CN1052187C - 基于固化淀粉泡沫的生物降解叠层复合材料及其制造方法 - Google Patents

基于固化淀粉泡沫的生物降解叠层复合材料及其制造方法 Download PDF

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CN1052187C
CN1052187C CN93117042A CN93117042A CN1052187C CN 1052187 C CN1052187 C CN 1052187C CN 93117042 A CN93117042 A CN 93117042A CN 93117042 A CN93117042 A CN 93117042A CN 1052187 C CN1052187 C CN 1052187C
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laminated composite
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foam
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J·洛克
W·波默雷茨
J·霍耶尔
K·克伦克
H·施米特
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Biotechnology biochemistry natural packing Research Development Co.,Ltd.
EUL Gense Taili Co.,Ltd. Parkinson
BioTec Biologische Naturverpackungen GmbH and Co KG
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    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
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    • B32B9/025—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch comprising leather
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Abstract

本发明提出基于固化淀粉泡沫的可生物降解叠层复合材料及其制造方法，在该制造过程中，淀粉泡沫同时与另一材料层结合。本发明的优点包括制造工艺简单，成本低并且制造的复合材料用途广。

Description

基于固化淀粉泡沫的生物降解叠层复合材料及其制造方法
本发明涉及基于固化淀粉泡沫的生物降解叠层复合材料及其制造方法。
这种复合材料可用作包装材料如结构材料，用以例如隔冷，隔热或隔音或减震。
由聚苯乙烯制成的常见泡沫包装材料(Styrofoam)尤其是食品包装材料突出的问题是其废弃处理，因为这种塑料本身不会腐烂，只能在用完后循环。
在已知方法中，已用淀粉悬浮液代替塑料，其中液态组分一旦引入加热模具就会蒸发并使悬浮液发泡或膨胀，而该材料在模具中保持规定的膨胀时间以进行干燥和固化，这期间湿份逸出。然后脱模，放出泡沫块，这样生产的泡沫块会腐烂并可再循环，而且具有隔冷和隔热以及减震性，但缺点是若其重量不够或不是相当厚，则其强度相当低。此外，因其呈现多孔表面，尤其是难于在其表面上印刷，所以这种材料不能用于某些领域。
相比之下，本发明目的是提出可生物降解叠层复合材料，其特征是其强度高，制造方法简单，成本低并且用途广。
该目的可通过下述本发明的叠层复合材料及其制造方法达到。
本发明提供一种叠层复合材料，它包括至少一层泡沫体和至少另一材料层，其中泡沫材料为固化淀粉泡沫，并且各层间不加粘结剂而就地相互结合。
本发明还提供了上述叠层复合材料的制造方法，其步骤包括：
a.将淀粉悬浮液和至少另一材料引入模具中，
b.使淀粉泡沫固化并同时与该另一材料结合而成叠层复合材料，以及
c.从模具中脱除该叠层复合材料。
以下详述本发明。
本发明叠层复合材料包括至少一层固化淀粉泡沫并结合至少另一层材料，从而形成叠层复合材料。而该另一材料优选为平面材料并优选单面覆盖淀粉泡沫。
