US20030100634A1 - Composite compositions - Google Patents

Composite compositions Download PDF

Info

Publication number
US20030100634A1
US20030100634A1 US10/123,757 US12375702A US2003100634A1 US 20030100634 A1 US20030100634 A1 US 20030100634A1 US 12375702 A US12375702 A US 12375702A US 2003100634 A1 US2003100634 A1 US 2003100634A1
Authority
US
United States
Prior art keywords
lubricant
composition
alkyl ester
present
coupling agent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/123,757
Other languages
English (en)
Inventor
Richard Heath
James Garft
Levante Koller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/123,757 priority Critical patent/US20030100634A1/en
Publication of US20030100634A1 publication Critical patent/US20030100634A1/en
Priority to US10/941,766 priority patent/US7816431B2/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M111/00—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential
    • C10M111/02—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential at least one of them being a non-macromolecular organic compound
    • 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
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
    • 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
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M105/00—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound
    • C10M105/08—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound containing oxygen
    • C10M105/32—Esters
    • C10M105/34—Esters of monocarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M105/00—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound
    • C10M105/08—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound containing oxygen
    • C10M105/32—Esters
    • C10M105/38—Esters of polyhydroxy compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D21J1/18—Hardboard
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
    • C08L2205/16—Fibres; Fibrils
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse

