Starch-plastic composite resins and profiles made by extrusion

• US 20060194902A1
• Filed: 01/25/2006
• Published: 08/31/2006
• Est. Priority Date: 01/25/2005
• Status: Active Grant

• Current Assignee: Green Dot Bioplastics LLC
• Original Assignee: MGPI Processing Incorporated (MGP Ingredients Incorporated)
• Inventors: Nie, Li, Maningat, Clodualdo C., Parker, Michael Douglas, Bassi, Sukh D.
• Granted Patent: US 8,802,754 B2
• Time in Patent Office: Days
• US Class Current: 524/47
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C08K 5/005 Stabilisers against oxidation, heat, light, ozone
• CPC Class Codes: C08K 5/098 Metal salts of carboxylic acids
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 1/02 Cellulose; Modified cellulose
• CPC Class Codes: C08L 2205/16 Fibres; Fibrils
• CPC Class Codes: C08L 23/02 not modified by chemical after-treatment
• CPC Class Codes: C08L 23/04 Homopolymers or copolymers of ethene
• CPC Class Codes: C08L 23/10 Homopolymers or copolymers of propene
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 2666/20 Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 2666/26 Natural polymers, natural resins or derivatives thereof according to C08L1/00 - C08L5/00, C08L89/00, C08L93/00, C08L97/00 or C08L99/00
• CPC Class Codes: C08L 3/02 Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C08L 51/06 grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• 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

Abstract

Composite materials containing non-plasticized, non-gelatinized starch, a compatibilizer and a synthetic resin, such as polyethylene and/or polypropylene, may be used to make wood replacement products for use as construction materials.

Claims

1. A manufactured product for use as a wood substitute, comprising:

from 20-80% by weight starch;

from 0.5-4% by weight of a compatibilizer; and

from 20-78% by weight of a synthetic resin.

2. The manufactured product of claim 1 having an artificial wood grain texture.

3. The manufactured product of claim 1, wherein the synthetic resin is selected from the group consisting of polyolefines, polyethylene, polypropylene, polyurethane, polystyrene, polyamides, polyesters, and combinations thereof.

4. The manufactured product of claim 1, further comprising fibers.

5. The manufactured product of claim 1, further comprising from 0-15% by weight of a fiber.

6. The manufactured product of claim 4, wherein said fiber is selected from the group consisting of glass fibers, cotton, hardwood fibers, softwood fibers, flax, abaca, sisal, ramie, hemp, bagasse, recycled paper fibers, cellulose fibers, polymer fibers, and mixtures thereof.

7. The manufactured product of claim 5, wherein said fiber is selected from the group consisting of glass fibers, cotton, hardwood fibers, softwood fibers, flax, abaca, sisal, ramie, hemp, bagasse, recycled paper fibers, cellulose fibers, polymer fibers, and mixtures thereof.

8. The manufactured product of claim 1, wherein the starch source is selected from the group consisting of wheat, corn, rice, tapioca, potato and mixtures thereof.

9. The manufactured product of claim 1, wherein the compatibilizer is selected from the group consisting of maleated polyethylene, maleated polypropylene, and mixtures thereof.

10. A method of making a substitute wood product, the method comprising the steps of:

combining ingredients including;

from 20-80% by weight starch,

from 0.5-4% by weight of a compatibilizer,

from 20-78% by weight of a synthetic resin, and

from 0-15% by weight fibers;

processing the ingredients to achieve a melt temperature of the synthetic resin; and

extrusion shaping the substitute wood product.

11. The method of claim 10 further comprising embossing the extrusion shaped product.

12. A manufactured product for use as a wood substitute, comprising:

from 20-80% by weight granular starch;

from 20-78% by weight of a synthetic resin;

from 0.5-4% by weight of a compatibilizer;

from 0-15% by weight of a fiber;

from 0.5-4% by weight of a lubricant, said lubricant containing no metal ions;

from 0-2% by weight of a foaming agent;

from 0-1% by weight of a colorant;

from 0-5% by weight talc;

from 0-2% by weight of an antimicrobial agent; and

from 0-0.3% by weight of a UV stabilizer.

13. The manufactured product of claim 12 having an artificial wood grain texture.

14. The manufactured product of claim 12, wherein the granular starch is selected from the group consisting of wheat, corn, rice, tapioca, potato and mixtures thereof.

15. The manufactured product of claim 12, wherein the compatibilizer is selected from the group consisting of maleated polyethylene, maleated polypropylene, and mixtures thereof.

16. The manufactured product of claim 12, wherein the synthetic resin is selected from the group consisting of polyolefines, polyethylene, polypropylene, polyurethane, polystyrene, polyamides, polyesters, and combinations thereof.

