CN1826379A - Biopolymer structures and components - Google Patents

Abstract

The present invention relates to a composition, which can be referred to as a biopolymer, including fermentation solid and thermoactive material. The present invention also includes methods of making the biopolymer, which can include compounding fermentation solid and thermoactive material. The present biopolymer can be formed into an article of manufacture. Methods of making such articles of manufacture include for example extruding, injection molding, or compounding fermentation solid and thermoactive material. Structures formed from biopolymer can include lumber replacements, window components, door components, siding assemblies, and other structures.

Description

Biopolymer structures and components

field of invention

The present invention relates to a composition (which may be referred to as a biopolymer) comprising fermentation solids and a thermoactive material. The invention also includes methods of making the biopolymers, which may include complexing fermentation solids and thermally active materials. The biopolymer of the present invention can be made into articles. Methods of production of the article include, for example, extrusion, injection molding or compounding of the fermented solids and the thermally active material. Structures made from biopolymers may include wood substitutes, window components, door components, siding components, and other structures.

Background of the invention

Filled plastics can be made into many products. For example, plastics can be made into wood substitutes, window components, door components, or siding for building structures.

Fillers have been used in the plastics industry for about 90 years. The reason most manufacturers use filled plastics is to reduce the price of high-cost polypropylene and other plastics with lower-cost fillers such as wood flour, talc, mica, and glass fibers. Fiberglass-filled plastics improve their properties by producing higher thermal stability and higher flexural and breaking strengths. But low-cost fillers such as wood flour can degrade some of the plastic's qualities and make it more difficult to process. Talc and mica add some strength to the plastic, but also add weight and reduce extruder life due to wear. Fiberglass provides a considerable increase in the strength of the product, but at a relatively high cost.

Existing plastics filled with plant material such as wood or grass suffer from a number of disadvantages. A major problem associated with the extrusion and injection molding of such plastics is the extremely small particle size of the plant material used in this process, mainly finely ground wood flour. Otherwise, the viscosity of the mixture is too high to be effectively extruded or molded. In addition, extrusion or injection molding is limited by the filler material that can be used, such as the ratio of wood to plastic. This places an undesired constraint on the producible product. Wood-plastic composites typically use between 30 and 65% wood flour or fine wood sawdust mixed with a single plastic. Ratio above this will cause processing problems and decrease in overall performance in terms of moisture absorption, rot, decay, and moisture resistance.

There remains a need for inexpensive bio-derived materials that can reduce the cost and consumption of thermally active materials and that perform better than fillers used in window and door assemblies, wood substitutes, building siding, and the like.

Summary of the invention

The present invention relates to a composition (which may be referred to as a biopolymer) comprising fermentation solids and a thermoactive material. The invention also includes methods of making the biopolymers, which may include complexing fermentation solids and thermally active materials. The biopolymer of the present invention can be made into articles.

The present invention relates to a composition comprising fermented solids and a thermally active material. The composition may comprise these ingredients in a wide range of amounts. For example, in one embodiment, the composition may comprise from about 5 to about 95% by weight fermentation solids and from about 1 to about 95% by weight thermally active material. In one embodiment, the fermented solids may comprise distillers dried grain or distillers dried grain with solubles, and may be derived from the fermentation of plant material such as grain (eg, corn). The thermally active material may include, for example, at least one of a thermoplastic material, a thermoset material, and a resin and an adhesive polymer. The compositions of the present invention can be used in a wide variety of articles of manufacture. The article of manufacture may comprise the composition comprising fermented solids and thermally active material.

The invention also relates to a process for the preparation of a composition comprising fermented solids and a thermally active material. The method includes compounding ingredients of the composition including, but not limited to, fermentation solids and thermally active materials. Recombination can include thermodynamic recombination. The composition can be formulated as a foam composition. Producing a foam composition may involve extruding a mass comprising fermented solids and thermally active material; the foam need not include a blowing agent.

The compositions of the invention may be used in methods of making articles. The method includes forming an article from a composition comprising fermented solids and a thermally active material.

The structure may be formed from a composition, which may be referred to as a biopolymer, comprising fermentation solids and a thermally active material. Preparation methods of biopolymer products include, for example, extrusion, injection molding or compounding of fermentation solids and thermally active materials. Structures made from biopolymers may include wood substitutes, window components, door components, siding components, and other structures.

In one embodiment, an article comprises a biopolymer material comprising a thermoactive material and a fermentation solid. In one embodiment, the biopolymer may comprise from about 5 to about 95% by weight fermentation solids and from about 1 to about 95% by weight thermally active material. In one embodiment, the fermentation solids comprise at least one of distiller's grain dried grain, distiller's dried starchy root crop grain, distiller's dried tuber grain, and distiller's dried root grain.

In one embodiment, the fermentation solids comprise at least one of distillers dried grains and distillers dried leguminous grains. In one embodiment, the fermented solids include distillers dried grains of corn, distillers dried grains of sorghum, distillers dried grains of barley, distillers dried wheat, distillers dried rye grains, distillers dried grains of rice, distillers dried grains of millet, distillers dried oats, and dried soybeans distiller's grains.

In one embodiment, an article comprising a biopolymer can be configured as part of a window, part of a door, part of furniture. For example, the article may be form assembled into at least one of a window assembly, a door assembly, and a furniture assembly.

In one embodiment, articles comprising biopolymers can be configured as wood replacement components. The wood replacement member may comprise a dense shell and a foam core. The wood replacement member may further include a textured surface on the dense shell.

In one embodiment, articles comprising biopolymers can be configured as decorative items.

In one embodiment, an article comprising a biopolymer may include a foam core. In one embodiment, an article comprising a biopolymer can be configured to be assembled with another article by heat welding.

In one embodiment, an article comprising a biopolymer can be configured to include an inner surface defining a lumen, a support extending into the lumen, and an anchor portion extending into the lumen configured to receive fastener.

In one embodiment, the article comprising a biopolymer may comprise at least one of a compression molded article, an extruded article, and an injection molded article.

In one embodiment, an article comprising a biopolymer can include a layer of a second material on top of the biopolymer. In one embodiment, the layer of second material may include embossed molded features, a coextruded material, or a powder coating.

In one embodiment, an article comprising a biopolymer can be configured as part of a building siding assembly. In one embodiment, a component of a building siding assembly may include a longitudinal member having a longitudinal body extending between first and second ends, the longitudinal member comprising a biopolymer material, the first and second ends At least one of them is configured to connect with the second component of the wall plate assembly. In one embodiment, the second component comprises a biopolymer material and is configured to be attached to one end of the longitudinal member by heat welding. In one embodiment, the longitudinal member includes a changing surface having a changing appearance, the changing surface comprising at least one of a powder coating, a textured surface, and a printed surface. In one embodiment, the siding product may include hollow portions, foam portions, webbed portions, or combinations thereof.

In one embodiment, the fermented solids comprise fermented protein solids. In one embodiment, the fermented solids comprise distiller's dried grains. In one embodiment, the distillers dried grains further comprises solubles, dried grains-200, and/or distillers dried grains.

In one embodiment, an article comprising a biopolymer comprises about 50 to about 70 wt% fermentation solids; and about 20 to about 50 wt% thermally active material.

In one embodiment, an article comprising a biopolymer comprises a thermally active material including thermoplastics, thermosets, and resins, adhesive polymers, polyethylene, polypropylene, polyvinyl chloride, epoxy material, at least one of melamine, polyester, phenolic polymer, and urea-containing polymer.

In one embodiment, the article comprising a biopolymer is in the form of a monolithic biopolymer, a complex biopolymer, or an aggregated biopolymer.

In one embodiment, the article comprising the biopolymer is in the form of a composite biopolymer having a granite-like appearance.

In one embodiment, articles comprising biopolymers include dyes, pigments, hydrolyzing agents, plasticizers, fillers, preservatives, antioxidants, nucleating agents, antistatic agents, biocides, fungicides, fireproofing agents agent, flame retardant, heat stabilizer, light stabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, crosslinking agent, blowing agent, and at least one of recycled plastics .

In one embodiment, an article comprising a biopolymer includes at least one of a plasticizer, a light stabilizer, and a coupling agent.

One method of making an article includes forming the article from a composition comprising from about 5 to about 95% by weight fermentation solids and from about 0.1 to about 95% by weight thermally active material. A method may further comprise one of extrusion molding, injection molding, blow molding, compression molding, transfer molding, thermoforming, casting, calendering, low pressure molding, high pressure lamination, reaction injection molding, foam molding, and coating or more.

A method of making a biopolymer wood substitute, window or door component, or siding component may include heating the biopolymer; applying pressure to the heated biopolymer; shaping the biopolymer; and cooling the biopolymer to maintain the shape of the article. A method may further include applying a surface texture to the article. Shaping the biopolymer can include injection molding, extruding the biopolymer through a die to produce an extrudate, or other methods. The step of applying can include extruding the article, which can include expelling water from the biopolymer. In one embodiment, the method may include forming hollow and/or foamed portions in the wood substitute, window, door, siding component, the hollow or foamed portion providing an increased R-value of the article or component .

Brief description of the drawings

Figure 1 shows a window assembly.

Figure 2 shows a cross-section of a window assembly.

Figure 3 shows a foam extruded product.

Figure 4 shows a door assembly.

Figure 5 shows a partially hollow extrudate.

Figure 6 shows a wood substitute that looks like wood.