Definitions

  • the present invention relates to composite compositions comprising thermoplastic polymer and cellulosic fibers, to lubricant/coupling agents for such composite compositions, and to structural members and structures formed from such compositions.
  • the composites of the present invention are well-suited for use as wood substitutes when formed into structural members.
  • Composite materials which comprise an organic resin and a filler have been known and used for a number of years. For example, there has been a need to find materials that exhibit the look and feel of natural wood. One reason for this need relates to efforts to conserve the limited supply of natural wood for construction purposes from the world's forest. Another reason is that certain composite materials can exhibit properties that are superior to natural wood in certain respects. For example, it is possible to formulate composite materials into synthetic wood that has enhanced moisture resistance.
  • the present invention has several aspects, including novel lubricant compositions, novel composite compositions, novel structural members and novel methods of manufacture. Each of these aspects flows, at least in part, from the recognition by the present inventors that certain lubricants, and in particular metal carboxylate lubricants, such as metal stearates, can negatively affect the performance of certain desirable coupling agents, and the discovery that certain lubricants operate in a synergistic manner with such coupling agents to produce unexpectedly superior performance.
  • compositions well suited for forming shaped articles such composition comprising polymer (preferably thermoplastic polymer), cellulose, a coupling agent comprising carboxylic functionality (for example, anhydride moieties), and a lubricant comprising electrophilic functionality (for example alkyl ester of a carboxylic acid or a functional derivative thereof).
  • the lubricant is free of an antagonistic amount of metal carboxylate, such as metal stearate, and is even more preferably is substantially free of metal carboxylate, such as metal stearate.
  • antagonistic amount refers to an amount of metal carboxylate which has a more than nominal negative impact on the properties of the composite (especially the processing properties, such as extrudeability) as compared to the same composite without any such metal carboxylate.
  • the present invention also provides lubricant compositions comprising an alkyl ester and an amide ester.
  • the methods of the present invention comprise forming a composite of the present invention into a shaped article, preferably by extruding the composite.
  • FIG. 1 is a cross-sectional, semi-schematic view of one structural member in accordance with one embodiment of the present invention.
  • FIG. 2 is a cross-sectional, semi-schematic view of one structural member in accordance with another embodiment of the present invention.
  • FIG. 3 is a cross-sectional, semi-schematic view of one structural member in accordance with another embodiment of the present invention.
  • the invention is directed to composite compositions which may be fabricated at high rates into shaped articles, and in particular structural members, exhibiting desirable strength properties.
  • the composition preferably comprises from about 10 to about 50 parts by weight of thermoplastic polymer, from about 50 to about 90 parts by weight of cellulosic fiber, effective amounts of a coupling agent and effective amounts of lubricant in accordance with the present invention.
  • effective amount refers to any amount which produces a noticeable, and preferably a substantial, improvement in the corresponding performance of the composition.
  • an effective amount of a coupling agent produces a noticeable improvement in the compatibility of and/or adherence between the thermoplastic an the cellulosic fiber, which will typically although not exclusively be manifested in an improvement in the tensile strength of the shaped article.
  • an effective amount produces a noticeable improvement in the processability of the composition, which will typically although not exclusively be manifested in an improvement in the speed and/or efficiency with which the composition can be effectively formed, and preferably extruded, into a shaped article.
  • the composite composition preferably comprises from about 20 to about 40 parts by weight, and even more preferably from about 25 to about 35 parts by weight of thermoplastic polymer, from about 50 to about 80 parts by weight, and even more preferably from about 50 to about 65 parts by weight, of cellulosic fiber, from about 1 to about 5 parts by weight of coupling agent, and from about 1 to about 5 parts by weight of lubricant.
  • Preferred embodiments of the present compositions produce shaped articles with unexpectedly improved performance properties relative to prior art compositions. More particularly, preferred composite compositions which include maleic anhydride-based coupling agents and lubricating agent in accordance with the present invention produce shaped articles with tensile strength properties that exhibit a tensile strength which is at least about 25 relative percent, and even more preferably at least about 50 relative percent, greater than the same compositions containing substantial amounts of the commonly used prior art lubricant zinc stearate.
  • the preferred composite compositions of the present invention exhibit a tensile strength of at least about 2000 psi, more preferably at least about 2500 psi, and even more preferably 3000 psi.
  • Another substantial and unexpected advantage of the present invention, and particularly the present lubricant compositions is a cost advantage which derives from the improved processing performance of the present lubricants. More particularly, the present lubricants are more effective in enhancing the formability, and particularly the extrudeability, of the composite compositions. This improvement is illustrated by the fact that the present compositions can be formed at substantially the same rate as those compositions using prior art zinc stearate lubricants with a lubricant loading that is no greater than about 90 relative percent, and even more preferably no greater than about 75 relative percent, of the loading required by the prior art to achieve the same processing speed.
  • thermoplastic polymer any substantially thermoplastic polymer is adaptable for use in accordance with the present invention.
  • thermoplastic polymer useful in the present compositions may include polyamides, polyvinyl halides, polyesters, polyolefins, polyphenylene sulfides, polyoxymethylenes, styrene polymers, and polycarbonates. Particular preferred is polyolefin polymer.
  • thermoplastic polymeric material retain sufficient thermoplastic properties to permit melt blending with cellulosic fiber and permit effective formation into shaped articles by extrusion or molding in a thermoplastic process. It is thus contemplated that minor amounts of thermosetting resins may be included in the present compositions without sacrificing these essential properties. Both virgin and recycled (waste) polymers can be used.
  • polyolefin refers to homopolymers, copolymers and modified polymers of unsaturated aliphatic hydrocarbons.
  • polyethylene and polypropylene are most preferred.
  • high density polyethylene (HDPE) is especially preferred.
  • regrinds of HDPE from bottles and film are preferred.
  • the present compositions include filler that comprises cellulose.
  • the filler component may be comprised of reinforcing (high aspect ratio) filler, non-reinforcing (low aspect ratio) filler, and combinations of both reinforcing and non-reinforcing filler.
  • Aspect ratio is defined as the ratio of the length to the effective diameter of the filler particle. High aspect ratio offers an advantage, i.e., higher strength and modulus for the same level of filler content.
