Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J191/00—Adhesives based on oils, fats or waxes; Adhesives based on derivatives thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/003—Oil-based binders, e.g. containing linseed oil
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/22—Natural resins, e.g. rosin
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/18—Manufacture of films or sheets
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/10—Esters; Ether-esters
  • C08K5/101—Esters; Ether-esters of monocarboxylic acids
  • C08K5/103—Esters; Ether-esters of monocarboxylic acids with polyalcohols
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/06—Vegetal fibres
  • B32B2262/062—Cellulose fibres, e.g. cotton
  • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof
  • B32B2419/04—Tiles for floors or walls
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2391/00—Characterised by the use of oils, fats or waxes; Derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2493/00—Characterised by the use of natural resins; Derivatives thereof
  • C08J2493/04—Rosin
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2497/00—Characterised by the use of lignin-containing materials
  • C08J2497/02—Lignocellulosic material, e.g. wood, straw or bagasse
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/24—Acids; Salts thereof
  • C08K3/26—Carbonates; Bicarbonates
  • C08K2003/265—Calcium, strontium or barium carbonate
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/019—Specific properties of additives the composition being defined by the absence of a certain additive

Definitions

• the presently disclosed subject matter relates to methods of producing construction materials from natural products.
• the presently disclosed subject matter further relates to methods of producing construction materials comprising plant-based materials including, but not limited to brewing trub, spent hops, and biomass with elevated lignin content.
• Existing resilient flooring products utilize fossil fuel-based products, e.g., polyvinyl chloride. These products may degrade into harmful microplastics and release dioxins and phthalates which disrupt the endocrine system. They may additionally utilize titanium dioxide and aluminum trihydrate, which pose health hazards. Thus, there is a need for sustainable and affordable alternative products that reduce health risks.
• fossil fuel-based products e.g., polyvinyl chloride. These products may degrade into harmful microplastics and release dioxins and phthalates which disrupt the endocrine system. They may additionally utilize titanium dioxide and aluminum trihydrate, which pose health hazards.
• titanium dioxide and aluminum trihydrate which pose health hazards.
• the present disclosure relates to products made of naturally occurring materials which are compostable, biodegradable, antimicrobial, and water resistant. Specifically, the disclosure relates to construction materials produced using a by-product of beermaking comprising plant material.
• the components of the by-product have natural properties that are useful as products for construction, e.g., for flooring, roofing, and fencing.
• the by-product could be used as a low cost “green” construction material for providing mechanical stability.
• the raw materials valorize streams typically destined for landfills since trub is discarded.
• the present disclosure provides methods for producing linseed oil-based polymer construction materials (e.g., flooring materials), comprising mixing a binder substrate comprising linseed oil and resin with at least one filler substrate into a mixture; wherein the at least one filler substrate comprises a plant material.
• the method further comprises pressing the mixture at a first temperature ranging from about 60 °C to about 150°C to form a sheet; and curing the sheet at a second temperature ranging from about 80 °C to about 100 °C for up to about 48 hours.
• the plant material is at least one selected from the group consisting of trub, spent hops, biomass comprising at least 15% lignin, and combinations thereof.
• the plant material is dried prior to use by filtration or by drying for about 48 hours at about 100 °C.
• the resin is at least one selected from the group consisting of rosin, trub-based resin, and any combination thereof.
• the binder substrate further comprises tung oil.
• the at least one filler substrate further comprises at least one selected from the group consisting of sawdust, wood flour, tomato powder, purple sweet potato powder, flax seed, calcium carbonate, and any combination thereof.
• the plant material makes up about 10% to about 20% of the mixture by weight.
• the method further comprises cutting the sheet into strips. In certain embodiments, the method further comprises overlaying the mixture onto a rigid, fibrous substrate prior to pressing so that a multi-layered sheet is produced. In certain embodiments, the method further comprises pressing the multi-layered sheet into tiles.
