Preserved Cellular Structures

The present invention relates generally to the preservation of flowers and other cellular structures, and more particularly to a process and novel composition of matter for the preservation of cellular structures after the structures have been dried.

The preservation of flowers and other naturally occurring materials has been practiced for many years, and many processes for such preservation have been described in literature. The main problem with the processes conventional in the art is that the preservation process has usually affected the appearance, shape and/or texture of the cellular structure. Thus, the natural colors of flowers tend to fade, and the cellular structures may be brittle, fragile and highly susceptible to damage due to extreme temperature or humidity.

It is therefore a general object of the present invention to provide a process and composition of matter for the preservation of cellular structures which will result in natural coloring, flexibility and freshness characteristics for relatively long periods of time after the preservation process.

Another object of the invention is to provide an economical and affordable method and process of preserving cellular material not previously known.

Another object of the present invention is to provide a freeze-drying process which significantly enhances the preservation of the cellular structure preserved thereby.

These and other objects will be apparent to those skilled in the art.

The process for preserving cellular structures of the present invention includes the steps of pre-treating the structures with a polymeric water solution, drying the structures and then post-treating the structures with a solvent-based solution. Once the structure has been treated with the pre-treatment solution, the specimen is allowed to sit for a predetermined period of time in order for the active ingredients of the solution to penetrate the surface area of the specimen. The specimen is then quick frozen in the specimen chamber of a freeze dryer to lock the water into an ice matrix. The specimens are then placed in a high vacuum to draw off the water and dry the specimens. The specimens are maintained at a temperature of about -10.degree. F. to 30.degree. F. for two to ten days while under vacuum. Once the specimens are dry, the specimen chamber temperature is allowed to climb to room temperature, thereby enhancing sublimation of any remaining water vapor. The specimens are removed from the freeze dryer into a controlled environment with a humidity of 50 percent or lower. The specimens are then treated with a non-water-based post-treatment solution to form a barrier coat on the finished product.

The basic concept of the present invention calls for pre-treatment of flowers and other natural cell structures with a unique polymeric water solution. A freeze-drying process is then preferably utilized to dry the cellular structures. A post-treatment with a solvent-based solution completes the process to produce preserved cellular material with natural structural integrity and durability, and with little sensitivity to normal variations of temperature, humidity and light. The preservation process enables the user to produce a viable, inexpensive and well-preserved product. The pre-treatment solution is a water-based solution so as to prevent damage to the freeze dryer during the freeze-drying process. It is for this reason that a standard petroleum-based solvent solution for pre-treatment is unacceptable. The pre-treatment solution preferably includes: (a) at least one monohydric alcohol; (b) at least one component selected from a group comprised of lower carbon- chained carboxylic acids; (c) at least one of a group comprised of antioxidants; (d) at least one of a group of sequestering agents; (e) at least one of a group comprised of humectants; (f) at least one from a group of pH dependent acids; (g) buffers; (h) transitional metallic salts; and (i) at least one component from the groups of sulfate, phosphates, nitrates and chlorides with stable equilibriums in the pH range from 1.0 to 7.4.

Preferably, the solution also includes: (1) a water-soluble film forming agent, such as starches, modified starches and cellulosic thickeners, such as carboxymethyl cellulose; (2) water suspended thermoplastic polymers, such as acrylics; (3) modified hydroxy-containing poly-alcohols; (4) plasticizers such as polyols, substituted water-soluble sulfonated vegetable oils and carbowaxes; (5) synthetic and natural vegetable gums; (6) water-soluble films catalyzed with metallic salts, including: ammonium salts and other chlorinated, halogenated salts; (7) additional cross-linkers, including glyoxal and other acetal, aldehyde; (8) functional resins such as melamine type reactants; (9) dispersible waxes and pseudo-waxes; (10) emulsifying agents from the group comprising methoxylated, ethoxylated, vegetable oils, and esters and alcohols; (11) borax and boric acid derived complexes; and (12) biological preservatives.

The amount of each chemical required depends upon the type of cellular material being treated. Furthermore, the chemical formulation must take into consideration the material treated, the ease of formulation, the process of application, the toxicity to the environment, and the cost of formulated materials as well as the overall final market value of the finished product.

