U.S. patent application number 09/772593 was filed with the patent office on 2002-01-24 for cellulosic and lignocellulosic materials and compositions and composites made therefrom.
Invention is credited to Lagace, Arthur P., Medoff, Marshall.
Application Number | 20020010229 09/772593 |
Document ID | / |
Family ID | 27540738 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020010229 |
Kind Code |
A1 |
Medoff, Marshall ; et
al. |
January 24, 2002 |
Cellulosic and lignocellulosic materials and compositions and
composites made therefrom
Abstract
Cellulosic or lignocellulosic materials, and compositions and
composites made therefrom, are disclosed.
Inventors: |
Medoff, Marshall;
(Brookline, MA) ; Lagace, Arthur P.; (Newtonville,
MA) |
Correspondence
Address: |
CHARLES J. BOUDREAU
Fish & Richardson P.C.
Suite 2800
45 Rockefeller Plaza
New York
NY
10111
US
|
Family ID: |
27540738 |
Appl. No.: |
09/772593 |
Filed: |
January 30, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09772593 |
Jan 30, 2001 |
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09337580 |
Jun 22, 1999 |
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6207729 |
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09337580 |
Jun 22, 1999 |
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08961863 |
Oct 31, 1997 |
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5973035 |
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09337580 |
Jun 22, 1999 |
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09338209 |
Jun 22, 1999 |
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09338209 |
Jun 22, 1999 |
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08921807 |
Sep 2, 1997 |
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5952105 |
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09338209 |
Jun 22, 1999 |
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09290031 |
Apr 9, 1999 |
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6258876 |
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Current U.S.
Class: |
523/129 |
Current CPC
Class: |
A61K 9/2068 20130101;
Y10T 428/249925 20150401; B29B 17/0026 20130101; C08L 101/00
20130101; Y10T 428/249924 20150401; Y02W 30/701 20150501; C08J
11/06 20130101; Y02W 30/62 20150501; B29K 2311/12 20130101; B32B
27/10 20130101; C08J 5/04 20130101; C08J 5/045 20130101; A23L 33/24
20160801; B29L 2007/002 20130101; A01N 25/34 20130101; C08L 101/00
20130101; C08L 2666/26 20130101 |
Class at
Publication: |
523/129 |
International
Class: |
C08K 011/00 |
Claims
1. A composite comprising a resin and fiber, wherein the fiber is
cellulosic or lignocellulosic fiber that has been sheared.
2. The composite of claim 1, comprising at least about 5% by weight
sheared fiber.
3. The composite of claim 1, wherein the fiber is newsprint.
4. The composite of claim 1, wherein the fiber is jute.
5. The composite of claim 1, wherein the fiber is kenaf.
6. The composite of claim 1, wherein the fiber is magazine
paper.
7. The composite of claim 1, wherein the fiber is bleached kraft
board.
8. The composite of claim 1, wherein the fiber is poly-coated
paper.
9. The composite of claim 1, wherein the resin is a thermoplastic
resin.
10. The composite of claim 9, wherein the resin is selected from
the group consisting of polystyrene, polycarbonate, polybutylene,
thermoplastic polyesters, polyethers, thermoplastic polyurethane,
PVC, and Nylon.
11. The composite of claim 9, wherein the thermoplastic resin is
polyethylene.
12. The composite of claim 9, wherein the thermoplastic resin is
polypropylene.
13. The composite of claim 1, wherein the composite comprises about
30% to about 70% by weight resin and about 30% to about 70% by
weight fiber.
14. A composite comprising polyethylene and fiber, wherein the
fiber is cellulosic or lignocellulosic fiber that has been
sheared.
15. A composite comprising a resin and fiber, wherein the composite
has a flexural strength of at least 3,000 psi, wherein the fiber is
cellulosic or lignocellulosic fiber that has been sheared.
16. The composite of claim 15, wherein the composite has a flexural
strength of at least 6,000 psi.
17. The composite of claim 15, wherein the composite has a flexural
strength of at least 10,000 psi.
18. A process for manufacturing a composite, the process comprising
shearing cellulosic or lignocellulosic fiber, and combining the
sheared cellulosic or lignocellulosic fiber with a resin.
19. The process of claim 18, wherein the resin is a thermoplastic
resin.
20. The process of claim 18, wherein the step of shearing the
cellulosic or lignocellulosic fiber comprises shearing with a
rotary knife cutter.