  • Inorganic fillers such as glass fibres, carbon fibres, talc, mica, kaolin, calcium carbonate and the like, may be included as an optional supplement to the cellulose.
  • other organic fillers, including polymeric fiber may also be used.
  • the cellulose filler in accordance with the present invention is particularly important and preferred because of its low cost and for other reasons, such as light weight, ability to maintain high aspect ratio after processing in high intensity thermokinetic mixer and low abrasive properties (thus, extending machine life).
  • the cellulose may be derived from any source, including wood/forest and agricultural by-products.
  • the cellulose fiber may include hard wood fiber, soft wood fiber, hemp, jute, rice hulls, wheat straw, and combinations of two or more of these.
  • the cellulose preferably comprises high aspect ratio fiber, such as are present in hard woods, in a substantial proportion. However, such high aspect ration fibers are generally more difficult to process and therefore may be less desirable in embodiments in which processing speed and efficiency are particularly important considerations.
  • the term coupling agent refers to a compound or composition which tends to promote dispersion and/or compatibilization of the cellulose particles and the thermoplastic polymer.
  • compounds including organic polymers, with electrophilic functionality, and in particular carboxylic functionality, have been found to be potentially effective for this purpose, and it is contemplated that all such compounds are adaptable for use in accordance with the present invention.
  • Preferred organic compounds include polymers with maleic anhydride functionality.
  • a coupling agent which is highly effective for use in connection with both different polyolefin polymers, more preferably C 2 -C 4 polyolefins, and even more preferably polyethylene and polypropylene.
  • a maleated polypropylene polymer and particular polypropylene having a molecular weight of from about 10,000 to about 15,000 and about 1.5 to about 2.5 maleic anhydride functionalities, on average, per polymer chain.
  • the coupling agent comprise functionalized polyolefin, and preferably functionalized polyethylene, functionalized polypropylene, and/or combinations of functionalized polyethylene and functionailzed polypropylene having a molecular weight of from about 10,000 to about 25,000 (and even more preferably from about 10,000 to about 20,000) and about 0.6 to about 3 maleic anhydride functionalites (and even more preferably from about 0.8 to about 2.5), on average, per polymer chain.
  • functionalized polyolefins are available, for example, from Honeywell International under trade designations A-C 1221, 597, 596 and 575.
  • functionalized polyethylene and polypropylene are disclosed in U.S. Pat. Nos. 3,882,1945, 4,404,312 and 5,001,197, each of which is incorporated herein by reference.
  • silane coupling agent(s) alone or in combination with other preferred coupling agents.
  • other effective coupling compounds not specifically mentioned herein, but which are now known or become known to those skilled in the art, may also be used in addition to, or in certain cases as substitutes for, the preferred coupling agents described herein.
  • compositions include an effective amount of a lubricant or a lubricant package.
  • the lubricant comprises alkyl ester.
  • Particularly preferred are polyol esters formed by the reaction of polyol (that is, polyhydroxyl compounds) with one or more mono- or poly-basic carboxylic acid or carboxylic acid functional groups.
  • polyols are those represented by the general formula R(OH) n wherein R is any aliphatic or cyclo-aliphatic hydrocarbyl group (preferably an alkyl) and n is at least 2.
  • R is any aliphatic or cyclo-aliphatic hydrocarbyl group (preferably an alkyl) and n is at least 2.
  • the hydrocarbyl group may contain from about 2 to about 20 or more carbon atoms, and the hydrocarbyl group may also contain substituents such as chlorine, nitrogen and/or oxygen atoms.
  • the polyhydroxyl compounds generally may contain one or more oxyalkylene groups and, thus, the polyhydroxyl compounds include compounds such as polyetherpolyols.
  • the number of carbon atoms i.e., carbon number, wherein the term carbon number as used throughout this application refers to the total number of carbon atoms in either the acid or alcohol as the case may be
  • number of hydroxy groups i.e., hydroxyl number
  • the following alcohols are particularly useful as polyols: neopentyl glycol, trimethylolethane, trimethylolpropane, trimethylolbutane, mono-pentaerythritol, technical grade pentaerythritol, and di-pentaerythritol.
  • the most preferred alcohols are technical grade (e.g., approximately 88% mono-, 10% di- and 1-2% tri-pentaerythritol) pentaerythritol, monopentaerythritol, and di-pentaerythritol.
  • Preferred carboxylic acids include any C 2 to C 20 mono- and di-acids, including preferably adipic and stearic acid.
  • anhydrides of polybasic acids can be used in place of the polybasic acids, when esters are being formed. These include, for example, succinic anhydride, glutaric anhydride, adipic anhydride, maleic anhydride, phthalic anhydride, trimellitic anhydride, nadic anhydride, methyl nadic anhydride, hexahydrophthalic anhydride, stearic anhydride and mixed anhydrides of polybasic acids.
  • Particularly preferred lubricating compounds in accordance with the present invention are the complex esters described in U.S. Pat. Nos, 4,487,874 and 5 6,069,195, each of which is incorporated herein by reference.
  • the preferred alkyl ester of the present invention comprises a mixture of alkyl esters of the formula 1 below,
  • R is independently hydrogen, or —C(O)R′ and wherein at least on of R is —C(O)R′;
  • R′ is hydrogen, an unsaturated or saturated alkyl chain having from about 3 to about 18 carbon atoms, or —C(O)—X—COOH;
  • X is a unsaturated or saturated alkyl chain, which may be mono- or poly-valent, having from about 3 to about 18 carbon atoms.
  • the alkyl ester preferably comprises pentaerythritol adipate-stearate, which is a mixture of alkyl esters of formula 1 wherein about 14% of the organic moieties are —C(O)—X—COOH moieties derived from adipic acid and about 71% of the organic moieties are —C(O)R′ moieties derived from stearic acid and its associated acids (chiefly palmitic acid).
  • Such material is sold under the trade designation RL 710 by Honeywell International Inc.
  • the lubricant packages in accordance with the present invention also preferably include carboxyamide wax, and even more preferably stearamide wax, as disclosed in U.S. Pat. No. 3,578,621, which is incorporated herein by reference. Especially preferred is ethylenebis stearamide (“EBS”).
  • EBS ethylenebis stearamide
  • the alkyl ester and the amide wax may be used over a wide range of relative concentrations in the lubricant package, it is preferred that the weight ratio alkyl ester to amide wax is from about 30:1 to about 1:1, with 20:1 to about 2:1 being more preferred.
  • the lubricating package contains no more than about 25% by weight of metal carboxylate, even more preferably no more than 10% by weigh of metal carboxylate, and most preferably is substantially free of metal carboxylate.
  • the lubricating package contains no more than about 25% by weight of zinc stearate, even more preferably no more than 10% by weigh of zinc stearate, and most preferably is substantially free of zinc stearate.
  • the composite composition contains no more than 0.5% by weight of metal carboxylate, and more preferably no more than 0.25% by weigh of metal carboxylate. It is especially preferred that the composite contains no more than 0.5% by weight of zinc stearate, and more preferably no more than 0.25% by weigh of zinc stearate.
  • the lubricant comprises hydrogenated castor oil.
