EP2593508A1

EP2593508A1 - Novel cellulose composite materials

Info

Publication number: EP2593508A1
Application number: EP11740589.4A
Authority: EP
Inventors: Daniel Samain; Camélia STINGA
Original assignee: Centre National de la Recherche Scientifique CNRS
Current assignee: Centre National de la Recherche Scientifique CNRS
Priority date: 2010-07-13
Filing date: 2011-07-08
Publication date: 2013-05-22
Also published as: US9193851B2; FR2962735B1; JP2013533916A; FR2962735A1; CA2804662A1; CN103097447B; CN103097447A; WO2012007397A1; US20130199409A1

Abstract

The invention relates to novel cellulose composites and to methods for producing same, including the partial peracetylation of cellulose fibers having a degree of crystallinity of less than 80%.

Description

New cellulose composite materials

The present invention relates to novel cellulose / cellulose composites and methods for their manufacture.

Thermoplastic composites are conventionally made with a mixture of reinforcing fibers (glass, Kevlar, etc.) and a thermoplastic matrix. The field of thermoplastics offers numerous examples of substitution of mineral fibers by cellulose fibers (Michaud, F. 2003). The mechanical properties requirements are indeed lower than in the case of thermosets and water sensitivity problems related to the hydrophilic nature of the cellulose fibers can be overcome by a strategy of encapsulation of the fibers by the polymer matrix. This operation is made possible by the current low cost of polymer matrices, but this situation could change with the long-term evolution of oil prices. The results obtained, however, are poor mainly because of the poor accounting between the hydrophilic surface of the fibers and the hydrophobic polymer matrix. Moreover this strategy if it is carried out with polymeric matrices resulting from petrochemistry only leads to mixed semi-natural semi-synthetic materials whereas it would be much more interesting in a context of sustainable development to prepare composites that are entirely of natural origin using thermoplastic matrices of renewable origin.

Among the polymer matrices of renewable origin that can be used for thermoplastic applications, there is one which stands out in particular and which is cellulose acetate (Zugenmaier, P. 2004). The latter compound has a long history as a thermoplastic and is still an important industrial product in the field of membranes (Cerqueira, DA, et al., 2008) and cigarette filters in particular. It is, in fact, a family of products since are also marketed specialties of propionate, butyrate and cellulose acetate butyrate. Cellulose acetates are not considered to be truly biodegradable, which in many cases is actually an advantage but they are clearly recyclable by the conventional alkaline regeneration of cellulose acetate to cellulose. This regeneration is particularly advantageous in the case of cellulosic materials because the recycling of printed papers takes place precisely in alkaline conditions. These compounds are therefore extremely attractive for use as a thermoplastic matrix provided that the problem of compatibility of the cellulose acetate / cellulose fiber matrix interface is solved. Indeed, although they are both made of cellulose, these two materials do not have the same chemical and physicochemical properties and they even a priori very poor compatibility. The conventional use as a cellulose acetate filler of vegetable cellulosic materials is for example described in the patent FR 519 822. However, cellulose fibers and cellulose acetate have a very poor compatibility.

GB 570,529 discloses a molding powder containing a synthetic resin and cellulose acetate fibers. Cellulose acetate fibers were obtained by partial acetylation of the cellulose under fibrous conditions to maintain the fiber structure. This document essentially concerns the substitution of cellulosic reinforcing fibers with acetylated cellulose reinforcement fibers. This document does not specify the nature of the synthetic resin used.

DE 295 22 229 describes a material based on cellulose acetate and natural cellulose fibers. The cellulose fibers are used without special pretreatment and the relative incompatibility of the cellulose fibers and the cellulose acetate matrix is therefore not resolved.

US patent application 2003/0124937 discloses a material comprising native cellulose fibers and cellulose ester fibers. This material does not include a thermoplastic matrix in which reinforcing fibers are dispersed.

A first approach to solve this problem of the compatibility of the reinforcing fibers and the thermoplastic matrix has been developed via the acetylation of cellulose whiskers (Sassi, J.-F. 1995). The potential of whiskers as nanomechanical reinforcement structures for the improvement of the mechanical properties of thermoplastic composites is, in fact, now widely recognized (Dufresne, A. 2008, Favier, V., Chanzy, H., et al. Hajji, P., et al., 1996, Helbert, W., et al., 1996, Petersson, L., et al., 2007). Whiskers are cellulose nanocrystals obtained by controlled acid hydrolysis of cellulose fibers. Due to their high hydrophilicity, however, they still pose delicate problems of manipulation and dispersion in hydrophobic media (Petersson, L., Kvien, L, et al., 2007). It was therefore tempting to take advantage of the high specific surface area of the whiskers to perform their superficial acetylation in order to make them compatible with cellulose acetate matrices. The results obtained indeed show a clear improvement of the dispersion properties. On the other hand, the mechanical properties are practically not improved. Our hypothesis is that these results can be interpreted by considering that the conditions that were used by Sassi for the acetylation of whiskers induce a cleavage of the cellulose acetate oligomer chain in formation. As a result, acetylated whiskers can only have very short cellulose acetate oligomer chains on their surface. However, we know from Lönnberg's work (Lönnberg, H., et al., 2008) that the improvement of the dispersion properties and the mechanical properties of micro-fibrils dispersed in an organic polymer can only be obtained by covalent grafting. polycaprolactone oligomer of sufficient molecular weight on the surface of the microfïbriUes. Our hypothesis is that the cellulose acetate ohgomer chains present on the surface of the whiskers would not be long enough to interact effectively with the cellulose acetate matrix. In fact Sassi reports that the results obtained with acetylated micro fibrils using trifluoroacetic anhydride as an activator, that is to say leading to less cleavage reaction of the cellulose acetate chains in formation would give slightly better results. than those obtained with whiskers. We can therefore speculate that a way to substantially improve the mechanical properties of composites using cellulose fibers as reinforcement could be to graft around cellulose fibers, pendant chains of a sufficiently close chemical nature and of molecular weight sufficient to interact effectively with the cellulose acetate chains of the exogenous polymeric matrix (Ly, B., et al., 2008).