Figure 7 shows a sheet product.

Figure 8 shows a siding product for building construction.

FIG. 9 shows a rear perspective view of the siding product of FIG. 8 .

Figure 10 shows a siding product including an interior region which may be foam or hollow.

Figure 11 illustrates a method of processing a biopolymer composition.

Figure 12 illustrates a method of forming an article from a biopolymer.

Figure 13 is a front perspective view of a trim system.

Figure 14 is a front perspective view of the base member and support.

Figure 15 is a front perspective view of the column and base components.

Figure 16 is a front perspective view of the column, base member, and top cover.

Figure 17 is a front perspective view of components of the railing assembly.

18 is a side view of components of a railing assembly.

Figure 19 is a side view of the railing assembly with rail cover.

Figure 20 is a perspective view of the base.

Figure 21 is a top view of the panel assembly.

Fig. 22 is a cross-sectional view of a corner.

Figure 23 is a perspective view of the top cover.

Figure 24 is a top view of a railing post.

Figure 25 is a side view of the lower rail.

Figure 26 is a side view of the cross bar cover.

Detailed description of the invention

definition

The term "biopolymer" as used herein means a material comprising thermally active materials and fermentation solids.

The term "fermentation solids" as used herein means solid material recovered from a fermentation process, such as the production of alcohol (eg, ethanol).

The term "fermented protein solids" as used herein means fermented solids recovered from the fermentation of a protein-containing material. The fermented protein solids also include protein.

As used herein, the term "distillers dried grains" (DDG) means the dry residue remaining after starch in a grain, such as corn, has been fermented with selected yeasts and enzymes to produce products including ethanol and carbon dioxide. DDG may contain a balance of solubles, for example about 2 wt%. Dried grain distillers grains contain a composition called distillers grains and waste solids.

The term "dried distillers grains with solubles" (DDGS) as used herein means the soluble fraction of the crude material remaining after fermentation of starch in cereals (such as corn) plus the residue left after fermentation that has been concentrated by evaporation to produce solubles dry preparations. The solubles can be added to DDG to form DDGS.

As used herein, the term "wet cake" or "wet grain distillers grains" means the crude wet residue remaining after starch in a grain, such as corn, has been fermented with selected yeasts and enzymes to produce products including ethanol and carbon dioxide.

As used herein, the term "solvent washed wet cake" means a wet cake that has been washed with a solvent such as water, alcohol or hexane.

The term "gluten meal" as used herein means the by-product of wet milling starch from plant material such as corn, wheat or potato. Corn gluten meal can also be a by-product of the conversion of starch from whole or various fractions of dry ground corn to corn syrup. Gluten meals contain prolamins and gluten (a mixture of water-insoluble proteins found in most grains) with small amounts of fat and fiber.

The term "plant material" as used herein means all or part of any plant (eg grain), typically a starch-containing material. Suitable plant materials include grains such as corn (e.g., whole ground corn), sorghum (milo), barley, wheat, rye, rice, millet, oats, soybeans, and other grain or leguminous crops; and starchy root crops , tubers, or roots such as sweet potatoes and cassava. The plant material may be such materials and by-products of such materials such as corn fiber, corn cobs, post-harvest crop feed stock (stover), or other fibrous and semi-fibrous materials such as wood or plant residues. mixture. Preferred plant materials include corn, standard corn or waxy corn. Preferred plant materials are fermentable to produce fermented solids.

The term "prolamin" as used herein means any of a group of globular proteins found in plants such as cereals. Prolamins are generally soluble in 70-80% alcohol but insoluble in water and absolute alcohol. These proteins contain large amounts of glutamic acid and proline. Suitable prolamins include gliadins (wheat and rye), zeins (corn), and kafirins (sorghum and millet). Suitable gliadins include alpha-, beta-, gamma-, and omega-gliadins.

The term "zein" as used herein means a prolamin protein found in corn which has a molecular weight of about 40,000 (eg 38,000) and is free of tryptophan and lysine.

The term "glass transition point" or "Tg" as used herein means the temperature at which particles of a material, such as fermentation solids or thermally active materials, reach a "softening point" so that they become viscoelastic and can be more easily compacted. Below Tg the material is in a "glassy state", having a form that does not deform easily under simple pressure. As used herein, the term "melting point" or "Tm" means the temperature at which a material (eg, fermentation solids or thermally active material) melts and begins to flow. Suitable methods for measuring these temperatures include differential scanning calorimetry (DSC), dynamic mechanical thermal analysis (DTMA), and thermomechanical analysis (TMA).

As used herein, weight percent (wt%) and % by weight and the like mean the concentration of a substance expressed by dividing the weight of the substance by the weight of the composition and multiplying by 100. Amounts of ingredients mean the amount of active ingredient unless otherwise stated.

The term "about" used herein to modify any amount is intended to mean variations in the amount encountered under actual conditions for producing polymers or composites or the like, eg, in a laboratory, pilot plant, or production facility. For example, the amount of an ingredient used in a mixture when modified by approx. includes the degree of care employed in variation and measurement in the equipment or laboratory in which the material or polymer is produced. For example, quantities of product components when modified by approx. include variations between equipment or laboratory batches and variations inherent in analytical methods. Whether or not modified by about, stated amounts include equivalents to those amounts. Any amount mentioned herein and modified by "about" may also be used in the present invention as an amount not modified by about.

biopolymer

The present invention relates to biopolymers comprising one or more fermentation solids and one or more thermally active materials. The biopolymers of the invention may exhibit properties characteristic of plastic materials, properties superior to conventional plastic materials, and/or properties superior to aggregates comprising plastics and eg wood or cellulosic materials. The biopolymers of the present invention can be constructed into useful articles by any of a variety of conventional methods of forming articles from plastics. The biopolymers of the invention can take any of a variety of forms.

In one embodiment, the biopolymers of the invention comprise fermentation solids integrated with a thermally active material. Biopolymers comprising fermentation solids integrated with thermally active materials are referred to herein as "monolithic biopolymers." The bulk biopolymer may include covalent linkages between the thermally active material and the fermentation solids. In one embodiment, the monolithic biopolymer forms a homogeneous mass in which fermentation solids have been blended into the thermally active material.

In one embodiment, the biopolymer of the invention comprises visible residual fermentation solids. Biopolymers comprising visible residual fermentation solids are referred to herein as "complex biopolymers". The composite biopolymer may have a granite appearance, a matrix of thermally active material having a first appearance surrounding fermented solid particles having a second appearance. In one embodiment, even in complex biopolymers, the majority of the fermentation solids can be blended in and/or associated with the thermally active material. In one embodiment, the complex biopolymer having a granite appearance can form a single substance from which fermentation solids cannot be removed.

In yet another embodiment, the biopolymer of the present invention comprises a plurality of fermentation solids in the form of discrete particles surrounded by or embedded in a thermally active material. Biopolymers comprising discrete particles of fermented solids surrounded by or embedded in a thermally active material are referred to herein as "aggregate biopolymers." In this aggregated biopolymer, the bulk of the fermentation solids in the form of discrete particles can be considered a bulking agent or filler. However, small amounts of fermentation solids may be blended in and/or combined with the thermally active material.

In one embodiment, the composite fermentation solids and thermally active material (ie, soft or raw biopolymer) is in the form of a dough prior to hardening, which may be substantially homogeneous. As used herein, a "substantially homogeneous" dough means a material with a consistency similar to a baked dough (eg, bread or cookie dough) with most of the fermentation solids incorporated into the thermally active material and no longer present as separate particles. In one embodiment, the soft or raw biopolymer contains no detectable fermentation solids, eg, is a homogeneous dough. In one embodiment, the soft or raw biopolymer may comprise up to 95% by weight (eg 90% by weight) of fermentation solids in the form of a substantially homogeneous or homogeneous dough. In one embodiment, the soft or raw biopolymer may comprise from about 50 to about 70 wt% fermentation solids in the form of a substantially homogeneous or homogeneous dough.

In one embodiment, the feedstock or soft biopolymer comprises appreciable amounts of fermentation solids. Visible amounts of fermentation solids, as used herein, means particles that are clearly visible to the naked eye, giving the immobilized biopolymer a granite-like appearance. The visible fermented solids can be colored for decorative effects in immobilized biopolymers. The granite-like appearance can be produced by using fermented solids that are larger in particle size than would produce a homogeneous or substantially homogeneous dough.

In certain embodiments, the biopolymer may comprise about 0.01 to about 95 wt%, about 1 to about 95 wt%, about 5 to about 95 wt%, about 5 to about 80 wt%, about 5 to about 70 wt%, about 5 to about 20 wt%, about 50 to about 95 wt%, about 50 to about 80 wt%, about 50 to about 70 wt%, about 50 to about 60 wt%, about 60 to about 80 wt%, or about 60 to about 70 wt% fermentation solid. In certain embodiments, the biopolymer may comprise about 5 wt%, about 10 wt%, about 20 wt%, about 50 wt%, about 60 wt%, about 70 wt%, or about 75 wt% fermentation solids. The biopolymers of the invention may comprise any of these amounts or ranges unmodified by about.