21. A process for preparing a texturized fibrous material, the
process comprising: shearing a cellulosic or lignocellulosic
material having internal fibers.
22. The method of claim 21, wherein said cellulosic or
lignocellulosic material is selected from the group consisting of
flax, hemp, cotton, jute, rags, paper, paper products, and
byproducts of paper manufacturing.
23. The method of claim 21, wherein the cellulosic or
lignocellulosic material is pulp board.
24. The method of claim 21, wherein the cellulosic or
lignocellulosic material is a synthetic material.
25. The method of claim 21, wherein the cellulosic or
lignocellulosic material is a non-woven material.
26. The method of claim 21, wherein the cellulosic or
lignocellulosic material is poly-coated paper.
27. The method of claim 21, wherein at least about 50% of the
fibers have a length/diameter ratio of at least about 5.
28. The method of claim 21, wherein at least about 50% of the
fibers have a length/diameter ratio of at least about 25.
29. The method of claim 21, wherein at least about 50% of the
fibers have a length/diameter ratio of at least about 50.
30. A fibrous material comprising a cellulosic or lignocellulosic
material, wherein said cellulosic or lignocellulosic material is
sheared to the extent that it has a bulk density less than about
0.5 g/cm.sup.3.
31. The fibrous material of claim 30, wherein said material is
incorporated into a structure or carrier.
32. The fibrous material of claim 31, wherein the structure or
carrier also comprises a fibrous material having a bulk density
less than about 0.5 g/cm.sup.3.
33. The fibrous material of claim 30, wherein said texturized
fibrous material has a bulk density less than about 0.2 grams per
cubic centimeter.
34. The fibrous material of claim 30, wherein said texturized
fibrous material has a bulk density on the order of about 0.1 grams
per cubic centimeter.
35. The fibrous material of claim 30, wherein said cellulosic or
lignocellulosic material comprises paper or paper products.
36. A composition comprising the fibrous material of claim 30 and a
chemical or chemical formulation.
37. The composition of claim 36, wherein the chemical formulation
comprises a pharmaceutical.
38. The composition of claim 36, wherein the chemical formulation
an agricultural compound.
39. The composition of claim 36, wherein the chemical formulation
comprises an enzyme.
40. A composition comprising the fibrous material of claim 30 and a
liquid.
41. A composition comprising the fibrous material of claim 30 and
particulate, powdered, or granulated solid.
42. The composition of claim 41, wherein the solid comprises plant
seed.
43. The composition of claim 41, wherein the solid comprises a
foodstuff.
44. The composition of claim 41, wherein the solid comprises
bacteria.
45. The composite of claim 1, further comprising an inorganic
additive.
46. The composite of claim 45, wherein the inorganic additive is
selected from the group consisting of calcium carbonate, graphite,
asbestos, wollastonite, mica, glass, fiber glass, chalk, talc,
silica, ceramic, ground construction waste, tire rubber powder,
carbon fibers, and metal fibers.
47. The composite of claim 46, wherein the inorganic additive
comprises from about 0.5% to about 20% of the total weight of the
composite.
48. The composite of claim 1, wherein said composite is in the form
of a pallet.
49. The composite of claim 48, wherein said pallet is injection
molded.
50. The composite of claim 1, wherein said composite is in the form
of an article selected from the group consisting of panels, pipes,
decking materials, boards, housings, sheets, poles, straps,
fencing, members, doors, shutters, awnings, shades, signs, frames,
window casings, backboards, wallboards, flooring, tiles, railroad
ties, forms, trays, tool handles, stalls, bedding, dispensers,
staves, films, wraps, totes, barrels, boxes, packing materials,
baskets, straps, slips, racks, casings, binders, dividers, walls,
indoor and outdoor carpets, rugs, wovens, and mats, frames,
bookcases, sculptures, chairs, tables, desks, art, toys, games,
wharves, piers, boats, masts, pollution control products, septic
tanks, automotive panels, substrates, computer housings, above- and
below-ground electrical casings, furniture, picnic tables, tents,
playgrounds, benches, shelters, sporting goods, beds, bedpans,
thread, filament, cloth, plaques, trays, hangers, servers, pools,
insulation, caskets, bookcovers, clothes, canes, crutches, and
other construction, agricultural, material handling,
transportation, automotive, industrial, environmental, naval,
electrical, electronic, recreational, medical, textile, and
consumer products.
51. The composite of claim 1, wherein said composite is in the form
of a fiber, filament, or film.
