Cellulose-reinforced thermoplastic composite and methods of making same

• US 6,758,996 B2
• Filed: 07/13/2001
• Issued: 07/06/2004
• Est. Priority Date: 07/13/2001
• Status: Expired due to Term

• Current Assignee: Green Bay Decking LLC
• Original Assignee: Kadant Composites Inc.
• Inventors: Leeman, David, Anderson, Steven J., Klyosov, Anatole A., Monovoukas, Yiannis A., Philippidis, George P.
• Primary Examiner(s): Colaianni, Michael
• Assistant Examiner(s): HUSON, MONICA ANNE
• Application Number:
  US09/905,431
• Publication Number:
  US 20030030176A1
• Time in Patent Office: 1,089 Days
• Field of Search: 264/176.1, 264/328.17, 264/331.11, 428/311.11, 428/326, 162/218, 162/293, 162/DIG.9
• US Class Current: 264/176.1
• CPC Class Codes: C08L 1/00 Compositions of cellulose, modified cellulose or cellulose derivatives
• CPC Class Codes: C08L 1/02 Cellulose; Modified cellulose
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds
• CPC Class Codes: C08L 23/04 Homopolymers or copolymers of ethene
• CPC Class Codes: C08L 23/06 Polyethene
• 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 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; 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 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 77/00 Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 77/02 Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08L77/10 takes precedence
• CPC Class Codes: C08L 77/06 Polyamides derived from polyamines and polycarboxylic acids C08L77/10 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
• CPC Class Codes: Y10S 162/09 Uses for paper making sludge
• CPC Class Codes: Y10T 428/249962 Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]

Abstract

Granulated papermaking sludge is combined with plastic to form composite materials that may be shaped into structural and non-structural articles.

Claims

1. A method of making a composite material, the method comprising the step of combining papermaking sludge in granulated form comprising a composite of organic and inorganic materials and having a porous structure with a polymer composition comprising a synthetic polymer resin.

2. The method of claim 1 wherein the sludge comprises at least 5% by weight of the mixture.

3. The method of claim 1 wherein the sludge comprises at least 20% by weight of the mixture.

4. The method of claim 1 wherein the sludge comprises at least 50% by weight of the mixture.

5. The method of claim 1 wherein the sludge comprises at least 70% by weight of the mixture.

6. The method of claim 1 wherein the polymer composition is a plastic.

7. The method of claim 6 wherein the plastic comprises at least one of high-density polyethylene, low-density polyethylene, polypropylene, polyvinyl chloride, and nylon.

8. The method of claim 1 wherein the combining step further comprises adding cellulose fibers to the sludge and polymer composition.

9. The method of claim 8 wherein the cellulose fibers are in the form of rice hulls.

10. The method of claim 1 further comprising the step of extruding, injection molding, or compression molding the mixture.

11. A composite material comprising a mixture of:

a. papermaking sludge in granulated form comprising a composite of organic and inorganic materials and having a porous structure; and

b. a polymer composition comprising a synthetic polymer resin.

12. The material of claim 11 wherein the sludge comprises at least 5% by weight of the mixture.

13. The material of claim 11 wherein the sludge comprises at least 20% by weight of the mixture.

14. The material of claim 11 wherein the sludge comprises at least 50% by weight of the mixture.

15. The material of claim 11 wherein the sludge comprises at least 70% by weight of the mixture.

16. The material of claim 11 wherein the polymer composition is a plastic.

17. The material of claim 16 wherein the plastic comprises at least one of high-density polyethylene, low-density polyethylene, polypropylene, polyvinyl chloride, and nylon.

18. The material of claim 11 wherein the mixture is amenable to processing by at least one of extrusion, injection molding, and compression molding.

19. The material of claim 11 further comprising cellulose fibers.

20. The material of claim 19 wherein the cellulose fibers are in the form of rice hulls.