# US 2017/0282467 A1 · Composite materials comprising cellulose filaments and fillers and methods for the preparation thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0282467 A1 - Document ID: US20170282467A1 - Status: Published application - Kind: A1 - Application number: 15/476,334 - Filed: 2017-03-31 - Published: 2017-10-05 - Earliest claimed: 2016-04-04 - Applicants: FPInnovations - Inventors: Annie DORRIS; Gilles DORRIS; Josée DESMEULES; Otman OULANTI; Danielle GAGNÉ; Norayr GURNAGUL - Web page: https://patentgrep.com/patent/US20170282467A1 ## CPC - B29C 70/48: and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} - B32B 1/00: Layered products having a non-planar shape - B29C 70/42: for producing articles of definite length, i.e. discrete articles - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres} - B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder - B32B 13/02: with fibres or particles {being present as additives in the layer} - B32B 27/04: as impregnant, bonding, or embedding substance {(not used)} - B32B 27/08: of synthetic resin - B32B 27/12: next to a fibrous or filamentary layer - B32B 27/14: next to a particulate layer - B32B 27/26: using curing agents - B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers} - B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers} - B32B 27/308: {comprising acrylic (co)polymers} - B32B 27/36: comprising polyesters - B32B 27/38: comprising epoxy resins - B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines - C04B 30/02: containing fibrous materials - C04B 41/009: {characterised by the material treated} - C04B 41/4826: {Polyesters} - C04B 41/4853: {Epoxides} - C04B 41/63: Macromolecular compounds - C08J 5/045: {with vegetable or animal fibrous material} - D21H 11/04: Kraft or sulfate pulp - D21H 17/25: Cellulose - D21H 17/53: Polyethers; Polyesters - D21H 17/67: Water-insoluble compounds, e.g. fillers, pigments - D21H 19/24: comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds - D21H 19/28: Polyesters - D21H 27/30: Multi-ply (for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00) - B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material - B29K 2201/00: Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as reinforcement - B32B 2250/42: Alternating layers, e.g. ABAB(C), AABBAABB(C) - B32B 2260/023: Two or more layers - B32B 2260/046: Synthetic resin - B32B 2262/0269: Aromatic polyamide fibres - B32B 2262/062: Cellulose fibres, e.g. cotton - B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo - B32B 2262/067: Wood fibres - B32B 2262/101: Glass fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2262/14: Mixture of at least two fibres made of different materials - B32B 2264/10: Inorganic particles - B32B 2264/101: Glass - B32B 2264/102: Oxide or hydroxide - B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles - B32B 2264/108: Carbon, e.g. graphite particles - B32B 2264/12: Mixture of at least two particles made of different materials - B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers - B32B 2307/202: Conductive - B32B 2307/206: Insulating - B32B 2307/54: Yield strength; Tensile strength - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2307/738: Thermoformability - B32B 2451/00: Decorative or ornamental articles - B32B 2471/00: Floor coverings (B32B2419/04 takes precedence) - B32B 2605/00: Vehicles - B32B 2607/00: Walls, panels - C04B 2111/00612: {as one or more layers of a layered structure} - C08J 2300/00: Characterised by the use of unspecified polymers - C08J 2401/02: Cellulose; Modified cellulose - C08J 2497/02: Lignocellulosic material, e.g. wood, straw or bagasse - Y02W 30/91: Use of waste materials as fillers for mortars or concrete - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT ## Abstract The present disclosure relates to composite materials comprising a resin and at least one sheet that comprise optionally cellulose filaments (CF), fillers and optionally reinforcing fibers as well as methods for the preparation thereof. The methods comprise impregnating the sheets comprising the cellulose filaments, fillers and optionally the reinforcing fibers or a stack thereof with resin. The composite materials can optionally comprise at least one other sheet, the at least one other sheet being different from the at least one sheet and comprising fibers chosen from wood pulp, fiberglass, natural fibers and mixtures thereof. The sheet can also be in the form of a panel of a preform. ## Claims ### Claim 1 A composite material comprising: at least one sheet that comprises about 50 to about 95% of fillers, and about 0 to about 40% of reinforcing fibers, all of said percentages being expressed by weight, based on the total weight of the fillers and the reinforcing fibers; and a resin. ### Claim 2 (depends on 