Before attempting to solve this problem, attention must also be drawn to another difficulty that arises in the use of cellulosic fibers as reinforcement for composite materials. The latter, which we have already mentioned, is related to the dimensional instability of the fibers in the presence of water. When we analyze this dimensional instability with regard to the knowledge we have on the structure of cellulose fibers, it appears that the latter is related to the presence of amorphous zones of cellulose surrounding crystalline zones and connecting them together. The highly structured crystalline zones are characterized by very strong hydrogen bonds that are not displaceable by water while the amorphous zones are characterized by weak hydrogel bonds displaceable by water. The whole concept underlying the use of whiskers comes from the perception of this dual structure and the desire to eliminate amorphous parts of the fiber to obtain the most perfect nanocrystals possible and therefore the most resistant and the most resistant. less sensitive to the presence of water.

The invention lies at this level. Instead of attempting to solve the problem of dimensional instability by eliminating the amorphous parts of the fibers by acidic hydrolysis or other means, the invention is to make them lose their sensitivity to water by taking advantage of their obvious more high chemical reactivity and transforming them via appropriate chemical modification into high molecular weight cellulose acetate oligomers capable of effectively interacting with a polymeric matrix of cellulose acetate. This operation, however, would be pointless if the oligomers thus synthesized were, as a result of the chemical modification in question, detached from the structure of the fiber. It is essential, in fact, that the formed cellulose acetate oligomer chains remain firmly bonded by covalent bonding to the main structure of the fiber. It is therefore essential to choose mild acylation conditions preserving the glycosidic bonds of cellulose or in other words not leading to hydrolysis of these cellulose molecules.

Various methods of acylation or acetylation of cellulose are known from the prior art. The acylation of the cellulose is generally carried out in the presence of a catalyst such as a strong acid. This acylation leads not only to the acylation of the cellulose but also to a cut in the fibers of the celluloses. The product obtained - typically cellulose acetate - thus has a reduced DP following the hydrolysis of the cellulose molecules. It then becomes soluble in organic solvents such as chloroform or acetone while the cellulose is not soluble in these solvents. This acylation can also take place under fibrous conditions. In all cases, however, the acylation is accompanied by hydrolysis of the cellulose molecules.

US Pat. No. 2,772,944 mentions the difficulty of acetylating cellulose at the surface while retaining its fibrous structure. This document describes a process comprising impregnating the fibers with glacial acetic acid and then reacting with acetic anhydride in the presence of perchloric acid. This acetylation under fibrous conditions, however, leads to partial lysis of the cellulose fibers.

No. 2,535,919 discloses that the cellulose fibers comprise amorphous cellulose as well as crystalline cellulose and this document describes the partial acetylation of these cellulose fibers. However, the acetylation conditions used include impregnation of the fibers with glacial acetic acid followed by reaction with acetic anhydride in the presence of a strong acid. This acetylation is conducted in fibrous conditions in the absence of solvent, but it is nonetheless a "hard" acetylation condition leading to cleavage of the cellulose chains. This is illustrated by the fact that the formed cellulose acetate is soluble in the methylene chloride used in this document to make the fibers sticky.

The acylation process used in the present invention is based on activation and selective acylation of the amorphous zones of the cellulose fibers under conditions that preserve the glycosidic bonds of the cellulose molecules. These conditions were already described in the literature (Fraizy, J. 1966, Nagai, K. and Saito, M. 1960).

However, to arrive at the results of the present invention, it is not enough simply to use chemical modification conditions which do not lead to cuts of glycosidic bonds, but it is also necessary that the molecular chains of cellulose which are part of the amorphous zones. present part of themselves in crystalline form. The cellulose molecules themselves must therefore have crystalline zones and amorphous zones. To our great surprise, we found by taking a particularly low crystalline cellulose fiber model, rayon fibers, where we were most likely to encounter molecular chains of cellulose located entirely in the amorphous zones that the vast majority of Molecular chains contained segments present in both crystalline and amorphous zones.

To verify this point, we subjected the rayon fibers to a particular acetylation treatment based on the specific and quantitative activation of the cellulose hydroxyls present in the amorphous zones and not leading to reactions of cuts of the glycosuric bonds (Fraizy J. 1966, Nagai, K. and Saito, M. 1960). This treatment therefore normally leads to the quantitative acetylation of all the hydroxyls present in the amorphous zones. After treatment, we weighed the samples and verified that the weight of the latter had increased by 38% in accordance with the known crystallinity rate of the rayon fibers is 50%. We then extracted the treated fibers with chloroform which is a solvent known for its solubilizing properties of cellulose tri-acetate oligomers which are the species synthesized under our conditions. To our surprise, the quantities of tri-acetate that we were able to extract were very low, less than 4%. The IR spectra made before and after the chloroform washing are also superimposable, which indicates that most of the cellulose acetate oligomers have remained associated with the structure of the fiber.

This result unambiguously indicates that the molecular chains of cellulose contain segments belonging to the crystalline and amorphous zones and that acetylation conditions such as the one we used led to a supramolecular assembly with on one side all the crystalline zones. undifferentiated and other chains of cellulose acetate oligomers connected to these crystalline areas by the glycosidic bonds that previously connected the different crystalline and amorphous segments of the molecular chains of cellulose.

The invention therefore consists in achieving two important objectives by carrying out a single key operation, the peracetylation of all the amorphous zones of the cellulose fibers. This modification makes it possible to eliminate the dimensional sensitivity of the cellulose fibers by transforming the hydrophilic amorphous zones into hydrophobic apolar zones (40% reduction in the water uptake of the acetylated fibers). Cellulose acetate oligomers are thus generated which represent between 30 and 50% of the starting cellulosic material. These oligomers obtained without any cleavage of glycosidic bonds are therefore necessarily of high molecular weight and will thus be able to establish a very good interaction with cellulose acetate matrices. At the extreme, it is even possible to fuse together fibers whose amorphous parts have been acetylated without having to add cellulose acetate exogenous. The invention thus relies on the use of native cellulose fibers in preference to whiskers or microfibrils which are not only complex and expensive to manufacture but which by definition have lost this amorphous cellulose which we now make particular use of.

