Cellulosic biolaminate composite assembly and related methods

• US 8,389,107 B2
• Filed: 07/14/2011
• Issued: 03/05/2013
• Est. Priority Date: 03/24/2008
• Status: Expired due to Fees

• Current Assignee: Biovation Acquisition Company (Biovation Holdings, Inc.)
• Original Assignee: Biovation LLC
• Inventors: Riebel, Michael J., Riebel, Milton
• Primary Examiner(s): Higgins, Gerard
• Assistant Examiner(s): POLLEY, CHRISTOPHER M
• Application Number:
  US13/182,767
• Publication Number:
  US 20110262720A1
• Time in Patent Office: 600 Days
• Field of Search: 428/195.1, 428/211.1, 428/480, 428/481, 428/534, 428/535
• US Class Current: 428/211.1
• 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 wall paper B32B2607/02
• 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

polylactic acid substantially completely saturating the first cellulosic layer and the second cellulosic layer;

wherein the first cellulosic layer and the second cellulosic layer are fused together to form a rigid film composition to be adhered to a substrate for making walls, flooring, or work surfaces; and

a film layer comprising polylactic acid, the film layer being printed with an image and provided over the rigid film composition.

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

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

4. 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.

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

6. The structure of claim 1, wherein an additive is contacted with one or more of the layers or the polylactic acid.

7. The structure of claim 6, wherein the additive is selected from the group consisting of drying agents, polymerizing agents, peroxides, crosslinking agents, colorants, fire retardants, impact modifiers, processing aids, lubricants, and pH modifiers.

8. 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 consisting of hemp, baggase, wheat straw, and corn stover.

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

10. A biolaminate structure, comprising:

a first layer comprising a paper substrate substantially completely saturated with polylactic acid; and

a second layer substantially completely saturated with polylactic acid, the second layer in contact with the first layer;

wherein the biolaminate structure exhibits substantially no formaldehyde emission and meets NEMA LD3 testing requirements; and

wherein the first layer and the second layer are adhered together to from a rigid film composition; and

a film layer comprising polylactic acid, the film layer being printed with an image and provided over the rigid film composition.

11. The biolaminate structure of claim 10, wherein the second layer is a paper substrate.

12. The biolaminate structure of claim 10, wherein the second layer is a biobased film comprising a polylactic acid sheet.

13. The biolaminate structure of claim 10, wherein the second layer is a clear polylactic acid surface layer.