IP Library › Patent Application 19056573
Patent Application
App. No. 19/056,573

STARCH-CELLULOSE COMPOSITE MATERIAL

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Quick Facts
Patent No.
US None
App. No.
19/056,573
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 (26)

1 . A method comprising:

mixing a plurality of ingredients to form a pre-foam mixture;

foaming the pre-foam mixture to produce a water-based foam;

mixing the water-based foam with cellulose fiber to form a composite material; and

curing the composite material to define a maximum pore diameter of about 3 mm.

2 . The method of claim 1 , further comprising drying the composite material after curing the composite material.

3 . The method of claim 1 , further comprising laminating the composite material with a film.

4 . The method of claim 3 , further comprising shaping the composite material before laminating the composite material.

5 . The method of claim 3 , further comprising shaping the composite material after laminating the composite material.

6 . The method of claim 1 , further comprising shaping the composite material.

7 . The method of claim 6 , wherein shaping the composite material comprises depositing the composite material in a mold.

8 . The method of claim 6 , wherein shaping the composite material occurs prior to curing the composite material.

9 . The method of claim 6 , wherein curing the composite material occurs prior to shaping the composite material.

10 . The method of claim 6 , wherein shaping the composite material and curing the composite material occur simultaneously.

11 . The method of claim 6 , wherein shaping the composite material comprises cutting the composite material into sheets.

12 . The method of claim 1 , wherein the plurality of ingredients comprises polyvinyl acetate, sodium coco sulfate, and hydroxypropyl methyl cellulose.

13 . The method of claim 1 , wherein the plurality of ingredients comprises starch, liquid egg whites, polyvinyl acetate, baking soda, and citric acid.

14 . The method of claim 1 , wherein a density of the pre-foam mixture is 13-14 times greater than the density of the water-based foam prior to curing.

15 . A composite comprising:

cellulose fiber; and

a water-based foam binding the cellulose fiber, wherein the water-based foam defines a maximum pore diameter of about 3 mm.

16 . The composite of claim 15 , wherein the water-based foam defines an average pore diameter of about 1-2 mm and the composite is formed into an insulation batt.

17 . The composite of claim 15 , wherein the water-based foam comprises at least one of the group consisting of: polyvinyl acetate, sodium coco sulfate, and hydroxypropyl methyl cellulose.

18 . The composite of claim 15 , wherein the water-based foam comprises starch, liquid egg whites, polyvinyl acetate, baking soda, and citric acid.

19 . The composite of claim 15 , wherein the cellulose fiber comprises edge trim, and a length of each cellulose fiber exceeds one foot (12 inches) in length.

20 . The composite of claim 15 , further comprising a laminated coating that encapsulates the composite material.