The quality of the accounting obtained by the acetylation of the amorphous zones with respect to thermoplastic matrices of cellulose acetate was determined by dispersion tests of partially acetylated fibers in cellulose acetate matrices.

The results obtained indicate that native rayon fibers are not dispersed at all in cellulose acetate where they are in the form of entangled fiber clusters. On the contrary, the acetylated fibers are capable of dispersing in this matrix of cellulose acetate, even going as far as to melt in the latter. However, this is only an optical illusion because an extraction of the cellulose acetate matrix with chloroform restores the starting fibers. The facies analysis of the composite wafer, acetylated fibers / cellulose acetate, in electron microscopy confirms the good quality of the fiber matrix interface.

The improvement of the mechanical properties was determined by the measurement of the Young's modulus which shows a significant increase of 21%.

The quality of the compatibilization obtained was also characterized by the regeneration of the acetylated cellulose fiber / cellulose acetate composites in a basic medium. It is known that it is possible to regenerate cellulose II by alkaline treatment of cellulose acetate. This is notably the process for obtaining Fortisan fibers (Kim, I.S., et al., 2002, Koh, J., et al., 2004).

In our case, the electron microscopic analysis of the fracture facies after alkaline treatment clearly indicates a total disappearance of the matrix fiber interface whereas this interface is very visible if nonacetylated cellulose fibers dispersed in acetate are used. of cellulose and subjected to regeneration by alkaline treatment

Interestingly, the co-regeneration of the acetylated fiber / cellulose acetate composites itself leads to novel materials that are thermostable cellulose / cellulose composites.

Heat-stable composites are conventionally obtained by in situ polymerization processes and lead to crosslinked assemblies in all three dimensions. A major disadvantage of these composites is their almost total absence of recycling properties (apart from thermal recovery or to make charges).

The non-recyclability of these composites is related to the fact that the crosslinking bonds are of a covalent nature and that it is practically impossible to break them.

However, there are already thermostable composites recyclable. These are prepared from cellulose matrix reinforced with cellulose fibers. They are prepared for example by using the solvent power towards the cellulose of certain solutions like DMAc / LiCl. As the solubilization is a progressive phenomenon, it suffices to block it by dilution after a defined period thus leading to a cellulose / cellulose composite in which the fibers not yet solubilized constitute the reinforcing part, the matrix being constituted by the regenerated cellulose . What characterizes this type of cellulose / cellulose composites is the fact that the crosslinking is no longer carried out through irreversible covalent chemical bonds but via reversible hydrogen bonds. There is no chemical denaturation of cellulose macromolecules which thus retain all their biodegradability and recyclability properties. Practically, however, it is, according to the work described in the literature, (Nishino, T. and Arimoto, N. 2007) a phenomenon difficult to control and whose industrialization is difficult to envisage given the time required for molding parts. It is indeed necessary to keep the sample in compression for the duration of the removal of the solvent.

The method we propose allows to consider a real industrial implementation. The advantage of preparing these thermostable composites by this method comes from the fact that the precursor composites are thermoplastic composites which can therefore be prepared industrially with conventional tools. The improvement of the mechanical properties was measured by the significant increase of the Young's modulus of 25%.

The method we propose allows more to prepare thermostable composites not completely saponified with different properties such as less dimensional instability or greater plasticity related to the presence of residual acetates.

SUMMARY OF THE INVENTION

The present invention relates to processes for manufacturing a cellulose-based composite material characterized in that it comprises the following steps:

a) provision of cellulose fibers comprising crystalline zones and at least 20% of amorphous zones,

b) Activation of the amorphous zones of the cellulose fibers by an alkaline treatment, c) Selective acylation of the amorphous zones of the cellulose fibers by low molecular weight fatty acids chosen from acetate, propionate, butyrate and their mixtures, in reaction conditions preserving the glycosidic linkages of the cellulose, until cellulose fibers having an acylation level of between 10% and -50% by weight are obtained,

d) Adding a thermoplastic polymeric matrix chosen from cellulose acetates, cellulose proprionates, cellulose butyrates, cellulose acetobutyrates and mixtures thereof, e) Optionally, shaping the composite material obtained in the previous step by hot molding, hot injection and / or hot pressing.

In one embodiment, the activation of the amorphous areas of the cellulose fibers by an alkaline treatment is carried out with an aqueous alkaline solution of sodium hydroxide or potassium hydroxide.

In another embodiment, activation of the amorphous areas of the cellulose fibers by alkaline treatment is carried out with potassium acetate or sodium acetate.

Preferably, the acylation of the amorphous areas of the cellulose fibers comprises contacting the cellulose fibers with an acylating agent under neutral conditions.

In preferred embodiments, the acylating agent is selected from acetic anhydride, butyric anhydride, propionic anhydride, mixed anhydrides, acetic acid chloride, propionic acid chloride, butyric acid chloride, activated acetates, activated propionates, activated butyrates and mixtures thereof.

In a first embodiment, step d) comprises the addition of 1% to 50% by weight of thermoplastic matrix relative to the weight of the cellulose fibers.

In a second embodiment, step d) comprises immersing the cellulose fibers in the form of braided yarns in the matrix followed by drying the fibers.

In a third embodiment, step d) comprises dispersing the cellulose fibers in the thermolastic matrix.

Preferably, the cellulose fibers are chosen from fibers of rayon, abaca, bamboo, hemp, coir, coconut, cotton, originating from the seed, broom, stem broth , gucca, jute, kapok, kennaf, flax, shackle, nettle, straw, ramie, raffia or sisal or mixtures thereof.

In a preferred embodiment of the invention, the cellulose fibers are rayon fibers and the thermoplastic polymeric matrix is cellulose triacetate.

In a particular embodiment of the invention, the method further comprises a step of partial or total saponification of the cellulose-based composite material obtained in step d) or in step e).