• the fibrous substrate comprises a natural backing material. In certain embodiments, the natural backing material comprises at least one selected from the group consisting of coir, jute, sisal, hemp, canvas, and any combination thereof.
• the mixture does not contain fossil fuel-based materials. In certain embodiments, the mixture does not contain titanium dioxide or aluminum trihydrate.
• the present disclosure provides a composition comprising linseed oil, resin, and plant material.
• the plant material is at least one selected from the group consisting of trub, spent hops, biomass comprising at least 15% lignin, and combinations thereof.
• the resin is at least one selected from the group consisting of rosin, trub-based resin, and any combination thereof.
• the composition further comprises tung oil.
• the composition further comprises at least one selected from the group consisting of sawdust, wood flour, tomato powder, purple sweet potato powder, flax seed, calcium carbonate, and any combination thereof.
• the plant material makes up about 10% to about 20% of the total composition by weight.
• the composition does not contain fossil fuel-based materials. In certain embodiments, the composition does not contain titanium dioxide or aluminum trihydrate.
• Figures 1 A-1B provide images of multi-layered sheets produced by pressing a mixture of binder and filler substrates comprising linseed oil, rosin, tung oil, flaxseed, wood flour, purple sweet potato powder, and calcium carbonate onto a solid support at 1A) 80 °C and IB) 60 °C.
• Figures 2A-2B provide images of multi-layered sheets produced by pressing a mixture of binder and filler substrates comprising trub, linseed oil, rosin, tung oil, wood flour, purple sweet potato powder, and calcium carbonate onto a solid support at 2A) 80 °C and 2B) 60 °C.
• Figures 3A-3G provide images of tensile samples produced from a multi-layered sheet comprising trub: 3A) tensile samples punched using a clicker press; 3B) side view of a tensile sample,; 3C) trub-based surface at 20X magnification; side view of a first tensile sample at 3D) 20X magnification, and 3E) 40X magnification; and side view of a second tensile sample at 3F) 20X magnification, and 3G) 30X magnification.
• Figures 4A-4D provide images during production of pressed sheets from linseed oilbased polymer materials.
• Figure 4A shows a liquid binder substrate comprising raw linseed oil, tung oil, and rosin.
• Figure 4B shows a composition of trub, wood flour, purple sweet potato powder, and calcium carbonate to the liquid binder substrate prior to mixing.
• Figure 4C shows the composition of Figure 4B after mixing.
• Figure 4D shows an image of multi-layered sheets produced by pressing the mixture of Figure 4C onto a solid support.
• Figures 5A-5B show thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) of materials comprising trub.
• TGA thermogravimetric analysis
• DSC differential scanning calorimetry
• Figures 6A-6B show characterization of materials comprising trub versus conventional materials using Fourier Transform Infrared Spectroscopy (FTIR).
• Figure 6A shows analysis of materials comprising trub.
• Figure 6B shows analysis of conventional flooring materials comprising calcium carbonate and ethylene-vinyl acetate.
• FIG. 7 shows thermogravimetric analysis (TGA) of materials comprising trub.
• the use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification can mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” Still further, the terms “having,” “including,” “containing” and “comprising” are interchangeable and one of skill in the art is cognizant that these terms are open ended terms. Further, the term “comprising” encompasses “including” as well as “consisting,” e.g., a composition “comprising” X can consist exclusively of X or can include something additional, e.g., X + Y.
• the term “about” or “approximately” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within 3 or more than 3 standard deviations, per the practice in the art. Alternatively, “about” can mean a range of up to 20%, preferably up to 10%, more preferably up to 5%, and more preferably still up to 1% of a given value. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, preferably within 5-fold, and more preferably within 2-fold, of a value.
• hop bract refers to leafy plant material covering the exterior of hop flowers. Hop flowers can be utilized without being separated from the hop bract.
• trub refers to natural materials produced during the fermentation process of making beer which collect at the bottom of brewing tanks and filtered from the beer.
• trub comprises hop debris and/or and dead yeast cells.
