Composite Materials having a Surface Texture for Absorbing Liquid

Abstract

Composite materials of this invention include an absorbent layer and a non-absorbent layer, the absorbent layer having a textured surface for absorbing and trapping liquids, for example, oil, grease, or water, and the non-absorbent layer having an oleophobic surface that acts as an oil and grease specific liquid barrier. In one example, the surface texture includes a system of ridges and valleys that enhance the composite materials' ability to absorb and hold liquids. The material further includes one or more lamination layers. The lamination layer acts as a general liquid barrier between the absorbent layer and non-absorbent layer. This additional liquid barrier enhances the liquid repelling effect of the non-absorbent layer to more effectively trap liquids in the absorbent layer, thereby preventing liquids from seeping through the material onto an external surface.

We claim: 
     
         1 . A composite material comprising:
 an absorbent layer having a surface texture configured to absorb liquids from a food surface, the surface texture including a system of ridges and valleys; and   a non-absorbent layer joined to at least one side of the absorbent layer, the non-absorbent layer including an oil and grease resistant material that forms a liquid barrier between the absorbent layer and the non-absorbent layer.   
     
     
         2 . The composite material of  claim 1 , wherein the system of ridges and valleys includes valleys positioned between ridges. 
     
     
         3 . The composite material of  claim 2 , wherein the valleys are encompassed in a main body portion of the absorbent layer. 
     
     
         4 . The composite material of  claim 3 , wherein the ridges comprise a network of elevated line segments extended out from the main body portion. 
     
     
         5 . The composite material of  claim 4 , wherein the ridges are dimensioned and positioned on the absorbent layer to facilitate absorption of liquid into the main body portion of the absorbent layer by adsorbing liquid from a food surface when placed in contact with a food surface. 
     
     
         6 . The composite material of  claim 5 , wherein the valleys are dimensioned and positioned on the absorbent layer to receive liquid adsorbed and absorbed by the ridges and trap said liquid in the absorbent layer to prevent liquid from flowing out of the absorbent layer. 
     
     
         7 . The composite material of  claim 6 , wherein the valleys further trap liquid in the absorbent layer to prevent liquid from passing through the absorbent layer and reaching other layers in the composite material. 
     
     
         8 . A composite material comprising:
 a absorbent layer having a surface texture configured to adsorb and absorb liquids from a food surface;   a non-absorbent layer laminated to at least one surface of the absorbent layer, the non-absorbent layer including an oil and grease resistant material that forms a first liquid barrier between the absorbent layer and the non-absorbent layer; and   a lamination layer applied to at least one surface of the absorbent layer, the lamination layer joining the absorbent layer to the non-absorbent layer to create a second liquid barrier between the absorbent layer and the non-absorbent layer.   
     
     
         9 . The composite material of  claim 8 , wherein the lamination layer is applied to the absorbent layer as a surface coating that seals gaps left on the surface of the absorbent layer by the surface texture. 
     
     
         10 . The composite material of  claim 9 , further comprising a network of pockets between the top surface of the surface texture and the bottom surface of the lamination layer, wherein the network of pockets is created by the seal over the surface texture of the absorbent layer from the lamination layer. 
     
     
         11 . The composite material of  claim 10 , wherein liquid absorbed into the main body of the absorbent layer is compressed into the network of pockets. 
     
     
         12 . The composite material of  claim 11 , wherein compressing liquid into the network of pockets horizontally displaces absorbed liquid across a wider surface area, said horizontal displacement creates a wicking effect that draws absorbed liquid away from saturated areas of the absorbent layer and distributes liquid to unsaturated areas of the absorbent layer. 
     
     
         13 . The composite material of  claim 11 , wherein the horizontal displacement of liquid created compressing absorbed liquid into the network of pockets holds liquid in the composite material and prevents liquid from pooling on the absorbent layer. 
     
     
         14 . The composite material of  claim 9 , wherein, after application, the lamination layer is left sitting on the absorbent layer for a period of time before the non-absorbent layer is stacked on top of the laminated absorbent layer, giving the lamination layer time to set-in before stacking the non-absorbent layer creates a uniform surface on the absorbent layer to receive the non-absorbent layer, the uniform surface for receiving additional layers fortifies the bond between layers in the composite material, thereby increasing the lamination strength and flash point of the composite material. 
     
     
         15 . The composite material of  claim 14 , wherein the uniform surface is generated by giving the lamination layer one to five seconds to set in on top of the absorbent layer. 
     
     
         16 . The composite material of  claim 9 , wherein the combination of the first liquid barrier included in the non-absorbent layer and the second liquid barrier included in the lamination layer prevents absorbed liquid from passing through the composite material. 
     
     
         17 . The composite material of  claim 16 , wherein the liquid barriers repel liquid contacting the composite material to protect a surface covered by the composite material from contaminants in the liquid. 
     
     
         18 . The composite material of  claim 17 , wherein the surface covered by the composite material includes at least one of food packaging assembly, a piece of cookware, or a hand of a person. 
     
     
         19 . A composite material comprising:
 a absorbent layer having a main body configured to trap liquids and a surface texture configured to adsorb and absorb liquids from a food surface, the surface texture comprising:
 a system of ridges extending out from the main body, the ridges spread across at least one surface of the absorbent layer to create a network of narrow, elevated segments that contact liquid on a food surface, the elevated segments provide a capillary force for absorbing liquids from a food surface; and 
 a system of valleys spaced between the ridges and included in the main body of the absorbent layer, the valleys receive absorbed liquid from the ridges and store the absorbed liquid in the main body; 
   a non-absorbent layer laminated to at least one surface of the absorbent layer via a lamination layer, the non-absorbent layer having a liquid resistant material that forms a first liquid barrier between the absorbent layer and the non-absorbent layer, the first liquid barrier positioned between the absorbent layer and an external surface to prevent absorbed liquid trapped in the absorbent layer from seeping through non-absorbent layer and contacting the external surface; and   a lamination layer applied to at least one surface of the absorbent layer, the lamination layer joins the absorbent layer to the non-absorbent layer to create a second liquid barrier between the absorbent layer and the non-absorbent layer, the second liquid barrier compresses absorbed liquid into the space between the top surface of the ridges and the bottom surface of the valleys to prevent pooling of absorbed liquid in the absorbent layer and promote more even liquid absorption in the absorbent layer by wicking absorbed liquid across the surface of the absorbent layer.   
     
     
         20 . The composite material of  claim 19 , wherein the system of ridges and valleys is continuous across the entire surface of the composite material, the system of ridges and valleys is continuous to increase the overall liquid carrying capacity of the absorbent layer and increase the local absorbance and absorbance capacity of ridges in contact with- or in close proximity to liquid.