Composite materials from corncob granules and process for preparation

• US 20070287795A1
• Filed: 06/08/2007
• Published: 12/13/2007
• Est. Priority Date: 06/08/2006
• Status: Abandoned Application

• Current Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Original Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Inventors: Dale, Bruce, Chundawat, Shishir, Drzal, Lawrence, Balan, Venkatesh, Misra, Manjusri, Huda, Masud
• Application Number:
  US11/811,063
• Publication Number:
  US 20070287795A1
• Time in Patent Office: Days
• US Class Current: 524/703
• CPC Class Codes: B29B 7/92 Wood chips or wood fibres
• CPC Class Codes: C08L 19/006 Rubber characterised by functional groups, e.g. telechelic diene polymers
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence
• 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

A composite composition which comprises a synthetic polymer, and corncob granules which have been modified, such as with a chemical reacted with the hydroxyl groups on the granules is described. The corncob granules are modified so as to be compatible with the polymer.

Claims

1. A composite composition which comprises:

(a) a synthetic polymer; and

(b) corncob granules which have been modified so as to be compatible with the polymer to form the composition.

2. The composite of claim 1 wherein the corncob granules surface and cell wall ultra-structural properties have been modified with a chemical.

3. The composite of claim 1 wherein the corncob granules have been modified by UV-ozone or plasma treatment of the corncob granules.

4. The composite of claim 1 wherein the corncob granules have been modified by mechanical modification with high-frequency ultrasound.

5. The composite of claim 1 wherein the polymer is biodegradable.

6. The composite of claim 1 wherein the polymer is polylactic acid (PLA).

7. The composite of claim 2 wherein the chemical is a silane, maleic anhydride grafted polylactic acid (PLA), maleic anhydride grafted polyhydroxyalkanoate (PHA), maleic anhydride grafted polyolefin, maleic anhydride grafted rubber, unsaturated polyester, epoxy or isocyanate.

8. The composition of claim 7 wherein the polyolefin is polypropylene (PP), polyethylene (PE) or copolymers thereof.

9. The composite of any one of claims 1, 2, 3 or 4 which has been extruded.

10. The composite of any one of claims 1, 2, 3 or 4 which has been extruded, pelletized and then injection molded.

11. The composite of claim 2 wherein the corncob granules have been expanded in an AFEX ammonia process, wherein the ammonia reacts with the granules.

12. The composite of any one of claims 1, 2, 3 or 4 wherein the granules are up to about 80% by weight of the composition.

13. The composite of claim 2 wherein the corn cob granules have been modified with gaseous ozone.

14. The composite of claim 2 wherein the corn cob granules have been modified with organosolvent.

15. The composite of claim 2 wherein the corn cob granules have been modified by reaction with an alkali metal hydroxide.

16. The composite of claim 3 wherein the corn cob granules have been modified by UV-ozone or plasma treatment in the presence of an aqueous silane.

17. A process for the preparation of a composite composition comprising:

a synthetic polymer and corncob granules which have been modified to be compatible with the polymer, which comprises;

blending at elevated temperatures, the polymer so as to be thermoplastic and the corncob granules to form the composite composition.

18. The process of claim 17 wherein the blending is by extrusion.

19. The process of claims 17 or 18 wherein the corncob granules have been modified with a chemical which reacted with the hydroxyl groups on the granules.

20. The process of claims 17 or 18 wherein the corncob granules have been modified by UV-ozone or plasma treatment of the corncob granules.

21. The process of claims 17 or 18 wherein the corncob granules have been modified by mechanical modification with high-frequency ultrasound.

22. The process of claims 17 or 18 wherein the polymer is biodegradable.

23. The process of claims 17 or 18 wherein the polymer is polylactic acid (PLA).

24. The process of claim 19 wherein the chemical is a silane, maleic anhydride grafted polylactic acid (PLA), maleic anhydride grafted polyhydroxyalkanoate (PHA), maleic anhydride grafted polyolefin, maleic anhydride grafted rubber, unsaturated polyester, epoxy or isocyanate.

25. The process of claim 24 wherein the polyolefin is polypropylene (PP), polyethylene (PE) or copolymers thereof.

26. The process of claim 18 which has been extruded, pelletized and then injection molded.

27. The process of claim 17 wherein the corncob granules have been expanded in an AFEX ammonia process, wherein the ammonia reacts with the granules.

28. The process of claims 17 or 18 wherein the granules are up to about 80% by weight of the composition.

29. The process of claims 17 or 18 wherein the corn cob granules have been modified with gaseous ozone.

30. The process of claims 17 or 18 wherein the corn cob granules have been modified with organosolvent.

31. The process of claims 17 or 18 wherein the corn cob granules have been modified by reaction with an alkali metal hydroxide.

32. The process of claims 17 or 18 wherein the corn cob granules have been modified by UV-ozone or plasma treatment in the presence of an aqueous silane.