Cellulose materials and methods of making and using the same

Abstract

The present disclosure provides materials such as cellulose based materials and composite materials. Also provided herein are methods for making or using the materials.

What is claimed is: 
     
         1 . A composite material comprising:
 a first layer comprising at least pulp, wherein the pulp is derived from a first plant fiber;   a second layer comprising at least fibrillated cellulose, wherein the fibrillated cellulose is based on a second plant fiber, and   wherein the first layer is impregnated with the second layer to form a substantially continuous layer.   
     
     
         2 . The composite material of  claim 1 , wherein the plant fiber comprises a fiber from one or more of the following: bagasse, flax, hemp, and palm. 
     
     
         3 . The material of  claim 1 , wherein the fibrillated cellulose comprises micro-fibrillated cellulose (MFC). 
     
     
         4 . The material of  claim 1 , wherein the fibrillated cellulose comprises nano-fibrillated cellulose (NFC). 
     
     
         5 . The composite material of  claim 1 , wherein the material further comprising:
 a third layer that comprises a fibrillated cellulose, and   wherein the first layer is disposed between the second layer and the third layer, wherein the first layer is impregnated with the second layer and the third layer to form the substantially continuous layer.   
     
     
         6 . The composite material of  claim 1 , wherein the material further comprising:
 another layer that comprises the at least pulp; and   wherein the second layer is disposed between the first layer and the another layer, wherein the first layer and the another layer are impregnated with the second layer to form the substantially continuous layer.   
     
     
         7 . The composite material of  claim 1 , wherein the fibrillated cellulose has an average diameter less than 100 nm. 
     
     
         8 . The composite material of  claim 1 , wherein the first layer comprises a polymer. 
     
     
         9 . The composite material of  claim 8 , wherein the polymer comprises one of the following:
 polylactic acid (PLA), chitin, sodium alginate, thermoplastic starch, polyethylene, chitosan, polyhydroxyalkanoates (PHA, bacterial polyesters), or polypropylene.   
     
     
         10 . The composite material of  claim 8 , wherein the polymer is in a form of fiber or powder. 
     
     
         11 . The composite material of  claim 1 , wherein the first layer is impregnated with the second layer in a shape of a consumer product. 
     
     
         12 . The composite material of  claim 11 , wherein the consumer product comprises one of the following: a food package, a food serving vehicle, a motor vehicle, a home or office appliance, an electronic device, home or office furniture, or a children's product. 
     
     
         13 . The composite material of  claim 11 , wherein the consumer product comprises one of the following: a sheet, a bag, a container, a plate, tray, a container for instant noodles, a coffee capsule, a coffee pod, a coffee pouch, or a single-use coffee container. 
     
     
         14 . The composite material of  claim 13 , wherein the coffee capsule comprises a capsule main body (CMB) and a capsule lid (CL). 
     
     
         15 . The composite material of  claim 1 , wherein the second plant fiber comprises a fiber from bamboo. 
     
     
         16 . A method of making a composite comprising:
 preparing a material via mixing plant cellulose, fibrillated cellulose, and a polymer in a liquid resin;   receiving the liquid resin by a base layer, wherein the base layer comprises at least pulp, wherein the base layer is impregnated with the material to form the composite at a cellulose level; and   forming the composite to a three dimensional object.   
     
     
         17 . The method of  claim 16 , wherein the three dimensional object comprises at least one of the following: a food package, a food serving vehicle, a motor vehicle, a home or office appliance, an electronic device, home or office furniture, or a children's product. 
     
     
         18 . The method of  claim 16 , wherein the three dimensional object comprises at least one of the following: a sheet, a bag, container, plate, tray, a container for instant noodles, a coffee capsule, a coffee pod, a coffee pouch, or a single-use coffee container. 
     
     
         19 . A method of manufacturing a consumer product, comprising:
 preparing a material having at least fibrillated cellulose in a liquid resin;   receiving the liquid resin by a base layer, wherein the base layer comprises at least pulp; and   wherein the base layer is impregnated with the material to form the composite at a cellulose level before moisture is removed from the base layer.   
     
     
         20 . The method of manufacturing of  claim 19 , wherein the base layer comprises a polymer, wherein the polymer comprises one of the following: polylactic acid (PLA), chitin, sodium alginate, thermoplastic starch, polyethylene, chitosan, polyhydroxyalkanoates (PHA, bacterial polyesters), or polypropylene.