Preferably, the saponification comprises treating the material with sodium hydroxide solution followed by washing and drying the material.

The subject of the invention is also a thermoplastic composite material based on cellulose which can be obtained by the process according to the invention.

The invention also relates to a process for recycling a cellulose-based thermoplastic composite material in which the material is subjected to complete acetylation in the presence of a strong acid. The invention also relates to a thermostable composite material based on cellulose obtainable by the method according to the invention comprising a saponification step. The subject of the invention is a cellulose-based composite material comprising: cellulose fibers comprising crystalline zones and at least 20% of amorphous zones, at least 80% of these amorphous zones being acylated by low-weight fatty acids; molecular compounds selected from acetate, propionate, butyrate and mixtures thereof;

a compatible thermoplastic polymer matrix chosen from cellulose acetates, cellulose proprionates, cellulose butyrates and cellulose acetate butyrates, and mixtures thereof.

Preferably, the cellulose-based composite material comprises from 1% to 50% by weight of thermoplastic matrix.

Preferably, the cellulose-based composite material comprises from 50% to 99% by weight of cellulose fibers.

In preferred embodiments, the cellulose fibers are selected from rayon, abaca, bamboo, hemp, coir, coconut, cotton, seed, broom, cottons with rods of rush, gucca, jute, kapok, kennaf, flax, manila, nettle, straw, ramie, raffia, sisal or their mixtures.

In an advantageous embodiment, the cellulose-based composite material comprises partially acetylated rayon fibers having a degree of acetylation of between 20% and 40% by weight.

Preferably, the thermoplastic polymeric matrix is cellulose triacetate.

In some embodiments the composite material is at least partially saponified.

Another object of the invention is a method of manufacturing a composite material based on cellulose comprising the following steps:

a) Partial acylation of cellulose fibers by low molecular weight fatty acids selected from acetate, propionate, butyrate and mixtures thereof, said cellulose fibers comprising crystalline zones and at least 20% of amorphous zones, in mild reaction conditions leading to the acetylation of at least 80% of the amorphous areas of the cellulose and not leading to the hydrolysis of the cellulose, b) Addition of a Compatible Thermoplastic Polymer Matrix Selected from Cellulose Acetates, Cellulose Propionates, Cellulose Butyrates, Cellulose Acetobutyrates and Their Mixtures, c) Optionally, Shaping the Composite Material Obtained in Step previous by hot molding, hot injection and / or hot pressing.

Preferably, the partial acylation of the cellulose fibers comprises:

activation of the amorphous zones of the cellulose fibers by an alkaline treatment, contacting the treated cellulose fibers obtained in the preceding step with an acylating agent.

In a first embodiment, the activation of the amorphous zones of the cellulose fibers by an alkaline treatment is carried out by impregnating the cellulose fibers with an aqueous alkaline solution of sodium hydroxide or potassium hydroxide.

In a second embodiment, the activation of the amorphous zones of the cellulose fibers by an alkaline treatment is carried out by impregnating the cellulose fibers with potassium acetate or sodium acetate.

Preferably, the acylating agent is chosen from acetic anhydride, butyric anhydride, propionic anhydride, mixed anhydrides, acetic acid chloride, propionic acid chloride and acid chloride. butyric acid, activated acetates, activated propionates, activated butyrates and mixtures thereof.

In preferred embodiments, the cellulose fibers are selected from rayon, abaca, bamboo, hemp, coir, coconut, cotton, seed, broom, cottons with rods of rush, gucca, jute, kapok, kennaf, flax, manila, nettle, straw, ramie, raffia or sisal or their mixtures.

In the processes according to the invention, the cellulose fibers are preferably rayon fibers and the thermoplastic polymeric matrix is preferably cellulose triacetate.

Preferably, step b) comprises the addition of 1% to 50% by weight of thermoplastic matrix relative to the weight of the cellulose fibers.

Preferably, step b) comprises immersing the cellulose fibers in the form of braided yarns in the matrix followed by drying the fibers.

Preferably, step b) comprises dispersing the cellulose fibers in the matrix.

In some embodiments, the methods according to the invention further comprise a step of partial or total saponification of the cellulose-based composite material obtained in step b) or in step c). Preferably, this saponification comprises treating the material with sodium hydroxide solution followed by washing and drying the material.

The invention also relates to cellulose-based thermoplastic composite materials that can be obtained by the methods according to the invention.

The invention also relates to thermostable composite materials based on cellulose that can be obtained by the processes according to the invention.

DESCRIPTION OF THE INVENTION The invention thus relates to processes for the manufacture of various cellulose-based composites and in particular cellulose / cellulose acetate composite materials and cellulose / cellulose composite materials.

Conventional acylation and especially cellulose acetylation processes use a strong acid as a catalyst such as sulfuric acid, perchloric acid or phosphoric acid, under these conditions, acetylation and hydrolysis of the molecules. cellulose then leads to a cellulose acetate dissolved in various organic solvents such as chloroform and acetone, for example.

In the processes of the present invention, milder reaction conditions permit selective acylation of the amorphous areas of the cellulose not accompanied by hydrolysis of the glycosidic linkages of the cellulose molecules. In the processes according to the present invention, the integrity of the cellulose molecules and in particular glycosidic bonds of the cellulose molecules is maintained. This selective acetylation of the amorphous areas of the cellulose is not carried out in the presence of a catalyst such as a strong acid and therefore a prior step of activating the amorphous areas of the cellulose fibers is generally required.

In the present invention, the acylation reaction is therefore conducted under neutral conditions and in particular under ionically neutral conditions. The acylation conditions are therefore neither acidic nor basic. Methods for selective acylation of the amorphous zones of cellulose fibers by maintaining the integrity of the cellulose molecules have also been described in the prior art (Fraizy, 1966, Nagai and Sato, 1960).

