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US 2023/0074931 A1Published application
Process for Manufacturing Non-Woven Fabric-Like Composite Materials from Shredded Polymer-Coated Paper Products and Coffee Grounds
AssigneeEcobrain Co., Ltd.
InventorDirk Harste
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Abstract
The invention relates to a process for producing non-woven fabric-like composite materials, novel non-woven fabric-like composite materials, articles made therefrom and their use. In particular the fabric-like composite materials are derived from shredded polymer-glued or polymer-coated paper products and coffee grounds as raw material.
Claims21
1-15. (canceled)
16:
- A process of manufacturing a fabric-like composite material, the process comprising:
- (i) providing a particulate substrate S, comprising a mixture of (a) shredded polymer-glued or polymer-coated paper products and (b) coffee grounds,
- (ii) dispersing the substrate S in a dispersant to obtain a dispersion,
- (iii) adding a polymer P to the dispersion,
- (iv) adding a precipitation agent to the dispersion to afford a precipitated particle composition, and
- (v) depositing the precipitated particle composition on a sieve to shape the precipitated particle composition to afford a formed material,
- (vi) subjecting the formed material to vacuum to remove dispersant, and
- (vii) pressing the formed material to remove dispersant,
- (viii) drying the resulting formed material to obtain a non-woven fabric material.
6 more elements
17:
- The process of claim 16, wherein the substrate S is obtained by shredding, cutting, chopping, milling, or crushing paper products, the paper products comprising a polymer-based glue and/or a polymer-coating.
18:
- The process of claim 16, wherein the polymer-glued or polymer-coated paper products are selected from polymer-coated disposable paper products, including polymer-coated paper take-away cups, dishes, bowls, bags, beverage cartons or packages.
19:
- The process of claim 16, where in the polymer P is provided in the form of an aqueous dispersion.
20:
- The process of claim 18, where in the polymer P is provided in the form of an aqueous dispersion.
21:
- The process of claim 16, wherein the non-woven fabric material is provided in the form of a layer, sheet or floor.
22:
- The process of claim 19, wherein the non-woven fabric material is provided in the form of a layer, sheet or floor.
23:
- The process of claim 16, wherein the dry matter weight ratio among the components of the mixture of the formed material is in the range of 40-85% paper products (PP):
- 0-60% coffee grounds (CG):
- 15-45% polymer (P).
24:
- The process of claim 20, wherein the dry matter weight ratio among the components of the mixture of the formed material is in the range of 40-85% paper products (PP):
- 0-60% coffee grounds (CG):
- 15-45% polymer (P).
25:
- The process of claim 22, wherein the dry matter weight ratio among the components of the mixture of the formed material is in the range of 40-85% paper products (PP):
- 0-60% coffee grounds (CG):
- 15-45% polymer (P).
26:
- The process of claim 16, wherein the weight ratio of substrate S to polymer P is ≥1 and ≤9.
27:
- The process of claim 20, wherein the weight ratio of substrate S to polymer P is ≥1 and ≤9.
28:
- The process of claim 16, wherein the paper-based particle/polymer composite obtained is sheet-like and has a basis weight ≥150 and ≤30 000 g/m2.
29:
- The process of claim 20, wherein the paper-based particle/polymer composite obtained is sheet-like and has a basis weight ≥150 and ≤30 000 g/m2.
30:
- The process of claim 22, wherein the paper-based particle/polymer composite obtained is sheet-like and has a basis weight ≥150 and ≤30 000 g/m2.
31:
- The process of claim 25, wherein the paper-based particle/polymer composite obtained is sheet-like and has a basis weight ≥150 and ≤30 000 g/m2.
32:
- The process of claim 16, wherein the so-obtained non-woven fabric material has a density of 0.50 to 0.98 g/cm.
33:
- A non-woven fabric-like composite produced by the process of claim 16.
34:
- A shoe, bag or article of apparel comprising the non-woven fabric-like composite of claim 16.
35:
- An article comprising the non-woven fabric-like composite according to claim 31 that has been embossed.