Multilayer article comprising a biodegradable polymer-based layer and a cellulose-fiber based support; method of manufacturing multilayer article and food accessory comprising a multilayer article

Abstract

Invention relates to a multilayer article comprising successively: a non-woven layer of fibers (3) comprising at least 50% by weight of at least one biodegradable polymer melting point of which is below 220 C.; a layer of food-safe adhesive (2); a cellulose-fiber based support (1).

Claims

1. A thermoformably shapeable multilayer article for a food product comprising: (i) a non-woven fiber layer comprising at least 50% by weight of fibers formed of at least one biodegradable polymer which comprises polylactic acid (PLA) having a melting point which is below 220 C., a thickness between 75 and 150 micrometers and a weight between 10 and 30 g/m.sup.2; (ii) a cellulose-fiber based support layer which comprises a greaseproof paper; and (iii) an adhesive layer comprised of a food-safe adhesive selected from the group consisting of acrylic adhesives, polyurethane adhesives and vinyl ethylene acetate, the adhesive layer adhesively joining the non-woven fiber layer to the cellulose fiber based support layer.

2. The multilayer article according to claim 1, wherein the at least one biodegradable polymer further comprises a polymer which is selected from the group consisting of PHA (polyhydroxyalkanoate), PHB (poly(hydroxybutyrate)), PHB(V) (poly(hydroxybutyrate-co-hydroxyvalerate)), PBS (poly(butylenesuccinate)), biopolyesters and mixtures thereof.

3. The multilayer article according to claim 1, wherein the cellulose-fiber based support comprises a laminated structure comprised of a kraft paper layer and a vegetable parchment layer.

4. The multilayer article according to claim 1, wherein the non-woven layer of fibers comprises 50- 100% by weight of the at least one biodegradable polymer and a remaining portion of the non-woven layer of fibers comprises cellulosic fibers.

5. The multilayer article according to claim 1, which further comprises a protective layer covering the non-woven layer of fibers comprising the at least one biodegradable polymer.

6. The multilayer article according to claim 1, wherein the non-woven layer of fibers comprises 100% by weight of the at least one biodegradable polymer melting point of which is below 220 C.

7. The multilayer article according to claim 3, wherein the vegetable parchment layer has a grammage of 40-45 g/m.sup.2 and the kraft paper has a grammage of 40-15 g/m.sup.2.

8. The multilayer article according to claim 3, wherein the cellulose-fiber based support has a siliconized side which is positioned next to the vegetable parchment layer.

9. The multilayer article according to claim 1, wherein the non-woven fiber layer comprises a layer of thermally bound fibers.

10. The multilayer article according to claim 1, wherein the adhesive is present in the adhesive layer in an amount between 3 and 5 g/m.sup.2 relative to the surface of the multilayer article.

11. The multilayer article according to claim 1, wherein the adhesive is present in the adhesive layer in an amount between 8 and 10 g/m.sup.2 relative to the surface of the multilayer article.

12. The multilayer article according to claim 1, wherein the cellulose-fiber based support comprises a paper having at least one side which is treated with silicone.

13. The multilayer article according to claim 1, wherein the cellulose-fiber based support comprises a parchment layer.

14. The multilayer article according to claim 5, which comprises a protective layer having a melting point which is over 220 C.

15. A multilayer article for a food product comprising: (i) a non-woven fiber layer of thermally bound fibers comprising at least 50% by weight of fibers formed of at least one biodegradable polymer which comprises polylactic acid (PLA) having a melting point which is below 220 C. and having a thickness between 75 and 150 micrometers and weight between 10 and 30 g/m.sup.2; (ii) a cellulose-fiber based support layer which comprises a parchment paper; and (iii) an adhesive layer comprised of an adhesive selected from the group consisting of acrylic adhesives, polyurethane adhesives and vinyl ethylene acetate, the adhesive layer adhesively joining the non-woven fiber layer to the cellulose fiber based support layer.

16. The multilayer article according to claim 15, wherein the at least one biodegradable polymer further comprises a polymer which is selected from the group consisting of PHA (polyhydroxyalkanoate), PHB (poly(hydroxybutyrate)), PHB(V) (poly(hydroxybutyrate-co-hydroxyvalerate)), PBS (poly(butylenesuccinate)), biopolyesters and mixtures thereof.

17. The multilayer article according to claim 15, wherein the cellulose-fiber based support comprises a laminated structure comprised of a kraft paper layer and a vegetable parchment layer.

18. The multilayer article according to claim 15, wherein the non-woven layer of fibers comprises 50-100% by weight of the at least one biodegradable polymer and a remaining portion of the non-woven layer of fibers comprises cellulosic fibers.

19. The multilayer article according to claim 15, which further comprises a protective layer covering the non-woven layer of fibers comprising the at least one biodegradable polymer.

20. The multilayer article according to claim 15, wherein the non-woven layer of fibers comprises 100% by weight of the at least one biodegradable polymer melting point of which is below 220 C.

21. The multilayer article according to claim 17, wherein the vegetable parchment layer has a grammage of 40-45 g/m.sup.2 and the kraft paper has a grammage of 40-15 g/m.sup.2.

22. The multilayer article according to claim 17, wherein the cellulose-fiber based support has a siliconized side which is positioned next to the vegetable parchment layer.

23. The multilayer article according to claim 15, wherein the non-woven fiber layer comprises a layer of thermally bound fibers.