This partial acylation of the cellulose fibers preserving the integrity of the cellulose molecules is based on the use of cellulose fibers having a large amorphous phase, the latter being more reactive than the crystalline phase. Acylation under mild reaction conditions is therefore limited to acylation of the amorphous regions of the fiber leading to partial acylation of the cellulose without hydrolysis of the glycosidic linkages. The almost total absence of hydrolysis of the cellulose is illustrated by the fact that the acetylated cellulose fibers obtained according to the invention do not comprise Extractable fraction with solvents such as chloroform or acetone corresponding to cellulose acetate of lower DP and thus soluble in these solvents.

It has now been found in the present invention that these partially acylated fibers have exceptional complementarity with thermoplastic polymeric matrices consisting of cellulose acyls. The composite materials thus obtained may be totally or partially saponified to lead to thermostable materials.

The invention thus relates to new composite materials consisting of two elements having exceptional complementarity:

a fibrous reinforcement structure constituted by cellulose fibers whose amorphous part has been selectively acylated by low molecular weight fatty acids under mild conditions which do not lead to the hydrolysis of the cellulose acyl chains thus produced. This selective acylation makes it possible to reduce the dimensional instability of the cellulose fibers and to generate a high density of pendant cellulose acyl chains.

A thermoplastic polymeric matrix consisting of perfectly soluble cellulose acyl matrices with the cellulose acyl chains present on the cellulose fibers.

Typically, acylation is performed under neutral conditions to preserve the integrity of the glycosidic linkages of the cellulose molecules.

The invention also describes a variant of these new composite materials where all or part of the acyl groups has been removed by alkaline treatment to produce a thermostable material.

The invention thus relates to composite materials based on cellulose comprising:

cellulose fibers comprising crystalline zones and at least 20% of amorphous zones, at least 80% of these amorphous zones being acylated by low molecular weight fatty acids chosen from acetate, propionate and butyrate, and mixtures thereof; ;

In the materials of the present invention, the cellulose fibers are partially acylated under mild conditions (neutral conditions) leading to selective acylation of the amorphous areas of the cellulose and not accompanied by hydrolysis of the glycosidic linkages of the cellulose. cellulose.

In preferred embodiments, the amorphous areas of cellulose fibers are selectively acetylated. In the composite materials of the present invention, the cellulose fibers comprise at least 10, 20, 30 or 40% amorphous areas. The cellulose fibers therefore have a degree of crystallinity of less than 90, 80, 70 or 60%. The amorphous areas of the cellulose being acylated to at least 80%>, 85% or 90%. In other embodiments, the amorphous areas of the cellulose are fully acylated.

All common papermaking fibers can be used in the materials and methods of the present invention.

In preferred embodiments, the cellulose fibers selected from rayon, abaca, bamboo, hemp, coir, coconut, cotton, from seed, broom, cottons rods of rush, gucca, jute, kapok, kennaf, flax, manila, nettle, straw, ramie, raffia, sisal or their mixtures.

In preferred embodiments, the cellulose fibers are rayon and linen fibers.

In the materials of the present invention, the cellulose fibers have an acylation level of between 10% and 50% by weight and preferably between 20% and 40% by weight.

Preferably, the cellulose fibers have an acetylation level of between 10% and 50% by weight and preferably between 20% and 40% by weight.

In advantageous embodiments, the cellulose fibers used in the materials of the present invention are rayon fibers having a level of acylation, and preferably acetylation, of between 20% and 40% by weight.

The second component of the materials is a thermoplastic polymeric matrix selected from cellulose acetate, cellulose propionates, cellulose butyrates, cellulose acetate butyrates and mixtures thereof.

By "thermoplastic matrix" is meant a matrix that melts or softens under the effect of heat. Typically, the melting temperature of a thermolplastic material is lower than its decomposition temperature.

Preferably, the thermoplastic matrices are chosen from the following matrices: cellulose triacetate, cellulose diacetate, cellulose tripropionate, cellulose acetate butyrate (commercial product CAB: 13.5% by weight of acetate and 38% mass of butyrate, molar ratio approximately 1 acetate for 2 butyrates), cellulose tributyrate. Among the cellulose acetobutyrates, mention will be made in particular of CAB comprising 13.5% by weight of acetate and 38% by weight of butyrate (molar ratio of about 1 acetate for 2 butyrates). This product is commercially available. These thermoplastic matrices are well known to those skilled in the art.

Typically these thermoplastic matrices have a sufficiently low DP to be soluble in organic solvents such as acetone or chloroform. By a "compatible" matrix is meant a matrix that is soluble with the acyl chains of the partially acylated cellulose fibers.

For fibers partially acylated with acetates, the compatible matrices are for example chosen from triacetates and cellulose diacetate.

For partially acylated fibers with propionates, the compatible matrices are for example chosen from cellulose propionates.

For partially acylated fibers with butyrates, the compatible matrices are for example chosen from cellulose acetate butyrate and cellulose tributyrate.

In one embodiment of the invention, the cellulose-based composite material comprises rayon fibers having a degree of acetylation of between 20% and 40% by weight, preferably between 25% and 35% by weight and a cellulose triacetate matrix.

In another embodiment of the invention, the composite material comprises flax fibers with an acylation level with a mixture of acetate and butyrate (1 acetate for 2 butyrates) of between 30 and 50% by weight and as matrix an acetobutyrate and in particular CAB comprising 13.5% by weight of acetate and 38% by weight of butyrate.

The compatibility between the matrix and the fiber makes it possible to reduce the amount of matrix in the composite materials of the present invention.

Preferably, the composite materials comprise 1%, 5%, 10%, 20%, 30%, 40% to 50% by weight of thermoplastic matrix. Preferably the composite materials according to the invention comprise less than 50%, 40%, 30%, 20%, 10% or less than 5% by weight of thermoplastic matrix.

The composite materials according to the invention thus comprise 50%, 60%, 70%,

80%), 90%) to 99% by weight of cellulose fibers. Preferably the materials according to the invention comprise more than 50%, 60%, 70%, 80%, 90% or more than 95% of partially acylated cellulose fibers.

The invention also relates to composite materials as described above partially or totally saponified. This saponification makes the composite material thermostable.