In certain embodiments, the biopolymer may comprise about 0.01 to about 95 wt%, about 1 to about 95 wt%, about 5 to about 30 wt%, about 5 to about 40 wt%, about 5 to about 50 wt%, about 5 to about 85 wt%, about 5 to about 95 wt%, about 10 to about 30 wt%, about 10 to about 40 wt%, about 10 to about 50 wt%, or about 10 to about 95 wt% thermally active material. In certain embodiments, the biopolymer may comprise about 95 wt%, about 75 wt%, about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt%, about 25 wt%, about 20 wt%, About 15 wt%, about 10 wt%, or about 5 wt% thermally active material. The biopolymers of the invention may comprise any of these amounts or ranges unmodified by about.

In certain embodiments, the biopolymer may comprise from about 5 to about 95 wt% fermentation solids and from about 5 to about 95 wt% thermally active material, and may comprise from about 50 to about 70 wt% fermentation solids and from about 30 to about 70 wt% thermally active material. material, which may comprise from about 50 to about 70 wt% fermentation solids and from about 20 to about 70 wt% thermally active material, may comprise from about 50 to about 60 wt% fermentation solids and from about 30 to about 50 wt% thermally active material, or may comprise from about 60 to about 70 wt% % fermentation solids and about 20 to about 40 wt % thermally active material. In certain embodiments, the biopolymer may comprise about 5 wt% fermentation solids and about 70 to about 95 wt% thermally active material, about 10 wt% fermentation solids and about 70 to about 90 wt% thermally active material, about 50 wt% fermentation solids and about 30 to about 50 wt% thermally active material, about 55 wt% fermentation solids and about 30 to about 45 wt% thermally active material, about 60 wt% fermentation solids and about 20 to about 40 wt% thermally active material, about 65 wt% fermentation solids and about 20 to about 40 wt% Thermally active material, about 70 wt% fermentation solids and about 10 to about 30 wt% thermally active material, about 90 wt% fermentation solids, and about 5 to about 10 wt% thermally active material. The biopolymers of the invention may comprise any of these amounts or ranges unmodified by about.

Specific embodiments of biopolymers

In one embodiment, the biopolymers of the present invention may have higher thermal conductivity than conventional thermoplastic materials. For example, in one embodiment, the biopolymers of the invention can be cooled or heated faster than thermally active materials without fermented solids. In one embodiment, the biopolymers of the invention can be cooled as rapidly as the device in which they are formed. While not limiting the invention, it is believed that this increase in thermal conductivity may be due to the nature of the fermentation solids. For example, increased thermal conductivity may result from the integration of fermentation solids with thermally active materials. For example, the increased thermal conductivity using fermented protein solids may be due to the interaction of the protein with the thermally active material.

In one embodiment, the biopolymers of the invention have a granite-like appearance. Biopolymers with a granitic appearance may contain larger particles of fermentation solids than the bulk biopolymer. For example, a biopolymer having a granite-like appearance can be formed from fermentation solids having a particle size of from about 2 to about 10 mesh. In one embodiment, the biopolymer comprising the larger fermented solids has flow properties suitable or even favorable for compounding and shaping. In one embodiment, the biopolymer comprising the larger fermentation solids is in the form of a complex biopolymer.

fermented solids

The biopolymers of the present invention may comprise any of a variety of fermentation solids. Fermentation solids can be recovered from various fermentation processes such as the production of alcohols (eg, ethanol). Fermentation solids can be recovered, for example, from fermentation of plant material. In one embodiment, fermented solids may be recovered from the fermentation of starch-containing plant material such as cereals (eg, cereals or legumes), starchy root crops, tubers or roots. In one embodiment, fermented solids (eg, fermented protein solids) may be recovered from the fermentation of plant materials comprising starch and protein, such as cereals (eg, cereals or legumes), starchy root crops, tubers, or roots. In one embodiment, fermentation solids are recovered from the fermentation of grain. For example, fermented solids known as "dried distillers grains" can be recovered from the fermentation of grain to ethanol.

Fermentation consumes carbohydrates such as starch in the plant material, resulting in a material with reduced starch content compared to the plant material. In one embodiment, the fermented solids comprise less wt% starch than the plant material used for the fermentation. In certain embodiments, the fermented solids comprise less than or equal to about 10 wt % carbohydrates, less than or equal to about 5 wt % carbohydrates, or less than or equal to about 2 wt % carbohydrates. Fermentation solids with greater than 10 wt% carbohydrates may be used in the biopolymers of the present invention.

Many fermented solids have been characterized primarily as animal feed. Fermentation solids that have been characterized include those known as distillers dried grains (DDG), distillers dried grains with solubles (DDGS), wet cake (WC), solvent washed wet cake (WWC), fractionated distillers dried grains (FDDG ), and gluten meal. Fermentation solids may contain, for example, protein, fiber, and optional fat. Fermentation solids may also contain residual starch.

For example, dry grain distillers grains with solubles in fermentation solids recovered from dry mill fermentation of corn may contain 30 wt% or more protein. For example, dry grain distillers grains with solubles in fermented solids recovered from conventional dry mill fermentation of corn may comprise about 30 to about 35 wt % protein, about 10 to about 15 wt % fat, about 5 to about 10 wt % fiber, and about 5 wt % to about 10 wt% ash. For example, dry grain distillers grains with solubles in fermented solids recovered from conventional dry mill fermentation of corn may comprise about 5 wt % starch, about 35 wt % protein, about 15 wt % fat, about 25 wt % fiber, and about 5 wt % ash. In one embodiment, the fermented solids comprise or are DDGS comprising about 30-38 wt% protein, about 11-19 wt% fat, and about 25-37 wt% fiber. In one embodiment, the fermentation solids comprise or are DDGS comprising about 10 wt% starch, about 35 wt% protein, about 15 wt% fat, about 30 wt% fiber, and about 5 wt% ash. This DDGS can be produced by fermentation of raw corn starch. The fermentation solids of the present invention may comprise any of these amounts or ranges unmodified by about.

Dried grain distillers grains or other dried plant material distillers grains can be derived from any of a variety of agricultural products. "Dried distiller's grain" as used herein in conjunction with a plant name or plant type means the fermented solids produced by the fermentation of that plant or plant type. For example, dry grain distillers grains means the fermented solids produced by the fermentation of grains. As a more specific example, distillers grains means the fermented solids produced by the fermentation of corn. Dried sorghum distiller's grains means fermented solids produced from the fermentation of sorghum (miloth millet). Distiller's grains means the fermented solids produced by the fermentation of wheat. Dried plant material distillers grains are not necessarily derived solely from the plant material in question. Rather, the plant material referred to is the predominant plant material or the only plant material in the fermented solids.

The biopolymers of the present invention may comprise any of a variety of fermented solids including, for example, distiller's grain dried grains, distiller's dried starchy root crop grains, distiller's dried grains of tubers, distiller's dried grains of root crops. Suitable dry grain distillers grains include dry grain distillers grains and dried leguminous distillers grains. Suitable dried grain distillers grains include dried corn distillers grains (e.g. dry whole ground distillers grains or dry graded corn distillers grains), dried sorghum (milo) distillers grains, dried barley distillers grains, dried wheat distillers grains, dried rye distillers grains, dried rice distillers grains, dried millet distillers grains , Dried oat distiller's grains, dried soybean distiller's grains. Suitable dried root distillers grains include dried sweet potato distillers grains and dried cassava distillers grains. Suitable dried tuber distillers grains include dried potato distillers grains.

The plant material may comprise the whole of a plant or a part of a plant. Alternatively, plants or plant parts can be graded. Fermentation solids derived from graded plant material are referred to herein as dry graded plant material distillers grains, such as dry graded grain distillers grains. The biopolymers of the present invention may comprise any of a variety of fractionated fermentation solids. For example, the biopolymers of the present invention may include dry graded distillers grains. For example, the biopolymers of the present invention may include DDG germ and/or DDG endosperm.

Dried grain distillers grains or other dried plant material distillers grains can come from any of a variety of fermentation processes. As the term implies, distiller's grains, a dry plant material, have been dried. Drying can be accomplished at elevated temperature within the fermentation plant or apparatus. Drying may include contacting the wet plant material distillers grains with air, which may be at a temperature of 1000 to 1500°F. Despite mixing with the hot air, the distiller's grains, the plant material, do not reach as high a temperature as the hot air. The plant material distillers grains can be tumbled or circulated with air. Thus, for example, after exposure to air of 1000 to 1500°F, the distiller's dried plant material may reach a temperature of only about 200°F (eg, at the outlet of the drying unit).

In certain embodiments, the fermented solids (e.g., fermented protein isolates) of the present invention reach no higher than about 500°F, about 400°F, about 300°F, about 250°F, about 200°F, or about 180°F. °F (e.g. at the outlet of a dryer). In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of not greater than about 500°F. In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of no greater than about 400°F. In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of not greater than about 300°F. In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of no greater than about 250°F. In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of not greater than about 200°F. In one embodiment, the fermented solids (eg, fermented protein isolate) of the present invention reach a temperature (eg, at the outlet of a dryer) of not greater than about 180°F. Fermentation solids of the present invention include any of these temperatures unmodified by about.

