Cellulosic fiber composites

Details Cellulosic fiber composites Cellulosic fiber composites

1999-04-09

2001-07-10

Nutter, Nathan M. (Department: 1711)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Processes of preparing a desired or intentional composition...

C524S014000, C524S076000, C523S129000

Reexamination Certificate

active

06258876

ABSTRACT:

BACKGROUND OF THE INVENTION
The invention relates to composites of resins and cellulosic or lignocellulosic fibers.
Resins are used in a variety of applications, for example, in food packaging. Food containers made of resins are typically used once, then discarded.
Cellulosic and lignocellulosic materials are produced, processed, and used in large quantities in a number of applications. Once used, these fibers are usually discarded as waste materials. As a result, there is an ever-increasing amount of waste cellulosic and lignocellulosic fiber, as well as waste resin.
SUMMARY OF THE INVENTION
In general, the invention features composites including a resin and texturized cellulosic or lignocellulosic fiber.
The invention features a composite including a resin, such as a thermoplastic resin, and at least about 2% by weight, more preferably at least about 5% by weight, texturized cellulosic or lignocellulosic fiber. The invention also features a composite that includes polyethylene and at least about 50% by weight texturized cellulosic or lignocellulosic fiber.
The invention further features composites, including a resin and cellulosic or lignocellulosic fiber, that have flexural strengths of at least about 3,000 psi, or tensile strengths of at least about 3,000 psi.
In addition, the invention features a process for manufacturing a composite; the process includes shearing cellulosic or lignocellulosic fiber to form texturized cellulosic or lignocellulosic fiber, then combining the texturized fiber with a resin. A preferred method includes shearing the fiber with a rotary knife cutter. The invention also features a process for manufacturing a composite that includes shearing cellulosic or lignocellulosic fiber and combining the fiber with a resin.
The term “texturized cellulosic or lignocellulosic fiber” as used herein, means that the fiber has been sheared to the extent that the internal fibers are substantially exposed. At least about 50%, more preferably at least about 70%, of these fibers have a length/diameter (L/D) ratio of at least 5, more preferably at least 25, or at least 50. An example of texturized fiber is shown in FIG.
1
.
The composites of the present invention are strong, light-weight, and inexpensive. The raw materials used to make the composites are readily available; for example, they may include discarded containers composed of resins, and waste cellulosic or lignocellulosic fiber.
Other features and advantages of the invention will be apparent from the description of the preferred embodiments thereof, and from the claims.


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