U.S. patent application number 14/206557 was filed with the patent office on 2014-09-18 for system and methods for treatment of biomass products or residues and resulting composition.
The applicant listed for this patent is University of Louisiana at Lafayette. Invention is credited to William Chirdon.
Application Number | 20140261075 14/206557 |
Document ID | / |
Family ID | 51521553 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140261075 |
Kind Code |
A1 |
Chirdon; William |
September 18, 2014 |
SYSTEM AND METHODS FOR TREATMENT OF BIOMASS PRODUCTS OR RESIDUES
AND RESULTING COMPOSITION
Abstract
The present invention is directed to a system and methods for
treatment of biomass products or residues to obtain valuable
adhesives and composite materials. Certain embodiments require no
purification of a biomass product or residue to produce an
adhesive. Certain embodiments include a treatment of post
extraction algae residue configured to produce an adhesive.
Advantageously, such use of post extraction algae residue adds
value to alternative energy produced by extracting oil from
algae.
Inventors: |
Chirdon; William;
(Lafayette, LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
University of Louisiana at Lafayette |
Lafayette |
LA |
US |
|
|
Family ID: |
51521553 |
Appl. No.: |
14/206557 |
Filed: |
March 12, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61777921 |
Mar 12, 2013 |
|
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Current U.S.
Class: |
106/124.1 ;
435/134 |
Current CPC
Class: |
C09J 189/04
20130101 |
Class at
Publication: |
106/124.1 ;
435/134 |
International
Class: |
C09J 189/04 20060101
C09J189/04 |
Claims
1. A method for producing an adhesive from biomass products or
residues, comprising the steps of: a. processing the biomass
product or residue; and b. mixing the biomass product or residue
with a solution configured to denature proteins in the biomass
product or residue.
2. The method of claim 1, wherein said processing step is comprised
of: a. cultivating the biomass product or residue in an
environment; b. harvesting the biomass product or residue from the
environment; and c. extracting oil from the biomass product or
residue, thereby generating a byproduct of the biomass product or
residue.
3. The method of claim 1, further comprising a step of grinding the
biomass product or residue into ground post extraction algae
residue before said mixing step.
4. The method of claim 1, further comprising a step of heating the
adhesive at a temperature condition between 20.degree. C. and
70.degree. C. for a reaction time of between 30 minutes and 3
hours.
5. The method of claim 1, further comprising a step of adjusting at
least one parameter selected from the group of temperature
condition, reaction time, and concentration of solution to regulate
a level of denaturation of proteins in the adhesive.
6. The method of claim 1, further comprising a step of removing
insoluble solids from the adhesive, wherein said removing step
includes at least filtering or centrifuging the adhesive.
7. The method of claim 1, further comprising a step of adding a
preservative configured to provide mold resistance.
8. An adhesive prepared by from biomass product comprising the
steps of: a. processing biomass product to produce a residue; and
b. mixing the residue with a solution configured to denature
proteins in the residue to create adhesive.
9. The adhesive of claim 8, wherein the processing step is
comprised of: a. cultivating the biomass product or residue in an
environment; b. harvesting the biomass product or residue from the
environment; and c. extracting oil from the biomass product or
residue, thereby generating a byproduct of the biomass product or
residue.
10. The adhesive of claim 8, further comprising a step of grinding
the residue into ground post extraction algae residue before said
mixing step.
11. The adhesive of claim 8, further comprising a step of heating
the adhesive at a temperature condition between 20.degree. C. and
70.degree. C. for a reaction time of between 30 minutes and 3
hours.
12. The adhesive of claim 8, further comprising a step of adjusting
at least one parameter selected from the group of temperature
condition, reaction time, and concentration of solution to regulate
the level of denaturation of proteins in the adhesive.
13. The adhesive of claim 8, further comprising a step of removing
insoluble solids from the adhesive, wherein the removing step
includes at least filtering or centrifuging the adhesive.
14. The adhesive of claim 8, further comprising a step of adding a
second adhesive to the adhesive mixture.
15. The adhesive of claim 8, further comprising a step of adding a
preservative configured to provide mold resistance.