52. A composite comprising a resin and fibrous reinforcement,
wherein the fibrous reinforcement has a bulk density less than
about 0.5 g/cm.sup.3.
53. The composite of claim 52, wherein the fibrous reinforcement
has a bulk density less than about 0.2 g/cm.sup.3.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 09/337,580, filed Jun. 22, 1999, which is a
continuation in part of U.S. patent application Ser. No.
08/961,863, filed Oct. 31, 1997, now issued as U.S. Pat. No.
5,973,035; is a continuation-in-part of U.S. patent application
Ser. No. 09/338,209, filed Jun. 22, 1999, which is a
continuation-in-part of U.S. patent application Ser. No.
08/921,807, filed Sep. 2, 1997, now issued as U.S. Pat. No.
5,952,105; and is a continuation in part of U.S. patent application
Ser. No. 09/290,031, filed Apr. 9, 1999, which is a division of
U.S. patent application Ser. No. 08/961,863, filed Oct. 31, 1997,
now issued as U.S. Pat. No. 5,973,035.
BACKGROUND OF THE INVENTION The invention relates to texturized
cellulosic or lignocellulosic materials and compositions and
composites made from such texturized materials.
[0002] Cellulosic and lignocellulosic materials are produced,
processed, and used in large quantities in a number of
applications. Once used, these materials are usually discarded. As
a result, there is an ever-increasing amount of waste cellulosic
and lignocellulosic material.
SUMMARY OF THE INVENTION
[0003] In general, the invention features texturized cellulosic or
lignocellulosic materials and compositions and composites made
therefrom.
[0004] In one embodiment, the invention features a process for
preparing a texturized fibrous material. The process involves
shearing a cellulosic or lignocellulosic material having internal
fibers (e.g., flax; hemp; cotton; jute; rags; finished or
unfinished paper, paper products, including poly-coated paper, or
byproducts of paper manufacturing such as pulp board; or synthetic
cellulosic or lignocellulosic materials such as rayon), to the
extent that the internal fibers are substantially exposed,
resulting in texturized fibrous material. The cellulosic or
lignocellulosic material can be a woven material such as a woven
fabric, or a non-woven material such as paper or bathroom tissue.
The exposed fibers of the texturized fibrous material can have a
length/diameter (L/D) ratio of at least about 5 (at least about 5,
10, 25, 50, or more). For example, at least about 50% of the fibers
can have L/D ratios of this magnitude.
[0005] In another embodiment, the invention features a texturized
fibrous material that includes a cellulosic or lignocellulosic
material having internal fibers, where the cellulosic or
lignocellulosic material is sheared to the extent that the internal
fibers are substantially exposed.
[0006] The texturized fibrous material can, for example, be
incorporated into (e.g., associated with, blended with, adjacent
to, surrounded by, or within) a structure or carrier (e.g., a
netting, a membrane, a flotation device, a bag, a shell, or a
biodegradable substance). Optionally, the structure or carrier may
itself be made from a texturized fibrous material (e.g., a
texturized fibrous material of the invention), or of a composition
or composite of a texturized fibrous material.
[0007] The texturized fibrous material can have a bulk density less
than about 0.5 grams per cubic centimeter, or even less than about
0.2 g/cm.sup.3.
[0008] Compositions that include the texturized fibrous materials
described above, together with a chemical or chemical formulation
(e.g., a pharmaceutical such as an antibiotic or contraceptive,
optionally with an excipient; an agricultural compound such as a
fertilizer, herbicide, or pesticide; or a formulation that includes
enzymes) are also within the scope of the invention, as are
compositions that include the texturized fibrous materials and
other liquid or solid ingredients (e.g., particulate, powdered, or
granulated solids such as plant seed, foodstuffs, or bacteria).
[0009] Composites that include thermoplastic resin and the
texturized fibrous materials are also contemplated. The resin can
be, for example, polyethylene, polypropylene, polystyrene,
polycarbonate, polybutylene, a thermoplastic polyester, a
polyether, a thermoplastic polyurethane, polyvinylchloride, or a
polyamide, or a combination of two or more resins.
[0010] In some cases, at least about 5% by weight (e.g., 5%, 10%,
25%, 50%, 75%, 90%, 95%, 99%, or about 100%) of the fibrous
material included in the composites is texturized.