As used herein, "dried distiller's grain" followed by a number means fermented solids at or below this temperature (eg, at the outlet of a dryer). For example, Distillers Dried Grain-200 means distillers dried grains that have reached a temperature of 200°F or below (eg, at the outlet of a dryer). During some distillations, plant material may also be ground. Grinding warms the plant material. As used herein, "dried distillers grains" followed by a number with the suffix "gd" means fermented solids that have been ground and dried to this temperature or below (eg, at the outlet of a dryer). For example, Distiller's grain dry - 200gd means distiller's grain dry grain that has been ground and dried to a temperature of 200°F or below (eg, at the outlet of the dryer). Fermentation solids prepared using cryogenic grinding and/or drying are referred to herein as "mildly processed fermentation solids." Fermented protein solids prepared using cryogenic grinding and/or drying are referred to herein as "protein fermented solids". Suitable mildly processed fermentation solids include mildly processed DDG and mildly processed DDGS. Mildly processed fermented solids include fermented solids derived from a fermentation process without a cooking step.

Fermentation solids suitable for use in the biopolymers of the present invention can have a wide range of moisture contents. In one embodiment, the water content may be less than or equal to about 15 wt%, such as about 1 to about 15 wt%. In one embodiment, the water content may range from about 5 to about 15 wt%. In one embodiment, the water content may be from about 5 to about 10 (eg, 12) wt%. In one embodiment, the water content may be about 5 (eg, 6) wt%.

The biopolymers of the present invention may comprise or be prepared from any fermentation solid having a wide range of particle sizes. In certain embodiments, the particle size of the fermentation solids used in the biopolymer is from about 2 mesh to less than about 1 micron (e.g., from about 0.1 to about 0.01 micron), from about 2 to about 10 mesh, from about 12 to about 500 mesh , about 60 mesh to less than about 1 micron, about 60 mesh to about 1 micron, about 60 to about 500 mesh. Biopolymers comprising fermentation solids having a particle size of less than about 1 micron (eg, about 0.1 to about 0.01 micron) can be considered nanomaterials, or in some cases nanocomposites.

In certain embodiments, the fermented solids used in the biopolymer may be colored, ground and sieved (e.g., to a consistent particle size range), dried, or used to treat agricultural materials prior to mixing with thermally active materials. Any one of the known methods or have been subjected to such treatment before compounding.

In certain embodiments, the biopolymer may comprise about 0.01 to about 95 wt%, about 1 to about 95 wt%, about 5 to about 95 wt%, about 5 to about 80 wt%, about 5 to about 70 wt%, about 50 to about 95 wt%, about 50 to about 80 wt%, about 50 to about 70 wt%, about 50 to about 60 wt%, about 60 to about 80 wt%, or about 60 to about 70 wt% fermentation solids. In certain embodiments, the biopolymer may comprise about 5 wt%, about 10 wt%, about 50 wt%, about 60 wt%, about 70 wt%, or about 75 wt% fermentation solids. The biopolymers of the invention may comprise any of these amounts or ranges unmodified by about.

Fermentation solids suitable for use in the biopolymers of the present invention include those derived from a dry milling process known as the "raw starch" process. Raw starch methods for producing fermentable solids include those described in U.S. Patent Application No. 10/798,226 and U.S. Provisional Patent Application No. 60/552,108, filed March 10, 2004, entitled "Process for Ethanol Production from Raw Starch." methods, all of which are incorporated herein by reference.

Specific embodiments of fermented solids

While not limiting the invention, it is believed that in certain embodiments the fermented solids (eg, fermented protein solids) of the present invention may be advantageously suitable for the formation of biopolymers. For example, in one embodiment, the fermented solids (e.g., fermented protein solids) of the present invention can be characterized by a glass transition point (Tg) and/or a softening point (Tm) or can have a glass transition point (Tg) and/or Softening point (Tm). For example, in one embodiment, the fermented solids (eg, fermented protein solids) of the invention can form bulk biopolymers. While not limiting the invention, it is believed that one embodiment of the monolithic biopolymer may include covalent linkages between the fermentation solids (eg, fermented protein solids) and the thermally active material. As a further example, in one embodiment, the fermented solids (eg, fermented protein solids) of the present invention are believed to impart desirable thermal conductivity (eg, advantageously rapid heating and cooling) to biopolymers.

While not limiting the invention, it is believed that in certain embodiments, the fermented solids of the present invention (eg, fermented protein solids such as DDG or DDGS) can be characterized by two temperatures - a glass transition point (Tg) and a softening point (Tm). In one embodiment, the fermentation solids may be complexed at a temperature at which they exhibit viscoelasticity, eg, between Tg and Tm. In one embodiment, the fermentation solids can be complexed at a temperature at which they have melted or can melt, eg, at or above the Tm. In one embodiment, the biopolymer comprises a thermally active material with a melting point lower than about Tg of the fermentation solid. In one embodiment, the biopolymer comprises a thermally active material with a melting point lower than about the Tm of the fermentation solid. In one embodiment, the fermentation solid may have a Tm approximately equal to that of the polymer.

While not limiting the invention, it is believed that complexing fermented solids with thermally active materials at temperatures below the Tg and/or Tm of the fermented solids does not produce bulk biopolymers or soft or raw biopolymers in the form of doughs. Polymer. DDG from the raw starch hydrolysis ethanol process is believed to have a Tm of about 150°C.

The Tm of a fermented solid (eg, a fermented protein solid such as DDG or DDGS) may be related to its oil or syrup (eg, solubles) content from plant material or other additives. In one embodiment, the Tm of the fermented solids (eg, fermented protein solids such as DDG or DDGS) can be selected by controlling the amount of oil or syrup (eg, solubles) in the feed. For example, it is believed that high levels of oil or syrup (eg, solubles) lower Tm and Tg, and low levels of oil or syrup (eg, solubles) increase Tm.

The Tm of a fermented solid (eg, a fermented protein solid such as DDG or DDGS) may be related to its plasticizer (eg, water, liquid polymer, liquid thermoplastic, or fatty acid, etc.) content. In one embodiment, the Tm of a fermented solid (eg, a fermented protein solid such as DDG or DDGS) can be selected by controlling the amount of plasticizer in the feed. For example, it is believed that high levels of plasticizer lower Tm and Tg, and lower levels of plasticizer increase Tm.

While not limiting the invention, it is believed that complexing the biopolymers of the invention at temperatures between the Tg and Tm of the fermentation solids facilitates the interaction between the thermoactive material and the fermentation solids, resulting in biopolymers with beneficial properties. things. In one embodiment, the selected temperature may also be above the melting point of the thermally active material to be suitable for compounding with the thermally active material. In certain embodiments, the Tg and Tm of the fermentation solids allow for compounding with higher melting point polymers such as polyethylene terephthalate (PET), polycarbonate, and other engineering plastics.

While not limiting the invention, it is believed that the fermented solids (eg, fermented protein solids such as DDG or DDGS) of the present invention may comprise plant material that facilitates processing. Fermenting the plant material removes most of the starch and carbohydrates. Fermentation is believed to hydrolyze proteins. It is believed that proteolysis may provide functional groups capable of covalently interacting with thermally active materials, which may impart beneficial properties to the resulting biopolymers. It is also believed that, in certain embodiments, fermentation can render the protein less soluble in water.

While not limiting the invention, it is believed that in certain embodiments, the biopolymers of the present invention may comprise fermented solids (e.g., fermented protein solids such as DDG or DDGS) that advantageously comprise high levels of prolamins found in grains. ). These prolamins include zeins (eg, zein) and kafirins (eg, sorghin).

While not limiting the invention, it is believed that in certain embodiments, the biopolymers of the invention may comprise fermentation solids recovered from a fermentation process in which the material was in the presence of a relatively high concentration of alcohol. For example, in one embodiment, the fermentation solids of the present invention are recovered from a fermentation process in which the alcohol concentration in beer reaches or exceeds about 60% by weight. For example, in one embodiment, the fermentation solids of the present invention are recovered from a fermentation process in which the alcohol concentration in the fermenter is at or above about 19, about 20, or about 21 vol%. While not limiting the invention, it is believed that such high alcohol concentrations can produce fermentation solids with increased prolamin content.

In one embodiment, the biopolymers of the present invention may comprise fermentable materials such as fermented solids with reduced starch content. In one embodiment, fermented solids may be produced by fermenting fractionated plant material. For example, removal of the bran and/or germ fraction prior to fermentation can concentrate prolamins (eg, zein) in the plant material and resulting fermented solids. Corn endosperm contains zein. While not limiting the invention, it is believed that fermentation of the corn endosperm results in an increase in the zein content of the fermented solids.

In one embodiment, the biopolymers of the present invention may have more favorable flow characteristics than conventional thermoplastic materials. The melt flow index represents the flow ability of plastic materials. The higher the melt flow index, the more flowable the material is at a given temperature. Melt Flow Index can be measured by a standard test called MFR or MFI.

Briefly, the test consists of extruding a specified force (generated with precise weights) of heated plastic material through a circular die of fixed dimensions at a specified temperature. The amount of extruded thermally active material in 10 minutes is called MFR. This test is specified by ASTM D 3364, Standard Test Method for Plastics.

Most olefinic thermoplastics are tested at 230°C. The biopolymers of the present invention can achieve the melt index of homogeneous thermally active materials at lower temperatures. For example, consider a plastic with a melt index of 10 at 230°C. The plastic can be used as thermally active material in the biopolymers of the invention in amounts of only about 30 wt% thermally active material and about 70 wt% fermented solids (eg, fermented protein solids such as DDG or DDGS). The resulting biopolymer will have a melt index of about 10 at only about 160°C, which is much lower than 230°C. Also, the resulting biopolymer has a melt flow index significantly lower than 10 at 230°C. Such favorable flow properties allow the biopolymers of the invention to be processed at lower temperatures. Processing at lower temperatures saves energy and allows faster cooling.