The preferred embodiment of the invention includes the following components and ranges of each component:

0.1 to 3 g EDTA acid

3 to 20 ml ammonium lauryl sulfate

0.1 to 2 g acetylsalicylic acid

0.1 to 5 g copper sulfate

5 to 75 g citric acid

25 to 200 g synthetic vegetable gum

10 to 500 ml blended ethanol

1 to 35 g isoascorbic acid

800 to 1600 ml water

100 to 750 ml sorbitol

25 to 250 ml glycerine

25 to 200 ml ethoxylated alcohol

25 to 300 ml ethoxylated triglyceride

15 to 100 g glycerol monostearate

5 to 75 ml glyoxal

0.5 to 2 g PABA

1 to 20 g aluminum sulfate

1 to 150 g ammonium chloride

20 to 300 ml phosphate ester

1 to 35 g boric acid

25 to 200 g benzoic acid

50 to 300 ml ethoxylated sorbitol

10 to 150 ml ethoxylated sorbitan ester

5 to 50 g ethoxylated stearic acid

25 to 200 ml ethoxylated alkyl phenol

1 to 25 g sodium metabisulfite

5 to 100 g acrylate resin

1 to 10 g potassium chloride

1 to 55 g zinc sulfate

The pre-treatment solution described above is applied to all surfaces of the cellular material specimen to be preserved. The application may be sprayed as a fine mist, or the specimen may be dipped or soaked in the solution, so as to cover all surfaces of the specimen. The specimen is then placed on a tray, rack or suitable receptacle and allowed to sit for a pre-determined amount of time in order for the active ingredients of the solution to penetrate the surface area of the specimen. The specimen tray is then loaded into the specimen chamber of a freeze dryer to freeze the specimens. It is preferable that the specimen chamber temperature be -10.degree. F. or lower, in order to achieve a quick freeze of the specimen with minimal changes in the specimen condition. While a very lower temperature is the preferred method for freezing the specimen, acceptable results may be achieved with specimen chamber temperatures as high as 34.degree. to 45.degree. F. during loading of the specimens. Once the loading is completed, the temperature would then be lowered to -10.degree. F. or lower.

The specimens are maintained within the specimen chamber at a temperature between -10.degree. and -30.degree. F. for a period of eight to 24 hours before the chamber is placed in a vacuum. The step of freezing the specimen will lock the water into an ice matrix, and thereby minimize shrinking and distortion that would otherwise occur if liquid water were present when the vacuum is pulled on the system.

It can be seen that the main reason for a water-based polymer complex in the pre-treatment solution is because petroleum-based solvents would damage the condensation chambers of commercially available freeze dryers, contaminating the vacuum pump oil and thus damaging the entire vacuum system. In the freeze- drying process, water within the cell structure of the specimen is frozen and will sublimate in a high vacuum. The water vapor is collected in a condensation chamber which may be defrosted periodically without disturbing the specimen chamber. Thus, water is continuously removed from the specimen chamber so as to dry the specimens.

Preferably, a high vacuum (25 to 100 microns mercury) is necessary in order to dry the frozen specimens efficiently. Gradually, the specimen chamber temperature is then increased to allow for complete sublimation of the water in the specimen. For example, the standard temperature range of the specimen chamber for most flowers (such as roses, carnations, pansies, irises, narcissus, asters, etc.) is -10.degree. F. to +30.degree. F. over a two to ten day period. Thick petaled or stemmed items (such as orchids, ginger, heliconia, protea, banksia, strelitzia, oriental lilies, etc.) require a longer period of time to achieve a complete sublimation of the water, at a temperature range from -10.degree. F. to +20.degree. F. or higher. A load of fruits and vegetables will dry in the -10.degree. to +30.degree. F. temperature range in four to sixteen days depending upon the water content and density of the specimens, the amount of specimens, as well as the overall efficiency of the freeze dryer itself.

As noted above, the condensation chamber is defrosted as necessary to maintain operational efficiency of the freeze dryer. The specimens within the freeze dryer are considered dry when ice does not form in the condensation chamber over a 12 to 24 hour period, the vacuum reading is sustained between 10 to 15 microns and the temperature is in the 20.degree. to 30.degree. F. range. At this point, the specimen chamber refrigeration compressor may be turned off, allowing the specimen chamber temperature to climb to 60.degree. to 80.degree. F. over a 12 to 24 hour period. This increase in temperature will drive the remaining ice in the specimen into water vapor and complete the drying process.