[0011] The composite may include, for example, about 30% to about
70% by weight resin and about 30% to about 70% by weight texturized
fibrous material, although proportions outside of these ranges may
also be used. The composites can be quite strong, in some cases
having a flexural strength of at least about 6,000 to 10,000
psi.
[0012] In another embodiment, the invention features a composite
including a resin, such as a thermoplastic resin, and at least
about 2% by weight, more preferably at least about 5% by weight,
texturized cellulosic or lignocellulosic fiber. The invention also
features a composite that includes polyethylene and at least about
50% by weight texturized cellulosic or lignocellulosic fiber.
[0013] The invention further features composites, including a resin
and cellulosic or lignocellulosic fiber, that have flexural
strengths of at least about 3,000 psi, or tensile strengths of at
least about 3,000 psi.
[0014] In addition, the invention features a process for
manufacturing a composite; the process includes shearing cellulosic
or lignocellulosic fiber to form texturized cellulosic or
lignocellulosic fiber, then combining the texturized fiber with a
resin. A preferred method includes shearing the fiber with a rotary
knife cutter. The invention also features a process for
manufacturing a composite that includes shearing cellulosic or
lignocellulosic fiber and combining the fiber with a resin.
[0015] The composites can also include inorganic additives such as
calcium carbonate, graphite, asbestos, wollastonite, mica, glass,
fiber glass, chalk, talc, silica, ceramic, ground construction
waste, tire rubber powder, carbon fibers, or metal fibers (e.g.,
stainless steel or aluminum). The inorganic additives can represent
about 0.5% to about 20% of the total weight of the composite.
[0016] The composite can be in the form of, for example, a pallet
(e.g., an injection molded pallet), pipes, panels, decking
materials, boards, housings, sheets, poles, straps, fencing,
members, doors, shutters, awnings, shades, signs, frames, window
casings, backboards, wallboards, flooring, tiles, railroad ties,
forms, trays, tool handles, stalls, bedding, dispensers, staves,
films, wraps, totes, barrels, boxes, packing materials, baskets,
straps, slips, racks, casings, binders, dividers, walls, indoor and
outdoor carpets, rugs, wovens, and mats, frames, bookcases,
sculptures, chairs, tables, desks, art, toys, games, wharves,
piers, boats, masts, pollution control products, septic tanks,
automotive panels, substrates, computer housings, above- and
below-ground electrical casings, furniture, picnic tables, tents,
playgrounds, benches, shelters, sporting goods, beds, bedpans,
thread, filament, cloth, plaques, trays, hangers, servers, pools,
insulation, caskets, bookcovers, clothes, canes, crutches, and
other construction, agricultural, material handling,
transportation, automotive, industrial, environmental, naval,
electrical, electronic, recreational, medical, textile, and
consumer products. The composites can also be in the form of a
fiber, filament, or film.
[0017] The terms "texturized cellulosic or lignocellulosic
material" and "texturized fibrous material" as used herein, mean
that the cellulosic or lignocellulosic material has been sheared to
the extent that its internal fibers are substantially exposed. At
least about 50%, more preferably at least about 70%, of these
fibers have a length/diameter (L/D) ratio of at least 5, more
preferably at least 25, or at least 50. An example of texturized
cellulosic material is shown in FIG. 1.
[0018] The texturized fibrous materials of the invention have
properties that render them useful for various applications. For
example, the texturized fibrous materials have absorbent
properties, which can be exploited, for example, for pollution
control. The fibers are generally biodegradable, making them
suitable, for example, for drug or chemical delivery (e.g., in the
treatment of humans, animals, or in agricultural applications). The
texturized fibrous materials can also be used to reinforce
polymeric resins.
[0019] Those composites that include texturized fibrous material
and resin are strong, lightweight, and inexpensive. The raw
materials used to make the composites are available as virgin or
recycled materials; for example, they may include discarded
containers composed of resins, and waste cellulosic or
lignocellulosic fiber.
[0020] Other features and advantages of the invention will be
apparent from the following detailed description, and from the
claims.
BRIEF DESCRIPTION OF THE DRAWING
[0021] FIG. 1 is a photograph of a texturized newspaper, magnified
fifty times.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Examples of cellulosic raw materials include paper and paper
products such as newsprint, poly-coated paper, and effluent from
paper manufacture; examples of lignocellulosic raw materials
include wood, wood fibers, and wood-related materials, as well as
materials derived from kenaf, grasses, rice hulls, bagasse, cotton,
jute, other stem plants (e.g., hemp, flax, bamboo; both bast and
core fibers), leaf plants (e.g., sisal, abaca), and agricultural
fibers (e.g., cereal straw, corn cobs, rice hulls, and coconut
hair). Aside from virgin raw materials, post-consumer, industrial
(e.g., offal), and processing waste (e.g., effluent) can also be
used as fiber sources.