16. A method for producing an adhesive, comprising the steps of: a.
processing biomass product to produce a residue; and b. grinding
the residue into a flour to create an adhesive.
17. The method of claim 16, wherein the processing step is
comprised of a. cultivating the biomass product or residue in an
environment; b. harvesting the biomass product or residue from the
environment; and c. extracting oil from the biomass product or
residue, thereby generating a byproduct of the biomass product or
residue.
18. The method of claim 16, further comprising the step of mixing
the residue with a solution configured to denature proteins.
19. The method of claim 16, further comprising the steps of: a.
adding a second adhesive to the adhesive; and b. combining the
adhesive and second adhesive with a preservative configured to
provide mold resistance.
20. The method of claim 16, further comprising the steps of: a.
heating the adhesive at a temperature condition between 20.degree.
C. and 70.degree. C. for a reaction time of between 30 minutes and
3 hours; and b. removing insoluble solids from the adhesive,
wherein the removing step includes at least filtering or
centrifuging the adhesive.
21. The method of claim 16, further comprising a step of adding a
preservative configured to provide mold resistance.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
application 61/777,921 filed Mar. 12, 2013, which is incorporated
by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a system and
methods for treatment of a process product or byproduct and the
resulting composition. An example of a byproduct includes "post
extraction algae residue", which is a byproduct from the process of
extracting oil from algae for alternative energy production and
other purposes. However, additional embodiments of the present
invention may include treatment of any proteinaceous byproduct of a
process or products made intentionally for this treatment. Certain
embodiments of the treated byproduct can be used as an
adhesive.
BACKGROUND OF THE INVENTION
[0003] Conventional fuel sources include fossil fuels such as
petroleum, coal, and natural gas. Fossil fuels are associated with
many disadvantages including limited reserves, long regeneration
time, emitting carbon dioxide when burned which may contribute to
global warming, emitting sulfur dioxide when burned which
contributes to acid rain, environmental hazards during transporting
(e.g., oil spills), drilling, producing, and refining crude oil,
and health hazards during removal of the fossil fuel (e.g., coal
mine pollution), to name a few.
[0004] In light of the many disadvantages of fossil fuels, many
alternative energy sources have been created, including, for
example, solar power, wind power, hydropower, and geothermal power.
There are many disadvantages associated with each of these
alternative energy sources. For example, solar power requires a
large upfront cost and requires back-up sources of energy for times
when no solar input is available. Wind power requires large wind
turbines and only generates power when sufficient wind is present.
Hydropower often requires building large, expensive dams that alter
the natural environment around the dam. Geothermal power requires
tapping hot spots accessible within the Earth's crust, but these
hot spots may be challenging to locate and often occur in unstable
locations such as near volcanoes or fault lines subject to
earthquakes.
[0005] Another alternative energy source is biodiesel prepared from
animal fat or vegetable oil. Biodiesel is a fuel consisting of
long-chain alkyl (methyl, propyl, or ethyl) esters and may be mixed
with other compounds. Biodiesel can be used as fuel for biodiesel
engines in automobiles, trains, or aircraft, or as heating oil for
domestic and commercial boilers. Alternative energy technologies
that create liquid fuels--such as biodiesel--are particularly
valuable, since they allow the energy to be safely stored until
needed. In contrast, gaseous fuels have higher risks associated
with their use, transport, and storage.
[0006] Certain disadvantages are associated with biodiesel made
from vegetable oil and animal fat.
[0007] For example, animal fat is produced as a result of certain
types of meat processing and cooking. However, the quantity of
animal fat currently produced for food purposes is not sufficient
to generate quantities of animal fat-based biodiesel to keep up
with energy consumption demands.
[0008] Also, plants and animals needed to produce vegetable oil and
animal fat compete with plants and animals used for human food. For
example, the land on which corn, soybeans, or other plants used to
create vegetable oil is created is a finite resource and only so
much corn, soybean, and other plants can be grown on such land.