  • One aspect of the present invention involves additive compositions useful in connection with the formation of composite compositions having advantageous processing and end-use properties. More particularly, the additive packages comprise a unique combination of lubricating agents and/or coupling agents which are effective at improving the processing characteristics of the composite without detracting from, and in some cases enhancing, the strength characteristics of the finished product.
  • the additive is a lubricating agent which contains less than an antagonistic amount of metal carboxylate.
  • Particularly preferred lubricants in accordance with the present invention are substantially free of metal carboxylate and comprises a major proportion by weight of alkyl ester and/or hyrdrogenated Castor Oil, and a minor proportion by weight of carboxyamide wax.
  • the lubricating package further comprises a minor proportion by weight of polyolefin, preferably a polyethylene or polypropylend, and even more preferably substantially linear polyethylene or polypropylene.
  • the lubricating composition comprises from about 80 parts by weight to about 97 parts by weight of a compound selected from the group of alkyl esters, hydrogenated castor oils, and combinations of two or more of these, from about 1 part to about 10 parts by weight of carboxyamide wax and from about 1 part to about 10 parts by weight of polyolefin.
  • the lubricating packages of the present invention can beneficially be used alone in certain embodiments, it is generally preferred to provide an additive package which includes a lubricant agent/package according to the present invention in combination with a coupling agent/package in accordance with the present invention. Furthermore, while it is contemplated that these packages can be combined in a wide range of relative proportions in accordance with the present invention, it is generally preferred to provide an additive package having a lubricant:coupling agent weight ratio of from about 1:1 to about 4:1, and even more preferably in certain embodiments of about 3:2.
  • the present compositions can be used to form a wide variety of structural members, and all such structural members are within the broad scope of the present invention. Applicants have found, however, that the present methods and compositions can be utilized to form structural members, and particularly extruded structural members, that would otherwise be exceptionally difficult to form and/or practically unfeasible from an economic stand point because of high processing costs. More specifically with respect to FIGS. 1 - 3 , it can be seen that the present invention includes structural members that are at once both strong and lightweight. It will be appreciated by those skilled in the art that such lightweight structural members would not have been practically possible to manufacture by extrusion from prior composite compositions because of the high cross-sectional area of the structures.
  • the present composite compositions have a unique combination of high-strength and high lubricity that permit the extrusion of such high surface area configurations under relatively higher rate, economical extrusion conditions. Applicants believe that such structural members could not have been produced in a commercially efficient and cost-effective manner in accordance with prior art techniques.
  • the present methods involve forming a shaped article comprising the steps providing a composite composition in accordance with the invention as described herein and forming said composition into the desired shaped article.
  • the composition can be provided by combing the components in accordance with any of the techniques well known in the art for combing components to form homogeneous composite compositions, as disclosed in U.S. Pat. Nos.3,943,079; 4,338,228; 5,886,066; and 5,997,784 each of which is incorporated herein by reference.
  • the forming step can also comprise any of the techniques well known in the art for forming homogeneous composites into shaped articles, including injection molding and extruding, as disclosed in the aforementioned patents. Forming by extrusion is preferred.
  • the present comparative example does not necessarily represent an item of prior art and may in fact be closer to the present invention than the closest item of prior art. Nevertheless, this example serves as a basis for illustrating the superior performance of the present invention.
  • a composite composition is prepared by extrusion compounding 62 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 3 pbw of a lubricant consisting essentially of EBS and zinc stearate in a 1:2 weight ratio.
  • the composite composition is formed into a shaped article by known methods under known conditions.
  • the resultant article exhibits a tensile strength of approximately 2000 psi.
  • a composite composition is prepared by extrusion compounding 62.8 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 2.2 pbw of a lubricant consisting essentially of EBS, zinc stearate and pentaerythritol adipate-stearate in a 1:1:20 weight ratio.
  • the composite composition is formed into a shaped article by the same methods under the same conditions as in the comparative example.
  • the resultant article exhibits a tensile strength of approximately 2900 psi, representing an improvement of 45% over the comparative example.
  • a composite composition is prepared by extrusion compounding 62.75 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 2.25 pbw of a lubricant consisting essentially of EBS and pentaerythritol adipate-stearate in a 2.5:20 weight ratio.
  • the composite composition is formed into a shaped article by the same methods under the same conditions as in the comparative example.
  • the resultant article exhibits a tensile strength of approximately 3500 psi, representing an improvement of 75% over the comparative example.
  • a composite composition is prepared by extrusion compounding 62.5 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 2.5 pbw of a lubricant consisting essentially of pentaerythritol adipate-stearate.
  • the composite composition is formed into a shaped article by the same methods under the same conditions as in the comparative example.
  • the resultant article exhibits a tensile strength of approximately 3200 psi, representing an improvement of 60% over the comparative example.
  • the present comparative example does not necessarily represent an item of prior art and may in fact be closer to the present invention than the closest item of prior art. Nevertheless, this example serves as a basis for illustrating the superior performance of the present invention.
  • a composite composition is prepared by extrusion compounding 60.5 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 4.5 pbw of a lubricant consisting essentially of EBS and zinc stearate in a 1:2 weight ratio.
  • the composite composition is formed into a shaped article by known extrusion methods under known conditions.
  • a composite composition is prepared by extrusion compounding 62 parts by weight (“pbw”) of wood fiber, 33 pbw of HDPE, 2 pbw of maleated polyethylene coupling agent, and 3 pbw of a lubricant consisting essentially of EBS and pentaerythritol adipate-stearate in a 2.5:20 weight ratio.
  • the composite composition is formed into a shaped article by the same methods under the same conditions as in the comparative example 2. Despite using approximately 50 percent less on both a weight and cost basis of lubricant than comparative example 2, the forming operation proceeds at least as efficiently as and at at least about the same production rate as in comparative example 2.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • General Chemical & Material Sciences (AREA)
  • Emergency Medicine (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Lubricants (AREA)
US10/123,757 2001-04-16 2002-04-16 Composite compositions Abandoned US20030100634A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/123,757 US20030100634A1 (en) 2001-04-16 2002-04-16 Composite compositions
US10/941,766 US7816431B2 (en) 2001-04-16 2004-09-14 Composite compositions