The invention also relates to processes for producing a cellulose-based composite material comprising the following steps:

Partial acylation of cellulose fibers by low molecular weight fatty acids selected from acetate, propionate, butyrate and mixtures thereof, said cellulose fibers comprising crystalline zones and at least 20% of amorphous zones, under conditions sweet reactionaries leading to the acetylation of at least 80% of the amorphous zones of the cellulose and not leading to the hydrolysis of the cellulose,

o Adding a compatible thermoplastic polymeric matrix chosen from cellulose acetate, cellulose propionates, cellulose butyrates, cellulose acetobutyrates and mixtures thereof,

o Optionally, shaping the composite material obtained in the previous step by hot molding, hot injection and / or hot pressing.

Typically, the acylation is carried out under neutral conditions to preserve the integrity of the glycoside bonds of the cellulose molecules. Only the amorphous zones of the previously activated cellulose are acylated at this stage without hydrolyzing the cellulose.

The first step of the processes according to the invention is a partial acylation step of the cellulose fibers and preferably a partial acetylation step of the cellulose fibers.

In a preferred embodiment, the invention relates to processes for manufacturing a cellulose-based composite material comprising the following steps:

o Activation of cellulose fibers by an alkaline treatment,

contacting the treated cellulose fibers obtained in the preceding step with an acylating agent,

The cellulose fibers used in the processes of the present invention have an amorphous phase, preferably this zone or amorphous phase represents at least 10%, 20%, 30% or 40% of the cellulose fibers.

The cellulose fibers obtained have an acylation level of between 10% and 50% by weight and preferably between 20% and 40% by weight.

Preferably, the cellulose fibers obtained have an acetylation level of between 10% and 50% by weight and preferably between 20% and 40% by weight.

The partial acylation of the cellulose fibers is carried out under mild conditions - typically neutral conditions - according to techniques known to those skilled in the art. Partial acylation of the cellulose fibers under these conditions leads selectively to the acylation of the amorphous zones of the cellulose fibers without hydrolysis of the cellulose.

In addition, partial acetylation under mild reaction conditions preserves the integrity of the cellulose molecules. The partial acylation of the cellulose fibers comprises a first step of activating the cellulose fibers by an alkaline treatment. This alkaline treatment may include impregnating the cellulose fibers with an aqueous alkaline solution of sodium hydroxide or potassium hydroxide. Alternatively, this alkaline treatment may comprise impregnation of the cellulose fibers with potassium acetate or sodium acetate.

This activation is typically performed by dipping or impregnating the fibers with a potassium acetate solution having a concentration of 20% (g / g) at 60 ° C-80 ° C.

After the alkaline treatment, the fibers are usually dewatered and dried according to usual techniques.

The acylation is carried out by contacting the activated fibers with an acylating agent preferably chosen from acetic anhydride, butyric anhydride, propionic anhydride, mixed anhydrides, acetic acid chloride, propionic acid chloride, butyric acid chloride, activated acetates, activated propionates, activated butyrates and mixtures thereof.

This bringing into contact is carried out under neutral conditions and more particularly at ionically neutral conditions. Catalysts such as strong acids are not used at this stage.

This step comprises, for example, immersing the previously activated fibers in acetic anhydride heated at 100 ° C. for a variable time ranging from a few minutes to a few hours. The acetylation rate then varies according to the reaction time. After the reaction, the partially acetylated fibers are generally washed and dried.

Preferably, the cellulose fibers are rayon fibers and their degree of acetylation is between 25 and 35% by weight.

To obtain the composite materials according to the invention, a compatible thermoplastic matrix is added to the fibers. These thermoplastic matrices based on cellulose are described above.

This step preferably comprises immersing the cellulose fibers in the form of braided yarns in the matrix followed by drying the fibers.

Preferably, acetylated fibers in the form of braided yarns are immersed in a triacetate solution (for example a 5% solution in chloroform). After incubation, the fibers are removed, excess solution is removed and the threads are dried. The son obtained are much more rigid because of the cohesion between the fibers provided by the cellulose acetate.

In another embodiment, this step comprises dispersing the cellulose fibers in the matrix. In a preferred embodiment, partially acetylated fibers are dispersed in a solution of cellulose triacetate (2% cellulose triacetate solution in chloroform, for example). After evaporation, cellulose acetate films containing reinforcing fibers are obtained.

In advantageous embodiments, the cellulose fibers are partially acetylated rayon fibers and the thermoplastic polymeric matrix is cellulose triacetate.

Preferably, the processes according to the invention comprise the addition of 1% to 50% by weight of thermoplastic matrix relative to the weight of the cellulose fibers and preferably the addition of less than 50%, 40%,> 30% >, 20%>, 10%> or less than 5% by weight of thermoplastic matrix.

The composite materials obtained are distinguished by improved mechanical properties (measured by the Young's Modulus) and a decrease in water intake (water sensitivity).

The invention also relates to a process for recycling a cellulose-based thermoplastic composite material in which the material is subjected to complete acetylation in the presence of a strong acid.

Cellulose acetate-cellulose composite materials have low potential for biodegradation but can be fully recycled. Unlike other composite materials requiring a separation of their components as a prerequisite for recycling, thermoplastic cellulose-matrix composite materials according to the present invention are directly and fully recyclable including complete acylation of the composite material. Two recycling paths are conceivable: regeneration (alkaline treatment) when all the acyl groups are removed and the cellulose acetate of the composite material is converted into cellulose or nonfibrous acetylation when the cellulose of the composite material is completely transformed into triacetate of cellulose and fibers lose their fibrous appearance.

For example, a cellulose-cellulose acetate composite according to the invention can be directly converted into cellulose acetate in conventional industrial cellulose acetylation chains, which implement so-called non-fibrous or homogeneous acylation conditions. These use a strong acid as a catalyst such as sulfuric acid or perchloric acid and comprise two steps: the pretreatment during which the composite material, acetic acid and catalyst are intimately mixed before adding the reagent. acetylation (acetic anhydride, for example) and the actual treatment, when the material reacts with the reagent added to the reaction medium. During the reaction, the cellulose of the composite material is converted into cellulose acetate which is soluble in the reaction medium. The acetate formed is then recovered by filtration, after its precipitation following the addition to the mixture of a aqueous solution of acetic acid. Such methods of acylation of cellulose have existed for a long time and are well described in the literature (Malm et al., (1946), Sassi and Chanzy (1995)). More recently, Barud et al. (2008), following the protocol used by Sassi and Chanzy (1995), acetylated bacterial cellulose and obtained, for reaction times ranging from 0.5 h to 24h, 2,3 degrees of substitution. at 2.77.