• Hop debris can include one or more of hop bract and spent exterior hop leaves.
• oir refers to the natural fibrous material obtained from the outer husk of coconuts.
• Linseed oil-based polymer flooring materials can be constructed from one or more of solidified linseed oil, resin, and solid filler substrates.
• Linseed oil and resin can be combined to form a viscous binder substrate.
• the resin is a tree (gum) rosin.
• the binder substrate can further comprise additives for improving one or more characteristics including, but not limited to water resistance, appearance, chemical resistance, UY resistance, refractive index or opacity, binder properties, tensile strength, electrical resistivity, or antimicrobial properties.
• the binder substrate comprises a drying oil.
• the binder substrate comprises tung oil. Once prepared, the binder substrate can be stored in an airtight container.
• Filler substrates can be included in the flooring compositions of the present disclosure. Filler substrates can provide solid support for the composition when mixed with the liquid binder substrate. In certain embodiments, the filler substrates further comprise sawdust, wood flour, cork, tomato powder, or purple sweet potato powder, calcium carbonate, and any combination thereof.
• Modem flooring products deviate from traditional linseed oil-based polymer by incorporating fossil fuel-based additives, ethylene-vinyl acetate, or polyvinyl chloride, to improve integrity and water resistance.
• Polyvinyl chloride degrades into harmful microplastics and releases dioxins and phthalates which disrupt the endocrine system.
• Other common additives include titanium dioxide and aluminum trihydrate which pose health hazards.
• the compositions of the present disclosure do not include fossil fuel-based materials.
• the compositions of the present disclosure do not include titanium dioxide or aluminum trihydrate.
• Plant materials can be advantageous components for construction materials, including, but not limited to flooring, roofing, or fencing materials.
• Such materials include brewing byproducts including, but not limited to brewing trub and spent hops.
• the use of trub and spent hops in construction materials is advantageous due to their high lignin content.
• woody biomass with high lignin content can be used as an alternative to toxic, synthetic materials traditionally used to improve the mechanical stability of construction materials comprising recycled plastic and rubber.
• this function of lignin is due to its polymeric structure, which allows it to act as a compatibilizer for promoting mechanical stability and compatibility between materials.
• plant materials including, but not limited to brewing trub, spent hops, or biomass comprising elevated lignin content (e.g., Eucalyptus), are used to enhance linseed oil-based polymer construction materials by improving adhesion between components without the use of synthetic additives (e.g., polyvinyl chloride).
• Spent hops have antimicrobial, antifungal, and antibacterial properties, which is advantageous for use in polymers for sensitive indoor or outdoor applications.
• the plant material is biomass comprising at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, or at least 30% lignin by weight.
• the plant material is biomass comprising about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30% lignin by weight.
• Trub and spent hops are further advantageous materials because they are typically discarded. Thus, utilizing trub for producing construction materials is more cost-effective than traditional materials and reduces waste.
• plant materials can be supplied in a wet state and can be dried prior to use. However, purification of critical components or separation from toxic or other undesirable contents are not required.
• the plant materials can be dried by filtration or incubation in a drying oven.
• Plant materials e.g., brewing trub and spent hops
• the construction materials are used for flooring, roofing, and/or fencing.
• sources of suitable plant materials include breweries and distilleries.
• the plant material comprises trub or spent hops.
• the plant materials can be supplied in a wet or dry state. Materials obtained in a wet state can be dried prior to use. In certain embodiments, the plant material is obtained in a wet state. In certain embodiments, the wet plant material is dried by filtration or by drying for one or more days at 110 °C.
• the plant materials can be used as filler substrates for construction materials.
• the plant material can be mixed with one or more other filler substrates, e.g., sawdust, wood flour, cork, tomato powder, or purple sweet potato powder, calcium carbonate, and then mixed with a binder substrate to produce a binder-filler composition.
• the binder-filler composition can be pressed and cured to produce a linseed oil-based polymer sheet product.