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US28413101P 2001-04-16 2001-04-16
US10/123,757 US20030100634A1 (en) 2001-04-16 2002-04-16 Composite compositions

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/941,766 Continuation US7816431B2 (en) 2001-04-16 2004-09-14 Composite compositions

Publications (1)

Publication Number Publication Date
US20030100634A1 true US20030100634A1 (en) 2003-05-29

Family

ID=23088963

Family Applications (2)

Application Number Title Priority Date Filing Date
US10/123,757 Abandoned US20030100634A1 (en) 2001-04-16 2002-04-16 Composite compositions
US10/941,766 Expired - Fee Related US7816431B2 (en) 2001-04-16 2004-09-14 Composite compositions

Family Applications After (1)

Application Number Title Priority Date Filing Date
US10/941,766 Expired - Fee Related US7816431B2 (en) 2001-04-16 2004-09-14 Composite compositions

Country Status (8)

Country Link
US (2) US20030100634A1 (ko)
EP (1) EP1409619B1 (ko)
JP (3) JP2004532315A (ko)
KR (1) KR100826000B1 (ko)
CN (2) CN100383224C (ko)
CA (1) CA2444252A1 (ko)
ES (1) ES2393185T3 (ko)
WO (1) WO2002083824A1 (ko)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050094630A1 (en) * 2003-10-31 2005-05-05 Ezio Valdevit Network path tracing method
US20060091578A1 (en) * 2004-11-02 2006-05-04 Bravo Juan M Wood-polymer composites and additive systems therefor
US20070023954A1 (en) * 2001-04-26 2007-02-01 Laver Terry C Method for low-density cellular wood plastic composites
US20070027234A1 (en) * 2005-07-28 2007-02-01 Sigworth William D Cellulosic-thermoplastic composite and method of making the same
US20070093585A1 (en) * 2005-10-21 2007-04-26 Abuzar Syed Thermoplastic blend compositions as soft coupling agents
US20070213238A1 (en) * 2006-03-13 2007-09-13 Sigworth William D Lubricant composition for cellulosic-thermoplastic composite
US7709557B2 (en) 1997-09-02 2010-05-04 Xyleco, Inc. Compositions and composites of cellulosic and lignocellulosic materials and resins, and methods of making the same
US7971809B2 (en) 2005-03-24 2011-07-05 Xyleco, Inc. Fibrous materials and composites
US8550386B2 (en) 2010-12-22 2013-10-08 Kimberly-Clark Worldwide, Inc. Oil absorbing material and processes of recycling absorbent articles to produce the same
WO2015021148A1 (en) * 2013-08-06 2015-02-12 Biovation, Llc Biohydrogenated plastics
US9238731B2 (en) 2008-02-29 2016-01-19 Saco Polymers, Inc. Reinforcing additives for composite materials
WO2023014996A1 (en) * 2021-08-05 2023-02-09 Applied Bioplastics Corp. Methods and systems for producing composite materials