According to general supply and demand principals, food suppliers
and biodiesel producers compete for the limited supplies of corn,
soybeans, and other crops, which will drive up the cost of such
resources for both food and fuel purposes. The same issues arise
when creating ethanol from food crops. This also poses ethical
implications since rising food prices may cause an in increase
starvation rates, especially in impoverished countries.
[0009] Another alternative energy source is algae. Certain types of
algae may be used to produce a variety of biofuels including,
biodiesel, bioethanol, biogasoline, biomethanol, biobutanol, and
others.
[0010] Advantageously, algae may be grown without competing for
land currently used for growing food crops, since algae can grow on
certain land unsuitable for other crops or in ocean water, sewage,
or wastewater. Another benefit of fuel produced from algae is that
algae are generally biodegradable. In addition, many types of algae
can be cultivated in a much shorter period of time relative to
crops that otherwise might be used for fuel production, and
accordingly, more algae can be grown at a faster rate.
[0011] Algae may be cultivated for energy production, for example,
in an open pond, vertical growth/closed loop system, a closed tank
bioreactor, fermentation system or other environment. Many
different types of algae, including macroalgae (e.g., seaweed) and
microalgae may be a substrate from which oil for biofuel may be
extracted. For example, algae known to be capable of oil production
include: Ankistrodesmus TR-87, Bacilliarophy, Botryococcus braunii,
Chlorella sp., Chlorella
protothecoides(autotrophic/heterothrophic), Chlorophyceae,
Cyclotella DI-35, Crypthecodinium cohnii, Dunaliella tertiolecta,
Euglena gracilis, Hantzschia DI-160, Isochrysis galbana,
Nannochloris, Nannochloropsis salina, Neochloris oleoabundans,
Nitzschia TR-114, Phaeodactylum tricornutum, Pleurochrysis
carterae, Scenedesmus TR-84, Scenedesmus acuminatus, Scenedesmus
dimorphus, Scenedesmus longispins, Schiochytrium, Stichococcus,
Tetraselmis chui, Tetraselmis suecica, and Thalassiosira
pseudonana.
[0012] During cultivation of the algae, conditions may be optimized
for proliferation. In certain circumstances, environmental
conditions, intended to induce increased oil storage, may be
provided to the algae.
[0013] The algae may be harvested and processed to extract certain
lipids--also termed "algae oil" for purposes of this
application--for production of biofuels. Many algae oil extraction
methods include an oil press step which may require putting
pressure on the harvested algae such that liquid extract emerges
from the mass of algae cells. Additional oil extraction methods may
include ultrasonic-assisted extraction, hexane solvent method,
soxhlet extraction, supercritical fluid extraction, enzymatic
extraction, osmotic shock, or other methods known in the art. The
liquid extract may be then processed, possibly using
transesterification, to make some type of biofuel.
[0014] The various methods of extraction may be classified into
disruptive or non-disruptive. Disruptive methods involve lysing
cells by mechanical, thermal, enzymatic, or chemical methods. Most
disruptive methods of extraction involve emulsions and require an
expensive cleanup process. Non-disruptive methods are typically
less complex but produce low yields of resulting material. During
extraction, byproducts can form.
[0015] Such disruptive and non-disruptive extraction methods
produce a byproduct from the remaining components of the harvested
algae. The byproduct may be termed "algae cake", or "post
extraction algae residue", or "PEAR" for purposes of this
application.
[0016] It is known that a purification and/or enrichment process is
necessary to convert PEAR or similar biowaste material into a
residue that has adhesive properties. Such processes include
fermenting biomass material into a residue, liquefaction oil
prepared from lignin-bearing plant material, and phenolic fraction
extraction.
[0017] One disadvantage of using algae to create biofuels is that
certain steps in the cultivation, harvesting, and processing of
algae are expensive. In order to add value to the process, some
efforts have been made to identify commercial uses for PEAR.
Certain known commercial uses include burning the PEAR for fuel,
preparing PEAR for use as soil fertilizer, or compounding the PEAR
into animal feed. However, such known uses have limited commercial
value.
[0018] There is a demand for an improved commercial use for post
extraction algae residue and a method of manufacturing an adhesive
derived from the residue of PEAR and other similar biomaterials.