17. The manufactured product of claim 12, wherein the compatibilizer is selected from the group consisting of maleated polyethylene, maleated polypropylene, and mixtures thereof.

18. A method of making a substitute wood product, the method comprising the steps of:

combining ingredients including;

from 20-80% by weight predried starch,

from 20-78% by weight of a synthetic resin,

from 0.5-4% by weight of a compatibilizer, said compatibilizer having a melt index of 2-150,

from 0-15% by weight fiber,

from 0.5-4% by weight of a lubricant, said lubricant containing no metal ions,

from 0-2% by weight of a foaming agent,

from 0-1% by weight of a colorant,

from 0-5% by weight talc,

from 0-2% by weight of an antimicrobial agent, and

from 0-0.3% by weight of a UV stabilizer;

processing the ingredients to achieve a melt temperature of 260-400°

F.; and

extrusion shaping the substitute wood product.

19. The method of claim 18, wherein the predried starch has a moisture content of less than 6%.

20. The method of claim 18, further comprising embossing the extrusion shaped product.

21. A manufactured product for use as a wood substitute, comprising:

from 20-80% by weight granular starch;

from 20-78% by weight of a synthetic resin;

from 0.5-4% by weight of a compatibilizer; and

from 0-15% by weight of a fiber.

22. The manufactured product of claim 21, wherein the fiber is chosen from the group consisting of glass fibers, cotton, hardwood fibers, softwood fibers, flax, abaca, sisal, ramie, hemp, bagasse, recycled paper fibers, cellulose fibers, polymer fibers, and mixtures thereof.

23. The manufactured product of claim 21 having an artificial wood grain texture.

24. The manufactured product of claim 21, wherein the granular starch is selected from the group consisting of corn, wheat, tapioca, potato, and rice.

25. The manufactured product of claim 21, wherein the granular starch is selected from chemically, physically and genetically modified starch.

26. The manufactured product of claim 21, wherein the compatibilizer is selected from the group consisting of maleated polyethylene, maleated polypropylene, and mixtures thereof.

27. The manufactured product of claim 21, wherein the synthetic resin is selected from the group consisting of polyolefines, polyethylene, polypropylene, polyurethane, polystyrene, polyamides, polyesters, and combinations thereof.

28. The manufactured product of claim 21 further comprising at least one lubricant in an amount of 0.5-4%, said lubricant containing no metal ions.

29. The manufactured product of claim 21 further comprising from 0-2% by weight of a foaming agent.

30. The manufactured product of claim 21 further comprising from 0-1% by weight of a colorant.

31. The manufactured product of claim 21 further comprising from 0-5% by weight talc.

32. The manufactured product of claim 21 further comprising from 0-2% by weight of an antimicrobial agent.

33. The manufactured product of claim 21 further comprising from 0-0.3% by weight of a UV stabilizer.

34. A method of making a substitute wood product, the method comprising the steps of:

combining ingredients including;

from 20-80% by weight predried starch,

from 20-78% by weight of a synthetic resin,

from 0.5-4% by weight of a compatibilizer, said compatibilizer having a melt index of 2-150, and

from 0-15% by weight of a fiber;

processing the ingredients to achieve a melt temperature of 260-400°

F.; and

extrusion shaping the substitute wood product.

35. The method of claim 34 wherein the fiber is chosen from the group consisting of glass fibers, cotton, hardwood fibers, softwood fibers, flax, abaca, sisal, ramie, hemp, bagasse, recycled paper fibers, cellulose fibers, polymer fibers, and mixtures thereof.

36. The method of claim 34, wherein the predried starch has a moisture content of less than 6%.

37. The method of claim 34, wherein the predried starch is selected from the group consisting of corn, wheat, tapioca, potato, and rice.

38. The method of claim 34, wherein the predried starch is selected from chemically, physically and genetically modified starch.

39. The method of claim 34, wherein the compatibilizer is selected from the group consisting of maleated polyethylene, maleated polypropylene, and mixtures thereof.

40. The method of claim 34, wherein the synthetic resin is selected from the group consisting of polyolefines, polyethylene, polypropylene, polyurethane, polystyrene, polyamides, polyesters, and combinations thereof.

41. The method of claim 34 further comprising from 0.5-4% by weight of a lubricant, said lubricant containing no metal ions.

42. The method of claim 34 further comprising from 0-2% by weight of a foaming agent.

43. The method of claim 34 further comprising from 0-1% by weight of a colorant.

44. The method of claim 34 further comprising from 0-5% by weight talc.

45. The method of claim 34 further comprising from 0-2% by weight of an antimicrobial agent.

46. The method of claim 34 further comprising from 0-0.3% by weight of a UV stabilizer.

47. The method of claim 34 further comprising embossing the extrusion shaped product.