Biocomposite material and method of making

• US 5,635,123 A
• Filed: 06/07/1995
• Issued: 06/03/1997
• Est. Priority Date: 08/11/1992
• Status: Expired due to Fees

• Current Assignee: Phenix Biocomposites, LLC
• Original Assignee: Phenix Biocomposites, Inc.
• Inventors: Anderson, Donald E., Riebel, Michael J., Roos, Kenneth D., Torgusen, Paul L., Gruber, Carl
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): Mayes, M. Curtis
• Application Number:
  US08/487,498
• Time in Patent Office: 727 Days
• Field of Search: 156/328, 156/336, 156/62.2, 264/109, 264/115, 264/120, 264/128, 264/245, 264/73, 264/176.1, 264/207, 264/123, 264/124, 264/125, 428/537.5, 428/903.3, 428/533, 428/402
• US Class Current: 264/125
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• 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 75/04 Polyurethanes
• CPC Class Codes: C08L 89/00 Compositions of proteins; Compositions of derivatives thereof foodstuff preparations A23J3/00
• 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: D21B 1/00 Fibrous raw materials or their mechanical treatment pretreatment of the finely-divided materials before digesting D21C1/00; methods of beating or refining pulp D21D1/00; purification of the pulp suspension by mechanical means D21D5/00
• CPC Class Codes: D21J 3/00 Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/31975 Of cellulosic next to another carbohydrate
• CPC Class Codes: Y10T 428/31978 Cellulosic next to another cellulosic

Abstract

Fiber-reinforced protein-based biocomposite particulate material containing a legume-based thermosetting resin and cellulosic material, and rigid biocomposite pressure-formed materials produced therefrom, are provided. The particulate material and resultant pressure-formed materials contain the legume-based resin and fibrous cellulosic material in amounts such that the ratio of cellulose solids to resin solids is about 0.8:1.0 to about 1.5:1.0. Particularly preferred pressure-formed materials also include a secondary thermosetting binder, such as an isocyanate.

Claims

1. A biocomposite particulate material comprising discrete fiber-reinforced protein-based particles having a moisture content of about 55-75% by weight and a particle size of no greater than about 0.5 inch;

said discrete particles comprising an aqueous legume-based resin and fibrous cellulosic material, wherein the ratio of cellulose solids to resin solids is about 0.8;

1.0 to about 1.5;

1.0.

2. The biocomposite particulate material of claim 1 wherein the ratio of cellulose solids to resin solids is about 1.0:

1.0 to about 1.3;

1.0.

3. The biocomposite particulate material of claim 1 wherein the legume-based resin comprises a ground leguminous material having a protein dispersion index of about 20-100 pdi.

4. The biocomposite particulate material of claim 3 wherein the leguminous material has a protein dispersion index of about 70-100 pdi.

5. The biocomposite particulate material of claim 3 wherein the ground leguminous material is a pulse crop.

6. The biocomposite particulate material of claim 5 wherein the ground pulse crop is a ground soybean material.

7. The biocomposite particulate material of claim 6 wherein the ground soybean material is soy flour.

8. The biocomposite particulate material of claim 1 wherein the legume-based resin includes an amount of ground leguminous material effective to produce a resin having a viscosity of about 37,000-640,000 cps at 65°

F.

9. The biocomposite particulate material of claim 8 wherein the leguminous material is present in the resin in an amount of about 15-40% by weight based on the total weight of the resin.

10. A biocomposite particulate material comprising discrete fiber-reinforced protein-based particles having a moisture content of less than about 20% by weight and a particle size of no greater than about 0.5 inch;

said discrete particles comprising a legume-based resin and fibrous cellulosic material, wherein the ratio of cellulose solids to resin solids is about 0.8;

1.0 to about 1.5;

1.0.

11. The biocomposite particulate material of claim 10 wherein the ratio of cellulose solids to resin solids is about 1.0:

1.0 to about 1.3;

1.0.

12. The biocomposite particulate material of claim 11 wherein the moisture content of the discrete particles is about 6-18% by weight.

13. The biocomposite particulate material of claim 12 wherein the discrete particles are coated with a secondary thermosetting binder.

14. The biocomposite particulate material of claim 10 wherein the legume-based resin comprises a ground leguminous material having a protein dispersion index of about 20-100 pdi.

15. The biocomposite particulate material of claim 14 wherein the leguminous material has a protein dispersion index of about 70-100 pdi.

16. A rigid biocomposite pressure-formed material comprising fused discrete fiber-reinforced protein-based particles wherein said discrete particles prior to being fused have a moisture content of less than about 20% by weight and a particle size of no greater than about 0.5 inch, and comprise a legume-based resin and fibrous cellulosic material in a ratio of cellulose solids to resin solids of about 0.8:

1.0 to about 1.5;

1.0.

17. A method for preparing a biocomposite particulate material comprising discrete fiber-reinforced protein-based particles;

said method comprising;

(a) preparing an aqueous legume-based resin having a pH of about 10-14; and

(b) combining a fibrous cellulosic material with the aqueous legume-based resin in an amount and manner effective to form discrete biocomposite particles having a moisture content of about 55-75% by weight, a particle size of no greater than about 0.5 inch, and a ratio of cellulose solids to resin solids of about 0.8;

1.0 to 1.5;

1.0.

19. A biocomposite particulate material preparable by the method of claim 17.

18. A method of preparing a rigid pressure-formed biocomposite material comprising:

(a) preparing an aqueous legume-based resin having a pH of about 10-14;

(b) combining a fibrous cellulosic material with the aqueous legume-based resin in an amount and manner effective to form discrete biocomposite particles having a moisture content of about 55-75% by weight, a particle size of no greater than about 0.5 inch, and a ratio of cellulose solids to resin solids of about 0.8;

1.0 to 1.5;

1.0;

(c) reducing the moisture content of the discrete biocomposite particles to less than about 20% by weight to form dry biocomposite particles; and

(d) pressing the dry biocomposite particles under an elevated temperature and pressure for a time effective to fuse the particles into a rigid biocomposite pressure-formed material.

20. A biocomposite pressure-formed material preparable by the method of claim 18.