24. The multilayer article according to claim 15, wherein the adhesive is present in the adhesive layer in an amount between 3 and 5 g/m.sup.2 relative to the surface of the multilayer article.

25. The multilayer article according to claim 15, wherein the adhesive is present in the adhesive layer in an amount between 8 and 10 g/m.sup.2 relative to the surface of the multilayer article.

26. The multilayer article according to claim 15, wherein the cellulose-fiber based support comprises a paper having at least one side which is treated with silicone.

27. The multilayer article according to claim 15, wherein the cellulose-fiber based support comprises a parchment layer.

28. The multilayer article according to claim 19, which comprises a protective layer having a melting point which is over 220 C.

29. A method of manufacturing the multilayer article for a food product according to claim 1, comprising the following steps: (a) applying the food-safe adhesive onto the cellulose-fiber based support comprising a grease proof paper; (b) applying the non-woven layer onto the cellulose-fiber based support on a side of the applied adhesive; and (c) drying of the resulting multilayer article.

30. A food accessory comprising the multilayer article according to claim 1, the food accessory comprising a flat bottom and a rim arranged by turning an edge area forming an inside of the accessory.

31. The food accessory according to claim 30, wherein the cellulose-fiber based support is arranged towards an inside of the food accessory.

32. A process for manufacturing the food accessory according to claim 30, comprising the steps of arranging a piece of the multilayer article, shaping the multilayer article and folding the edges of the multilayer article.

33. The process according to claim 32, wherein the process further comprises a step of heating the article after the step of shaping such that during the heating the at least one biodegradable polymer in the non-woven layer of fibers melts and adheres to surfaces in contact therewith.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) In the following, the invention will be described with reference to the accompanying exemplary, schematic drawings, in which

(2) FIG. 1 illustrates the multilayer article according an embodiment to the invention,

(3) FIG. 2 shows the multilayer article according to another embodiment of the invention,

(4) FIG. 3 shows the multilayer article according to another embodiment of the invention, and

(5) FIG. 4 shows a food product made of the multilayer article according to an embodiment of the invention.

DETAILED DESCRIPTION OF DRAWINGS

(6) A multilayer article is shown in FIG. 1 comprising successively: a cellulose-fiber based support 1; a layer of food-safe adhesive 2; a layer 3 comprising at least 50% by weight of a biodegradable polymer melting point of which is below 220 C., advantageously 100% by weight.

(7) The multilayer article shown in the FIG. 1 is manufactured by practising at least the following steps: applying a food-safe adhesive on the cellulose-fiber based support; applying a layer comprising at least 50% by weight of at least one biodegradable polymer melting point of which is below 220 C. on the cellulose-fiber based support on the side of the applied adhesive, and drying of the resulting multilayer article.

(8) FIG. 2 shows a specific embodiment of a multilayer article according to the invention where a protective layer 4 covers the layer 3 which is a non-woven fabric of PLA.

(9) This type of multilayer article comprises successively: a cellulose-fiber based support 1; a layer of food-safe adhesive 2; a non-woven fabric 3 comprising at least 50% by weight of polylactic acid (PLA) fibers, advantageously 100% by weight; a layer of food-safe adhesive 2; a protective layer 4.

(10) In FIG. 3 there is shown a multilayer article according to the invention where a specific layered structure of a cellulose-fiber based support 1 is provided. Namely, the cellulose-fiber based support 1 comprises successively a kraft paper layer 1, adhesive layer 2 and vegetable parchment layer 1 so that the kraft paper layer 1 is towards the non-woven fabric 3. The non-woven layer of fibers comprises advantageously 100% of PLA non-woven.

(11) In FIG. 4 there is shown a partial view a food accessory 10 in extremely schematic manner, which comprise a multilayer article shown in FIG. 1. The food accessory is here in the form of a mold, such as a baking mold. It has a generally a flat bottom 12 and a rim 14 arranged to circumscribe the bottom. The rim has been provided by turning the edge area from the plane of the bottom so that an inside 16 of the accessory is formed. As can be seen in the FIG. 4 the cellulose-fiber based support 1 is arranged towards inside of the food accessory. The raised rim 14 may be provided by pleating, in which cases the edges include pleats as depicted in section 4b showing a partial cross sectional view of the rim at a location of one pleat. The food accessory advantageously has rolled rims 18 on the periphery thereof. The mold form is selected suitably according to the need and may be similar in shape to those used in the agri-food industry and especially in the preparation of quiches. Advantageously it has a circular shape. Advantageously the food accessory is a mold. The food accessory is manufactured advantageously so that piece of the multilayer article as shown in FIG. 1 is provided and shaped according to requirements of the case and the edges of the multilayer article are folded to form the rim 18. The accessory may be heated in order to increase and/or strengthen the bonds of the non-woven layer of fibers 3. During the heating the at least one biodegradable polymer in the non-woven fabric 3 melts and adheres to surfaces being in contact with it making the food accessory more rigid.

(12) In case the heating is not done during the process of manufacturing the food accessory, which may be the for example when the food accessory is a baking mold, the mold is heated in an oven during the baking and the above mentioned melting biodegradable polymer in the non-woven fabric 3 takes place during baking and solidifying after the baking, which makes the food accessory rigid as well.

(13) While the invention has been described herein by way of examples in connection with what are, at present, considered to be the most preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but is intended to cover various combinations or modifications of its features, and several other applications included within the scope of the invention, as defined in the appended claims. The details mentioned in connection with any embodiment above may be used in connection with another embodiment when such a combination is technically feasible.