Biocomposite material and method of making
AssigneePhenix Biocomposites, Inc.
InventorsMichael J. Riebel, Paul L. Torgusen, Kenneth D. Roos, Donald E. Anderson, Carl Gruber
Life of this patent
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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.
Claims58
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.
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.
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.
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.
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.
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.
Dependencies are inferred from the claim text.