1) The composite material of claim 1, wherein said at least one sheet is impregnated with said resin. ### Claim 3 (depends on 1) The composite material of claim 1, wherein the sheet further comprises cellulose filaments (CF). ### Claim 4 (depends on 3) The composite material of claim 3, wherein the sheet comprises about 5% to about 25% of cellulose filaments by weight, based on the total weight of the cellulose filaments, the fillers and the reinforcing fibers. ### Claim 5 (depends on 4) The composite material of claim 4, wherein the sheet comprises at least about 70% of fillers by weight, based on the total weight of the cellulose filaments, the fillers and the reinforcing fibers. ### Claim 6 (depends on 1) The composite material of claim 1, wherein the sheet comprises about 65% to about 90% of fillers by weight, based on the total weight of the fillers and the reinforcing fibers. ### Claim 7 (depends on 6) The composite material of claim 6, wherein the sheet comprises about 1% to about 40% of reinforcing fibers by weight, based on the total weight of the fillers and the reinforcing fibers. ### Claim 8 (depends on 1) The composite material of claim 1, wherein the sheet comprises about 5% to about 40% of reinforcing fibers by weight, based on the total weight of the fillers and the reinforcing fibers. ### Claim 9 (depends on 6) The composite material of claim 6, wherein the sheet comprises about 10% to about 25% of reinforcing fibers by weight, based on the total weight of the fillers and the reinforcing fibers. ### Claim 10 (depends on 7) The composite material of claim 7, wherein the reinforcing fibers are Kraft fibers. ### Claim 11 (depends on 6) The composite material of claim 6, wherein the fillers are chosen from calcium sulfate, clay, calcium carbonate, alumina trihydrate (ATH), magnesium hydroxide (MDH), hollow glass microspheres, exfoliated graphite nano-platelets and mixtures thereof. ### Claim 12 (depends on 1) The composite material of claim 1, wherein the sheet is prepared by a method comprising: preparing a dry mat comprising a mixture of optional cellulose filaments, the fillers and the reinforcing fibers. ### Claim 13 (depends on 12) The composite material of claim 12, wherein the dry mat has a basis weight of about 100 g/m2 to about 300 g/m2. ### Claim 14 (depends on 12) The composite material of claim 12, wherein the dry mat has a basis weight of about 300 g/m2 to about 2000 g/m2. ### Claim 15 (depends on 12) The composite material of claim 12, wherein the dry mat has a basis weight of about 1500 g/m2 to about 4000 g/m2. ### Claim 16 (depends on 12) The composite material of claim 12, wherein the dry mat is prepared by a method comprising: draining an aqueous suspension comprising the optional cellulose filaments, the fillers and the reinforcing fibers under conditions to obtain a wet fiber mat; pressing said wet fiber mat under conditions to remove water and obtain a pressed mat; and drying said pressed mat under conditions to obtain said dry mat. ### Claim 17 (depends on 1) The composite material of claim 1, wherein the sheet has a 3D geometry and is prepared by a method comprising: preparing a dry mat comprising a mixture of optional cellulose filaments, the fillers and the reinforcing fibers, wherein the dry mat is prepared by: spraying an aqueous suspension comprising the optional cellulose filaments, the fillers and the reinforcing fibers through a perforated 3D mold mounted on a rotatory base and connected to vacuum system for filtration or drainage to obtain a wet pad; pressing said wet pad under conditions to remove water and obtain a pressed pad; and drying said pressed pad under conditions to obtain the dry mat ### Claim 18 (depends on 1) The composite material of claim 1, wherein said composite material is a laminate material comprising a plurality of said sheets. ### Claim 19 (depends on 1) The composite material of claim 1, wherein the sheet is a panel or a preform. ### Claim 20 (depends on 19) A method of preparing the composite material of claim 19, the method comprising: impregnating said panel or preform with resin to obtain a resin-impregnated panel or preform; and curing the resin under conditions to obtain the composite material. ### Claim 21 (depends on 1) A method of preparing a composite material, the method comprising: impregnating a plurality of said at least one sheet as defined in claim 1 with resin to obtain a plurality of resin-impregnated sheets; stacking said plurality of resin-impregnated sheets; and curing said resin under conditions to obtain said composite material or stacking a plurality of said at least one sheet as defined in claim 1 to form a stack of sheets; impregnating said stack of sheets with resin; and curing said resin under conditions to obtain said composite material.