The present invention satisfies these demands.
[0019] The present invention also allows for the conversion of
biomass resulting from treatment of wastewater or other organic
wastes into marketable products such as adhesives or
composites.
SUMMARY OF THE INVENTION
[0020] For purposes of this application, the present invention is
discussed in reference to creating an adhesive from post extraction
algae residue, which is generally a byproduct of processing algae
for creation of biofuel, but the discussion is merely exemplary.
The present invention may be applicable to the use of any
proteinaceous product or byproduct of any process.
[0021] One embodiment of systems and methods for creating an
adhesive may include a first step--obtaining post extraction algae
residue/PEAR. The PEAR may be obtained by cultivating algae in the
environment, harvesting the algae from the environment, and
extracting algae oil from algae, thereby generating a byproduct of
post extraction algae residue. Certain embodiments of PEAR may
include proteins, carbohydrates, small amounts of deoxyribonucleic
acid (DNA) and other cellular components, and possibly other
impurities.
[0022] Any type of algae may be used to obtain PEAR including, for
example, but not limited to: Ankistrodesmus TR-87, Bacilliarophy,
Botryococcus braunii, Chlorella sp., Chlorella
protothecoides(autotrophic/heterothrophic), Chlorophyceae,
Cyclotella DI-35, Crypthecodinium cohnii, Dunaliella tertiolecta,
Euglena gracilis, Hantzschia DI-160, Isochrysis galbana,
Nannochloris, Nannochloropsis salina, Neochloris oleoabundans,
Nitzschia TR-114, Phaeodactylum tricornutum, Pleurochrysis
carterae, Scenedesmus TR-84, Scenedesmus acuminatus, Scenedesmus
dimorphus, Scenedesmus longispins, Schiochytrium, Stichococcus,
Tetraselmis chui, Tetraselmis suecica, and Thalassiosira
pseudonana. The algae used to create PEAR may be naturally
occurring algae or genetically modified algae that are known in the
art or not yet known. In preferred embodiments, the algae used to
create PEAR may have one or more of the following qualities: high
algae oil content, rapid proliferation, simple to harvest, easy
extraction of oil, low cost nutrients, permit human/artificial
control of growth and development, and minimal maintenance. Some
algae may be specially adapted for an environment, such as an open
pond, vertical growth/closed loop system, a closed tank bioreactor,
fermentation system or other artificial environment or natural
environment.
[0023] Once the PEAR is obtained, it may be ground into a small
sized ("fine") flour to improve the consistency and homogeneity of
the PEAR. Grinding the PEAR also may permit faster and more
complete denaturization reactions.
[0024] In certain embodiments, the ground PEAR may be wetted with
water, while in other embodiments, such wetting step may be
omitted.
[0025] The ground PEAR may be mixed with a solution configured to
denature proteins in the post extraction algae residue--that is, a
denaturant--to create an adhesive mixture, which is also termed as
"mixture" for purposes of this application. The solution may be
composed of, for example, an urea or alkaline solution. While the
method may take place at any temperature, in certain embodiments,
the mixture may be treated at a temperature condition of any
temperature between 20.degree. C. and 70.degree. C. The treatment
time may be between 0 minutes and 3 hours, or, more specifically,
between 1 minute and 29 minutes or between 30 minutes and 3 hours,
for certain embodiments. However, this temperature treatment step
may be omitted in certain embodiments.
[0026] Generally, if the mixture is treated at a higher
temperature, the optimized treatment time may be lower, and, if the
mixture is treated at a lower temperature, the optimized treatment
time may be higher. In certain embodiments, the PEAR-denaturant
mixture may be maintained at generally room temperature (e.g.,
20.degree. C. to 25.degree. C.) at all times. In other embodiments,
the PEAR-denaturant mixture may be subjected to a temperature
condition of 26.degree. C.-70.degree. C. for between 0 minutes and
3 hours, or more specifically, between 1 minute and 29 minutes or
30 minutes and 3 hours, for certain embodiments.
