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.
Claims20
A biocomposite particulate material comprising discrete fiber-reinforced protein-based particles having a moisture content of about 55-75% by weight and a particle size of no greater than about 0.5 inch;
- said discrete particles comprising an aqueous legume-based resin and fibrous cellulosic material, wherein the ratio of cellulose solids to resin solids is about 0.8:1.0 to about 1.5:1.0.
A biocomposite particulate material comprising 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;
- said discrete particles comprising a legume-based resin and fibrous cellulosic material, wherein the ratio of cellulose solids to resin solids is about 0.8:1.0 to about 1.5:1.0.
A rigid biocomposite pressure-formed material comprising fused discrete fiber-reinforced protein-based particles 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 0.8:1.0 to about 1.5:1.0.
A method for preparing a biocomposite particulate material comprising discrete fiber-reinforced protein-based particles;
- said method comprising:
- (a) preparing an aqueous legume-based resin having a pH of about 10-14;
- and
- (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, and a ratio of cellulose solids to resin solids of about 0.8:1.0 to 1.5:1.0.
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, 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;
- and
- (d) pressing the dry biocomposite particles under an elevated temperature and pressure for a time effective to fuse the particles into a rigid biocomposite pressure-formed material.
Dependencies are inferred from the claim text.