Compositions and composites of cellulosic and lignocellulosic materials and resins, and methods of making the same

Abstract

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

What is claimed is:  
     
         1 . A process for manufacturing a composite comprising, in any order or concurrently, (a) shearing cellulosic or lignocellulosic fiber to the extent that its internal fibers are substantially exposed to form texturized cellulosic or lignocellulosic fiber, and (b) combining the cellulosic or lignocellulosic fiber with a resin.  
     
     
         2 . The process of  claim 1 , wherein the resin is a thermoplastic resin.  
     
     
         3 . The process of  claim 1 , wherein the resin is selected from the group consisting of polystyrene, polycarbonate, polybutylene, thermoplastic polyesters, polyethers, thermoplastic polyurethane, PVC, and Nylon.  
     
     
         4 . The process of  claim 1 , wherein the resin is selected from the group consisting of a thermosetting resin, an elastomer, a tar, an asphalt, and a lignin.  
     
     
         5 . The process of  claim 1 , wherein the resin is selected from the group consisting of alkyds, diallyl phthalates, epoxies, melamines, phenolics, silicones, ureas, thermosetting polyesters, natural rubber, isoprene rubber, styrene-butadiene copolymers, neoprene, nitrile rubber, butyl rubber, ethylene propylene copolymer, ethylene propylene diene terpolymer, hypalon, acrylic rubber, polysulfide rubber, silicones, urethanes, fluoroelastomers, butadiene, and epichlorohydrin rubber.  
     
     
         6 . The process of  claim 1 , wherein the fiber is selected from the group consisting of jute, kenaf, flax, hemp, cotton, rags, paper, paper products, and byproducts of paper manufacturing.  
     
     
         7 . The process of  claim 6 , wherein the cellulosic or lignocellulosic material is pulp board.  
     
     
         8 . The process of  claim 6 , wherein the paper is selected from the group consisting of newsprint, magazine paper, poly-coated paper, and bleached kraft board.  
     
     
         9 . The process of  claim 1 , wherein the cellulosic or lignocellulosic material is a synthetic material.  
     
     
         10 . The process of  claim 1 , wherein the cellulosic or lignocellulosic material is a non-woven material.  
     
     
         11 . The process of  claim 1 , wherein the step of shearing the cellulosic or lignocellulosic fiber comprises shearing with a screw in a compounding machine or extruder.  
     
     
         12 . The process of  claim 1 , wherein the composite comprises about 30% to about 70% by weight resin and about 30% to about 70% by weight fiber.  
     
     
         13 . The process of  claim 1 , wherein step (a) is carried out prior to step (b).  
     
     
         14 . The process of  claim 1 , wherein step (b) is carried out prior to step (a).  
     
     
         15 . The process of  claim 1 , wherein steps (a) and (b) are carried out concurrently.  
     
     
         16 . The process of  claim 13 , further comprising, after step (a) but prior to step (b), densifying the texturized fiber.  
     
     
         17 . The process of  claim 16 , wherein the densifying step comprises compressing at least some of the texturized fiber into pellets.  
     
     
         18 . A composite manufactured by the process of  claim 1 .  
     
     
         19 . The composite of  claim 18 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 5.  
     
     
         20 . The composite of  claim 18 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 25.  
     
     
         21 . The composite of  claim 18 , wherein at least about 50% of the fibers have a length/diameter ratio of at least about 50.  
     
     
         22 . A composition comprising the composite of  claim 18  and a chemical or chemical formulation.  
     
     
         23 . The composition of  claim 22 , wherein the chemical formulation comprises a compatibilizer.  
     
     
         24 . The composite of  claim 18 , further comprising an inorganic additive.  
     
     
         25 . The composite of  claim 24 , 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.  
     
     
         26 . The composite of  claim 24 , wherein the inorganic additive comprises from about 0.5% to about 20% of the total weight of the composite.  
     
     
         27 . The composite of  claim 18 , wherein said composite is in the form of a pallet.  
     
     
         28 . The composite of  claim 18 , 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, book covers, clothes, canes, crutches, and other construction, agricultural, material handling, transportation, automotive, industrial, environmental, naval, electrical, electronic, recreational, medical, textile, and consumer products.  
     
     
         29 . The composite of  claim 18 , wherein said composite is in the form of a fiber, filament, or film.  
     
     
         30 . A process comprising 
 (a) shearing cellulosic or lignocellulosic fiber to the extent that its internal fibers are substantially exposed to form texturized cellulosic or lignocellulosic fibers, and    (b) densifying the texturized cellulosic or lignocellulosic fibers.    
     
     
         31 . The process of  claim 30 , wherein the densifying step comprises compressing at least some of the texturized fibers into pellets.  
     
     
         32 . The process of  claim 30 , further comprising, prior to the densifying step, the texturized cellulosic or lignocellulosic fibers with a substance that aids in densification.  
     
     
         33 . The process of  claim 30 , further comprising combining the texturized cellulosic or lignocellulosic fibers with a resin before the densifying step.  
     
     
         34 . The process of  claim 30 , further comprising combining the texturized cellulosic or lignocellulosic fiber with another substance before densification.  
     
     
         35 . The process of  claim 34 , wherein the combining step comprises the texturized cellulosic or lignocellulosic fibers with a solution of an enzyme or pharmaceutical.  
     
     
         36 . The process of  claim 34 , wherein the combining step comprises blending the texturized cellulosic or lignocellulosic fibers with a solid.  
     
     
         37 . A composite manufactured by the process of  claim 30 .  
     
     
         38 . Densified texturized cellulosic or lignocellulosic fibers.  
     
     
         39 . The densified fibers of  claim 38 , wherein the densified fibers have a bulk density of from 10 to 50 pounds per cubic foot.  
     
     
         40 . The densified fibers of  claim 38 , wherein the densified fibers have a bulk density of from 20 to 30 pounds per cubic foot.  
     
     
         41 . The densified fibers of  claim 38 , in the form of a pellet.