Biolaminate composite assembly including polylactic acid and natural wax laminate layer, and related methods

Abstract

Biolaminate composite assemblies are provided. Generally, the biolaminate composite assemblies may comprise one or more biolaminate layers and at least one biolaminate layer may comprise polylactic acid. In one embodiment, a biolaminate composite assembly is provided comprising one or more biolaminate layers wherein the biolaminate composite assembly is three-dimensionally formable over a rigid non-plastic substrate. At least one of the biolaminate layers comprises polylactic acid and a natural wax. In another embodiment, a method for forming a biolaminate composite assembly is provided.

1 . A biolaminate composite assembly, comprising:
 one or more biolaminate layers, at least one of the biolaminate layers comprising polylactic acid and a natural wax;   wherein the biolaminate composite assembly is three-dimensionally formable over a rigid non-plastic substrate.   
     
     
         2 . The biolaminate composite assembly of  claim 1 , wherein the natural wax is soy wax. 
     
     
         3 . The biolaminate composite assembly of  claim 1 , wherein the natural wax is present at about 5% by weight of the biolaminate composite assembly. 
     
     
         4 . The biolaminate composite assembly of  claim 1 , further comprising the rigid non-plastic substrate, wherein the one or more biolaminate layers is laminated to the rigid non-plastic substrate. 
     
     
         5 . The biolaminate composite assembly of  claim 4 , further comprising an adhesive layer, in contact with the substrate and the one or more biolaminate layers. 
     
     
         6 . The biolaminate composite assembly of  claim 1 , wherein the at least one of the biolaminate layers comprises over 50% polylactic acid. 
     
     
         7 . The biolaminate composite assembly of  claim 1 , wherein the at least one of the biolaminate layers comprises blend of biopolymers including the polylactic acid. 
     
     
         8 . The biolaminate composite assembly of  claim 1 , wherein the at least one biolaminate layer is blended with a plasticizer to form a flexible biolaminate sheet. 
     
     
         9 . The biolaminate composite assembly of  claim 1 , wherein the one or more biolaminate layers are thermoformed over the non-rigid substrate. 
     
     
         10 . The biolaminate composite assembly of  claim 1 , wherein the one or more biolaminate layers include a three dimensional profile. 
     
     
         11 . A biolaminate composite assembly, comprising:
 one or more biolaminate layers, at least one of the biolaminate layers comprising polylactic acid and a natural wax.   
     
     
         12 . The biolaminate composite assembly of  claim 11 , wherein the natural wax is soy wax. 
     
     
         13 . The biolaminate composite assembly of  claim 11 , wherein the biolaminate composite assembly is three-dimensionally formable over a rigid non-plastic substrate. 
     
     
         14 . The biolaminate composite assembly of  claim 11 , further comprising a rigid non-plastic substrate, the one or more biolaminate layers being laminated on the rigid non-plastic substrate. 
     
     
         15 . A method for forming a biolaminate composite assembly;
 forming one or more biolaminate layers comprising a biopolymer, at least one of the biolaminate layers comprising polylactic acid and a natural wax;   providing a non-rigid substrate; and   laminating the one or more biolaminate layers to the non-rigid substrate.   
     
     
         16 . The method of  claim 15 , wherein foaming one or more biolaminate layers is done at a temperature below a melting point of the biopolymer such that the biopolymer is processed in its viscoelastic state and thereby maintaining a high degree of crystallinity in the one or more biolaminate layers. 
     
     
         17 . The method of  claim 16 , wherein the temperature between about 280° F. and about 340° F. 
     
     
         18 . The method of  claim 16 , wherein fanning one or more biolaminate layers further comprises blending an additive with the biopolymer. 
     
     
         19 . The method of  claim 18 , wherein the additive is a plasticizer. 
     
     
         20 . The method of  claim 19 , further comprising laminating a secondary nonwoven cloth to a backside of the one or more biolaminate layers. 
     
     
         21 - 23 . (canceled)