Biocomposite material and method of making

• US 5,593,625 A
• Filed: 06/10/1994
• Issued: 01/14/1997
• 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., Torgusen, Paul L., Gruber, Carl, Roos, Kenneth D.
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): MAYES, MELVIN C
• Application Number:
  US08/258,187
• Time in Patent Office: 949 Days
• Field of Search: 156/328, 156/336, 156/62.2, 428/537.5, 428/903.3, 428/534, 428/535, 428/357, 428/402, 428/403, 428/407, 264/109, 264/115, 264/128, 264/123, 264/124, 264/125, 264/126
• US Class Current: 264/115
• 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 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 (1.3 cm), 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;

(d) coating the dry biocomposite particles with a secondary thermosetting binder; and

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

2. The method of claim 1 wherein the secondary thermosetting binder is an isocyanate binder.

3. The method of claim 1 further including a step of coating the dry biocomposite particles with a water-repellant sizing agent.

4. The method of claim 1 wherein the step of preparing the legume-based resin includes a step of adding a colorant.

5. The method of claim 1 wherein the step of preparing an aqueous legume-based resin comprises combining about 15-40% ground leguminous material, based on the total weight of the resin, with a highly alkaline aqueous solution.

6. The method of claim 5 wherein the aqueous legume-based resin has a viscosity of about 37,000-640,000 cps at 65°

F. (18°

C.).

7. The method of claim 1 wherein the pressing step occurs at a temperature of about 250°

-340°

F. (121°

-171°

C.).

8. The method of claim 7 wherein the pressing step occurs at a pressure of about 450-750 psi.

9. The method of claim 1 wherein the pressing step comprises pressing the particulate material in an electrically heated platen press.

10. The method of claim 1 wherein the step of combining includes mixing the fibrous cellulosic material and the aqueous legume-based resin under shearing forces sufficient to form the discrete biocomposite particles.

11. A rigid biocomposite pressure-formed material preparable by a process comprising:

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

(b) combining a fibrous cellulosic material with the aqueous, legume-based resin in an amount and manner effective to form discrete bicomposite particles having a moisture content of about 55-75% by weight a particle size of no greater than about 0.5 inch (1.3 cm), and a ratio of cellulose solids to resin solids of about 0.8;

1.0 to 1.5;

10;

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

(d) coating the dry biocomposite particles with a secondary thermosetting binder;

(e) coating the dry biocomposite particles with a water-repellant sizing agent; and

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

12. The rigid biocomposite pressure-formed material preparable by the process of claim 11 wherein the secondary thermosetting binder is isocyanate binder.

13. A rigid biocomposite pressure-formed material comprising fused discrete fiber-reinforced protein-based particles and a secondary thermosetting binder;

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 8;

1.0 to about 1.5;

1.0.

14. The rigid composite pressure-formed material of claim 13 having a density of about 45-100 pounds per cubic foot.

15. The rigid biocomposite pressure-formed material of claim 13 having a Modulus of Rupture of about 1000-10,000 psi and a Modulus of Elasticity of about 100,000-1,000,000 psi.

16. The rigid biocomposite pressure-formed material of claim 15 having a Modulus of Rupture of greater than about 2000 psi and a Modulus of Elasticity of greater than about 200,000 psi.

17. The rigid biocomposite pressure-formed material of claim 16 having a Modulus of Rupture of greater than about 2800 psi and a Modulus of Elasticity of greater than about 350,000 psi.

18. The rigid biocomposite pressure-formed material of claim 17 having a Modulus of Rupture of greater than about 3000 psi and a Modulus of Elasticity of greater than about 450,000 psi.

19. The rigid biocomposite pressure-formed material of claim 13 further including an inlay material that is an integral part of the pressure-formed material.

20. The rigid biocomposite pressure-formed material of claim 13 further including at least one colorant.

21. The rigid biocomposite pressure-formed material of claim 13 further including a water-repellant sizing agent.

22. The rigid biocomposite pressure-formed material of claim 21 wherein the water-repellant sizing agent is present in an amount of about 0.5-2.5% by weight.

23. The rigid biocomposite pressure-formed material of claim 22 wherein the water-repellant sizing agent is selected from the group consisting of a slack wax, a wax emulsion, an unmodified agricultural oil, and a modified agricultural oil.

24. The rigid biocomposite pressure-formed material of claim 13 wherein the fibrous cellulosic material comprises newspaper.

25. The rigid biocomposite pressure-formed material of claim 13 wherein the fibrous cellulosic material comprises agricultural fiber.

26. The rigid biocomposite pressure-formed material of claim 13 wherein the legume-based resin includes a formaldehyde-based cross-linker.

27. A rigid biocomposite pressure-formed material comprising fused discrete fiber-reinforced protein-based particles and an isocyanate binder;

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.

28. The rigid biocomposite pressure-formed material of claim 27 wherein the legume-based resin and fibrous cellulosic material are present in amounts such that the ratio of cellulose solids to resin solids is about 0.8:

1.0 to about 1.5;

1.0.