In contrast, filled plastics such as wood/plastic, fiber-filled plastics, mineral-filled plastics, and other inert fillers generally lower the melt index of the thermally active material, resulting in poorer flow or greater force required to induce flow. Therefore, these conventional filled plastics are more difficult to process than pure plastics, and higher temperatures may be required for processing and maintaining melt flow index.

thermally active material

The biopolymer may comprise any of a variety of thermally active materials. For example, the biopolymer can comprise any thermally active material in which fermentation solids can be embedded. In one embodiment, the thermally active material may be selected for its ability to form a homogeneous or substantially homogeneous dough comprising fermentation solids. In one embodiment, the thermally active material can be selected for its ability to covalently bond to the fermentation solids. In one embodiment, the thermally active material can be selected based on its ability to flow when mixed or compounded with the fermentation solids. In one embodiment, the thermally active material can be set after shaping. Many such thermally active materials are commercially available.

Suitable thermally active materials include thermoplastics, thermosets, resins, adhesive polymers, and the like. As used herein, the term "thermoplastic" means a plastic material which, after hardening, can be melted and reformed. As used herein, the term "thermoset" material means a material (eg, a plastic material) that does not readily melt and reformat after hardening. As used herein, the term "resin and adhesive polymer" means a polymer that is more reactive or more polar than thermoplastics and thermosets.

Suitable thermoplastic materials include polyamides, polyolefins (such as polyethylene, polypropylene, ethylene-propylene copolymers, ethylene-α-olefin copolymers, polybutenes, polyvinyl chloride, acrylates, and acetates, etc.), Polystyrene (such as polystyrene homopolymer, polystyrene copolymer, polystyrene terpolymer, and styrene-acrylonitrile (SAN) copolymer), polysulfone, halogenated polymers (such as polyvinyl chloride , polyvinylidene chloride), or polycarbonate, etc., and copolymers and mixtures of these materials. Suitable vinyl polymers include those produced by homopolymerization, binary copolymerization, and terpolymerization. Suitable homopolymers include polyolefins such as polyethylene, polypropylene, poly-1-butene, etc., polyvinyl chloride, polyacrylates, substituted polyacrylates, polymethacrylates, polymethylmethacrylate, And copolymers and mixtures of these materials, etc. Suitable alpha-olefin copolymers include ethylene-propylene copolymers, ethylene-hexene copolymers, ethylene-methacrylate copolymers, ethylene-methacrylate copolymers, copolymers and mixtures of these materials, and the like. In certain embodiments, suitable thermoplastic materials include polypropylene (PP), polyethylene (PE), and polyvinyl chloride (PVC), copolymers and blends of these materials, and the like. In certain embodiments, suitable thermoplastic materials include polyethylene, polypropylene, polyvinyl chloride (PVC), low density polyethylene (LDPE), ethylene-vinyl acetate copolymers, copolymers and blends of these materials, and the like.

Suitable thermosetting materials include epoxy materials, melamine materials, copolymers and blends of these materials, and the like. In certain embodiments, suitable thermoset materials include epoxy materials and melamine materials. In certain embodiments, suitable thermosetting materials include epichlorohydrin, bisphenol A, diglycidyl ether of 1,4-butanediol, diglycidyl ether of neopentyl glycol, diglycidyl ether of cyclohexanedimethanol Glyceryl ethers, aliphatic; aromatic amine hardeners such as triethylenetetramine, ethylenediamine, N-cocoalkyltrimethylenediamine, isophoronediamine, diethyltoluenediamine, triethylenediamine, (dimethylaminomethylphenol); carboxylic anhydrides such as methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, maleic anhydride, polyazelaic acid polyanhydride and phthalic anhydride, and these mixture of materials, etc.

Suitable resins and adhesive polymeric materials include resins such as polycondensed materials, vinyl polymeric materials and alloys thereof. Suitable resinous and adhesive polymer materials include polyesters (such as polyethylene terephthalate, and polybutylene terephthalate, etc.), methyl diisocyanate (polyurethane or MDI), organic isocyanates Compounds, aromatic isocyanides, phenolic polymers, urea-based polymers, and copolymers and mixtures of these materials. Suitable resin materials include acrylonitrile-butadiene-styrene (ABS), polyacetyl resins, polyacrylic resins, fluorocarbon resins, nylon, phenoxy resins, polybutene resins, polyarylethers such as polyphenylene Ether, polyphenylene sulfide materials, polycarbonate materials, chlorinated polyether resins, polyethersulfone resins, polyphenylene ether resins, polysulfone resins, polyimide resins, thermoplastic polyurethane elastomers, and copolymers of these materials and mixtures etc. In certain embodiments, suitable resinous and adhesive polymeric materials include polyesters, methyl diisocyanate (polyurethane or MDI), phenolic polymers, and urea-based polymers, among others.

Suitable thermally active materials include polymers from renewable resources, such as polymers including polylactic acid (PLA) and a class of polymers known as polyhydroxyalkanoates (PHA). PHA polymers include polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), and polyhydroxybutyrate-hydroxyvalerate copolymer (PHBV), polycaprolactone (PCL) (ie TONE) , polyesteramide (i.e. BAK), modified polyethylene terephthalate (PET) (i.e. BIOMAX), and "aliphatic-aromatic" copolymers (i.e. ECOFLEX and BASTAR BIO), and their mixture etc.

In certain embodiments, the biopolymer may comprise about 0.01 to about 95 wt%, about 1 to about 95 wt%, about 5 to about 30 wt%, about 5 to about 40 wt%, about 5 to about 50 wt%, about 5 to about 85 wt%, about 5 to about 95 wt%, about 10 to about 30 wt%, about 10 to about 40 wt%, about 10 to about 50 wt%, or about 10 to about 95 wt% thermally active material. In certain embodiments, the biopolymer may comprise about 95 wt%, about 75 wt%, about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt%, about 25 wt%, about 20 wt%, About 15 wt%, about 10 wt%, or about 5 wt% thermally active material. The biopolymers of the invention may comprise any of these amounts or ranges unmodified by about.

Specific Embodiments of Thermally Active Materials

In one embodiment, the biopolymers of the invention comprise a thermally active material provided in liquid (eg, MDI) form. The liquid thermally active material imparts beneficial properties to the biopolymer. MDI, organic isocyanides, aromatic isocyanides, phenol, melamine, and urea-based polymers can be considered polymers with high water content, which may be beneficial for extrusion. Such thermally active materials can be used to produce foam extrudates for lower weight applications.

additive

The biopolymers of the present invention may further comprise one or more additives. Suitable additives include one or more dyes, pigments, other colorants, hydrolyzing agents, plasticizers, fillers, extenders, preservatives, antioxidants, nucleating agents, antistatic agents, biocides, fungicides , fire retardant, flame retardant, heat stabilizer, light stabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, crosslinking agent, foaming agent, and recycled plastics, etc., or its mixture. Suitable additives include plasticizers, light stabilizers, and coupling agents, etc., or mixtures thereof. In certain embodiments, additives can be used to tailor the properties of the biopolymers of the invention for the end use. In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 20 wt % additives.

Hydrolyzing agent

Fermentation solids can be hydrolyzed with a superbasic aqueous solution containing a basic dispersant such as a strong inorganic or organic base. The base may be a strong inorganic base such as KOH, NaOH, CaOH, _NH4OH , slaked lime or combinations thereof. Hydrolysis can be achieved mechanically by heat and pressure. Hydrolysis can be achieved by lowering the pH of the mixture. Compounds such as maleic acid or maleated polypropylene can be added to the fermented solids. Maleated polypropylenes such as G-3003 and G-3015 from Eastman Chemicals are examples of hydrolyzing and/or linking materials. Fermentation solids and thermally active materials can be cross-linked by means of the hydrolysis process and the conditions of the molding process (high temperature and pressure). In one embodiment, the biopolymers of the present invention may optionally contain from about 0.01 to about 20 wt % hydrolyzing agent.

plasticizer

Conventional plasticizers can be used in the biopolymers of the present invention. Plasticizers can modify the properties of the biopolymer, for example making it more flexible and/or altering flow characteristics. The biopolymers of the present invention may contain plasticizers in amounts used in conventional plastics. Suitable plasticizers include natural or synthetic compounds such as at least one of the following: polyethylene glycol, polypropylene glycol, polyethylene-propylene glycol, triethylene glycol, diethylene glycol, dipropylene glycol, propylene glycol, ethylene glycol, glycerin, Glyceryl monoacetate, diglycerin, glycerol diacetate or triacetate, 1,4-butanediol, diacetin sorbitol, sorbitan, mannitol, maltitol, polyvinyl alcohol, Sodium cellulose glycolate, urea, cellulose methyl ether, sodium alginate, oleic acid, lactic acid, citric acid, sodium diethylsuccinate, triethyl citrate, sodium diethylsuccinate, 1,2 , 6-hexanetriol, triethanolamine, polyethylene glycol fatty acid ester, oil, epoxidized oil, natural rubber, other known plasticizers, and mixtures or combinations thereof, etc. In certain embodiments, the biopolymers of the present invention may optionally comprise from about 1 to about 15 wt % plasticizer, from about 1 to about 30 wt % plasticizer, or from about 1 to about 50 wt % plasticizer.

crosslinking agent

Crosslinkers have been found to reduce creep observed in plastic composite products and/or can alter water resistance. Cross-linking agents also have the ability to enhance the mechanical and physical properties of the biopolymers of the invention. Crosslinking as used herein means bonding the thermally active material to the fermentation solids. Crosslinking can be different from coupling agents that form bonds between plastic materials. Suitable crosslinking agents include one or more metal salts (such as NaCl or halite) and salt hydrates (to improve mechanical properties), formaldehyde, urea-formaldehyde, phenol and phenolic resins, melamine, methyl diisocyanate compounds (MDI), other binders or resin systems, and mixtures or combinations thereof. In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 20 weight percent crosslinker.

lubricant

In one embodiment, the biopolymers of the invention may contain a lubricant. Lubricants can alter the melting (melting) point during compounding, extrusion or injection molding to achieve desired processing characteristics and physical properties.

