 ¨ 33.
[0000124] Figure 3a is a schematic representation of the production of a
polymeric
laminate formed in accordance with yet another alternative embodiment of the
present
invention. This embodiment is similar to that of Figure 3 with layers 37, 38
and 39 being
equivalent to layers 30, 31 and 32; and wherein layers 34 and 35 have been
replaced with
layers 40 and 41 which are the same as layers 4 and 5 of Figure 1, and wherein
layer 43 is
the same as layer 6 of Figure 1 with optional adhesive layer 42 where the food
grade
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layer is separately produced.
[0000125] Figure 4 is a schematic representation of the production of a
polymeric
laminate of the construction shown in Figure 3a, and wherein like reference
numerals
indicate the respective layers, and formed into a bag and containing grain 44,
in
accordance with one embodiment of the present invention. This schematic shows
the
detailed construction of the cooperative layers 38 and 39 which provide an
insecticide in
powder form, and a rodent repellent, respectively.
[0000126] It will be appreciated that the logical order of the steps are
used for
purposes of illustration only, and that the constituent layers, their
measurements and
active ingredient determinations may be varied where not otherwise
inconsistent with the
purpose and result obtained in the practice of the invention.
[0000127] The invention may be embodied in other specific forms without
departing
from the spirit or essential characteristics thereof. The foregoing
embodiments are
therefore to be considered in all respects illustrative rather than limiting
on the invention
described herein. The scope of the invention is thus indicated by the appended
claims
rather than by the foregoing description, and all changes that come within the
meaning
and range of equivalency of the claims are intended to be embraced therein.
[0000128] Figure 5 is a schematic representation depicting multiple active
ingredients dosed on one substrate wherein Figure 5a depicts one bubble
encapsulating
multiple active ingredients adjacent to another bubble containing only one
active
ingredient as shown in Figure 5b.
[0000129] Figure 6 is a schematic representation of active ingredients
encapsulated
or otherwise contained within raised portions on two sides, portraying the
film having the
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capacity to encapsulate multiple active ingredients on both sides.
[0000130] Figure 7 is the schematic representation to display one method, a
horizontal partitioning of the metal drum roller for dosing multiple active
ingredients on
one substrate. Figures 7a, 7b and 7c represent the centrally located but
partitioned
containment units which receive the active ingredient from the external feed
unit which is
also partitioned as indicated in 7d. After the active ingredients have been
transferred to
their respective containment units, the active ingredient is released through
the perforated
pipes of the containment unit segregating the active ingredients into their
respective units
as portrayed in figures 7e, 7f and 7g, while the drum is rotating, the active
ingredients
then pass through to be dosed on the substrate.
[0000131] Figure 8 is a schematic representation of another method of
segregating
the distribution of active ingredients to combine multiple active ingredients
on one
substrate with the use of a pressurized, automatic dosing units which
separates the active
ingredients, as depicted by Fig 8a, 8b, 8c, 8d, 8e, which are then transferred
through the
channeled core and dosed in a segregated release as portrayed in figures 8f,
8g, 8h, 8i,
and 8j.
[0000132] Figure 9 is a schematic representation of vertically partitioning
the drum
rollers as depicted in figures 9a, 9b and 9 c, being fed from overhead mounted
containment units receiving the active ingredient from an external unit which
is also
segregated as depicted in 9e. As depicted in 9f and 9g, the two drums rotate
in opposite
directions, resulting in the active ingredients being released when the
perforations and or
mesh apertures align.
[0000133] Figure 10 is the schematic representation of the drum roll set
which is fed
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with one active ingredient as depicted in 10a, by an external feed unit
whereby the active
ingredient travels through the hollow core depicted in figure 10b to the inner
drum
portrayed in figure 10c, rotating in one direction as portrayed in figure 10e,
releasing the
active ingredient through the perforations, whereby the active ingredient
flows to the
second drum as displayed in figure 10d, which is rotating in the opposite
direction as
depicted in figure 10f, upon which the active ingredient is dosed on the
surface of the
substrate.
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