US 12,264,227 B2
Foam formed solid composite comprising nanocellulose and solid low-density particles
Kaj Backfolk, Lappeenranta (FI); and Isto Heiskanen, Imatra (FI)
Assigned to Stora Enso OYJ, Helsinki (FI)
Appl. No. 17/756,983
Filed by Stora Enso OYJ, Helsinki (FI)
PCT Filed Dec. 15, 2020, PCT No. PCT/IB2020/061948
§ 371(c)(1), (2) Date Jun. 7, 2022,
PCT Pub. No. WO2021/124090, PCT Pub. Date Jun. 24, 2021.
Claims priority of application No. 1951498-3 (SE), filed on Dec. 18, 2019.
Prior Publication US 2023/0016725 A1, Jan. 19, 2023
Int. Cl. C08J 9/35 (2006.01); B82Y 30/00 (2011.01); C08J 9/00 (2006.01); C08L 1/02 (2006.01)
CPC C08J 9/35 (2013.01) [B82Y 30/00 (2013.01); C08J 9/0061 (2013.01); C08L 1/02 (2013.01); C08J 2301/02 (2013.01); C08L 2203/14 (2013.01)] 19 Claims
 
1. A foam formed solid composite, comprising:
a matrix phase consisting of a mixture of nanocellulose, at least one polymeric foaming agent, optional additives, and an optional polymeric binder, wherein the matrix phase comprises 50-99.5 wt % of nanocellulose and 0.5 to 50 wt % of the at least one polymeric foaming agent, based on a total dry weight of the matrix phase; and
a dispersed phase consisting of porous, solid low-density particles having a density of less than 1 kg/dm3;
wherein the porous, solid low-density particles comprise a specific surface area above 50 m2/g,
wherein said nanocellulose comprises cellulosic nanofibers having an average diameter in a range of 1-1000 nm,
wherein the at least one polymeric foaming agent is selected from a group consisting of: polysaccharides, proteins, polyvinyl alcohol, polyvinyl acetate, and mixtures thereof,
wherein the solid low-density particles are selected from a group consisting of polysaccharide, lignin, and protein particles,
wherein the solid low-density particles are hydrophobized, and,
wherein the composite comprises in a range of 0.1-90 wt % of the porous, solid low-density particles, based on a total dry weight of the composite.