Families Citing this family (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6942829B2 (en) 2003-04-30 2005-09-13 Ferro Corporation Polymer-wood composites and additive systems therefor
US7402625B2 (en) 2003-06-11 2008-07-22 3M Innovative Properties Company Compositions and method for improving the processing of polymer composites
US8236874B2 (en) 2003-06-11 2012-08-07 3M Innovative Properties Company Compositions and method for improving the processing of polymer composites
DE10335139A1 (de) * 2003-07-31 2005-02-24 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung von Leichtbauteilen sowie mit dem Verfahren herstellbare Leichtbauprofile
CN1309751C (zh) * 2003-11-28 2007-04-11 中国石油天然气股份有限公司 一种改性偶联剂的制备方法和用途
EP1584669A1 (en) * 2004-04-07 2005-10-12 SOLVAY POLYOLEFINS EUROPE - BELGIUM (Société Anonyme) Bonding of plastic-wood composites
US7605197B2 (en) * 2004-07-30 2009-10-20 Board Of Trustees Of Michigan State University Process for the preparation of maleated polyolefin modified wood particles in composites and products
US20060084729A1 (en) * 2004-10-14 2006-04-20 Honeywell International Inc. Composite compositions, structural articles and production thereof
JP2006131729A (ja) * 2004-11-05 2006-05-25 Mitsubishi Plastics Ind Ltd 合成木材製造用樹脂組成物および合成木材成形品
KR20070100406A (ko) * 2005-02-02 2007-10-10 이 아이 듀폰 디 네모아 앤드 캄파니 셀룰로오스 및 열가소성 중합체를 포함하는 복합물
US20070048343A1 (en) * 2005-08-26 2007-03-01 Honeywell International Inc. Biocidal premixtures
US7659330B2 (en) * 2005-09-16 2010-02-09 University Of Maine System Board Of Trustees Thermoplastic composites containing lignocellulosic materials and methods of making same
WO2007050324A1 (en) * 2005-10-24 2007-05-03 Arkema Inc. Pvc/wood composite
DE102006013988A1 (de) 2006-03-22 2007-09-27 Concert Gmbh Faserverstärkter Thermoplast
EP1918324A1 (de) * 2006-10-31 2008-05-07 Cognis Oleochemicals GmbH Zellulose-Kunststoff-Composites
US8475621B2 (en) * 2007-04-24 2013-07-02 Honeywell International Inc. Adhesion promotion to difficult substrates for hot melt adhesives
CA2686755A1 (en) * 2007-05-16 2008-11-27 Nova Chemicals, Inc. Plastic-cellulosic composite articles
CL2008003701A1 (es) * 2008-01-11 2009-05-08 Nova Chem Inc Método para producir un artículo de material compuesto espumado de fibra celulósica-termoplástico.
KR100941269B1 (ko) 2008-05-21 2010-02-11 현대자동차주식회사 자동차 내·외장재용 폴리프로필렌-대나무섬유 바이오복합재료
DE102008034013B4 (de) * 2008-07-15 2011-04-28 J. S. Staedtler Gmbh & Co. Kg Verwendung eines Holzersatzwerkstoff
KR101063227B1 (ko) * 2009-10-12 2011-09-07 현대자동차주식회사 나일론-4 복합재료 조성물
WO2013003591A2 (en) * 2011-06-28 2013-01-03 Interfacial Solutions Ip, Llc Moisture resistant polymeric composites
CN102690442A (zh) * 2012-06-06 2012-09-26 上海大学 制备纤维素填充的复合材料的方法
EP2712882A1 (en) * 2012-09-27 2014-04-02 UPM-Kymmene Corporation Method and system for manufacturing a polymer composite
AT513561B1 (de) * 2012-10-22 2016-02-15 Mondi Ag Nachwachsende Rohstoffe enthaltender Verbundwerkstoff sowie Verfahren zu seiner Herstellung
WO2016075593A1 (en) * 2014-11-13 2016-05-19 Sabic Global Technologies B.V. Polyester composition and article prepared therefrom
US10668700B2 (en) 2017-05-05 2020-06-02 Masonite Corporation Cellulosic articles made from cellulosic materials and methods therefor
US11111715B2 (en) 2018-04-25 2021-09-07 Endura Products, Llc Door assembly
JP7084895B2 (ja) * 2019-06-28 2022-06-15 大王製紙株式会社 セルロース繊維複合再生樹脂及びその製造方法
USD947663S1 (en) 2019-07-01 2022-04-05 Endura Products, Llc Door mullion
KR102235585B1 (ko) * 2020-01-21 2021-04-05 주식회사 가이아 폴리우레탄용 하이브리드 복합분해제의 제조방법 및 그 방법에 의해 제조된 복합분해제를 함유하는 복합분해성 폴리우레탄 조성물

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5776281A (en) * 1995-03-08 1998-07-07 Evans; Daniel W. Method of manufacturing a pallet made of composite fiber reinforced polyolefin
US5973035A (en) * 1997-10-31 1999-10-26 Xyleco, Inc. Cellulosic fiber composites
US6011091A (en) * 1996-02-01 2000-01-04 Crane Plastics Company Limited Partnership Vinyl based cellulose reinforced composite

