Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1997-07-28
2001-03-20
Cain, Edward J. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
Reexamination Certificate
active
06204312
ABSTRACT:
FIELD OF INVENTION
The present invention relates to the non chemical treatment of lignocellulosics, as organic materials and inorganic materials to facilitate complex formation. More particularly the invention relates to the use of these organic and inorganic materials as compositions being pressed or extruded into finished products, giving dimensional stability, added strength, improving resistance to biological degradation, using non-toxic resin combinations. The organic materials can be in fractionated particles, none fractionated particles or fibre in homogeneous configuration.
DESCRIPTION OF THE PRIOR ART
Lignocellulosics/organic material/s posses many unique and desirable properties. it has several undesirable properties which have limited the use for many applications. It is known that the structure of the cell wall in its component parts individually and collectively determine the physical and chemical properties.
This can be seen regarding dimensional changes in respect to moisture content as the cell wall polymers contain hydroxyl and other oxygen groups and these attract moisture by hydrogen bonding. With the moisture swelling the cell wall the material expands untill the cell wall is saturated with water, water going further than this point is free water in a void structure and does not contribute to further expansion. The process is reversible by losing moisture.
Because organic/lignocellulosic materials can be degraded biologically as organisms, can recognise the polysaccharides in the cell wall and having very specific enzyme systems capable of hydrolizing theses polymers into digestible units. High molecular weight cellulose is responsible for strength in organic materials. The strength is lost as this polymer takes on further biological degradation and dehydration reactions.
Because dimensional instability and strength along with biological degradation can be said to be chemical in nature, it is possible to improve these undesirable properties by changing the basic chemistry of the cell wall polymers by encapsulation and complex formation leading to chemical bonding. Completing reaction by complex formation, encapsulation and chemical bonding precasts the cellulose and hemicellulose components as an example. The highly specific enzymatic reactions cannot take place because the moisture, oxygen and chemical configuration by encapsulation and chemical bonding has substantially altered the substrate. This chemical reaction in bonding reacts the cell wall polymers with resin reacting chemicals and reduces the tendency to swell to an absolute minimum, and this when subjected to change in moisture because the lignocellulosic in organic materials is chemically swollen and reaction encapsulation by application of heat.
The hydroxyl groups therefore play a significant role in the organic and inorganic applications of the resins to produce the end product.
Organic materials as lignocellulosics and inorganic materials fractionated and blended with themselves and together.
Resin systems greatly improves dimensional stability and bond strength and is resistant to biological attack and is according to the invention, made in the absence of any co solvent or added catalyst and does not use combinations of urea formaldehyde resins or phenol resins and made in a simple way.
Partially dry or dried organic or inorganic materials or combinations of both are fractioned or unfractioned and blended with non toxic resin systems to give complete envelope and complex formation. The material is then dried, pressed, moulded, or extruded into finished items in a short period of time.
It cannot be stressed enough that the invention deals with aqueous resin application in liquid, solid dispersion and then dried.
Moulded Compositions—Organic and Inorganic
DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide a new and improved method of using organic or inorganic waste materials which would otherwise be discarded.
According to the present invention, a method of producing a shaped end product from organic or inorganic waste materials is provided, which comprises introducing raw waste material particles into a mixing chamber, introducing a non-toxic resin material into the mixing chamber at a first temperature at which the resin material is thermoplastic, mixing the waste material and resin material together to form a flowable mixture, forming the flowable mixture into a predetermined shape, and curing the shaped mixture to thermoset the resin material and form a rigid, shaped end product.
This method allows inorganic and organic waste materials, either alone or in combination, to be formed into a moldable composition and to be used for many possible applications, particularly as a substitute for wood or for natural building or construction materials. There has been a longstanding, worldwide need to reduce usage of natural wood, and this method allows otherwise unusable waste materials to provide a wood substitute.
Suitable organic and inorganic materials, which may be used in combinations or separately, for use as the starting waste material in this method are listed below.
Organic Materials
1) Hard Wood Dust
2) Rubber Wood
3) Softwood Flakes
4) Hemp Fibre Dust
5) Semphire
6) Salicornia
7) Bagasse
8) Rice Husk
9) Ground rice
10) Palm-Fronze-Bunch, Trunk
11) Paper
12) (1-9) As flour
13) Cloth
Used singly or in combinations.
Inorganic Materials
1) Slate Dust
2) Ceramic Dust
3) Pottery Waste
4) Dune Sand
5) Sea Shore Sand
6) Quarry Waste
7) Limestone
The above being used as single materials or in combination and in combination with other materials.
Some of these basically comprise reconstituted wood, whereby wood residues are applied into a homogeneous mass to form a solid product, which have many of the properties of wood.
Chipboard is an example of such a product, however, chipboard and similar products are only available in the form of flat boards and the manufacturing process by which such products are obtained does not lend itself to the production of shaped sections or mouldings which are required for many architectural features in the construction of buildings for example. Such shaped components, which were traditionally formed from solid wood by appropriate machining operations, are often replaced by equivalent components made from metal or from plastic materials, but such materials are generally environmentally disadvantageous with regard to such matters as the energy expanded in the production of the raw materials, and often the hazardous nature of the chemicals required for processing.
On the other hand the organic and inorganic materials listed offer vast quantities or relatively innocuous waste vegetable matter arising from numerous industrial processes—similar occurs with inorganic material as listed. All of these materials having little or no commercial use at the moment.
The object of this invention is to provide a novel mouldable composition in organic and inorganic materials, polymeric in nature, homogeneous in finish for use as a substitute or combination composites of low toxicity, low hazard, high stability and inner bond strength.
According to a first aspect of the invention we provide a moulding composition, homogeneous in structure comprising of organic or inorganic fractionated materials singularly or in combination, coated with a fully reacted high molecular weight polyurethane resin. Resin modified with hydrophilic groups such that the coating is not penetrative absorbent to the particles of the fraction.
From the outset it should be noted that the resin compositions exclude totally the use of:
1) UF Resins
2) FMUF Resins
3) MUF Resins
4) Isocyanate Resins
5) Phenolic resins—Resoles or Novolaks
According to the second aspect of the invention we provide mouldable compositions homogeneous in structure from the following types of resin for both organic and inorganic materials.
1) Polyurethane combinations
2) Acrylic combinations
3) Hybrid combinations
4) Compositions of resins synthesised from palm oil source.
5) Compositions of resins synthesis
Advance Enterprises Ltd.
Brown Martin Haller & McClain
Cain Edward J.
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