CELLULOSIC BIOLAMINATE COMPOSITE ASSEMBLY AND RELATED METHODS

• US 20110262720A1
• Filed: 07/14/2011
• Published: 10/27/2011
• Est. Priority Date: 03/24/2008
• Status: Active Grant

• Current Assignee: Biovation Acquisition Company (Biovation Holdings, Inc.)
• Original Assignee: Biovation LLC
• Inventors: Riebel, Milton, Riebel, Michael J.
• Granted Patent: US 8,389,107 B2
• Time in Patent Office: Days
• US Class Current: 428/195.1
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 23/06 of paper or cardboard
• CPC Class Codes: B32B 23/14 characterised by containing special compounding ingredients
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/06 specially treated, e.g. surfaced, parchmentised
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D21H 19/82 superposed D21H19/84 takes precedence
• CPC Class Codes: D21H 27/26 characterised by the overlay sheet or the top layers of the structures decorative panels B44C5/04; wood grain effects B44F9/02
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24934 including paper layer
• CPC Class Codes: Y10T 428/31634 Next to cellulosic
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/3179 Next to cellulosic
• CPC Class Codes: Y10T 428/31978 Cellulosic next to another cellulosic
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31993 : Of paper

Abstract

Cellulosic biolaminate assemblies are provided. In one embodiment, a biolaminate structure is provided comprising a first cellulosic layer, a second cellulosic layer, and a first bio-based polymer. The first bio-based polymer impregnates the first cellulosic layer and the second cellulosic layer. The first cellulosic layer and the second cellulosic layer are fused together.

Claims

1. A biolaminate structure, comprising:

a first cellulosic layer;

a second cellulosic layer; and

a first bio-based polymer that impregnates the first cellulosic layer and the second cellulosic layer;

wherein the first cellulosic layer and the second cellulosic layer are fused together.

2. The structure of claim 1, wherein the first bio-based polymer comprises one of polylactic acid and lactic acid.

3. The structure of claim 1, wherein the biolaminate structure is suitable for use as a decorative surfacing laminate layer.

4. The structure of claim 1, wherein the biolaminate structure exhibits substantially no formaldehyde emission and suitable for a replacement for high pressure laminates.

5. The structure of claim 1, wherein at least one of the first cellulosic layer and the second cellulosic layer comprises plain paper, kraft paper, treated paper, wood based paper, recycled papers, decorative paper, printed paper, fiber reinforced papers, glass fiber reinforced paper, thin wood veneers, fire retardant paper, chemically treated paper, ph adjusted papers, or a combination thereof.

6. The structure of claim 1, further comprising an overlay layer comprising a thermoset and thermoplastic standard overlay, a mineral plastic overlay, a bioplastic overlay, or a wear layer surface overlay.

7. The structure of claim 1, wherein an additive is contacted with one or more of the layers or the first bio-based polymer.

8. The structure of claim 7, wherein the additive is selected from the group consisting of drying agents, polymerizing agents, peroxides and other crosslinking agents, colorants, fire retardants, impact modifiers, processing aids, lubricants, and pH modifiers

9. The structure of claim 1, wherein at least one of the first cellulosic layer and the second cellulosic layer comprises a biobased paper from a renewable plant fiber selected from the group of hemp, baggase, wheat straw, and corn stover.

10. The structure of claim 1, further comprising additional cellulosic layers impregnated with a bio-based polymer to form a thicker biolaminate structure.

11. The structure of claim 1, further comprising a film layer comprising polylactic acid, the film layer being reverse printed with an image, the film layer being provided over the first and second cellulosic layers.

12. A biolaminate structure, comprising:

a first layer comprising a paper substrate impregnated with a bio-based polymer, the bio-based polymer being one of polylactic acid and lactic acid; and

a second layer in contact with the first layer;

wherein the biolaminate structure exhibits substantially no formaldehyde emission and suitable for a replacement for high pressure laminates.

13. The biolaminate structure of claim 12, wherein the second layer is a paper substrate impregnated with a bio-based polymer.

14. The biolaminate structure of claim 12, wherein the second layer is a biobased film including a polylactic acid sheet.

15. The biolaminate structure of claim 12, wherein the second layer is a clear polylactic surface layer.

16. A method for forming a biolaminate structure, the method comprising:

providing a first paper layer;

providing a biobased polymer film layer;

providing a second paper layer; and

at least partially saturating the first paper layer and the second paper layer with a biobased polymer, wherein saturation may be from the biobased polymer of the biobased polymer film layer or may be from an additional biobased polymer source;

fusing the first paper layer, the biobased polymer film layer, and the second paper layer under means of heat and pressure to form the biolaminate structure.

17. The method of claim 16, wherein fusing is done at a pressure between about 20 psi and about 1500 psi

18. The method of claim 16, wherein saturating the first paper layer and the second paper layer comprises submersing the first paper layer and the second paper layer in a bath of liquid lactic acid with a low viscosity sufficient to absorb into the saturated paper layers.

19. The method of claim 16, further comprising drying the saturated first paper layer and the saturated second paper layer prior to fusing.

20. The method of claim 19, further comprising texturizing a surface of the dried, saturated first paper layer.