Malm et al. (1946) describe a nonfibrous acetylation protocol that uses sulfuric acid as a catalyst. According to them, 5-10% sulfuric acid relative to the cellulose is sufficient to complete the acetylation (43-44% acetyl) in 1-3 h at 16-38 ° C. Thus, one part cellulose (5%> humidity) is added to 2.4 parts of glacial acetic acid and the mixture is stirred for 1 hour at 38 ° C. Then 4 parts of glacial acetic acid and 0.88% of sulfuric acid (relative to the cellulose) are added and the mixture is stirred at the same temperature for another 45 minutes, before it is cooled to 18 ° C. ° C. After this, 2.7 parts of acetic anhydride and the remainder of 6.12% of sulfuric acid are added. The temperature is then gradually increased to 32-35 ° C for 1.5 to 2 hours. At this stage of the reaction, the cellulose no longer has a fibrous structure. A mixture of one part of water and two parts of glacial acetic acid is then added to the reaction medium for one hour, in order to precipitate the formed cellulose acetate which is subsequently recovered by filtration and then dried.

These well-known methods of acylation of cellulose thus make it possible to directly and completely recycle the composite materials according to the invention without having recourse to a prior separation of the components of the composite material.

In order to obtain materials with improved mechanical and heat-stable properties, the processes according to the invention may further comprise a step of partial or total saponification of the composite material described above. This saponification is carried out according to usual techniques well known to those skilled in the art.

Typically, the materials obtained are placed in a 0.5 N sodium hydroxide solution for 24 hours at room temperature. The resulting materials are then washed and dried.

The subject of the invention is also the thermoplastic composite materials obtainable by the processes according to the invention as well as the thermostable composite materials based on cellulose that can be obtained by the processes according to the invention. FIGURES

Figure 1: Selective acetylation of the amorphous zones of cellulose fibers and formation of the composite with exogenous cellulose acetate

Figure 2: Alkaline treatment of composites Partially acetylated cellulose fibers / cellulose acetate to give a cellulose / cellulose composite

EXAMPLES Example 1 Acetylation of Cellulose Fibers Using the Potassium Acetate Method

The cellulose fibers are immersed in a potassium acetate solution at 60-80 ° C, having a concentration of 20% (g / g), for 20 minutes. The activated fibers are dewatered and dried at 80 ° C for 2h30. Then, they are immersed in acetic anhydride which is heated at 100 ° C for 20, 40, 80 or 160 minutes. After reaction, the fibers are washed with hot water and acetone, and then dried at 105 ° C for 24 hours. The acetylation rate is determined by weighing before and after the acetylation according to the following formula:

% acetate = ((m ₂ - mi) / m ₂ ) * 100 (1) where:

- mi represents the mass of the rayon fibers before acetylation, in grams,

m ₂ represents the mass of the rayon fibers after the acetylation, in grams.

The results are shown in Table 1.

Time Rayon Fibers

(min) Acetate level (%)

20 25

40 27

80 28

160 34

Table 1: Acetate levels of cellulosic materials as a function of acetylation time

The acetate level is variable depending on the reaction time. The maximum value corresponds to the acetylation of the entire amorphous domain of the cellulose fibers. Example 2 Washing Acetylated Fibers with Chloroform

The previously prepared acetylated fibers are exhaustively washed with Socksley for 24 hours with chloroform. Acetylated fibers are weighed before and after washing. The results are presented in the following table according to the acetylation time.

Acetate time

(min) extractable (%)

20 0

160 4

Table 2: Extractable Acetate Determined for Acetylated Rayon Fibers The results indicate that even with the maximum acetylation rate, the amount of extractable cellulose acetate is very small.

The fibers washed with chloroform were analyzed by transmission IR spectrometry. The spectra of the acetylated fibers after and before washing with chloroform have a characteristic ester band at 1735 cm -1 if they are stackable.

Example 3 Production of Composites Acetylated Fibers / Cellulose Acetate

The acetylated fibers in the form of braided fibers are immersed in a solution of 5% cellulose triacetate in chloroform. After incubation for one hour, the impregnated fibers are removed, the excess solution is removed and the yarns are dried at room temperature. The son obtained are much more rigid because of the cohesion between the fibers provided by the cellulose acetate. Control samples are prepared with nonacetylated threads.

EXAMPLE 4 Production of Composites Acetylated Compressed Fibers

The acetylated fibers in the form of braided yarns with the highest 38% acetylation level are compressed at 60 bar with a high temperature press (250 °). There is a very clear aggregation between the fibers reflecting the coalescence between the cellulose acetate domains of the fibers. EXAMPLE 5 Preparation of Cellulose Acetate Films-Rayon Fibers

Cellulose triacetate films containing rayon fibers were obtained by dispersing about 3 mg of virgin or acetylated rayon fibers in 1.5 ml of a TAC solution in 2% chloroform. After evaporation, cellulose acetate films containing the fibers are obtained.

The prepared samples were analyzed by light microscopy. The results obtained indicate that native rayon fibers are not dispersed at all in cellulose acetate where they are in the form of entangled fiber clusters. On the contrary, the acetylated fibers are capable of dispersing in this matrix of cellulose acetate, even going as far as to melt in the latter. However, this is only an optical illusion because an extraction of the cellulose acetate matrix with chloroform restores the starting fibers. The facies analysis of the composite wafer, acetylated fibers / cellulose acetate, in electron microscopy confirms the good quality of the fiber matrix interface.