29. The rigid biocomposite pressure-formed material of claim 28, wherein the moisture content of the fused discrete fiber-reinforced protein-based particles have a moisture content of about 6-8% by weight prior to fusing.

30. The rigid biocomposite pressure-formed material of claim 27 having a Modulus of Rupture of greater than about 3500 psi and a Modulus of Elasticity of greater than about 500,000 psi.

31. The rigid biocomposite pressure-formed material of claim 30 having a Modulus of Rupture of greater than about 4000 psi and a Modulus of Elasticity of greater than about 600,000 psi.

32. The rigid biocomposite pressure-formed material of claim 31 having a Modulus of Rupture of greater than about 4500 psi and a Modulus of Elasticity of greater than about 700,000 psi.

33. The rigid biocomposite pressure-formed material of claim 27 wherein the isocyanate binder comprises an aromatic isocyanate.

34. The rigid biocomposite pressure-formed material of claim 27 further including a water-repellant sizing agent.

35. The rigid biocomposite pressure-formed material of claim 34 wherein the water-repellant sizing agent is present in an amount of about 0.5-2.5% by weight.

36. The rigid biocomposite pressure-formed material of claim 34 wherein the water-repellant sizing agent is selected from the group consisting of a slack wax, a wax emulsion, an unmodified agricultural oil, and a modified agricultural oil.

37. The rigid biocomposite pressure-formed material of claim 27 wherein the isocyanate binder is present in an amount of about 2-20% by weight.

38. The rigid biocomposite pressure-formed material of claim 27 further including an inlay material than is an integral part of the pressure-formed material.

39. The rigid biocomposite pressure-formed material of claim 27 wherein the legume based resin includes at least one colorant.

40. The rigid biocomposite pressure-formed material of claim 27 wherein the fibrous cellulosic material comprises agricultural fiber.

41. The rigid biocomposite pressure-formed material of claim 27 wherein the legume-based resin includes a formaldehyde-based cross-linker.

42. A rigid biocomposite pressure-formed material prepared by fusing discrete fiber-reinforced protein-based particles having a moisture content of about 6-8% by weight and a particle size of no greater than about 0.5 inch in the presence of an isocyanate binder;

wherein said discrete particles comprise a legume-based resin and fibrous cellulosic material.

43. The rigid biocomposite pressure-formed material of claim 42 wherein the isocyanate binder comprises an aromatic isocyanate.

44. The rigid biocomposite pressure-formed material of claim 42 wherein the isocyanate binder is present in an amount of about 2-20% by weight.

45. The rigid biocomposite pressure-formed material of claim 42 prepared by fusing the discrete fiber-reinforced protein-based particles in the presence of an isocyanate binder and a water-repellant sizing agent.

46. The rigid biocomposite pressure-formed material of claim 45 wherein the water-repellant sizing agent is present in an amount of about 0.5-2.5% by weight.

47. The rigid biocomposite pressure-formed material of claim 42 wherein the discrete fiber-reinforced protein-based particles further include a colorant.

48. The rigid biocomposite pressure-formed material of claim 47 wherein the discrete fiber-reinforced protein-based particles comprise at least two different colored particles.

49. The rigid biocomposite pressure-formed material of claim 42 wherein the legume-based resin includes a formaldehyde-based cross-linker.

50. A rigid biocomposite pressure-formed material prepared by fusing 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 in the presence of an aromatic isocyanate binder;

wherein said discrete particles comprise a legume-based resin an fibrous cellulosic material in a ratio of cellulose solids to resin solids of about 0.8;

1.0 to about 1.5;

1.0.

51. The rigid biocomposite pressure-formed material of claim 50 wherein the legume-based resin has a pH of about 10-14 prior to combining with the fibrous cellulosic material.

52. The rigid biocomposite pressure-formed material of claim 51 wherein the legume-based resin includes a formaldehyde-based cross-linker.

53. The rigid biocomposite pressure-formed material of claim 50 prepared by fusing the discrete fiber-reinforced protein-based particles in the presence of the aromatic isocyanate binder and a water-repellant sizing agent.

54. The rigid biocomposite pressure-formed material of claim 53 wherein the water-repellant sizing agent is present in the amount of about 0.5-2.5% by weight.

55. The rigid composite pressure-formed material of claim 50 wherein the discrete fiber-reinforced protein-based particles further include a colorant.

56. The rigid biocomposite pressure-formed material of claim 55 wherein the discrete fiber-reinforced protein-based particles comprise at least two different colored particles.

57. The rigid biocomposite pressure-formed material of claim 50 wherein the discrete fiber-reinforced protein-based particles have a moisture content of about 6-8% by weight prior to fusing.

58. The rigid biocomposite pressure-formed material of claim 50 wherein the aromatic isocyanate binder is present in an amount of about 2-20% by weight.