Lubricants can be classified as external, internal, and external/internal types. These classifications are based on the action of the lubricant on the melt in the following plasticizing screws or thermodynamic compounding devices. The external lubricant can play a good role in stripping from the metal surface, and lubricate between each particle or the surface of the particle and the metal parts of the processing equipment. Internal lubricants provide lubrication within the composition, for example between resin particles, and can reduce melt viscosity. Internal/external lubricants can provide both external and internal lubrication.

Suitable external lubricants include at least one of non-polar molecules or paraffins such as paraffin, mineral oil, polyethylene, mixtures or combinations thereof, and the like. Such lubricants can help the biopolymers of the present invention (eg, comprising PVC) to slide on the hot melt surfaces of dies, barrels, and screws without sticking and to help the gloss of the final product surface. Additionally, the external lubricant maintains the shear point and reduces overheating of the biopolymer.

Suitable internal lubricants include polar molecules such as at least one of fatty acids, fatty acid esters, metal esters of fatty acids, mixtures or combinations thereof, and the like. Internal lubricants are compatible with thermally active materials such as olefins, PVC, and other thermally active materials and fermented solids. These lubricants reduce melt viscosity, reduce internal friction and associated heat due to internal friction, and facilitate melting.

Certain lubricants may also be natural plasticizers. Suitable natural plasticizing lubricants include oleic acid, linoleic acid, polyethylene glycol, glycerin, stearic acid, palmitic acid, lactic acid, sorbitol, waxes, epoxidized oils (e.g. soybean oil), heat modified oils Embodied oil), and mixtures or combinations thereof, etc. at least one.

In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 10 wt % lubricant.

Processing aids

In one embodiment, the biopolymers of the invention comprise processing aids. Suitable processing aids include acrylic polymers and alpha-methylstyrene. These processing aids can be used with PVC polymers. Processing aids can reduce or increase melt viscosity and reduce uneven mold flow. In thermally active materials, it facilitates melting and acts like an internal lubricant. An increase in the content of processing aids usually results in lower processing temperatures for compounding, extrusion, and injection molding. In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 10 weight percent processing aids.

impact modifier

In one embodiment, the biopolymers of the invention comprise impact modifiers. Certain applications require higher impact strength than common plastics. Suitable impact modifiers include acrylics, chlorinated polyethylene (CPE), and methacrylate-butadiene-styrene (MBS), among others. These impact modifiers can be used with PVC thermally active materials. In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 10 weight percent impact modifier.

filler

The biopolymers of the present invention need not but can contain fillers. Fillers can reduce the cost of the material and in some embodiments can enhance properties such as hardness, rigidity, and impact strength. Fillers can improve the properties of the biopolymer, such as increasing thermal stability, increasing flexibility or bendability, and improving breaking strength. In one embodiment, the biopolymers of the present invention may be in the form of a cementitious substance that allows inert fillers (such as wood, fibers, glass fibers, etc.) to be bonded to petroleum-based thermally active materials. Fillers such as wood flour do not significantly improve the quality of filled plastics or biopolymers. Conventional fillers such as talc and mica increase the impact resistance of the biopolymers of the present invention, but increase weight and reduce extruder life. Glass fiber is used as a filler to significantly increase the strength of the product, but the cost is relatively high. In one embodiment, the biopolymers of the present invention may optionally contain from about 1 to about 50 weight percent filler.

Wood flour and some other fillers used in plastics are not thermally stable. Wood flour does not mix or cross-link with plastic, and the individual particles are surrounded by plastic under heat and pressure. Minerals, glass fibers, and wood flour are known as "inert" fillers because they do not cross-link or bond with the plastic. Also, wood or cellulose-based fillers cannot handle the thermal demands of most plastics processing, such as extrusion and injection molding. Additionally, wood flour filler reduces and retains moisture.

fiber

The biopolymers of the present invention may contain fiber additives. Suitable fibers include any of a variety of natural and synthetic fibers such as wood; agricultural fibers including flax, hemp, kenaf, wheat, soybean, switchgrass, or grass; fiberglass, Kevlar, carbon fiber, nylon Synthetic fibers; and at least one of mixtures or combinations thereof, and the like. Fibers can modify the properties of biopolymers. For example, longer fibers can be incorporated into biopolymer structures to impart higher flexural and rupture moduli. In one embodiment, the biopolymers of the present invention may comprise from about 1 to about 20 weight percent fibers.

Foaming agent

Even when produced in foam form, the biopolymer compositions of the present invention need not contain or employ blowing agents. However, for certain applications where the composition is to be produced in the form of a foam, the biopolymer may contain or employ a blowing agent. Suitable blowing agents include at least one of pentane, carbon dioxide, methyl isobutyl ketone (MIBK), acetone, and the like.

Preparation method of biopolymer

The biopolymers of the present invention can be prepared by any of a variety of methods that enable the mixing of thermoactive materials with fermentation solids. In one embodiment, the thermally active material and fermentation solids are compounded. As used herein, the verb "to compound" means to bring parts together into a whole and/or to combine parts (eg, thermally active material and fermentation solids) into shape. Any combination of fermented solids and various thermally active materials such as thermosetting and thermoplastic materials can be made. Any of various additives or other suitable materials may be mixed or compounded with fermentation solids and thermally active materials to prepare the biopolymers of the present invention. In one embodiment, the fermentation solids are compounded with a thermally active material to produce a dough-like material as previously described herein.

Compounding may include one or more of heating the fermentation solids and the thermally active material, mixing (eg, kneading) the fermentation solids and the thermally active material, and crosslinking the fermentation solids and the thermally active material. Compounding may include thermodynamic compounding, extrusion, or high shear mixing compounding, among others. In one embodiment, the fermentation solids are complexed with the thermally active material in the presence of a hydrolyzing agent.

The fermentation solids and thermally active material can be melted together to form a biopolymer or a biopolymer dough. In contrast, thermodynamic recombination of wood particles with a thermoactive material produces a material in which the wood particles are readily visible as individual particles suspended in a plastic matrix or as wood particles coated with plastic. Advantageously, the composite fermentation solids and thermally active material may be a homogeneous or nearly homogeneous mass.

The composite, raw or soft biopolymers may be used directly or may be formed into pellets, granules, or other convenient forms for conversion into articles by molding or other methods.

thermodynamic compounding

Thermokinetic compounding ("TKC") can mix and compound using high-speed thermokinetic principles. Thermodynamic compounding involves mixing two or more components at high shear rates with a high speed mixer. Suitable thermodynamic compounding devices are commercially available, eg Gelimat G1 (Draiswerke Company). Such systems may include computer controlled metering and weighing batch systems.

One embodiment of a thermodynamic compounding device includes a horizontally positioned mixer and a mixing chamber having a central axis of rotation. Several staggered mixing elements are mounted on the shaft at different angles. The exact number and location of the mixing paddles will vary with the size of the chamber. Predicted batches of thermally active material and fermented solids may be fed to the blender, for example, by an integral screw, which may be part of a rotating shaft. Alternatively, the thermally active material and fermented solids can be supplied through a sliding door located on the mixer body. The unit may include an automatically operated discharge door at the bottom of the mixing chamber.

Inside the mixing chamber, thermally active materials and fermentation solids experience extremely high turbulence due to the high tip speeds of the mixing elements. The thermally active material is thoroughly mixed with the fermentation solids and is also subjected to the temperature rise generated by the impingement chamber walls, the mixing paddles, and the material particles themselves. Friction in the moving particles rapidly heats and dehumidifies.

Impingement of the mixture of thermally active material and fermented solids inside the mixing chamber heats the material. For example, the mass can be heated to about 140 to about 250° C. for a short period of about 5 to about 30 seconds. Process cycle can be controlled by microprocessor. The microprocessor can monitor parameters such as energy, input, temperature, and/or time. When the microprocessor determines that the process is complete, the unit may open the discharge door to discharge the composite thermally active material and fermentation solids (the biopolymer). In one embodiment, the exiting composite thermally active material and fermentation solids are a homogeneously blended melt compound ready for immediate processing.

Using the previously described commercially available thermodynamic compounding unit, the energy expended for blending, dispersing and melting can be about 0.04 kW/lb product, compared to 0.06-0.12 kW/lb product with a standard twin-screw compounding system .

The composite thermally active material and fermentation solids (the biopolymer) can then be subjected to a regrinding process to produce a uniform granular material. This regrinding can utilize a standard knife milling system using a screen, which produces smaller uniform particles of similar size and shape. This granular material can be used, for example, in extrusion, injection molding, and other plastics processing.