• the mixture can solidify, at least in part, due to the linseed oil in the binder substrate which polymerizes when exposed to oxygen.
• the binder substrate for linseed oil-based construction materials comprises linseed oil and a resin.
• the resin is selected from the group consisting of rosin, trub- based resin, and combinations thereof.
• the binder substrate comprises a drying oil, e.g., tung oil.
• the binder substrate further comprises tung oil.
• the components of the binder substrate can be heated to facilitate mixing.
• the binder substrate is incubated at about 300 °C for at least one day with stirring, and then set at room temperature with stirring until cooled to about 100 °C.
• binder and filler substrates can be achieved through methods known in the art, e.g., using a compounding mixer or a centrifugal speedmixer.
• the binder and filler substrates are mixed using a compounding mixer.
• the binder and filler substrates are mixed using a speedmixer.
• the binder and filler substrates are mixed in two or more stages.
• the binder and filler substrates are mixed using a speedmixer at 1,100 RPM for at least 1 minute and then at 1,600 RPM for at least 1 minute. The mixing step at 1,600 RPM can be repeated as needed.
• the binder and filler substrates are mixed using a speedmixer at 1,100 RPM for 1 minute and then at 1,600 RPM for 4 minutes.
• the binder substrate is heated to 40-50 °C prior to mixing with the filler substrate.
• the one or more filler substrates can be mixed with the binder substrate in separate steps.
• the binder substrate is mixed with plant material, calcium carbonate, wood flour, and purple sweet potato powder in separate steps.
• Additives necessary for construction applications can be mixed into the binder-filler composition.
• the composition comprises one or more colorants.
• the composition comprises calcium carbonate.
• the binder-filler composition can be pressed into a sheet product.
• the sheet can be produced as a single layer product, or the sheet can be pressed onto another substance to form a multi-layered product.
• the surface onto which the mixture can be pressed can be a solid support, e.g., coir,jute, sisal, hemp, or canvas.
• Agents can be applied to prevent sticking to the press, e.g., Kapton film or calcium carbonate.
• the linseed oil-based polymer sheet is a single-layered product.
• the linseed oil-based polymer sheet is a multi-layered product.
• the presently disclosed subject matter provides for a method for producing linseed oil-based polymer construction materials comprising mixing a binder substrate comprising linseed oil and resin with at least one filler substrate into a mixture; wherein the at least one filler substrate comprises a plant material.
• A2 The foregoing method of A-Al, wherein the plant material is at least one selected from the group consisting of trub, spent hops, biomass comprising at least 15% lignin, and combinations thereof.
• A3 The foregoing method of A-A2, wherein the plant material is dried prior to use by filtration or by drying for about 48 hours at about 100 °C.
• A4 The foregoing method of A-A3, wherein the resin is at least one selected from the group consisting of rosin, trub-based resin, and any combination thereof.
• A6 The foregoing method of A-A5, wherein the at least one filler substrate further comprises at least one selected from the group consisting of sawdust, wood flour, tomato powder, purple sweet potato powder, flax seed, calcium carbonate, and any combination thereof.
• A7 The foregoing method of A-A6, wherein the plant material makes up about 10% to about 20% of the mixture by weight.
• A13 The foregoing method of A-A12, wherein the mixture does not contain fossil fuelbased materials.
• A14 The foregoing method of A-A13, wherein the mixture does not contain titanium dioxide or aluminum trihydrate.
• composition comprising linseed oil, resin, and plant material.
• B2 The foregoing composition of B-Bl, wherein the resin is at least one selected from the group consisting of rosin, trub-based resin, and any combination thereof.
• B3 The foregoing composition of B-B2, further comprising tung oil.
• B4 The foregoing composition of B-B3, further comprising at least one selected from the group consisting of sawdust, wood flour, tomato powder, purple sweet potato powder, flax seed, calcium carbonate, and any combination thereof.
• B5. The foregoing composition of B-B4, wherein the plant material makes up about 10% to about 20% of the total composition by weight.