EXAMPLE 6 Preparation of Cellulose / Cellulose Composites by Saponification of Acetylated Fibers / Cellulose Acetate Composites

The acetylated fiber / cellulose acetate composites previously obtained in Example 3 are placed in a 0.5 N NaOH solution for 24 hours at room temperature. The resulting composites are then washed with distilled water and dried at 105 ° C for 24 hours.

Example 7 Analysis by Electron Microscopy

The results obtained by electron microscopy clearly demonstrate the cohesion between the acetylated fibers and the cellulose acetate. By comparison, nonacetylated fibers have very little cohesion with cellulose acetate. The results are even more remarkable after saponification by cryofracture or after mechanical stretching. We can clearly see the importance of the cohesion provided by the acetylation of the fibers and then by the co-crystallization of the cellulose acetate zones. Example 8 Improvement of the Thermoplastic and Thermostable Mechanical Properties

Young's modulus was determined for different samples. The acetylation of the fibers makes it possible to improve the value of the Young's modulus also at the level of the acetylated fiber / cellulose acetate composites as at the level of the cellulose / cellulose composites.

Fibers acetylation time - 160min

FNATAC = non acetylated fibers + cellulose triacetate

FATAC = acetylated fibers + cellulose triacetate

FNATACR = non-acetylated fibers + cellulose triacetate after regeneration with sodium hydroxide FATACR = acetylated fibers + cellulose triacetate after regeneration with sodium hydroxide

Example 9: Decrease of the water uptake of the fibers after partial acetylation immersion time = 19 h, then pressing with a 2 kg cylinder

These measurements are not very precise but the decrease of the sensitivity to water induces the acetylation is very clear. REFERENCES

Patent references

US 2,535,919

US 2,772,944

FR 519,822

DE 295 22 229

US 2003/0124937

GB 570, 529 Other references

Zugenmaier, P. 2004. Macromol. Symp., 208, 81-56

Cerqueira, D.A., et al. 2008. Polym. Bull, 60, 397-404

Sassi, J.-F. 1995. CERMAV. Thesis

Dufresne, A. 2008. Can J. Chem., 86, 484-494

Favier, V., Chanzy, H., et al. 1995. Macromol., 28, 6365-6367

Hajji, P., et al. 1996. Polym. Compos., 17, 612-619

Herbert, W., et al. 1996. Polym. Compos., 17, 604-611

Petersson, L., et al. 2007. Compos. Sci. Technol, 67, 2535-2544

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Fraizy, J. 1966. Teintex, 11, 781-790.

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Malm C. J., Tanghe L.J. and Laird B.C., (1946) Preparation of cellulose acetate. Action of sulfuric acid. Ind. Eng.Chem. 38, 77-82.

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Claims

Process for the production of a cellulose-based composite material characterized in that it comprises the following steps:

b) Activation of the amorphous zones of the cellulose fibers by an alkaline treatment,

c) Selective acylation of the amorphous zones of the cellulose fibers by low molecular weight fatty acids selected from acetate, propionate, butyrate and mixtures thereof, under conditions preserving the glycosidic bonds of the cellulose, up to obtaining cellulose fibers having an acylation level of between 10% and 50% by weight,

d) Adding a thermoplastic polymeric matrix chosen from cellulose acetates, cellulose proprionates, cellulose butyrates, cellulose acetobutyrates and mixtures thereof,

e) Optionally, shaping the composite material obtained in the previous step by hot molding, hot injection and / or hot pressing.

Process for producing a cellulose-based composite material according to Claim 1, characterized in that the activation of the amorphous zones of the cellulose fibers by an alkaline treatment is carried out with an aqueous alkaline solution of sodium hydroxide or hydroxide of potassium.

Process for producing a cellulose-based composite material according to Claim 1, characterized in that the activation of the amorphous zones of the cellulose fibers by an alkaline treatment is carried out with potassium acetate or sodium acetate .

Process for producing a cellulose-based composite material according to one of the preceding claims, characterized in that the acylation of the amorphous zones of the cellulose fibers comprises contacting the cellulose fibers with an acylating agent under conditions neutral.

Process for the production of a cellulose-based composite material according to one of claims 3-4, characterized in that the acylating agent is chosen from acetic anhydride, butyric anhydride, propionic anhydride, mixed anhydrides, acetic acid chloride, propionic acid chloride, butyric acid chloride, activated acetates, activated propionates, activated butyrates and mixtures thereof.

6. A method of manufacturing a composite material based on cellulose according to one of the preceding claims characterized in that step d) comprises the addition of 1% to 50% by weight of thermoplastic matrix relative to the weight of cellulose fibers.

7. A method of manufacturing a composite material based on cellulose according to one of claims 1-5 characterized in that step d) comprises immersing the cellulose fibers in the form of braided son in the matrix followed by drying the fibers.

8. A method of manufacturing a composite material based on cellulose according to one of claims 1-6 characterized in that step d) comprises dispersing the cellulose fibers in the thermolastic matrix.

9. A method of manufacturing a composite material based on cellulose according to one of the preceding claims characterized in that the cellulose fibers are selected from the fibers of rayon, abaca, bamboo, hemp, coir, coconut, cotton, from seed, broom, cedar stick, gucca, jute, kapok, kennaf, linen, shackle, nettle, straw, ramie , raffia or sisal or their mixtures.

10. A method of manufacturing a composite material based on cellulose according to one of the preceding claims characterized in that the cellulose fibers are rayon fibers and the thermoplastic polymer matrix is cellulose triacetate.

11. A method of manufacturing a composite material based on cellulose according to one of the preceding claims characterized in that it further comprises a partial saponification step or total cellulose composite material obtained in step d ) or step e).

12. A method of manufacturing a composite material based on cellulose according to claim 13 characterized in that the saponification comprises the treatment of the material with a sodium hydroxide solution followed by washing and drying the material.

13. Thermoplastic composite material based on cellulose obtainable by the method according to one of claims 1-10.

14. A method of recycling a composite material according to claim 13 characterized in that the material is subjected to a complete acetylation in the presence of a strong acid.

15. thermostable composite material based on cellulose obtainable by the method according to one of claims 11-12.