In one embodiment, the TKC process exposes the thermally active material and fermentation solids to high temperature and shear stress for only a short period of time. The duration of TKC can be chosen to prevent or reduce thermal degradation.

In one embodiment, thermodynamic compounding is performed on a mixture of as little as 10 wt% thermoactive material and as much as 90 wt% fermentation solids. Such a high proportion of fermentation solids is difficult to compound with conventional twin-screw compounding systems. In one embodiment, using thermodynamic compounding, product formulations can be changed relatively quickly. The mixing chamber of the device can be kept clean while the fermented solids and thermally active material are compounded. In one embodiment, thermodynamic compounding devices can also be started and shut down faster than standard compounding systems that require time consuming shut down and cleaning procedures.

While not limiting the invention, thermodynamic recombination can rapidly raise the temperature of the material comprising the fermented solids to the boiling point of water, at which point the temperature rise is slowed by the evaporation of the water. Once the moisture content of the material in the mixing chamber drops to a few tenths of a percent, a rapid increase in temperature can occur until the Tm point of the mixture of thermally active material and fermented solids is reached. The residence time in the mixing chamber can be from about 10 to about 30 seconds. The residence time can be selected based on variables such as the diffusion constant time of the particles, and the initial water content.

Thermodynamic compounding of fermentation solids and thermoactive materials can produce desired biopolymers using different process parameters. In one embodiment, compounding continues until the material has reached or exceeded its Tm point.

In one embodiment, the thermodynamic compounding of the fermentation solids and the thermoactive material produces a soft or raw biopolymer in the form of a dough, which may be substantially homogeneous. For example, thermodynamic compounding can produce a mass with a consistency similar to a baked dough (such as bread or cookie dough), with most of the fermented solids being incorporated into the thermoactive material and no longer appearing as separate particles. In one embodiment, thermodynamic compounding produces a soft or raw biopolymer wherein greater than or equal to 70-90 wt% of the fermentation solids are homogenized into a dough. In one embodiment, thermodynamic complexation produces soft or raw biopolymers that contain no detectable fermentation solids.

In one embodiment, thermodynamic compounding allows the fermentation solids and thermally active material to melt together. In contrast, thermodynamic recombination of wood particles with a thermoactive material produces a material in which the wood particles are readily visible as individual particles suspended in a plastic matrix or as wood particles coated with plastic. Advantageously, in one embodiment, thermodynamic compounding allows for the compounding of the fermentation solids and thermally active material to form a homogeneous or nearly homogeneous bulk mass.

In one embodiment, thermodynamic compounding can produce feedstock or soft biopolymers that contain appreciable amounts of fermentation solids. Fermentation solids having a particle size of about 2 to about 20 mesh can be used for this compounding.

Thermodynamic compounding may include batch compounding the amounts or concentrations previously recited for the fermentation solids and thermoactive materials to suit the apparatus. In one embodiment, thermodynamic complexing is effective to complex fermentation solids with a small amount of thermally active material (eg, about 5 to about 10 wt % thermally active material) to produce a feedstock or soft biopolymer. The amount of this thermally active material is less than that used in conventional processes for compounding plant materials such as wood with thermally active materials.

compounding by extrusion

The biopolymers of the present invention may be formed by any of a variety of extrusion methods suitable for mixing or compounding fermentation solids with thermally active materials. For example, conventional extrusion methods such as twin-screw compounding can be used to prepare the biopolymers of the present invention. Compounding by extrusion can provide higher internal temperatures within the extruder to facilitate the interaction of the thermoplastic with the fermented solids. Twin-screw compounding can use co-rotating or counter-rotating screws. The extruder may include a vent to allow moisture or volatiles to escape from the compounded mixture. The biopolymer can be compounded and shaped using a die on the extruder.

Removal of water and other substances

Processing machinery (eg, extruders) can be configured to remove water or other substances (gases, liquids, or solids) during processing of the material to form the biopolymer. Water can be removed, for example, during twin-screw extrusion or during thermodynamic compounding. For clarity, the following refers to the removal of water, but it is understood that other liquids, gases or solids may also be removed, such as impurities, decomposition products, and gaseous by-products, etc.

In one embodiment, the water can be removed mechanically. For example, pressure can be applied during extrusion to force water out of the material. In one embodiment, compressing the material during extrusion can force water or other liquids or gases out of internal cells that may form in the material.

Heat can also be used to drain water and/or to dry the material. In one embodiment, heat may be applied during extrusion or during other mechanical drainage processes. In one embodiment, immediately after the extrusion or compression molding process, the biopolymer can be processed through a microwave or hot air drying system to remove the remaining water to reach the equilibrium point of the material. This is usually between 3-8% moisture content. High addition ratios of thermally active materials tend to lower the equilibrium point and further increase chemical bonding efficiency, which results in high water resistance and mechanical strength.

Water and other impurities or gases can also be removed from the biopolymer using vacuum or suction techniques. In one embodiment, thermal, vacuum, and mechanical techniques can be used together to expel water and other substances from the biopolymer. In one embodiment, closed cells can be ruptured by using one or more of heat, compression, and vacuum suction.

Techniques for draining water from polymeric materials are further described in US 6,280,667, incorporated herein by reference. This patent discloses a method and apparatus for processing plastics with wood filler. These methods and devices may also be used to process the biopolymers of the invention to constitute embodiments of the biopolymers of the invention.

Forming biopolymers into products

The present invention relates to articles made from or comprising biopolymers comprising fermentation solids and thermoactive materials. The biopolymers of the invention may exhibit properties characteristic of plastic materials, properties superior to conventional plastic materials, and/or properties superior to aggregates comprising plastics and eg wood or cellulosic materials. The biopolymers of the present invention can be formed into useful articles by any of a variety of conventional methods for forming articles from plastics. The biopolymers of the invention may take any form.

Biopolymer materials can be formed into a wide variety of objects and structures. In one embodiment, the material biopolymer may be formed into pellets fed to a machine configured for injection molding, extrusion, or otherwise forming or processing the biopolymer. In one embodiment, pellets can be formed by first driving the polymer and fermentation solids through a die to produce a linear extrudate and then cutting the extrudate into pellet shapes. In one embodiment, the pellets are of substantially uniform size and shape. The cross-section of the pellets can be any of various shapes, such as square, circular, oval, rectangular, pentagonal, hexagonal, etc., depending on the shape of the extrusion die. A circular cross-section may be preferred in many applications, typically with a radius of a few millimeters and a length of about 2 to 4 times the radius.

Although specific biopolymer products are described below, other products are possible. For example, biopolymers can be used in boat hulls, playground tables, storage containers, and crown moldings, among others.

Injection molding of biopolymers

Embodiments of the biopolymers of the present invention may be injection molded. In one embodiment, the complexed biopolymers can be ground into uniform pellets for the injection molding process. In one embodiment, the biopolymers of the invention can be processed with less energy (per pound) than conventional thermoplastic materials. In one embodiment, the biopolymers of the present invention can exhibit faster heating and cooling times during injection molding than conventional thermoplastics. In one embodiment, the biopolymer of the present invention maintains the melt index of the plastic and has flowability allowing high speed injection molding. For example, biopolymers comprising fermentation solids and polypropylene were observed to have higher thermal conductivity than pure polypropylene. Higher thermal conductivity results in faster heating and/or cooling, speeding up processes such as injection molding.

Injection molding techniques are known to those skilled in the art. In one embodiment, the machine can be configured to injection mold the biopolymer into a desired shape. The mold determines the shape into which the heated thermally active material is injected. The material is then allowed to cool before being ejected from the mold.

Extrusion of Biopolymers

The biopolymer of the present invention can be extruded by any of various conventional extrusion methods to form articles. For example, the biopolymers of the present invention can be extruded by a dry process. For example, the biopolymers of the present invention can be extruded with any of a variety of conventional die designs. In one embodiment, the process of extruding a biopolymer of the present invention to form an article may include feeding the biopolymer to a compounding auger and converting it to a size suitable for extrusion. Extrusion can use any of a variety of conventional dies and any of a variety of conventional temperatures. Compounding by extrusion provides higher internal temperatures within the extruder and facilitates the interaction between the thermoplastic material and the fermented solids.

An extruder with one or more dies can be configured to shape the biopolymer. The biopolymer can be driven through a die to produce a desired cross-section. The extruded biopolymer can then be cut to desired lengths as desired. The biopolymer can also be hardened or otherwise cured to retain the cross-sectional shape. The extruded biopolymer can then be cut into shorter lengths as required.

In one embodiment, the biopolymer material may be heated above its melting point. The biopolymer can then be moved through a converging die, the die heated to reduce shear stress in the biopolymer adjacent the walls, and then passed through the forming zone to provide the desired cross-section. In one embodiment, the biopolymer is then passed through a low-friction unheated or insulated section having the same or similar cross-section as the forming zone to create Builds cross-sectional memory and reduces swelling after extrusion. The biopolymer material can then be quenched below the melting point to form a shell. In certain embodiments, the shell allows the biopolymer to substantially maintain a desired shape.

In another embodiment, the machine can be configured to move the biopolymer through a transition die and then through a strand extrusion die to produce a strand of biopolymer. The machine can further be configured to move the strands through a molding die to combine the strands into the desired extrudate. In one embodiment, this extrusion of strands and recombination can produce a product that resembles wood grain in structure and/or appearance.

