Method of making high strength fiber foam composite
OwnerGregory M. Glenninventor
Life of this patent
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Abstract
A biodegradable high strength cellulosic fiber foam material is made by combining cellulosic fibers with a sodium dodecyl sulfate, polyvinyl alcohol, and starch. Paperboard reinforcing/support elements/means are embedded in the high strength cellulosic fiber foam material wet mix to increase the compressive strength and other properties when the foam is dried. The foam comprises a light weight, high strength, insulative, biodegradable material that may be used for at least packaging materials and food containers. The biodegradable fiber foam composite material has mechanical properties similar to non-biodegradable petroleum-based, expanded polystyrene, polyurethane, and other petroleum-based products.
Claims20
A method of making a high strength biodegradable cellulosic fiber foam material, the method comprising the steps of:
- (a) combining cellulosic fiber, a foaming agent, polyvinyl alcohol, and water, to create a biodegradable cellulosic fiber foam wet mix, the biodegradable cellulosic fiber foam wet mix (FF−S) having a wet density (Dw) of 100-140 kg/m3;
- (b) adding starch to the cellulosic fiber foam wet mix to produce a fiber foam wet mix comprising about 0-6.0 weight percent starch;
- (c) providing paper-based reinforcing means;
- (d) adding the cellulosic fiber foam wet mix and the paper-based reinforcing means to a mold so that the cellulosic fiber foam wet mix binds with the paper-based reinforcing means;
- (e) drying the cellulosic fiber foam wet mix to produce a high strength fiber foam composite material, the high strength fiber foam composite material having a compressive strength (CS) of at least about 72 kPa, and a toughness (Ω) of at least 0.34 Joules at 10% compressive strain.
A method of making a biodegradable high strength cellulosic fiber foam material, the method comprising the steps of:
- (a) providing a high strength cellulosic fiber foam wet mix comprising cellulosic fiber, a sodium dodecyl sulfate foaming agent, polyvinyl alcohol fiber dispersant and binder, and starch;
- (b) pouring the high strength cellulosic fiber foam wet mix into a mold so that the mold cavity is overfilled;
- (c) either before or after pouring the wet mix into the mold, adding paper-based reinforcing means to the mold so that the wet mix binds with the paper-based reinforcing means;
- (d) drying the wet mix so that the wet mix binds with the paper-based reinforcing means to form a high strength fiber foam composite material, the high strength fiber foam composite material having a compressive strength of at least about 72 kPa and a toughness of at least 0.34 Joules at 10% compressive strain.
The method of step (c) wherein the paper-based reinforcing means has a grid-type or cylindrical shape.
Dependencies are inferred from the claim text.