Family Cites Families (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3645939A (en) * 1968-02-01 1972-02-29 Us Plywood Champ Papers Inc Compatibilization of hydroxyl containing materials and thermoplastic polymers
US3578621A (en) 1968-08-27 1971-05-11 Carlisle Chemical Works Diesters exhibiting internal-external lubricating properties in structural resins
DE2262266C2 (de) * 1972-12-20 1982-04-01 Neynaber Chemie Gmbh, 2854 Loxstedt Verwendung eines Estergemisches als Gleitmittel für die formgebende Verarbeitung thermoplastischer Massen
US3882194A (en) 1973-01-26 1975-05-06 Chemplex Co Cografted copolymers of a polyolefin, an acid or acid anhydride and an ester monomer
US3943079A (en) 1974-03-15 1976-03-09 Monsanto Company Discontinuous cellulose fiber treated with plastic polymer and lubricant
JPS5655450A (en) 1979-10-12 1981-05-16 Toa Nenryo Kogyo Kk Polyolefin composition
JPS599576B2 (ja) * 1981-01-06 1984-03-03 チッソ株式会社 ポリオレフイン樹脂組成物
DE3214118A1 (de) 1981-04-17 1982-11-18 Toyo Boseki K.K., Osaka Faserverstaerkte polymergemisch-zusammensetzung
JPS58217552A (ja) 1982-06-12 1983-12-17 Kasai Kogyo Co Ltd 複合樹脂組成物
US4487874A (en) 1983-04-14 1984-12-11 Henkel Corporation Polycarbonate processing
CA1332987C (en) 1989-04-19 1994-11-08 Govinda Raj Process for chemical treatment of discontinuous cellulosic fibers and composites of polyethylene and treated fibers
US5001197A (en) 1989-05-10 1991-03-19 Exxon Chemical Patents Inc. Polypropylene composition and method for functionalization of polypropylene
US5134185A (en) 1990-07-18 1992-07-28 Lindner Robert A Lubricant system for polyvinylchloride, polyvinylchloride articles, and a method for manufacturing the same
US5346930A (en) * 1991-06-13 1994-09-13 Lydall, Inc. Rigid fiberboard
US5981067A (en) 1992-08-31 1999-11-09 Andersen Corporation Advanced compatible polymer wood fiber composite
JPH07102145A (ja) 1993-10-05 1995-04-18 Sumitomo Chem Co Ltd 塩化ビニル系樹脂組成物
JPH07188489A (ja) 1993-11-22 1995-07-25 Sumitomo Chem Co Ltd 粉末成形用塩化ビニル系樹脂組成物及びその製造方法
US5849209A (en) * 1995-03-31 1998-12-15 Johnson & Johnson Vision Products, Inc. Mold material made with additives
JP3575125B2 (ja) 1995-07-31 2004-10-13 Ｊｓｒ株式会社 熱可塑性樹脂組成物
CA2208337C (en) * 1996-06-22 2002-05-14 Clifford P. Ronden Process for the production of lightweight cellular composites of wood waste and thermoplastic polymers
US6180257B1 (en) 1996-10-29 2001-01-30 Crane Plastics Company Limited Partnership Compression molding of synthetic wood material
DE19649290A1 (de) * 1996-11-28 1998-06-04 Bayer Ag Spezielle Wachsmischungen enthaltende thermoplastisch verarbeitbare Polyurethane
JPH10265614A (ja) 1997-03-26 1998-10-06 Techno Polymer Kk 熱可塑性樹脂組成物の製造方法
JPH10286863A (ja) 1997-04-16 1998-10-27 Misawa Homes Co Ltd 木質様部材の製法
US5886066A (en) * 1997-07-17 1999-03-23 Hoechst Celanese Corporation Thermoplastic polymer composition exhibiting improved wear
US5997784A (en) 1998-01-06 1999-12-07 Karnoski; Wayne Method of manufacture of wood substitute articles
JPH11279355A (ja) 1998-03-26 1999-10-12 Ajinomoto Co Inc 熱安定化されたハロゲン含有樹脂組成物
DE19934377C2 (de) * 1999-07-22 2002-12-05 Thueringisches Inst Textil Verfahren zur Herstellung von polyesterverstärkten Polypropylencompounds nach einer vorgegebenen Rezeptur
JP4250815B2 (ja) * 1999-07-27 2009-04-08 堺化学工業株式会社 塩素含有樹脂用安定剤滑剤固体組成物とそれを含む塩素含有樹脂組成物
EP1145788B1 (en) * 1999-10-29 2004-12-15 JFE Steel Corporation Lubricating agent for mold at elevated temperature and method for producing high density iron-based sintered compact
US6579605B2 (en) * 2000-07-31 2003-06-17 Crane Plastics Company Llc Multilayer synthetic wood component
JP2002138202A (ja) 2000-10-31 2002-05-14 Ykk Corp セルロース系粉体含有複合樹脂成形体及びその製造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5776281A (en) * 1995-03-08 1998-07-07 Evans; Daniel W. Method of manufacturing a pallet made of composite fiber reinforced polyolefin
US6011091A (en) * 1996-02-01 2000-01-04 Crane Plastics Company Limited Partnership Vinyl based cellulose reinforced composite
US5973035A (en) * 1997-10-31 1999-10-26 Xyleco, Inc. Cellulosic fiber composites

