Cellulosic biolaminate composite assembly and related methods

Abstract

Cellulosic biolaminate assemblies are provided. In one embodiment, a biolaminate structure is provided comprising a first cellulosic layer, a second cellulosic layer, and a first bio-based polymer. The first bio-based polymer impregnates the first cellulosic layer and the second cellulosic layer. The first cellulosic layer and the second cellulosic layer are fused together.

What is claimed is: 
     
         1 . A biolaminate structure, comprising:
 a first cellulosic layer;   a second cellulosic layer; and   a first bio-based polymer that impregnates the first cellulosic layer and the second cellulosic layer;   wherein the first cellulosic layer and the second cellulosic layer are fused together.   
     
     
         2 . The structure of  claim 1 , wherein the first bio-based polymer comprises one of polylactic acid and lactic acid. 
     
     
         3 . The structure of  claim 1 , wherein the biolaminate structure is suitable for use as a decorative surfacing laminate layer. 
     
     
         4 . The structure of  claim 1 , wherein the biolaminate structure exhibits substantially no formaldehyde emission and suitable for a replacement for high pressure laminates. 
     
     
         5 . The structure of  claim 1 , wherein at least one of the first cellulosic layer and the second cellulosic layer comprises plain paper, kraft paper, treated paper, wood based paper, recycled papers, decorative paper, printed paper, fiber reinforced papers, glass fiber reinforced paper, thin wood veneers, fire retardant paper, chemically treated paper, ph adjusted papers, or a combination thereof. 
     
     
         6 . The structure of  claim 1 , further comprising an overlay layer comprising a thermoset and thermoplastic standard overlay, a mineral plastic overlay, a bioplastic overlay, or a wear layer surface overlay. 
     
     
         7 . The structure of  claim 1 , wherein an additive is contacted with one or more of the layers or the first bio-based polymer. 
     
     
         8 . The structure of  claim 7 , wherein the additive is selected from the group consisting of drying agents, polymerizing agents, peroxides and other crosslinking agents, colorants, fire retardants, impact modifiers, processing aids, lubricants, and pH modifiers 
     
     
         9 . The structure of  claim 1 , wherein at least one of the first cellulosic layer and the second cellulosic layer comprises a biobased paper from a renewable plant fiber selected from the group of hemp, baggase, wheat straw, and corn stover. 
     
     
         10 . The structure of  claim 1 , further comprising additional cellulosic layers impregnated with a bio-based polymer to form a thicker biolaminate structure. 
     
     
         11 . The structure of  claim 1 , further comprising a film layer comprising polylactic acid, the film layer being reverse printed with an image, the film layer being provided over the first and second cellulosic layers. 
     
     
         12 . A biolaminate structure, comprising:
 a first layer comprising a paper substrate impregnated with a bio-based polymer, the bio-based polymer being one of polylactic acid and lactic acid; and   a second layer in contact with the first layer;   wherein the biolaminate structure exhibits substantially no formaldehyde emission and suitable for a replacement for high pressure laminates.   
     
     
         13 . The biolaminate structure of  claim 12 , wherein the second layer is a paper substrate impregnated with a bio-based polymer. 
     
     
         14 . The biolaminate structure of  claim 12 , wherein the second layer is a biobased film including a polylactic acid sheet. 
     
     
         15 . The biolaminate structure of  claim 12 , wherein the second layer is a clear polylactic surface layer. 
     
     
         16 . A method for forming a biolaminate structure, the method comprising:
 providing a first paper layer;   providing a biobased polymer film layer;   providing a second paper layer; and   at least partially saturating the first paper layer and the second paper layer with a biobased polymer, wherein saturation may be from the biobased polymer of the biobased polymer film layer or may be from an additional biobased polymer source;   fusing the first paper layer, the biobased polymer film layer, and the second paper layer under means of heat and pressure to form the biolaminate structure.   
     
     
         17 . The method of  claim 16 , wherein fusing is done at a pressure between about 20 psi and about 1500 psi 
     
     
         18 . The method of  claim 16 , wherein saturating the first paper layer and the second paper layer comprises submersing the first paper layer and the second paper layer in a bath of liquid lactic acid with a low viscosity sufficient to absorb into the saturated paper layers. 
     
     
         19 . The method of  claim 16 , further comprising drying the saturated first paper layer and the saturated second paper layer prior to fusing. 
     
     
         20 . The method of  claim 19 , further comprising texturizing a surface of the dried, saturated first paper layer.