本发明方法基于可含天然和/或改性淀粉的淀粉悬浮液，其中天然淀粉可为任何来源的天然或杂化物形态淀粉，并可用例如马铃薯，木薯，豌豆，蚕豆，玉米，wax corn，直链淀粉含量高的玉米，谷物如小麦及其部分制品，大麦或高梁，而改性淀粉为物理和/或化学改性生产的淀粉衍生物。优选用淀粉水悬浮液且该悬浮液优选包括20-45％淀粉颗粒，0-10％膨胀淀粉和水，并可混入与食品相容的染料。另外，淀粉悬浮液中可以含有纤维和/或填料。
而且，该方法所用的另一叠层材料优先选自纸，纸板，花纹板，纺织品，薄木片，皮革，人造皮，合成材料带，生物聚合物带和金属材料带，制造复合材料时就地形成的合成和/或生物聚合物材料薄膜以及这些材料的组合物。纺织品优选由天然和/或合成纤维、玻璃和/或陶瓷纤维制成或由其制成的混合织物。该另一叠层材料优选为平面材料，这可由叠层复合材料如包装材料的最终形式确定并可以坯料或预制品形式引入模具中，而且这优选在淀粉悬浮液加入之前进行。该另一材料可在加入淀粉悬浮液之前加入。此外，该另一材料可以以液态和/或固态粉状材料形式加入并就地形成薄层，然后与淀粉泡沫结合形成叠层复合材料。
该淀粉悬浮液优选以确定量注入模具中，悬浮液在该已加热的模具中减压发泡并填入空腔。优选将模具加热到180-270℃，更优选200-250℃。在这期间以及在干燥和化学物理固化过程中，淀粉与另一叠层材料结合成为整体，然后从模具中脱出而得叠层复合材料。固化优选进行30-90秒，更优选45-75秒，然后取出所得叠层复合材料。这些工艺操作可通过模具中的内压升高而加速并优选在控制压力和温度的情况下进行。
惊人的是，在适当地进行该方法时，相当高的模塑温度并不会影响该另一叠层材料，而且在引入模具和随后的变形之前，对于在该另一叠层材料，尤其是纸，纸板或花纹板上进行的任何印刷而言，也同样如此。尤其是如果将淀粉悬浮液单面涂到另一叠层材料，则在从模具中脱模时仅在该叠层复合材料一侧出现印刷图案。在单侧涂淀粉悬浮液时，循环花纹板材料可用来包装食品，其中该材料不会与包装材料外侧的食品接触。
为了得到几个可印刷或光滑的表面并提高强度，可将多层另一叠层材料送入模具中。在这种情况下，在该另一叠层材料层间引入淀粉悬浮液。
通过适当设计模具，可在叠层复合材料中形成开孔，空腔，网或带等结构，这从包装及强度角度看可能是有意义的。在形成空腔的情况下，空腔在叠板之间形成空心区域。从模具中脱出后，该材料可通过变形，贴签，打印和/或编号。
该方法优选用来生产包装材料，在这种情况下所用另一叠层材料可预成型为包装壳体形状。
另一叠层材料和淀粉泡沫的组合可使最终制品具有的强度高于各单一组分或其未加粘结的加合物的强度。该叠层材料比重小，厚度很薄，而且其隔冷和隔热以及减震性均大大高于常见塑料，还可抗静电。
例如，平面材料和淀粉泡沫的组合不要求加添加剂如热或冷胶或塑料等，致使该叠层复合材料除了可生物降解并可制成堆肥而外，还易于循环，因为可作为单一材料排除，而且费用极低。尤其是用纸，纸板或花纹板作平面材料时，所得叠层复合材料可循环进入纸，纸板或花纹板生产过程中。
本发明具有以下优点。
淀粉可在不另加添加剂的情况下应用，并且可用各种材料与淀粉泡沫结合而制成叠层复合材料，尤其是根据这另一叠层材料的情况，可使制成的叠层复合材料易于印刷或染色。该叠层复合材料因固化淀粉泡沫的多孔性而可在机械力作用下稳定，并且显示出优异的隔音效果以及热和电绝缘性。此外，该叠层材料还可有效减震。本发明材料可最有效地用作糖果包装材料，因为该叠层复合材料上可印制广告并可具有糖果所要求的吸收冲击和隔热性。
本发明叠层复合材料的性质可使其除了作包装材料而外，还可有多种用途，如用于建筑，电子和汽车制造业达到绝缘目的。此外，该材料还可用于具有高稳定性的装饰制品如家具，其中由于其寿命短，就必须可循环使用。
以下用实施例详述本发明。
在连续工艺中，制成淀粉悬浮液，其中液态和固态助剂自动测量，在均化步骤中细分散并进行反应。马铃著淀粉，玉米膨胀淀粉和水在悬浮液中的重量比为100∶5.2∶106。
操作中将结构类似于对开式铁芯并包括由铸铁制成包装壳体形状的模具的温度和压力可控膨胀模塑装置加热到220℃，其中该模塑装置的模板由两部分制成，平面花纹板预成型壳体材料放在下面的模件上。然后将21.5g淀粉悬浮液倒入壳体中并将两部分模板扣紧，其中淀粉悬浮液发泡，干燥，固化并与花纹板壳体紧密结合。膨胀约70秒后，取出最终成型的包装壳体，为叠层复合材料。该膨胀模塑装置可用来生产板状叠层复合材料的多层表面结构，其中仅需替换铸铁制成的模具而已。因此，可制成例如贮存各种小型零部件(如螺钉或小型家用制品)或贮存压敏和易腐食品(如巧克力或鸡蛋)的容器的各种分隔装置。
壳体比重190kg/m3，包装性能优异，其强度高，重量轻，并具有隔冷和隔热，减震和抗静电性能，而且易于生物降解和制成堆肥以及极易循环用于造纸业。

