Cellulosic and lignocellulosic materials and compositions and composites made therefrom

• US 7,470,463 B2
• Filed: 06/21/2006
• Issued: 12/30/2008
• Est. Priority Date: 09/02/1997
• Status: Expired due to Fees

• Current Assignee: Xyleco, Inc.
• Original Assignee: Xyleon Incorporated
• Inventors: Medoff, Marshall, Lagace, Arthur P.
• Primary Examiner(s): Peselev; Elli
• Application Number:
  US11/471,924
• Publication Number:
  US 20060240109A1
• Time in Patent Office: 923 Days
• Field of Search: None
• US Class Current: 428/292.4
• CPC Class Codes: A01N 25/34 Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
• CPC Class Codes: A23L 33/24 Cellulose or derivatives thereof
• CPC Class Codes: A61K 9/2068 Compounds of unknown constitution, e.g. material from plants or animals oils, fats, waxes, shellac A61K9/2013
• CPC Class Codes: B29B 17/0026 by agglomeration or compacting
• CPC Class Codes: B29K 2311/12 Paper, e.g. cardboard
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: C08J 11/06 without chemical reactions
• CPC Class Codes: C08J 5/04 Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: C08J 5/045 with vegetable or animal fibrous material
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds
• 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: Y02W 30/62 Plastics recycling; Rubber recycling
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249925 Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]

Abstract

Cellulosic or lignocellulosic materials, and compositions and composites made therefrom, are disclosed.

Claims

1. A composite comprising:

a fibrous material including fibers comprising a cellulosic or lignocellulosic material, wherein the cellulosic or lignocellulosic material has been sheared to the extent that it has a bulk density less than about 0.5 g/cm³, and wherein at least about 50% of the fibers have a length/diameter ratio of at least about 5; and

a resin.

2. The composite of claim 1, wherein the resin is a thermoplastic resin.

3. The composite of claim 1, wherein the resin is selected from the group consisting of polyethylene, polypropylene, polystyrene, polycarbonate, polybutylene, thermoplastic polyesters, polyethers, thermoplastic polyurethane, PVC, polyamides, and mixtures thereof.

4. The composite of claim 1, wherein the composite is in the form of an article selected from the group consisting of panels, pipes, decking materials, boards, housings, sheets, poles, straps, fencing, members, doors, shutters, awnings, shades, signs, frames, window casings, backboards, wallboards, flooring, tiles, railroad ties, forms, trays, tool handles, stalls, bedding, dispensers, staves, films, wraps, totes, barrels, boxes, packing materials, baskets, straps, slips, racks, casings, binders, dividers, walls, indoor and outdoor carpets, rugs, wovens, and mats, frames, bookcases, sculptures, chairs, tables, desks, art, toys, games, wharves, piers, boats, masts, pollution control products, septic tanks, automotive panels, substrates, computer housings, above- and below-ground electrical casings, furniture, picnic tables, tents, playgrounds, benches, shelters, sporting goods, beds, bedpans, thread, filament, cloth, plaques, trays, hangers, servers, pools, insulation, caskets, bookcovers, clothes, canes, crutches, and other construction, agricultural, material handling, transportation, automotive, industrial, environmental, naval, electrical, electronic, recreational, medical, textile, and consumer products.

5. The composite of claim 1, wherein the fibrous material has a bulk density less than about 0.2 g/cm³.

6. The composite of claim 1, wherein said cellulosic or lignocellulosic material comprises paper or paper products.

7. The composite of claim 1, wherein at least about 50% of the fibers have a length/diameter ratio of at least about 25.

8. The composite of claim 1, wherein at least about 50% of the fibers have a length/diameter ratio of at least about 10.

9. The composite of claim 1, wherein the cellulosic or lignocellulosic material is selected from the group consisting of paper, paper products, byproducts of paper manufacture, newsprint, effluent from paper manufacture, wood, wood fibers, wood-related materials, kenaf, grasses, rice hulls, bagasse, cotton, jute, hemp, flax, bamboo bast fibers, bamboo core fibers, leaf plants, sisal, abaca, agricultural fibers, cereal straw, corn cobs, rice hulls, coconut hair, offal, rags, and mixtures thereof.

10. The composite of claim 1, wherein the resin is polypropylene or polyethylene.