COMPOSITE MATERIALS

• US 20100003431A1
• Filed: 06/20/2009
• Published: 01/07/2010
• Est. Priority Date: 07/02/2008
• Status: Abandoned Application

• Current Assignee: John Raybuck
• Original Assignee: John Raybuck
• Inventors: Raybuck, John
• Application Number:
  US12/488,556
• Publication Number:
  US 20100003431A1
• Time in Patent Office: Days
• US Class Current: 428/34.2
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/21 Anti-static
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/716 Degradable
• CPC Class Codes: B32B 2307/7163 Biodegradable
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/734 Dimensional stability
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2439/00 : Containers; Receptacles
• CPC Class Codes: B32B 2439/80 : Medical packaging
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: Y10T 428/1303 : Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/251 : Mica
• CPC Class Codes: Y10T 428/258 : Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/259 : Silicic material
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

Composite materials having at least one of the following desirable properties is described. Such properties include: rigidity, printability, water-proofness, pliability, recyclable, thermochromic, antimicrobial, electrically conductive, compostable or biodegradability. The composite includes a filler-containing layer and a fiber-containing layer substantially coupled together continuously across the at least one surface of the layers. These composites maybe useful in various markets including, but not limited to, construction, packaging, shipping, consumer products and medical packaging. The inventive composites provide, advantages such as reduction of environmental footprint, improved mechanical properties, usefulness/cost ratio, reduction in material costs compared to prior art, and cosmetic performance are embodied in the present invention.

Claims

1. A composite material comprising:

a fiber-containing layer comprising at least one of natural and synthetic fibers, said fiber-containing layer having at least one surface; and

a filler-containing layer coupled to the fiber-containing layer substantially continuously across the at least one surface of the fiber-containing layer, said filler-layer comprises fillers having particle size of from about 0.01 to about 50 microns, in an amount of from about 50% to about 90% by weight;

wherein the filler-containing layer comprises at least one binding agent present as a continuous phase in the layer in an amount of from about 10% to about 50% by weight;

2. The composite material according to claim 1, wherein said pliability of the composite material is at least 15% higher than that of the fiber-containing layer alone.

3. The composite material according to claim 1 wherein the filler comprises wollastonite, hydrated and nonhydrated magnesium Silicate, barium sulfate, barium ferrite, magnesium hydroxide, magnesium carbonate, aluminum trihydroxide, aluminum hydroxide, natural silica, clay-calcined, muscovite, nepheline-syenite, feldspar, calcium suphate, clay-calcined, muscovite, nepheline-syenite, feldspar, calcium suphate, cristobalite, dolomite, silton, mica, hydratized aluminum silicates, coke, carbon black, pecan nut flour, wood flour, fly ash, starch, titanium dioxide, barium carbonate, terra alba, selenite, feldspar, nepheline-syenite, muscovite, pectolite, chrysotile, borates, and sulfates, or combinations therefore.

4. The composite material according to claim 1, wherein said binding agent comprises Polyolefin, thermoplastic elastomers, thermoplastic vulcinates, polymers and copolymers of polylactic acid, polystyrene, polyester, polyoxamethalyne, cellulosics, polyamides, polyamideimides, polybutylene-terephthylate, polyester elastomers, linear low density polyethylene, thermoplastic polyurethane, bi-axially oriented polypropylene, ethylene copolymers, Polyvinylchloride, block copolyetheresters derived from hydroxyl-terminated polyethers, polycarbonates, polyestercarbonates, polyketones, polysulfones, polyethersulfones, polyetherketones;

unsaturated polyesters derived from copolyesters of saturated and unsaturated dicarboxylic acids, crosslinked acrylic resins derived from substituted acrylates, starch, cellulose, polyhydroxy alcanoates (PHA), polycaprolactone (PCL), polybutylene succinate (PBS)), polymers and copolymers of N-vinylpyrrolidone, polymethylpentene, Methyl methacrylate-acrylonitrile-butadiene-styrene, polytetrafluoroethylene, polyphenylene oxide, polyphenylene sulfide, polyacrylonitrile, polycyanoacrylate, polyvinylpyrrolidone, polydicyclopentadiene, polyimides, aramids, polybutadiene, acrylonitrile-styrene, paracyclophane, parylene, ethylene vinyl alcohol, or combinations thereof.