[0023] Preparation of Texturized Fibrous Material
[0024] If scrap cellulosic or lignocellulosic materials are used,
they should be clean and dry. The raw material can be texturized
using any one of a number of mechanical means, or combinations
thereof. One method of texturizing includes first cutting the
cellulosic or lignocellulosic material into 1/4- to 1/2-inch
pieces, if necessary, using a standard cutting apparatus.
Counter-rotating screw shredders and segmented rotating screw
shredders such as those manufactured by Munson (Utica, N.Y.) can
also be used, as can a standard document shredder as found in many
offices.
[0025] The cellulosic or lignocellulosic material is then sheared
with a rotary cutter, such as the one manufactured by Sprout,
Waldron Companies, as described in Perry's Chem. Eng. Handbook, 6th
Ed., at 8-29 (1984). Although other settings can be used, the
spacing between the rotating knives and bed knives of the rotary
cutter is typically set to 0.020" or less, and blade rotation is
set to 750 rpm or more. The rotary cutter can be cooled to
100.degree. C. or lower during the process, for example, using a
water jacket.
[0026] The texturized material is passed through a discharge
screen. Larger screens (e.g., up to 6 mm) can be used in
large-scale production. The cellulosic or lignocellulosic feedstock
is generally kept in contact with the blades of the rotary cutter
until the fibers are pulled apart; smaller screens (e.g., 2 mm
mesh) provide longer residence times and more complete
texturization, but can result in lower length/diameter (L/D) aspect
ratios. A vacuum drawer can be attached to the screen to maximize
and maintain fiber length/diameter aspect ratio.
[0027] The texturized fibrous materials can be directly stored in
sealed bags or may be dried at approximately 105.degree. C. for
4-18 hours (e.g., until the moisture content is less than about
0.5%) immediately before use. FIG. 1 is an SEM photograph of
texturized newspaper.
[0028] Alternative texturizing methods include stone grinding,
mechanical ripping or tearing, and other methods whereby the
material's internal fibers can be exposed (e.g., pin grinding, air
attrition milling).
[0029] Uses of Texturized Fibrous Material
[0030] Texturized fibrous materials and compositions and composites
of such fibers with other chemicals and chemical formulations can
be prepared to take advantage of the material's properties. The
materials can be used to absorb chemicals, for example, potentially
absorbing many times their own weight. Thus, the materials could,
for instance, be used to absorb spilled oil, or for clean-up of
environmental pollution, for example, in water, in the air, or on
land. Similarly, the material's absorbent properties, together with
its biodegradability, also make them useful for delivery of
chemicals or chemical formulations. For example, the materials can
be treated with solutions of enzymes or pharmaceuticals such as
antibiotics, nutrients, or contraceptives, and any necessary
excipients, for drug delivery (e.g., for treatment of humans or
animals, or for use as or in animal feed and/or bedding), as well
as with solutions of fertilizers, herbicides, or pesticides. The
materials can optionally be chemically treated to enhance a
specific absorption property. For example, the materials can be
treated with silanes to render them lipophilic.
[0031] Compositions including texturized materials combined with
liquids or particulate, powdered, or granulated solids can also be
prepared. For example, texturized materials can be blended with
seeds (i.e., with or without treatment with a solution of
fertilizer, pesticides, etc.), foodstuffs, or bacteria (e.g.,
bacteria that digest toxins). The ratio of fibrous materials to the
other components of the compositions will depend on the nature of
the components and readily be adjusted for a specific product
application.
[0032] In some cases, it may be advantageous to associate the
texturized fibrous materials, or compositions or composites of such
materials, with a structure or carrier such as a netting, a
membrane, a flotation device, a bag, a shell, or a biodegradable
substance. optionally, the structure of carrier may itself be made
of a texturized fibrous material (e.g., a material of the
invention), or a composition or composite thereof.
[0033] Composites of Texturized Fibrous Material and Resin
[0034] Texturized fibrous materials can also be combined with
resins to form strong, lightweight composites. Materials that have
been treated with chemicals or chemical formulations, as described
above, can similarly be combined with biodegradable or
non-biodegradable resins to form composites, allowing the
introduction of, for example, hydrophilic substances into otherwise
hydrophobic polymer matrices. Alternatively, the composites
including texturized fibrous materials and resin can be treated
with chemicals or chemical formulations.