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7709557B2 (en) 1997-09-02 2010-05-04 Xyleco, Inc. Compositions and composites of cellulosic and lignocellulosic materials and resins, and methods of making the same
US20070023954A1 (en) * 2001-04-26 2007-02-01 Laver Terry C Method for low-density cellular wood plastic composites
US7825172B2 (en) 2002-03-21 2010-11-02 Xyleco, Inc. Compositions and composites of cellulosic and lignocellulosic materials and resins, and methods of making the same
US20050094630A1 (en) * 2003-10-31 2005-05-05 Ezio Valdevit Network path tracing method
US20060091578A1 (en) * 2004-11-02 2006-05-04 Bravo Juan M Wood-polymer composites and additive systems therefor
US20070138689A1 (en) * 2004-11-02 2007-06-21 Ferro Corporation Wood-Polymer Composites And Additive Systems Therefor
US7971809B2 (en) 2005-03-24 2011-07-05 Xyleco, Inc. Fibrous materials and composites
US7635731B2 (en) * 2005-07-28 2009-12-22 Chemtura Corporation Cellulosic-thermoplastic composite and method of making the same
US7731880B2 (en) 2005-07-28 2010-06-08 Chemtura Corporation Cellulosic-thermoplastic composite and method of making the same
US20070027234A1 (en) * 2005-07-28 2007-02-01 Sigworth William D Cellulosic-thermoplastic composite and method of making the same
US7825180B2 (en) * 2005-10-21 2010-11-02 Chemtura Corporation Thermoplastic blend compositions as soft coupling agents
US20070093585A1 (en) * 2005-10-21 2007-04-26 Abuzar Syed Thermoplastic blend compositions as soft coupling agents
US20070213238A1 (en) * 2006-03-13 2007-09-13 Sigworth William D Lubricant composition for cellulosic-thermoplastic composite
US9238731B2 (en) 2008-02-29 2016-01-19 Saco Polymers, Inc. Reinforcing additives for composite materials
US8550386B2 (en) 2010-12-22 2013-10-08 Kimberly-Clark Worldwide, Inc. Oil absorbing material and processes of recycling absorbent articles to produce the same
US9457339B2 (en) 2010-12-22 2016-10-04 Kimberly-Clark Worldwide, Inc. Oil absorbing material and processes of recycling absorbent articles to produce the same
WO2015021148A1 (en) * 2013-08-06 2015-02-12 Biovation, Llc Biohydrogenated plastics
WO2023014996A1 (en) * 2021-08-05 2023-02-09 Applied Bioplastics Corp. Methods and systems for producing composite materials

Also Published As

Publication number Publication date
WO2002083824A1 (en) 2002-10-24
CN101100530A (zh) 2008-01-09
KR20040038910A (ko) 2004-05-08
JP5078849B2 (ja) 2012-11-21
CN100383224C (zh) 2008-04-23
JP2012144731A (ja) 2012-08-02
JP2004532315A (ja) 2004-10-21
CA2444252A1 (en) 2002-10-24
EP1409619B1 (en) 2012-09-05
US20050154095A1 (en) 2005-07-14
US7816431B2 (en) 2010-10-19
EP1409619A4 (en) 2010-03-03
CN101100530B (zh) 2013-04-17
EP1409619A1 (en) 2004-04-21
CN1514872A (zh) 2004-07-21
ES2393185T3 (es) 2012-12-19
JP2009074096A (ja) 2009-04-09
KR100826000B1 (ko) 2008-04-29

Similar Documents

Publication Publication Date Title
US7816431B2 (en) Composite compositions
EP1799761B1 (en) Composite compositions, structural articles and production thereof
US7731880B2 (en) Cellulosic-thermoplastic composite and method of making the same
CA2426230C (en) Extruded non-wood fiber plastic composites
EP1831311B1 (en) Cellulose fiber-plastic composition containing a lubricant
US6942829B2 (en) Polymer-wood composites and additive systems therefor
US20060091578A1 (en) Wood-polymer composites and additive systems therefor
Cavus Selected properties of mahogany wood flour filled polypropylene composites: the effect of maleic anhydride-grafted polypropylene (MAPP)
CA2462329A1 (en) Wood filled composites
WO2007035415A2 (en) Thermoplastic composites containing lignocellulosic materials and methods of making the same
AU2002307314A1 (en) Composite composition
AU2006201611A1 (en) Composite compositions

Legal Events

Date Code Title Description
STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION