Composite material comprising bio-filler and specific polymer

• US 10,323,355 B2
• Filed: 06/28/2018
• Issued: 06/18/2019
• Est. Priority Date: 04/14/2011
• Status: Active Grant

• Current Assignee: Plantics B.V.
• Original Assignee: Plantics B.V.
• Inventors: Alberts, Albert Henderikus, Rothenberg, Gad
• Primary Examiner(s): Buie-Hatcher, Nicole M.
• Assistant Examiner(s): Asdjodi, M. Reza
• Application Number:
  US16/021,387
• Publication Number:
  US 20180313036A1
• Time in Patent Office: 355 Days
• CPC Class Codes: C08J 2367/00 Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08J2377/12; of polyester-imides C08J2379/08; Derivatives of such polymers
• CPC Class Codes: C08J 5/045 with vegetable or animal fibrous material
• CPC Class Codes: C08J 5/245 using natural fibres
• CPC Class Codes: C08L 1/02 Cellulose; Modified cellulose
• CPC Class Codes: C08L 2205/16 Fibres; Fibrils
• CPC Class Codes: C08L 67/00 Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 97/00 Compositions of lignin-containing materials of polysaccharides C08L1/00 - C08L5/00
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: C09K 21/14 Macromolecular materials
• CPC Class Codes: D21H 17/53 Polyethers; Polyesters

Abstract

A composite material comprising 10-98 wt. % of a bio-based particulate or fibrous filler and at least 2 wt. % of a polyester derived from an aliphatic polyalcohol with 2-15 carbon atoms and a polyacid, wherein the polyacid comprises at least 10 wt. % of tricarboxylic acid. Preferably, the filler is in the form of particles, fibers, and/or random or non-random layers. A plant-based filler may be used, in particular a cellulosic or lignocellulosic material, more in particular one or more materials selected from wood chips, wood flakes, sawdust, pulp, e.g., pulp of (recycled) paper or other fiber pulp, and plant-derived fibers such as cotton, linen, flax, and hemp. An animal-derived filler, in particular an animal-derived fiber such as wool, hair, silk, or feathers may also be used. Preferably the polyalcohol is selected from one or more of glycerol, sorbitol, xylitol, mannitol, 1,2-propane diol, 1,3-propane diol, and 1,2-ethane diol, in particular glycerol. The polyacid preferably is an aliphatic diacid or triacid with 3-15 carbon atoms. Examples of suitable acids include citric acid, succinic acid, and itaconic acid. The composite material according to the invention has fire-retardant properties, which makes it particularly suitable for applications where fire-retardancy is an issue.

Claims

1. A composite material comprising from 10 to 98 wt. % of a bio-based particulate or fibrous filler and at least 2 wt. % of a polyester derived from an aliphatic polyalcohol with from 2 to 15 carbon atoms and a polyacid, wherein the polyacid comprises at least 70 wt. % of tricarboxylic acid.

2. The composite material according to claim 1, wherein the filler is in the form of particles, fibers, and/or random or non-random layers.

3. The composite material according to claim 1, wherein a porous sheet-like material is used as filler.

4. The composite material according to claim 1, wherein a particulate material, optionally in the form of a powder, dust, flakes, or chips, is used as filler.

5. The composite material according to claim 1, wherein a plant-based filler is used, optionally a cellulosic or a lignocellulosic material, optionally at least one material selected from the group consisting of wood chips, wood flakes, sawdust, pulp, optionally pulp of recycled or unrecycled paper or other fiber pulp, and plant-derived fibers optionally comprising cotton, linen, flax, and/or hemp.

6. The composite material according to claim 1, wherein an animal-derived filler, optionally an animal-derived fiber optionally comprising wool, hair, silk, and/or feathers is used as filler.

7. The composite material according to claim 1, wherein the polyalcohol is selected from at least one of glycerol, sorbitol, xylitol, mannitol, 1,2-propane diol, 1,3-propane diol, and 1,2-ethane diol, and optionally comprises glycerol.

8. The composite material according to claim 1, wherein the polyester is a polyester of an aliphatic polyalcohol with from 2 to 15 carbon atoms with an acid selected from aliphatic diacids and triacids with from 3 to 15 carbon atoms, wherein the acid comprises at least 70 wt. % of tricarboxylic acid.

9. The composite material according to claim 8, wherein the acid comprises at least 90 wt. % of tricarboxylic acid.

10. The composite material according to claim 8, wherein the acid comprises 30 wt. % of dicarboxylic acid.

11. The composite material according to claim 1, wherein the filler is present in an amount of at least 20 wt. %, optionally at least 40 wt. %, optionally at least 50%, and/or optionally at most 95%, or optionally at most 90%.

12. A method for manufacturing a composite material according to claim 1, comprising combining the filler with the polymer or precursor thereof to form a combination, and subjecting the combination to curing.

13. The method for manufacturing a composite material according to claim 12, wherein the filler is combined with alcohol and acid monomers in a liquid phase, which is subjected to curing until polymer has solidified.

14. The method for manufacturing a composite material according to claim 12, comprising combining alcohol and acid and subjecting the alcohol and acid to polymerization conditions to form a polymer in liquid form, combining the liquid polymer with the filler, and subjecting the combined polymer and filler to curing until polymer has solidified.

15. The method according to claim 12, wherein the curing comprises subjecting the combination of filler and polymer to a temperature in a range of from 20 to 120°

C., optionally from 40 to 150°

C., or optionally from 80 to 130°

C. and a pressure of from 1 to 100 bar, optionally from 2 to 50 bar, or optionally from 2 to 20 bar, for a period of at least 5 minutes, until polymer has solidified.

16. A kit of parts comprising a part susceptible to degradation by a thermal load and a part comprising a composite material according to claim 1.

17. The kit of parts according to claim 16, which is an assembly comprising a part susceptible to degradation by a thermal load and a cover surrounding said part in whole or in part, wherein the cover comprises a polyester derived from an aliphatic polyalcohol with from 2 to 15 carbon atoms and a polyacid, wherein the polyacid comprises at least 70 wt. % of tricarboxylic acid.

18. A part, which is a cover capable of being used in a kit of parts according to claim 16.

19. A part capable of being used in a kit of parts, which comprises a composite material according to claim 1.

20. A composite material according to claim 1 capable of being used as flame retardant material.

21. A method for decreasing fire-propagating properties of a system comprising incorporating therein a part comprising a composite material according to claim 1.

22. A fire-protecting cover comprising a composite material according to claim 1.

23. A fire-protecting cover according to claim 22, which is intended for protecting a human and/or an animal body.