[0035] The texturized cellulosic or lignocellulosic material
provides the composite with strength. The composite may include
from about 10% to about 90%, for example from about 30% to about
70%, of the texturized cellulosic or lignocellulosic material by
weight.
[0036] The resin encapsulates the texturized cellulosic or
lignocellulosic material in the composites, and helps control the
shape of the composites. The resin also transfers external loads to
the fibrous materials and protects the fiber from environmental and
structural damage. Composites can include, for example, about 10%
to about 90%, more preferably about 30% to about 70%, by weight, of
the resin.
[0037] Resins are used in a variety of applications, for example,
in food packaging. Food containers made of resins are typically
used once, then discarded. Examples of resins that are suitably
combined with texturized fibers include polyethylene (including,
e.g., low density polyethylene and high density polyethylene),
polypropylene, polystyrene, polycarbonate, polybutylene,
thermoplastic polyesters (e.g., PET), polyethers, thermoplastic
polyurethane, PVC, polyamides (e.g., nylon) and other resins. It is
preferred that the resins have a low melt flow index. Preferred
resins include polyethylene and polypropylene with melt flow
indices of less than 3 g/10 min, and more preferably less than 1
g/10 min.
[0038] The resins can be purchased as virgin material, or obtained
as waste materials, and can be purchased in pelletized or
granulated form. One source of waste resin is used polyethylene
milk bottles. If surface moisture is present on the pelletized or
granulated resin, however, it should be dried before use.
[0039] The composites can also include coupling agents. The
coupling agents help to bond the hydrophilic fibers to the
hydrophobic resins. Examples of coupling agents include maleic
anhydride modified polyethylenes, such those in the FUSABOND.RTM.
(available from DuPont, Delaware) and POLYBOND.RTM. (available from
Uniroyal Chemical, Conn.) series. One suitable coupling agent is a
maleic anhydride modified high density polyethylene such as
FUSABOND.RTM. MB 100D.
[0040] The composites can also contain additives known to those in
the art of compounding, such as plasticizers, lubricants,
antioxidants, opacificers, heat stabilizers, colorants, flame
retardants, biocides, impact modifiers, photostabilizers, and
antistatic agents.
[0041] The composites can also include inorganic additives such as
calcium carbonate, graphite, asbestos, wollastonite, mica, glass,
fiber glass, chalk, silica, talc, ceramic, ground construction
waste, tire rubber powder, carbon fibers, or metal fibers (e.g.,
aluminum, stainless steel). When such additives are included, they
are typically present in quantities of from about 0.5% up to about
20-30% by weight. For example, submicron calcium carbonate can be
added to the composites of fiber and resin to improve impact
modification characteristics or to enhance composite strength.
[0042] Preparation of Compositions
[0043] Compositions containing the texturized cellulosic or
lignocellulosic materials and chemicals, chemical formulations, or
other solids can be prepared, for example, in various immersion,
spraying, or blending apparatuses, including, but not limited to,
ribbon blenders, cone blenders, double cone blenders, and
Patterson-Kelly "V" blenders.
[0044] For example, a composition containing 90% by weight
texturized cellulosic or lignocellulosic material and 10% by weight
ammonium phosphate or sodium bicarbonate can be prepared in a cone
blender to create a fire-retardant material for absorbing oil.
[0045] Preparation of Composites of Texturized Fiber and Resin
[0046] Composites of texturized fibrous material and resin can be
prepared as follows. A standard rubber/plastic compounding 2-roll
mill is heated to 325-400.degree. F. The resin (usually in the form
of pellets or granules) is added to the heated roll mill. After
about 5 to 10 minutes, the coupling agent is added to the roll
mill. After another five minutes, the texturized cellulosic or
lignocellulosic material is added to the molten resin/coupling
agent mixture. The texturized material is added over a period of
about 10 minutes.
[0047] The composite is removed from the roll mill, cut into sheets
and allowed to cool to room temperature. It is then compression
molded into plaques using standard compression molding
techniques.
[0048] Alternatively, a mixer, such as a Banbury internal mixer, is
charged with the ingredients. The ingredients are mixed, while the
temperature is maintained at less than about 190.degree. C. The
mixture can then be compression molded.
[0049] In another embodiment, the ingredients can be mixed in an
extruder mixer, such as a twin-screw extruder equipped with
co-rotating screws. The resin and the coupling agent are introduced
at the extruder feed throat; the texturized cellulosic or
lignocellulosic material is introduced about 1/3 of the way down
the length of the extruder into the molten resin. The internal
temperature of the extruder is maintained at less than about
190.degree. C. At the output, the composite can be, for example,
pelletized by cold strand cutting.
[0050] Alternatively, the mixture can first be prepared in a mixer,
then transferred to an extruder.
[0051] In another embodiment, the composite can be formed into
fibers, using fiber-forming techniques known to those in the art,
or into filaments for knitting, warping, weaving, braiding, or
making non-wovens. In a further embodiment, the composite can be
made into a film.
[0052] Properties of the Composites of Texturized Fibrous Material
and Resin
[0053] The resulting composites include a network of fibers,
encapsulated within a resin matrix. The fibers form a lattice
network, which provides the composite with strength. Since the
cellulosic or lignocellulosic material is texturized, the amount of
surface area available to bond to the resin is increased, in
comparison to composites prepared with un-texturized cellulosic or
lignocellulosic material. The resin binds to the surfaces of the
exposed fibers, creating an intimate blend of the fiber network and
the resin matrix. The intimate blending of the fibers and the resin
matrix further strengthens the composites.
[0054] Uses of the Composites of Texturized Fibrous Material and
Resin
[0055] The resin/fibrous material composites can be used in a
number of applications. The composites are strong and light weight;
they can be used, for example, as wood substitutes. The resin
coating renders the composites water-resistant, so they may be used
in outdoor applications. For example, the composites may be used to
make pallets, which are often stored outdoors for extended periods
of time, wine staves, rowboats, furniture, skis, and oars. Many
other uses are contemplated, including panels, pipes, decking
materials, boards, housings, sheets, poles, straps, fencing,
members, doors, shutters, awnings, shades, signs, frames, window
casings, backboards, wallboards, flooring, tiles, railroad ties,
forms, trays, tool handles, stalls, bedding, dispensers, staves,
films, wraps, totes, barrels, boxes, packing materials, baskets,
straps, slips, racks, casings, binders, dividers, walls, indoor and
outdoor carpets, rugs, wovens, and mats, frames, bookcases,
sculptures, chairs, tables, desks, art, toys, games, wharves,
piers, boats, masts, pollution control products, septic tanks,
automotive panels, substrates, computer housings, above- and
below-ground electrical casings, furniture, picnic tables, tents,
playgrounds, benches, shelters, sporting goods, beds, bedpans,
thread, filament, cloth, plaques, trays, hangers, servers, pools,
insulation, caskets, bookcovers, clothes, canes, crutches, and
other construction, agricultural, material handling,
transportation, automotive, industrial, environmental, naval,
electrical, electronic, recreational, medical, textile, and
consumer products. Numerous other applications are also envisioned.
The composites may also be used, for example, as the base or
carcass for a veneer product. Moreover, the composites can be, for
example, surface treated, grooved, milled, shaped, imprinted,
textured, compressed, punched, or colored. The surface of the
composites can be smooth or rough.
[0056] The following examples illustrate certain embodiments and
aspects of the present invention and not to be construed as
limiting the scope thereof.
EXAMPLES
Example 1
[0057] A 1500 pound skid of virgin, half-gallon juice cartons made
of polycoated white kraft board was obtained from International
Paper. Each carton was folded flat.
[0058] The cartons were fed into a 3 hp Flinch Baugh shredder at a
rate of approximately 15 to 20 pounds per hour. The shredder was
equipped with two rotary blades, each 12" in length, two fixed
blades, and a 0.3" discharge screen. The gap between the rotary and
fixed blades was 0.10".
[0059] The output from the shredder, consisting primarily of
confetti-like pieces, about 0.1" to 0.5" in width and about 0.25"
to 1" in length, was then fed into a Thomas Wiley Mill Model 2D5
rotary cutter. The rotary cutter had four rotary blades, four fixed
blades, and a 2 mm discharge screen. Each blade was approximately
2" long. The blade gap was set at 0.020".
[0060] The rotary cutter sheared the confetti-like pieces across
the knife edges, tearing the pieces apart and releasing a finely
texturized fiber at a rate of about one pound per hour. The fiber
had an average minimum L/D ratio of between five and 100 or more.
The bulk density of the texturized fiber was on the order of 0.1
g/cc.
Example 2
[0061] Composites of texturized fiber and resin were prepared as
follows. A standard rubber/plastic compounding 2-roll mill was
heated to 325-400.degree. F. The resin (usually in the form of
pellets or granules) was added to the heated roll mill. After about
5 to 10 minutes, the resin banded on the rolls (i.e., it melted and
fused on the rolls). The coupling agent was then added to the roll
mill. After another five minutes, the texturized cellulosic or
lignocellulosic material was added to the molten resin/coupling
agent mixture. The cellulosic or lignocellulosic fiber was added
over a period of about 10 minutes.
[0062] The composite was then removed from the roll mill, cut into
sheets, and allowed to cool to room temperature. Batches of about
80 g each were compression molded into 6".times.6".times.1/8"
plaques using standard compression molding techniques.
[0063] One composition contained the following ingredients:
1 Composition No. 1 Ingredient Amount (g) High density
polyethylene.sup.1 160 Old newspaper.sup.2 240 Coupling agent.sup.3
8 .sup.1Marlex 16007 .sup.2Texturized using rotary cutter with 2 mm
mesh .sup.3FUSABOND .RTM. 100D
[0064] The plaques were machined into appropriate test specimens
and tested according to the procedures outlined in the method
specified. Three different specimens were tested for each property,
and the mean value for each test was calculated. The properties of
Composition No. 1 are as follows:
2 Flexural strength (10.sup.3 psi) 9.81 (ASTM D790) Flexural
modulus (10.sup.5 psi) 6.27 (ASTM D790)
[0065] A second composition contains the following ingredients:
3 Composition No. 2 Ingredient Amount (g) High density
polyethylene.sup.1 150 Old magazines.sup.2 240 coupling agent.sup.3
8
[0066] The properties of Composition No. 2 are as follows:
4 Flexural strength (10.sup.3 psi) 9.06 (ASTM D790) Flexural
modulus (10.sup.5 psi) 6.78 (ASTM D790)
[0067] A third composition contains the following ingredients:
5 Composition No. 3 Ingredient Amount (g) HDPE.sup.1 160 Fiber
paper.sup.2 216 3.1 mm texturized kenaf 24 Coupling agent.sup.3
8
[0068] The properties of Composition No. 3 are as follows:
6 Flexural strength (10.sup.3 psi) 11.4 (ASTM D790) Flexural
modulus (10.sup.5 psi) 6.41 (ASTM D790)
[0069] A fourth composition contains the following ingredients:
7 Composition No. 4 Ingredient Amount (g) SUPERFLEX .TM. CaCO.sub.3
33 Fiber.sup.2,4 67 HDPE (w/3% compatibilizer).sup.1,3 100
.sup.4Virgin polycoated milk cartons
[0070] The properties of Composition No. 4 are as follows:
8 Flexural strength (10.sup.5 psi) 8.29 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural modulus (10.sup.5 psi)
10.1 (ASTM D790) Notch Izod (ft-lb/in) 1.39 (ASTM D256-97)
[0071] A fifth composition contains the following ingredients:
9 Composition No. 5 Ingredient Amount (parts) SUPERFLEX .TM.
CaCO.sub.3 22 Fiber.sup.2,4 67 HDPE (w/3% compatibilizer).sup.1,3
100
[0072] The properties of Composition No. 5 are as follows:
t,0194
[0073] A sixth composition contains the following ingredients:
Composition No. 6
[0074]
10 Ingredient Amount (parts) ULTRAFLEX .TM. CaCO.sub.3 33
Fiber.sup.2,4 67 HDPE/compatibilizer.sup.1,3 100
[0075] The properties of Composition No. 6 are as follows:
11 Flexural strength (10.sup.5 psi) 7.43 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural modulus (10.sup.5 psi)
11.6 (ASTM D790) Notch Izod (ft-lb/in) 1.27 (astm D256-97)
[0076] A seventh composition contains the following
ingredients:
Composition No. 7
[0077]
12 Ingredient Amount (pbw) HDPE (w/3% compatibilizer).sup.3,5 60
Kraftboard.sup.2 40 .sup.5HDPE with melt-flow index <1
[0078] The properties of Composition No. 7 are as follows:
13 Flexural Strength (10.sup.5 psi) 7.79 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural Modulus (10.sup.5 psi)
7.19 (ASTM D790)
[0079] other embodiments are within the claims.
* * * * *