Claims (24)

1.叠层复合材料，包括至少一层泡沫和至少另一材料层，其中泡沫材料为固化淀粉泡沫，并且各层间不加粘结剂而就地相互结合。
2.根据权利要求1所述的叠层复合材料，其中淀粉泡沫含天然淀粉。
3.根据权利要求1所述的叠层复合材料，其中淀粉泡沫含改性淀粉。
4.根据权利要求1-3中任一项所述的叠层复合材料，其中对淀粉泡沫进行染色。
5.根据权利要求1-3中任一项所述的叠层复合材料，其中淀粉泡沫含纤维和/或填料。
6.根据权利要求1-3中任一项所述的叠层复合材料，其中另一层由纸，纸板，花纹板，天然和/或合成纤维，玻璃和/或陶瓷纤维制成的纺织品和/或混合织物，薄木片，皮革，人造皮，合成材料带，生物聚合物带和金属材料带，制造复合材料时就地形成的合成和/或生物聚合物材料薄膜以及上述材料的组合物制成。
7.根据权利要求1-3中任一项所述的叠层复合材料，其中另一层单面与淀粉泡沫接触。
8.根据权利要求1-3中任一项所述的叠层复合材料，其中另一层已印刷或可印刷。
9.根据权利要求1-3中任一项所述的叠层复合材料，其中另一层由多层构成。
10.根据权利要求9所述的叠层复合材料，其中淀粉泡沫位于各层之间。
11.根据权利要求1-3中任一项所述的叠层复合材料，其中该复合材料制成具有空腔的板。
12.根据权利要求11所述的叠层复合材料，其中压在板中的空腔在叠板之间形成空心区域。
13.根据权利要求1所述的叠层复合材料的制造方法，其步骤包括：
a.将淀粉悬浮液和至少另一材料引入模具中，
b.使淀粉泡沫固化并同时与该另一材料结合而成叠层复合材料以及
c.从模具中脱除该叠层复合材料。
14.根据权利要求13所述的方法，其中模具在步骤a之前加热。
15.根据权利要求13或14所述的方法，其中步骤a中加入淀粉水悬浮液。
16.根据权利要求13或14所述的方法，其中步骤a中加入染色淀粉悬浮液。
17.根据权利要求13或14所述的方法，其中步骤a中注入淀粉悬浮液。
18.根据权利要求13或14所述的方法，其中步骤a中使淀粉悬浮液减压发泡。
19.根据权利要求13或14所述的方法，其中步骤a中在加入淀粉悬浮液之前加入另一材料。
20.根据权利要求13或14所述的方法，其中另一材料以液态和/或固态粉状材料加入并在步骤a中成为薄层而与淀粉泡沫结合形成叠层复合材料。
21.根据权利要求13或14所述的方法，其中另一材料先预成型后引入步骤a。
22.根据权利要求21所述的方法，其中另一材料预成型为壳体。
23.根据权利要求13或14所述的方法，其中步骤a中加入包括20-45％淀粉颗粒，0-10％膨胀淀粉和水的淀粉悬浮液，模具加热到180-270℃，并且在30-90秒后进行步骤c。
24.根据权利要求23所述的方法，其中将模具加热到200-250℃且在45-75秒后进行步骤c。
CN93117042A 1992-08-28 1993-08-28 基于固化淀粉泡沫的生物降解叠层复合材料及其制造方法 Expired - Fee Related CN1052187C (zh)

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DEP4317691.7 1993-05-27

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CA2143432A1 (en) 1994-03-17
EP0656830A1 (de) 1995-06-14
CN1083773A (zh) 1994-03-16
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