[0027] The denaturant may include an acidic solution (pH<7) or a
basic (alkaline) solution (pH>7) configured to permit control
over the pH of the mixture. In preferred embodiments, the solution
may be alkaline and may have a pH within the range of 10-14. Use of
a basic solution typically minimizes corrosion and other safety
hazards. Examples of such a solution may include a strong base such
as sodium hydroxide or potassium hydroxide, or a weak base such as
ammonia, calcium hydroxide, or borax. The solution also may include
urea or monosodium phosphate. An example of an alkaline solution
may include a sodium hydroxide solution up to 1 mole/L or potassium
hydroxide solution up to 1 mole/L.
[0028] The level of denaturation of proteins in the mixture may be
adapted by increasing the temperature condition, treatment time,
and/or concentration of denaturant.
[0029] In certain embodiments, the mixture of denaturant and PEAR
may be treated to remove any insoluble solids and yield an adhesive
with increased transparency. For example, the adhesive mixture may
be filtered, centrifuged, or separated by any other removal method
known in the art. A relatively fine filter or longer centrifugation
may be used to obtain a more transparent mixture. Comparatively, a
coarser filter or shorter centrifugation time results in a higher
yield, but not as much transparency.
[0030] Certain additional components also may be combined with the
adhesive mixture.
[0031] Certain embodiments of the method may also include blending
the mixture with a second adhesive, which may include conventional
synthetic adhesives such as epoxy-based or formaldehyde-based
resins, or natural glues derived from animal blood, casein, or
soybean flour. Advantageously, formaldehyde-based resin may improve
the mechanical properties and durability of the adhesive mixture.
Animal blood permits improved water resistance due to its
thermosetting properties. Casein also permits improved water
resistance. Soybeans may be an additive to increase quantity of the
adhesive mixture.
[0032] A preservative also may be combined with the adhesive
mixture. Certain preservatives are configured to provide mold
resistance. A preservative may include copper-8-quinolinolate,
copper naphthenate, chlorinated phenol, or orthophenyl phenol.
[0033] In addition, various cross-linkers may be inserted into the
adhesive mixture, for example, at a 0.1%-1% concentration. A
cross-linker is a component configured to link one polymer chain
(e.g., protein chain, other natural polymer, or synthetic polymer)
to another by, for example, covalent bond or ionic bond. A
cross-linker may include a formaldehyde donor, sulfur compound, or
an inorganic complexing salt. More specifically, cross-linkers
configured to improve water resistance may include dialdehyde
starch, dimethylol urea, sodium formaldehyde bisulfite, and
hexamethylenetetramine. Cross-linkers configured to improve working
properties and adhesive performance of the adhesive mixture may
include carbon disulfide, thiourea, and ethylene trithiocarbonate,
among the sulfur compounds, and the soluble salts of cobalt,
chromium, and copper.
[0034] In certain embodiments, an aliphatic epoxy resin at 5-20%
based on weight of ground PEAR may be introduced into the mixture
to generate a protein-epoxy copolymer.
[0035] In certain embodiments, cross-linkers may be added to the
PEAR generally right before or right after the addition of the
denaturant, while in other embodiments a cross-linker is added to
the mixture under a second set of reaction conditions relative to
the reaction conditions under which the denaturant is combined with
the PEAR.
[0036] Certain embodiments of a method according to the present
invention may include inserting a defoamer into the mixture. Such a
defoamer, such an oil-based defoamer may be configured to reduce or
hinder foam in the mixture.
[0037] In certain embodiments, a method of the present invention
may include integrating sodium silicate into the mixture to help
maintain a level viscosity for longer adhesive working life and
improve water resistance by forming insoluble proteinates.
[0038] In certain embodiments, no purification may be necessary to
modify the biomaterial converted into residue that may be used for
creating an adhesive.
[0039] In certain embodiments, no additional enrichment may be
necessary to modify the biomaterial converted into residue that may
be used for creating an adhesive.
[0040] In certain embodiments, some separation may be utilized to
extract components from the mixture that are valuable or useful for
other processes or applications.
[0041] In certain embodiments, some separation may be utilized to
modify the composition to improve the properties of the product.
For example, the mass fraction of the protein may be enhanced, or
components with a deleterious effect on the resultant mechanical
properties may be removed.
[0042] The final mixture--that is, an adhesive--may be used as a
binder for a composite material, which may include one or more of
the following raw materials: a wood product, rocks, sand, asphalt,
gravel, recycled paper, oyster shell, corn stalk, chicken feather,
rice husk, natural fiber, animal feed, pet feed, yard waste,
agricultural wastes, or other filler materials. The adhesive may be
applied to bind one or more composite materials, for example, by
spray, curtain coater, knife, brush, indirect roller, spreader
roller, or extrusion.
[0043] In certain embodiments, materials other than PEAR may be
used to create a residue that may have adhesive characteristics.
Such materials may include, but are not limited to algal or
microbial products resulting from CO2 sequestration or the
treatment of wastewater or other organic wastes. Such materials may
also include biomasses that have been cultivated for this
purpose.
[0044] An object of certain embodiments of the present invention is
to add value to a method for creating alternative energy.
[0045] An object of certain embodiments of the present invention is
to identify a commercial use for PEAR.
[0046] An object of certain embodiments of the present invention is
to identify a use for PEAR that does not require the expensive
process of protein isolation and purification.
[0047] An object of certain embodiments of the present invention is
to include a simple process for producing an adhesive.
[0048] An object of certain embodiments of the present invention is
to produce a formaldehyde-free adhesive.
[0049] An object of certain embodiments of the present invention is
to produce an adhesive free of Volatile Organic Compounds
(VOCs).
[0050] An object of certain embodiments of the present invention is
to produce an adhesive without using phenols.
[0051] An object of certain embodiments of the present invention is
to produce an adhesive that can be mixed with cross-linkers
configured to improve the adhesive mixture.
[0052] An object of certain embodiments of the present invention is
to produce a strong adhesive.
[0053] An object of certain embodiments of the present invention is
to produce a flexible adhesive.
[0054] An object of certain embodiments of the present invention is
to produce a transparent or nearly transparent adhesive.
[0055] An object of certain embodiments of the present invention is
to produce a durable adhesive.
[0056] An object of certain embodiments of the present invention is
to produce a mold-resistant adhesive.
[0057] An object of certain embodiments of the present invention is
to produce a water-resistant adhesive.
[0058] The present invention and its attributes and advantages will
be further understood and appreciated with reference to the
detailed description below of presently contemplated embodiments,
taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The preferred embodiments of the invention will be described
in conjunction with the appended drawings provided to illustrate
and not to the limit the invention, where like designations denote
like elements, and in which:
[0060] FIG. 1 illustrates an embodiment of a method according to
the present invention.
[0061] FIG. 2 illustrates an embodiment of a method according to
the present invention.
[0062] FIG. 3 illustrates an embodiment of a method according to
the present invention.
[0063] FIG. 4 illustrates an embodiment of a method according to
the present invention.
[0064] FIG. 5 illustrates an embodiment of a method according to
the present invention.
[0065] FIG. 6 illustrates an embodiment of a method according to
the present invention.
[0066] FIG. 7 illustrates an embodiment of a method according to
the present invention.
[0067] FIG. 8 illustrates an embodiment of a method according to
the present invention.
[0068] FIG. 9 illustrates an embodiment of a method according to
the present invention.
[0069] FIG. 10 illustrates an embodiment of a method according to
the present invention.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION
[0070] FIG. 1 illustrates one of the embodiments of the present
invention for creating an adhesive. The FIG. 1 embodiment
illustrates method 100 that includes first processing algae to
produce post extraction algae residue/PEAR 102. The PEAR may be
obtained by cultivating algae in an environment 102A, harvesting
algae from the environment 102B, and extracting algae oil from
algae, thereby generating a byproduct of post extraction algae
residue 102C, as illustrated in FIG. 2.
[0071] Once the PEAR is obtained, it may be ground into a fine
flour to improve the consistency and homogeneity of the PEAR 103.
Grinding the PEAR also may permit faster and more complete
denaturization reactions.
