Starch-cellulose composite material

Patent metadata

Field	Value
Publication number	US-12270153-B2
Application number	US-202217666206-A
Country	US
Kind code	B2
Filing date	Feb 7, 2022
Priority date	Feb 11, 2021
Publication date	Apr 8, 2025
Grant date	Apr 8, 2025

Abstract

A composite can include cellulose fiber; and foam binding the cellulose fiber. A method for manufacturing a composite can comprise mixing a plurality of ingredients to form a pre-foam mixture; foaming the pre-foam mixture to produce a foam; mixing the foam with cellulose fiber to form a composite material; and curing the composite material.

First claim

That which is claimed is:

1. A composite comprising:
cellulose fiber; and
a water-based foam binding the cellulose fiber, wherein the cellulose fiber defines a density of less than 1,450 grams per square meter (GSM), an average pore diameter is about 1-2 mm, and a maximum pore diameter within the water-based foam is about 3 mm.

2. The composite of claim 1 , wherein the composite is formed into an insulation batt.

3. The composite of claim 1 , wherein the water-based foam comprises polyvinyl acetate, sodium coco sulfate, xantham gum, and hydroxypropyl methyl cellulose.

4. The composite of claim 1 , wherein the water-based foam comprises starch, liquid egg whites, polyvinyl acetate, baking soda, and citric acid.

5. The composite of claim 1 , wherein the cellulose fiber comprises edge trim.

6. The composite of claim 1 , wherein the composite defines a density of about 0.15-0.20 g/ml prior to curing.

7. The composite of claim 1 , wherein a length of each cellulose fiber exceeds one foot (12 inches) in length.

8. The composite of claim 1 , wherein a length of each cellulose fiber exceeds one yard (36 inches) in length.

9. The composite of claim 1 , wherein the composite comprises a 0.75:1 ratio by weight of a PVA to the cellulose fiber.

10. A composite comprising:
a cellulose fiber; and
a foam defining a density of less than 1,450 grams per square meter (GSM), an average pore diameter between 1-2 mm, and comprising a maximum pore diameter of 3 mm, the foam binding the cellulose fiber.

11. The composite of claim 10 , wherein the cellulose fiber is a recycled fiber derived from recycled paper and cardboard products.

12. The composite of claim 10 , wherein the cellulose fiber comprises edge trim from a paper mill.

13. The composite of claim 10 , wherein the cellulose fiber comprises saw dust.

14. The composite of claim 1 , wherein the composite has a structural strength of plywood and the composite is suitable for machining.

15. The composite of claim 10 , wherein the composite forms a structural component of a cabinet.

16. The composite of claim 10 , wherein the composite is non-toxic.

17. The composite of claim 10 , wherein the composite is single-stream recyclable and repulpable.

Assignees

• Pratt Corrugated Holdings Inc

Inventors

• Anagnostopoulos John
• Sollie Greg
• Waltermire Jamie
• Chen Shifeng

Classifications

• B29B7/90

  Fillers or reinforcements {, e.g. fibres} · CPC title

• B29K2105/04

  cellular or porous · CPC title

• D21H23/64

  the material being non-fluent at the moment of transfer, e.g. in form of preformed, at least partially hardened coating · CPC title

• D21H21/08

  Dispersing agents for fibres · CPC title

• D21H17/74

  of organic and inorganic material · CPC title