While the specimens which are freeze dried according to the above process, and which have been pre-treated utilizing the solution described above, will possess greater durability and color intensity than untreated specimens, they are still susceptible to reabsorption of water vapor within a relatively short period of time. In order to sustain the finished product in a durable, flexible and resilient form and so as to retain natural life-like characteristics and prevent premature disintegration, fading and excessive reabsorption of water, a process of post-treatment of the specimens is utilized.

It is important that the specimens be unloaded from the freeze dryer into a controlled environment, with a humidity level of 50 percent or lower, and a temperature of 70.degree. F. or higher. The specimens are sprayed, dipped or soaked in a post-treatment solution, in a fashion to cover all surface areas of the specimens. This controlled environment will insure that the solvents in the post-treatment solution will evaporate quickly, usually within 12 to 24 hours, without absorbing water vapor during the process. Two or more coatings of the solution may be applied, depending upon the quality and thickness of the barrier coat desired on the finished product.

In general, the post treatment solution is an organic solvent, non-water-base solution which includes a water-resistant, film-forming polymeric resin. Elastomeric resins or a blend of elastomeric resins with thermoplastic resin and thermosetting resins yield excellent results. Elastomeric resins selected from the group of chlorinated sulfonated polyethylene resins used as the primary resin have been found to yield the best results.

Other preferable additions to this solution include: (1) a water resistant thermoplastic resin selected from the group of solvated chlorinated polyolefins and (2) a thermoset plastic selected from the group of alkyloxysilane resins.

This post-treatment solution assists in sustaining the desired structural integrity and color of the specimens after freeze-drying, and helps reduce deterioration.

Preferably, the post-treatment solution also includes: (1) ethanol; (2) C-1 to C-6 carbon chain alcohol blends; (3) thermosetting resin such as alkyloxysilane resin in petroleum solvent; (4) at least one of a group comprised of antioxidants, such as butylated hydroxyanisole, butylated hydroxytoluene, and propyl gallate; (5) at least one of the group comprised of polyols, derived polyols, and esters; (6) plasticizers, such as paraffin waxes and modified waxes; (7) polymerics, such as polyethylene glycols; (8) waxes; (9) phthalate types; (10) high molecular weight oils; (11) emulsified wax;(12) emulsifiers including polyoxyethylene sorbitan monooleate and other non-ionic emulsifiers such as polyoxyethylene ethers of octyl or nonyl phenol, ethoxylated alcohols, and similar surfactants; (13) catalysts, such as borax or boric acid; (14) salts; (15) preservatives, such as benzoic acid, benzoate salts, and their derivatives; (16) ultraviolet absorbers such as hydroxyphenyl benzotriazoles; (17) radical scavengers such as hindered tertiary amines; (18) colorants; and (19) fragrances, if needed.

The preferred embodiment of the post-treatment solution includes the following components and ranges of each component:

0 to 2 g acetylsalicylic acid;

0 to 1 g PABA;

0 to 4 g boric acid;

0 to 12 g citric acid;

0 to 4,000 ml blended alcohol;

100 to 4,800 ml non-flammable solvent blend;

0 to 15 ml polyethylene glycol;

0 to 15 ml glycerine;

0 to 35 g glycerol stearate;

0 to 30 ml ethoxylated triglyceride;

50 to 1,250 g chlorinated sulfonated polyethylene;

0 to 1,250 g acrylate resin;

0 to 60 g benzoic acid;

0 to 25 g butylated hydroxyanisole;

0 to 12 g hydroxyphenyl benzotriazole;

0 to 15 g zinc sulfate;

0 to 20 g thiourea;

0 to 20 g serulic acid;

0 to 20 g rutin;

0 to 20 g gallic acid derivatives;

0 to 5 ml synthetic rose fragrance; and

0 to 2 g FD & C Red #40

Whereas the invention has been described in connection with the preferred embodiments thereof, it will be understood that many modifications, substitutions and additions may be made which are within the intended broad scope of the appended claims. There has therefore been described a freeze-drying process with pre-treatment and post-treatment of cellular material specimens which accomplishes at least all of the above-stated objects.