• B6 The foregoing composition of B-B5, wherein the composition does not contain fossil fuel-based materials.
• B7 The foregoing composition of B-B6, wherein the composition does not contain titanium dioxide or aluminum trihydrate.
• a liquid binder substrate was produced according to the materials listed in Table 1. The materials were incubated at 300 °C for 24 hours with stirring, and then set at room temperature with stirring until cooled to 100 °C.
• Table 1 Composition of the binder substrate.
• the improved rheology provided an advantage in the production of the pressed sheets.
• the mixture remained on the surface of the coir.
• the mixture did not penetrate the coir or reach the edge of the 8” x 8” sheet ( Figures 2A-2B).
• Table 3 Composition of the mixture comprising binder substrate and trub.
• the binder substrate was prepared as shown in Table 4. The components of the binder substrate were mixed at 300 °C under continuous airflow for at least 24 hours.
• the binder substrate was heated to 40-50 °C (Figure 4A). Trub, calcium carbonate, wood flour, and purple sweet potato were added to the liquid binder ( Figure 4B and Table 5), and then the composition was mixed using a speedmixer ( Figure 4C). The composition was mixed first at 1,100 RMP for one minute, and then at 1,600 RPM for four minutes.
• Table 5 Composition of the mixture comprising binder substrate and trub.
• composition was then pressed into sheets using a hydraulic press ( Figure 4D). Kapton film was placed above and below the composition to prevent sticking. The platens were set to 110 °C ⁇ 20 °C. The composition was pressed into 2-4 mm sheets using rolling pressure applied at 1,000 lbs force. The sheets were cured in a drying oven at 110 °C.
• TGA thermogravimetric analysis
• DSC differential scanning calorimetry
• TGA evaluates changes in the sample mass as a function of temperature or time and under different gas atmosphere conditions in a controlled manner. Analysis includes monitoring the sample mass while heating at a constant rate or held at a constant temperature over time. TGA can be used to monitor thermal decomposition of materials. The changes in sample weight (mass) can be a result of deterioration in physical and chemical properties.
• DSC evaluates changes in the heat flow to and from the sample as a function of temperature or time. DSC measures how much energy a sample absorbs or releases during heating or cooling and measures how physical properties of a sample change, along with temperature against time. During TGA, the initial change in mass was observed when the temperature increased over about 200 °C ( Figure 5A and Figure 7). The DSC results showed a similar change in sample properties when tested at about 180 °C ( Figure 5B). [0076] Fourier Transform Infrared Spectroscopy (FTIR) was used to compare samples comprising trub (Figure 6A) versus conventional flooring materials ( Figure 6B). FTIR spectra can be used to identify unknown materials by identifying and distinguish among molecules.
• FTIR Fourier Transform Infrared Spectroscopy
• the conventional flooring material used for testing were obtained from a library of commonly used materials: calcium carbonate (CaCCh) and ethylene-vinyl acetate (EVA).
• the FTIR spectrum from the conventional materials revealed multiple peaks, e g., in the 3000-2800 cm' 1 wavenumber range, in the 1800-1700 cm' 1 wavenumber range, at about 1400 cm' 1 , at about 1240 cm' 1 , at about 875 cm' 1 , and at about 710 cm' 1 ( Figure 6B).
• the FTIR spectrum from the trub-based samples showed peaks that were similar to those observed from the conventional flooring materials.
• melt temperature and melt flow index were determined for trub-based samples. To evaluate melt temperature, the change in a 0.741 g sample was evaluate at it was heated to 350 °C and above. Melting was observed when the sample was heated to about 200 °C. The melt flow index for a sample heated to 205 °C was 3.875 g/min or 38.75 grams per 10 min.

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• General Chemical & Material Sciences (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
• Biological Depolymerization Polymers (AREA)

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• 2023
  • 2023-10-24 EP EP23883392.5A patent/EP4608909A1/de active Pending
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