Wear Resistant Biolaminate Composite Assembly and Related Methods
Biolaminate assemblies for use as high pressure laminates are provided. In one embodiment, the biolaminate assembly includes a surface wear layer including polylactic acid and at least one of a plastic and mineral. The surface wear layer is adapted to be laminated or thermoformed to a nonplastic rigid substrate. The surface wear layer has a wear resistant range greater than about 400 cycles using tabor abrasion and temperature resistance range from about 212° F. to about 356° F. such that the biolaminate assembly is suitable for use as a high pressure laminate.
1 . A biolaminate assembly for use as a high pressure laminate, comprising:
a surface wear layer including polylactic acid and at least one of a plastic and mineral, wherein the surface wear layer is adapted to be laminated or thermoformed to a nonplastic rigid substrate;
wherein the surface wear layer has a wear resistant range greater than about 400 cycles using tabor abrasion and temperature resistance range from about 212° F. to about 356° F. such that the biolaminate assembly is suitable for use as a high pressure laminate.
2 . The biolaminate assembly of claim 1 , further comprising a thermally fused plastic or bioplastic layer below the surface wear layer.
3 . The biolaminate assembly of claim 2 , wherein the biolaminate assembly has a thickness between about 0.004″ and about 0.3″.
4 . The biolaminate assembly of claim 1 , wherein the surface wear layer has a thickness between about 0.002″ and about 0.050″.
5 . The biolaminate assembly of claim 1 , wherein the surface wear layer further comprises a plasticizier, lubricant, or processing aid.
6 . The biolaminate assembly of claim 1 , wherein the mineral of the surface wear layer comprises quartz, silicon dioxide, silica sand, alumina, calcium carbonate, or a blend thereof.
7 . The biolaminate assembly of claim 6 , wherein the mineral comprises about 1% to 50% of the surface wear layer by weight.
8 . The biolaminate assembly of claim 6 , wherein the mineral has a particle size range from about 100 mesh to about 5 nanometers.
9 . The biolaminate assembly of claim 6 , wherein the mineral of the surface wear layer is semitransparent or clear.
10 . The biolaminate assembly of claim 1 , wherein the biolaminate assembly is suitable for use in countertop and flooring applications.
11 . The biolaminate assembly of claim 1 , wherein the plastic of the surface wear layer comprises at least one of acrylic, PE, PP, EVA, PET, PC, epoxy, polyester, urethane.
12 . The biolaminate assembly of claim 1 , wherein the rigid non-plastic substrate is a wood, wood composite, agrifiber composite, saturated paper composite, mineral composite, or fiberglass composite.
13 . The biolaminate assembly of claim 1 , further comprising a decorative print layer.
14 . The biolaminate assembly of claim 1 , wherein the surface wear layer further comprises soy wax.
15 . A three dimensional formable laminate for use as a high pressure laminate, comprising:
a surface wear layer including polylactic acid and at least one of a plastic and mineral,
wherein the surface wear layer is adapted to be laminated or thermoformed to a three dimensional surface;
wherein the surface wear layer has a wear resistant range greater than about 400 cycles using tabor abrasion and temperature resistance range from about 212° F. to about 356° F. such that the biolaminate assembly is suitable for use as a high pressure laminate.
16 . The three dimensional formable laminate of claim 15 , further comprising:
a plastic layer comprising at least one of a plastic or a bioplastic, the plastic layer being fused to the surface wear layer.
17 . The three dimensional formable laminate of claim 15 , further comprising a decorative print layer.
18 . The three dimensional formable laminate of claim 15 , wherein the surface wear layer further comprises soy wax.
19 . A three dimensional formable laminate assembly for use as a high pressure laminate, comprising:
a laminate comprising:
a surface wear layer including polylactic acid and at least one of a plastic and mineral, wherein the surface wear layer has a wear resistant range greater than about 400 cycles using tabor abrasion and temperature resistance range from about 212° F. to about 356° F. such that the three dimensional formable laminate assembly is suitable for use as a high pressure laminate,
a plastic layer comprising at least one of a plastic or a bioplastic, the plastic layer being fused to the surface wear layer; and
a decorative print layer; and
a rigid non-plastic three dimensional substrate;
wherein laminate is laminated over the rigid non-plastic three dimensional surface.
20 . The three dimensional formable laminated surface assembly of claim 19 , wherein the three dimensional formable laminate assembly forms a worksurface, countertop, flooring, table top or architectural component.