5. The composite material according to claim 1 further comprising a coupling agent selected from the group consisting of titinate, aluminate, siloxane, silane, zirconate and combinations thereof.

6. The composite material according to claim 1 wherein said filler-containing layer is substantially transparent or semi-transparent.

7. The composite material according to claim 1 further comprising a biodegradable additive in an amount up to about 3%.

8. The composite material according to claim 1 wherein the filler-containing layer comprises at least one antimicrobial agent, an antistatic agent, a conductive additive, or combinations thereof.

9. The composite material according to claim 1 wherein the fiber-containing layer comprises bleached or unbleached kraft board, recycled folding boxboard, folding box board, coated recycled board, uncoated recycled board, Lignocellulosics, White Jute, Tossa Jute, China Jute, Kenaf, Roselle, Sugar Cane, Bagasse, Wheat Straw, Hibiscus, Bark, Ramie, Hemp, Sunn Hemp, Flax, Reed, Bamboo, Paina, Piacava, Pineapple, Sisal, Sponge Gourd, Banana, Coir, Cotton, Curaua, sloss wool, seaweed or combinations thereof.

10. The composite material according to claim 1 wherein the fiber-containing layer has a density of from about 200 to about 430 g/m2 and a tensile strength of from about 125 to about 900 MD and about 55 to about 400 CD.

11. The composite material according to claim 1, wherein the composite is shaped to form a storage article.

12. The composite material according to claim 11 wherein the Storage article is selected from the group consisting of a retail box, a shipping box, and a pallet sheet.

13. The composite material according to claim 1 wherein the composite is shaped to form a sandwich core material.

14. The composite material according to claim 13 wherein the sandwich core material is in the shape of a honeycomb core or a honeycomb sandwich.

15. The composite material of claim 1 wherein said binding agent is biodegradable, compostable, or recyclable.

32. The composite structure of claim 1 wherein said composite is breathable.

16. A composite comprising:

a fiber-containing layer comprising at least one of natural and synthetic fibers, said fiber-containing layer having two surfaces; and

a filler-containing layer coupled to the fiber-containing layer substantially continuously across one of the surfaces of the fiber-containing layer, said ground filler-layer comprises at least one binding agent and at least one additive capable of converting a non-biodegradable binding agent into a biodegradable binding agent;

wherein the at least one binding agent is present as a continuous phase in the layer in an amount of from about 10% to about 50% by weight.

17. The composite of claim 16 further comprising a second filler-containing layer bonded to the other of the surfaces of the fiber-containing layer.

18. The composite of claim 16 wherein the filler-containing layer comprises particles sized from about 0.01 to about 25 microns, and present in an amount of from about 50% to about 90% by weight.

19. The composite of claim 16 wherein the filler-containing layer further comprises a coupling agent in the amount of 0.2% to 3% by weight of the filler.

20. The composite of claim 19 wherein said coupling agent is selected from the group consisting of titinate, aluminate, siloxane, silane, zirconate and combinations thereof.

21. The composite of claim 16 wherein said biodegradable additive is capable of fragmenting the polymeric chain.

22. The composite of claim 16 wherein said biodegradable additive is capable of transforming the binding agent to become more hydrophilic.

23. The composite of claim 16 wherein said biodegradable additive comprises up to 3% of a metal salt.

24. A composite structure comprising;

a fiber-containing layer comprising at least one of natural and inorganic fiber, the fiber-containing layer having a surface; and

a filler containing-layer applied to the fiber-containing layer, the ground filler layer being bonded to the fiber-containing layer substantially continuously across the surface of the fiber-containing layer;

wherein said filler has a density of less than about 3.0 g/cc and said filler layer comprises at least one binding agent present as a continuous phase in the layer.

25. The composite structure of claim 24 wherein said filler has a particle size from about 0.01 to about 25 microns.

26. The composite structure of claim 24 wherein said binding agent comprises a biodegradable, compostable, or recyclable polymer.

27. The composite structure of claim 24 wherein said filler containing-layer further comprises a conductive agent, an antimicrobial agent, an antistatic agent or combinations thereof.

28. The composite structure of claim 24 wherein said filler containing-layer is heat sealable.

29. The composite structure of claim 28 wherein said antimicrobial agent is covalently bonded to the filler or the binding agent.

30. The composite structure of claim 24 wherein said filler containing-layer further comprises a coupling agent.

31. The composite structure of claim 24 wherein said filler-containing layer is woven.