[0072] The ground PEAR may be mixed with a solution configured to
denature proteins in the post extraction algae residue--that is, a
denaturant--to create a mixture 104. While the method may take
place at any temperature, in certain embodiments, the mixture may
be treated at a temperature condition of any temperature between
20.degree. C. and 70.degree. C. for a treatment time of between 30
minutes and 3 hours 106.
[0073] Generally, if the mixture is treated at a higher
temperature, the treatment time may be lower, and if the mixture is
treated at a lower temperature, the treatment time may be higher.
In certain embodiments, the PEAR-denaturant mixture may be
maintained generally at room temperature (e.g., 20.degree. C. to
25.degree. C.) at all times. In other embodiments, the
PEAR-denaturant mixture is heated at a temperature condition of
between 26.degree. C.-70.degree. C. In certain embodiments, the
temperature condition is configured to be one target temperature
selected from the range between 26.degree. C.-70.degree. C. for the
entire treatment time. In other embodiments, the temperature
condition is configured to be a smaller range (e.g., between
2.degree. C. plus or minus a target temperature) within 26.degree.
C.-70.degree. C. for the entire treatment time. In still other
embodiments, the treatment condition is configured to be any
temperature between 20.degree. C. to 70.degree. C. at any time
during the treatment time.
[0074] The level of denaturation of proteins in the mixture may be
adapted by increasing the temperature condition, treatment time,
and/or concentration of denaturant.
[0075] In certain embodiments, the adhesive mixture of denaturant
and PEAR may be treated to remove any insoluble solids and yield an
adhesive with increased transparency. As illustrated in FIG. 3, the
adhesive mixture may be filtered, centrifuged, or any other removal
method known in the art 108.
[0076] Certain embodiments of the method may also include blending
the mixture with other adhesives, which may include conventional
synthetic adhesives such as epoxy-based or formaldehyde-based
resins, or natural glues derived from animal blood, casein, or
soybean flour 110, as illustrated in FIG. 4. Advantageously,
formaldehyde-based resin may improve the mechanical properties and
durability of the adhesive mixture. Animal blood permits improved
water resistance due to its thermosetting properties. Casein also
permits improved water resistance. Soybean products may be an
additive to increase quantity of the adhesive mixture.
[0077] As illustrated in FIG. 5, a preservative may be combined
with the adhesive mixture 112. Certain preservatives are configured
to provide mold resistance. A preservative may include
copper-8-quinolinolate, copper naphthenate, chlorinated phenol, or
orthophenyl phenol.
[0078] The adhesive mixture may be used as a binder for a composite
material 114 as illustrated in FIG. 6. The composite material may
include one or more of the following raw materials: a wood product,
rocks, sand, asphalt, recycled paper, oyster shell, corn stalk,
chicken feather, rice husk, natural fiber, animal feed, pet feed,
or other filler materials.
[0079] A number of specific examples of methods and compositions
and composites created from those methods are provided below. Such
examples are not intended to be limiting.
Example 1
[0080] In certain embodiments, 1 gram of PEAR may be mixed with a
denaturant comprising 30 mL of 0.1 M NaOH. The mixture may be
treated at a temperature condition of 50.degree. C. for a treatment
time of one hour.
Example 2
[0081] In certain embodiments, 1 gram of PEAR may be mixed with a
denaturant comprising 30 mL of 0.1 M NaOH. The mixture may be
treated at a temperature condition of 50.degree. C. for a treatment
time of one hour. In another step, the PEAR-denaturant mixture is
centrifuged to remove insoluble solids.
Example 3
[0082] In certain embodiments, 3 grams of PEAR may be mixed with a
denaturant comprising 30 mL of 3 M urea. The resulting mixture may
be treated at a temperature condition of 50.degree. C. for a
treatment time of two hours.
Example 4
[0083] In certain embodiments, 3 grams of PEAR may be mixed with a
denaturant comprising 30 mL of 3 M urea. The resulting mixture may
be treated at a temperature condition of 50.degree. C. for a
treatment time of two hours. In another step, the PEAR-denaturant
mixture is filtered to remove insoluble solids. Although any
suitable filter may be used for the filtering step, one example of
a filter is a simple coarse paper filter.
