Fibrous materials and composites

• US 10,059,035 B2
• Filed: 10/13/2016
• Issued: 08/28/2018
• Est. Priority Date: 03/24/2005
• Status: Expired due to Fees

• Current Assignee: Xyleco, Inc.
• Original Assignee: Xyleco, Inc.
• Inventors: Medoff, Marshall
• Primary Examiner(s): Joyner, Kevin
• Application Number:
  US15/292,588
• Publication Number:
  US 20170120480A1
• Time in Patent Office: 684 Days
• Field of Search: 422 22
• CPC Class Codes: A61L 2/081 Gamma radiation
• CPC Class Codes: A61L 2/082 X-rays
• CPC Class Codes: A61L 2/087 Particle radiation, e.g. electron-beam, alpha or beta radiation
• CPC Class Codes: B29B 13/08 by using wave energy or particle radiation
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 45/0005 using fibre reinforcements
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2201/00 Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as reinforcement
• CPC Class Codes: B29K 2995/0059 Degradable

Abstract

Fibrous materials, compositions that include fibrous materials, and uses of the fibrous materials and compositions are disclosed. For example, the fibrous materials can be operated on by a microorganism to produce ethanol or a by-product, such as a protein or lignin.

Claims

1. A method comprising:

providing a cellulosic or lignocellulosic fibrous material by (a) shearing a fiber source to provide a first fibrous material and (b) passing the first fibrous material though a first screen having an average opening size of 1.59 mm or less, so that the fibrous material has an average length-to-diameter ratio of greater than 5, an average length of the fibrous material is between 0.5 mm and 2.5 mm, and a standard deviation of a fiber length of less than sixty percent of an average fiber length;

irradiating the cellulosic or lignocellulosic fibrous material with an ionizing radiation; and

dispersing the irradiated fibrous material in a resin.

2. The method of claim 1, further comprising forming a composite by hardening the resin after the dispersing step, wherein the composite is in the form of an article selected from the group consisting of structures, ornamental articles, stepping stools, pipes, panels, decking materials, boards, housings, sheets, blocks, bricks, poles, fencing, members, doors, shutters, awnings, shades, signs, frames, window casings, backboards, flooring, tiles, railroad ties, trays, tool handles, stalls, films, wraps, tapes, boxes, baskets, racks, casings, binders, dividers, walls, mats, frames, bookcases, sculptures, chairs, tables, desks, toys, games, pallets, wharves, piers, boats, masts, septic tanks, automotive panels, computer housings, above- and below-ground electrical casings, furniture, picnic tables, benches, shelters, trays, hangers, servers, caskets, book covers, canes and crutches.

3. The method of claim 2, wherein the composite is in the form of a board.

4. The method of claim 2, wherein the composite includes the fibrous material, the resin and a dye.

5. The method of claim 2, wherein the standard deviation of the fiber length is less than eighty five percent of an average fiber length.

6. The method of claim 2, wherein the composite comprises a filler having a transverse dimension of less than 1000 nm, the fibrous material, and the cross-linked resin.

7. The method of claim 2, wherein the composite has been made using plastic processing machinery selected from the group consisting of injection molding equipment, compression molding equipment and extrusion equipment.

8. The method of claim 1, wherein irradiating is performed under conditions selected to sterilize the fibrous material.

9. The method of claim 1, wherein the irradiation is performed using electron beam radiation, x-ray radiation or gamma radiation and combinations thereof.

10. The method of claim 1, wherein the fibrous material is in densified form.

11. The method of claim 1, wherein the resin comprises a thermoplastic or thermoset resin.

12. The method of claim 11, wherein the thermoplastic resin is selected from the group consisting of polyolefins, polyesters, polyamides, polyethyleneimines, elastomeric styrenic copolymers, polyamide elastomers, ethylene-vinyl acetate copolymers, cast polyurethane, cast silicone and mixtures thereof.

13. The method of claim 1, wherein the resin comprises a polyolefin that has a polydispersity of greater than 2 and/or a melt flow rate greater than 10 g/10 minutes.

14. The method of claim 1 wherein the average length-to-diameter ratio is greater than 10/1.

15. The method of claim 1 wherein the cellulosic or lignocellulosic material has been sheared with a rotary knife cutter.

16. The method of claim 1 wherein the resin comprises a degradable polymer.