IP Library › Granted Patent US 12,270,153
Granted Patent B2
US 12,270,153 · App. 17/666,206 · Granted Apr 8, 2025

Starch-cellulose composite material

Inventors: John Anagnostopoulos (Atlanta, GA); Greg Sollie (Sharpsburg, GA); Jamie Waltermire (Peachtree City, GA); Shifeng Chen (Newport News, VA)
Assignee: Pratt Corrugated Holdings, Inc.
D21F11/002B29B7/90B29C69/001D21H17/09D21H17/15D21H17/22D21H17/26D21H17/28D21H17/31D21H17/36D21H17/66D21H17/74D21H21/08D21H23/64B29K2105/04B29K2201/00
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Quick Facts
Patent No.
US 12,270,153
App. No.
17/666,206
Granted
Apr 8, 2025
Kind
B2
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.

Claims (21)

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.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 1, 2022
From: ANAGNOSTOPOULOS, JOHN; SOLLIE, GREG; WALTERMIRE, JAMIE; CHEN, SHIFENG
To: PRATT CORRUGATED HOLDINGS, INC.
Reel/Frame 059138/0479 →
Continuity (2)
Provisional Application 63148474 · Feb 11, 2021
Related Publication 20220251783A1 · Aug 11, 2022
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