Cellulosic and lignocellulosic materials and compositions and composites made therefrom

Abstract

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

1 . A composite comprising a resin and fiber, wherein the fiber is cellulosic or lignocellulosic fiber that has been sheared.  
     
     
         2 . The composite of  claim 1 , comprising at least about 5% by weight sheared fiber.  
     
     
         3 . The composite of  claim 1 , wherein the fiber is newsprint.  
     
     
         4 . The composite of  claim 1 , wherein the fiber is jute.  
     
     
         5 . The composite of  claim 1 , wherein the fiber is kenaf.  
     
     
         6 . The composite of  claim 1 , wherein the fiber is magazine paper.  
     
     
         7 . The composite of  claim 1 , wherein the fiber is bleached kraft board.  
     
     
         8 . The composite of  claim 1 , wherein the fiber is poly-coated paper.  
     
     
         9 . The composite of  claim 1 , wherein the resin is a thermoplastic resin.  
     
     
         10 . The composite of  claim 9 , wherein the resin is selected from the group consisting of polystyrene, polycarbonate, polybutylene, thermoplastic polyesters, polyethers, thermoplastic polyurethane, PVC, and Nylon.  
     
     
         11 . The composite of  claim 9 , wherein the thermoplastic resin is polyethylene.  
     
     
         12 . The composite of  claim 9 , wherein the thermoplastic resin is polypropylene.  
     
     
         13 . The composite of  claim 1 , wherein the composite comprises about 30% to about 70% by weight resin and about 30% to about 70% by weight fiber.  
     
     
         14 . A composite comprising polyethylene and fiber, wherein the fiber is cellulosic or lignocellulosic fiber that has been sheared.  
     
     
         15 . A composite comprising a resin and fiber, wherein the composite has a flexural strength of at least 3,000 psi, wherein the fiber is cellulosic or lignocellulosic fiber that has been sheared.  
     
     
         16 . The composite of  claim 15 , wherein the composite has a flexural strength of at least 6,000 psi.  
     
     
         17 . The composite of  claim 15 , wherein the composite has a flexural strength of at least 10,000 psi.  
     
     
         18 . A process for manufacturing a composite, the process comprising shearing cellulosic or lignocellulosic fiber, and combining the sheared cellulosic or lignocellulosic fiber with a resin.  
     
     
         19 . The process of  claim 18 , wherein the resin is a thermoplastic resin.  
     
     
         20 . The process of  claim 18 , wherein the step of shearing the cellulosic or lignocellulosic fiber comprises shearing with a rotary knife cutter.  
     
     
         21 . A process for preparing a texturized fibrous material, the process comprising: 
 shearing a cellulosic or lignocellulosic material having internal fibers.    
     
     
         22 . The method of  claim 21 , wherein said cellulosic or lignocellulosic material is selected from the group consisting of flax, hemp, cotton, jute, rags, paper, paper products, and byproducts of paper manufacturing.  
     
     
         23 . The method of  claim 21 , wherein the cellulosic or lignocellulosic material is pulp board.  
     
     
         24 . The method of  claim 21 , wherein the cellulosic or lignocellulosic material is a synthetic material.  
     
     
         25 . The method of  claim 21 , wherein the cellulosic or lignocellulosic material is a non-woven material.  
     
     
         26 . The method of  claim 21 , wherein the cellulosic or lignocellulosic material is poly-coated paper.  
     
     
         27 . The method of  claim 21 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 5.  
     
     
         28 . The method of  claim 21 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 25.  
     
     
         29 . The method of  claim 21 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 50.  
     
     
         30 . A fibrous material comprising a cellulosic or lignocellulosic material, wherein said cellulosic or lignocellulosic material is sheared to the extent that it has a bulk density less than about 0.5 g/cm 3 .  
     
     
         31 . The fibrous material of  claim 30 , wherein said material is incorporated into a structure or carrier.  
     
     
         32 . The fibrous material of  claim 31 , wherein the structure or carrier also comprises a fibrous material having a bulk density less than about 0.5 g/cm 3 .  
     
     
         33 . The fibrous material of  claim 30 , wherein said texturized fibrous material has a bulk density less than about 0.2 grams per cubic centimeter.  
     
     
         34 . The fibrous material of  claim 30 , wherein said texturized fibrous material has a bulk density on the order of about 0.1 grams per cubic centimeter.  
     
     
         35 . The fibrous material of  claim 30 , wherein said cellulosic or lignocellulosic material comprises paper or paper products.  
     
     
         36 . A composition comprising the fibrous material of  claim 30  and a chemical or chemical formulation.  
     
     
         37 . The composition of  claim 36 , wherein the chemical formulation comprises a pharmaceutical.  
     
     
         38 . The composition of  claim 36 , wherein the chemical formulation an agricultural compound.  
     
     
         39 . The composition of  claim 36 , wherein the chemical formulation comprises an enzyme.  
     
     
         40 . A composition comprising the fibrous material of  claim 30  and a liquid.  
     
     
         41 . A composition comprising the fibrous material of  claim 30  and particulate, powdered, or granulated solid.  
     
     
         42 . The composition of  claim 41 , wherein the solid comprises plant seed.  
     
     
         43 . The composition of  claim 41 , wherein the solid comprises a foodstuff.  
     
     
         44 . The composition of  claim 41 , wherein the solid comprises bacteria.  
     
     
         45 . The composite of  claim 1 , further comprising an inorganic additive.  
     
     
         46 . The composite of  claim 45 , wherein the inorganic additive is selected from the group consisting of calcium carbonate, graphite, asbestos, wollastonite, mica, glass, fiber glass, chalk, talc, silica, ceramic, ground construction waste, tire rubber powder, carbon fibers, and metal fibers.  
     
     
         47 . The composite of  claim 46 , wherein the inorganic additive comprises from about 0.5% to about 20% of the total weight of the composite.  
     
     
         48 . The composite of  claim 1 , wherein said composite is in the form of a pallet.  
     
     
         49 . The composite of  claim 48 , wherein said pallet is injection molded.  
     
     
         50 . The composite of  claim 1 , wherein said 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.  
     
     
         51 . The composite of  claim 1 , wherein said composite is in the form of a fiber, filament, or film.  
     
     
         52 . A composite comprising a resin and fibrous reinforcement, wherein the fibrous reinforcement has a bulk density less than about 0.5 g/cm 3 .  
     
     
         53 . The composite of  claim 52 , wherein the fibrous reinforcement has a bulk density less than about 0.2 g/cm 3 .