[0084] Additional steps may be completed to configure the mixture
for use as an adhesive on a substrate such as paper, label, or any
other items that the user wishes to adhere together. For example,
the mixture may be applied to a surface of a first substrate unit
(e.g., one piece of paper or one side of a label). In certain
embodiments, a second substrate unit is placed adjacent to the
mixture such that the mixture is sandwiched between a first
substrate unit and a second substrate unit. Optionally, the first
substrate unit, second substrate unit, and mixture (together, a
"multiple substrate unit") may be clamped together or to a support
component (e.g., shelf, rack, board, etc.) using clamp
instruments.
[0085] Then, the multiple substrate unit may be permitted to dry.
In certain embodiments, the drying process may constitute merely
positioning the multiple substrate unit on a support unit (with or
without clamping) and then not altering the position for a period
of time. In addition, the drying process may be accelerated by
positioning the multiple substrate unit in a heating element, such
as a laboratory oven, industrial oven, other unit configured to
emit heat. The drying process may include using a drying
temperature of 105.degree. C. for a drying time of 24 hours. Such
an embodiment of the method may be configured to provide a mixture
having tensile strength sufficient to permit casual handling of the
multiple substrate unit without resulting in separation of the
first substrate unit and the second substrate unit.
Example 5
[0086] In certain embodiments, 15 grams of PEAR may be mixed with a
denaturant comprising 225 mL of 1 M NaOH. The mixture may be
treated at a temperature condition of 50.degree. C. for a treatment
time of one hour.
Example 6
[0087] In certain embodiments, 15 grams of PEAR may be mixed with a
denaturant comprising 225 mL of 1 M NaOH. The mixture may be
treated at a temperature condition of 50.degree. C. for a treatment
time of one hour. Subsequently, the resulting mixture may be merged
with 300 grams of wood product to obtain a mixture-wood product
composite. The wood product may include, for example, 70% core
furnish (coarse wood particles) and 30% face furnish (finer wood
particles).
[0088] Certain embodiments may require pressing the mixture-wood
product composite. The mixture-wood product composite may be
pressed at a pressing temperature of 450.degree. F. for a pressing
time of 2 to 6 minutes or until cessation of audible boiling. The
pressure applied in the pressing step may range between 1300 pounds
and 2000 pounds over a 5''.times.5'' plate. Generally, a higher
pressure within the range is configured to yield more dense and
more rigid composites, while lower pressures within the range is
configured to yield less dense and less rigid composites. The press
may be de-pressurized slowly to manage the release of steam.
[0089] Various combinations of the steps illustrated in FIG. 1-FIG.
6 may be conducted to produce an adhesive. Alternative additional
embodiments of the present invention that include a combination of
steps are illustrated in FIG. 7-FIG. 10.
[0090] FIG. 7 illustrates another embodiment of the present
invention in which purification and enrichment steps produce the
extracted algae residue that may be used as an adhesive.
[0091] FIG. 8 illustrates an additional embodiment of the present
invention in which purification steps are not necessary to produce
the extracted algae residue that may be used as an adhesive.
[0092] FIG. 9 illustrates an additional embodiment of the present
invention in which enrichment steps are not necessary to produce
the extracted algae residue that may be used as an adhesive.
[0093] FIG. 10 illustrates an additional embodiment of the present
invention in which neither purification nor enrichment steps are
necessary to produce the extracted algae residue that may be used
as an adhesive.
[0094] In addition, embodiments of the present invention include
adhesives generated by any of the embodiments of methods described
above.
[0095] While the disclosure is susceptible to various modifications
and alternative forms, specific exemplary embodiments of the
present invention have been shown by way of example in the drawings
and have been described in detail. It should be understood,
however, that there is no intent to limit the disclosure to the
particular embodiments disclosed, but on the contrary, the
intention is to cover all modifications, equivalents, and
alternatives falling within the scope of the disclosure as defined
by the appended claims.
* * * * *