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Multilayer microcellular compostable bioplastics and their method of manufacture

A thermoplastic and thermoplastic technology, applied in the direction of chemical instruments and methods, layered products, flat products, etc., can solve the problems of heat resistance cost, failure to achieve physical properties, fragile PLA, etc.

Pending Publication Date: 2022-02-01
CORUMAT INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

But they are often expensive to produce and / or do not achieve the desired physical properties
For example, polylactic acid (PLA) has not been widely used, in part because of its heat resistance and high cost
In addition, PLA is often brittle, and chemical plasticizers are usually used to solve this problem, which in turn may cause health problems

Method used

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  • Multilayer microcellular compostable bioplastics and their method of manufacture
  • Multilayer microcellular compostable bioplastics and their method of manufacture
  • Multilayer microcellular compostable bioplastics and their method of manufacture

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0216] Continuous Process for Solid Expanded Polylactic Acid (PLA) Sheets:

[0217] The PLA pellets were extruded into PLA sheets (0.005-0.100 inches) using a twin-screw extruder (note: the formed PLA rolls could optionally be stored at this step for later use). The PLA sheet is unrolled and fed into the dynamic seal / slit / opening. After dynamic sealing, at 28 °C with CO 2 The sheet was saturated at 900 psi for about 2 min. To achieve the desired gas uptake, the sample is pulled through the chamber at a rate and length to achieve a residence time of approximately 30 seconds, resulting in a 2 Impregnated PLA sheet. Next, the sample is pulled through the second dynamic seal water controlled at a temperature of 28°C to extract from the high-pressure CO 2 remove the sheet. The sheet was immediately cooled until the temperature of the sheet was about 5-10°C. The sheet is then exposed to atmospheric conditions (about 20-40°C) for about 10-30 seconds, and the cooled PLA is then ...

Embodiment 2

[0219] The method used to thermoform expanded PLA sheets into plates in a small green Sencorp thermoformer:

[0220] The expanded PLA sheet with a thickness of 0.065-0.085 inches is fed into the chain track and heated to 350-450℉ under a ceramic heater within 6-8 seconds. The sheet is then advanced to Zone 2 where it is heated to 200-300°F under a ceramic heater and held for 6-8 seconds. In the next step, the sheet is advanced into an unheated or cooled male-female mold for single or multi-cavity dishes or food applications. Close the mold to the desired gap (eg, 0.035 inch gap for a plate). The sheet is held under clamping force for 6-8 seconds. Apply pressurized air to one side of the mold for about 2-4 seconds. Optionally, a vacuum can be applied simultaneously on opposite sides of the mold, or with opposing air pressures on opposite sides of the product for overlapping durations. The air pressure (and optional vacuum if applied) is stopped and the mold is opened. For ...

Embodiment 3

[0222] The method used to thermoform expanded PLA sheets into plates in a large green Sencorp thermoforming machine:

[0223] The expanded PLA sheet with a thickness of 0.065-0.085 inches is fed into the chain track and heated to 90-120℉ under a ceramic heater within 6-10 seconds. The sheet is then advanced to Zone 2 where it is heated to 495-550°F under a ceramic heater and held for 6-10 seconds. In the next step, the sheet is advanced into an unheated or cooled male-female mold for single or multi-cavity dishes or food applications. Close the mold to the desired gap (eg, 0.035 inch gap for a plate). The sheet is held under clamping force for 6-10 seconds. Apply pressurized air to one side of the mold for about 2-6 seconds. Optionally, a vacuum can be applied simultaneously on opposite sides of the mold, or with opposing air pressures on opposite sides of the product for overlapping durations. The air pressure (and optional vacuum if applied) is stopped and the mold is op...

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Abstract

The present invention provides a continuous process for solid-state expansion of a biopolymer, e.g., polylactic acid, which can be used to manufacture reduced-density thermoplastic materials with improved physical and thermal properties. By incorporating multiple stages of heating into the process as a means to regulate heat flux, unprecedented control of microstructure and crystallinity can be achieved. Thermoplastic sheets with the distinct cellular characteristics imparted by the process disclosed herein were found to be thicker and stronger than materials prepared by conventional processes. Thermoforming sheets with such characteristics enabled the production of light-weight, thermally-stable, compostable products that resist warping, and are thus suitable for a range of industrial applications.

Description

[0001] Cross References to Related Applications [0002] This application claims priority and other benefits to U.S. Provisional Patent Application No. 62 / 824,964, filed March 27, 2019, entitled "Multilayer Microcellular Compostable Bioplastic and Their Method of Manufacture," the disclosure of which is incorporated herein by reference in its entirety. [0003] This application also claims priority and other benefits to U.S. Provisional Patent Application No. 62 / 925,095, filed October 23, 2019, entitled "Multilayer Microcellular Compostable Bioplastic and Their Method of Manufacture," the disclosure of which is incorporated herein by reference in its entirety . Background technique [0004] The end products of bio-based plastics offer an environmentally friendly alternative to petroleum-derived products. But they are often expensive to produce and / or do not achieve the desired physical properties. For example, polylactic acid (PLA) has not been widely used, in part because o...

Claims

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Application Information

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IPC IPC(8): B29C44/60B29C44/34C08J5/18C08J9/12B29L31/28B29L31/56
CPCB29C44/60B29C44/3492C08J9/122C08J5/18C08J2367/04C08J2203/06B29L2031/286B29L2031/7132B29L2031/7178B29L2031/7128B29L2031/56B29C44/3453B29C44/348B29C44/3415B29K2067/046B32B5/18B32B5/145B32B27/065B32B29/007B32B7/027B32B2250/02B32B2266/0264B32B2266/08B32B2266/10B32B2307/738B32B2307/704B32B2307/734B32B2307/308B32B2307/7163B32B2439/70B32B2439/40C08J2201/03C08J2201/032C08J9/36C08J9/0066C08J9/0061C08J2497/02C08J2403/02C08J2400/16C08J2205/044C08J9/34B32B1/00B29C44/20B32B7/02B29C51/002B29L2007/002B29L2031/712B29K2509/14B29K2507/04B29K2511/10B29K2403/00B32B7/022B29C44/24B29K2105/041B29K2105/16B32B5/20B32B27/36B32B2307/54B32B2307/542B32B2307/546B32B2307/718B32B2307/72B32B2307/732
Inventor M·瓦戈纳G·J·图德林Z·近藤
Owner CORUMAT INC
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