Co-extrusion materials with biopolymers

Other materials can be coextruded with the biopolymer. In one embodiment, a layer or sheet of another material, such as a coating or thermally active material, can be coextruded with the biopolymer. In one embodiment, the coextruded layer or sheet can provide desired surface properties, structural properties, and/or appearance.

Foaming of biopolymers

In one embodiment, the biopolymers of the present invention can be foamed from their soft, raw form or when melted without the addition of foaming agents. Surprisingly, the biopolymers of the present invention can be foamed upon extrusion to produce rigid, firm, hardened foams even in the absence of blowing agents. While not limiting the invention, it is believed that the foam of the present invention may be the result of protein foaming in the fermented solids.

The rigid or rigid foam can exhibit greater strength (eg, flexural modulus) than conventional foam of the same density. Conventional plastics lose strength when foamed. While not limiting the invention, it is believed that the biopolymer foams of the present invention may contain denatured proteins that interact with thermally active materials to produce beneficially strong biopolymer foams.

The biopolymers of the present invention (eg, in pellet form) can be converted into biopolymer foams by injection molding, extrusion, and similar methods used for plastic molding. While not limiting the invention, it is believed that the heat and kinetic energy applied during these processes, eg, by mixing screws, is sufficient to foam the biopolymers of the invention. In injection molding, the mold may be partially filled to allow foaming of the biopolymer to fill the cavity. This reduces the density of molded parts without the use of chemical blowing agents. Extrusion can also be used to foam the biopolymers of the invention. The die used in extrusion allows the foamed biopolymer to be shaped.

In one embodiment, foaming agents can be mixed with fermentation solids and thermally active materials to produce foamy biopolymers. In one embodiment, the biopolymer can be foamed without being pre-constructed into pellets by mixing the fermentation solids and thermally active material with a powdered foaming agent, heating and compounding the mixture , and then extruding the biopolymer. In one embodiment, vacuum can be used to remove the vapors. In one embodiment, greater expansion occurs in the center of the extruded profile than at the perimeter of the profile, so that the extruded product is denser near the exterior than the interior.

It may be desirable to process the biopolymer composition into fine particles to enable effective foaming. In one embodiment, the ingredients can first be processed into a biopolymer product, which can then be ground into fine particles to facilitate foaming into the shape of a foam product.

In one embodiment, foamed biopolymers can be produced by creating discontinuities within the biopolymer material. The discontinuity is expanded and then the biopolymer is stabilized by cooling or crosslinking to maintain the discontinuity. In one embodiment, foaming agents such as inert gases (such as nitrogen or carbon dioxide, hydrocarbons, chlorinated hydrocarbons, chlorofluorocarbons) or compounds that are dissolved or dispersed in the biopolymer in a liquid state and decompose into inert gases at elevated temperatures can be used. Decomposable chemical blowing agents for the preparation of biopolymers. Concomitant expansion of the blowing agent or decomposing chemical blowing agent expands the cell structure to form the foam biopolymer. This foaming process can be controlled by controlling extrusion temperature and other parameters.

One embodiment of a foam component includes a dense outer layer or shell and an interior formed from a foamed biopolymer. Foamed biopolymer parts can be constructed to provide lower weight and higher stiffness than dense parts. For example, foamed biopolymers can be formed into, for example, sized lumber, posts, beams, trim, moldings, furniture boards, and veneer parts. It may be desirable to form the part with a specific gravity lower than water so that the part is buoyant or close to the density of wood. Window or door components can also be constructed from foamed biopolymers. Combination hollow and foam core components are also possible.

Process parameters and structural parameters

In one embodiment, the biopolymer blend can provide higher flow or lower viscosity than typical blends using dry fibers and thermally active materials. This allows processing at significantly lower pressures during extrusion or injection molding. For example, pressures for compression molding conventional fiber/polymer materials can typically be in the range of 500-1000 psi. In contrast, in one embodiment, the biopolymers of the present invention can achieve maximum density at pressures below 150 psi. In one embodiment, the motor load for processing the biopolymers of the invention can be reduced from 50% of conventional polymers to 10% of the polymers of the invention.

The lower compression pressure requirements of the biopolymer embodiments of the present invention may allow for greater changes in the design and construction of compression or extrusion equipment for the biopolymers and reduce the cost of such equipment. In one embodiment, the equipment for processing the biopolymers can also be configured at lower processing temperatures. In one embodiment, the processing temperature can be reduced from 400°F for conventional polymers to 320°F for one embodiment of the biopolymer of the present invention.

The mechanical properties of a wood substitute (or other structure) can be quantified and tested for various parameters. The composition and production method of biopolymers can be controlled to obtain the desired combination of properties. Properties that may be considered include density, surface hardness, shear strength and flexural properties, retention (retaining nails, screws, or other fasteners), strip-out properties, thermal expansion system, and Young's modulus. In one embodiment, structural parameters can be controlled by varying the content of fermentation solids in the biopolymer.

Specific implementations illustrated

Figures 1-8 illustrate examples of structural embodiments that can be formed from biopolymers.

Sheet products

The biopolymers of the present invention can be configured into sheets. FIG. 7 shows one embodiment of a sheet product 700 . One embodiment of the sheet product can be configured to be textured and/or printed to simulate other materials.

structural member

In one embodiment, biopolymers can be configured as structural members. In one embodiment, structural members may be fabricated to mimic the performance and/or appearance of other materials. For example, in one embodiment, the biopolymers can be used to make structural members of assemblies typically constructed of wood, plastic, or metal, such assemblies being shown in FIGS. 1 and 2 . In one embodiment, the biopolymer can be configured into a wood replacement member, such as the wood replacement member 600 shown in FIG. 6 . The core 610 of the wood replacement member 600 may comprise solid biopolymer, foamed biopolymer, hollow pores, struts, webs, or combinations thereof. The wood replacement members may be sized according to common industry parameters such as 2x4, 2x2, and 2x6.

Sheets can also be formed from biopolymers to replace wood. For example, biopolymers can be formed into 4x8 sheets to replace standard plywood. It can also be formed into other types of sheets.

Biopolymers can also be shaped into more specialized wood replacement components or other structural components, including those with more complex shapes. A typical sheet is shown in FIG. 7 .

Components for window and door assemblies

In one embodiment, the biopolymers of the invention can be formed into door and window components. Figure 1 shows a window assembly, the components of which may be constructed from biopolymers. Window assembly 100 includes frame 25, which may be formed from top beams 30, bottom beams 35, and jambs 40, all constructed of the biopolymer material. The window frame 45 may be formed from rails 50 and mullions 55 . Crossbars 50 and mullions 55 may also be constructed from the biopolymer. The muntins 60, frame 65, and facing member 70 (shown in FIG. 2) may also be constructed from the biopolymer. Although Figure 1 shows a double-hung window, other types of window assemblies can also be constructed from the described biopolymers, including but not limited to vertical hinged windows, canopy skylights, fixed frame cupola windows, transom windows, skylights, Assemblies for sliding, slope-entry, bow, and bay windows.

In one embodiment, a specially designed cross-sectional shape can be formed so that the biopolymer window or door components can fit together and mate with glass, veneer or other components. FIG. 5 shows an example of a member with a complicated shape. In one embodiment, biopolymer components can be assembled using thermal welding, in which the components are heated to fuse them together. In one embodiment, thermal welding can produce welds that are stronger and stiffer than typical assemblies made of wood members. In one embodiment, the weld can be finished with a tool to provide an even transition and/or an aesthetic appearance. The tool may be, for example, a knife, profiling tool, or other shaping tool. In one embodiment, the tool can be heated to partially melt the biopolymer resulting in a clean and clean weld.

Figure 2 shows a cross-section of a window. Solid parts 80, hollow parts 85, and sheet parts 90 can all be formed from the biopolymer. In certain embodiments, the part is formed with a hollow cross-section and at least one structural web to provide light weight and sufficient strength and durability to withstand everyday use. Embodiments of the window assembly may include foam components. One embodiment of the foam part shown in FIG. 3 has a dense shell 95 and a foam core 100 . The core 97 shown in Figure 3 may also be hollow or reticulated.

Figure 4 shows a door assembly. Components for standard doors, French doors, sliding patio doors, and other types of doors can be constructed from the biopolymer. The door assembly in FIG. 4 includes a frame 105 that includes a top beam 110 , a door post 115 and a bottom beam 120 . The door includes a panel 125 , a door frame 130 , and a door stile 135 . These components can all be constructed from the biopolymer material. Nonstructural trim and moldings can also be constructed from the biopolymers.

Biopolymer parts can be formed into hollow or semi-hollow configurations. In one embodiment, the part formed from the biopolymer comprises a shell or wall and one or more internal supports. Figure 5 shows a typical semi-hollow part that can be formed from the biopolymer material. The component includes an outer wall 200 having an inner surface 205 and an outer surface 210 . Grooves 215 or other pre-stressed tracks or features may be formed in the outer surface to adapt the interface to associated components. One or more inner supports 220 may be provided. One or more anchors 225 may also be provided. Anchors may be shaped to receive fasteners such as screws or bolts. A bonding surface 230 may also be provided to allow the biopolymer component to be thermally welded to other thermally active or biopolymer materials.

Siding Products

Siding products for building structures can also be constructed from the biopolymers. In one embodiment, the siding product may be provided in sheet form. Siding products can imitate stone or marble, for example.

In another embodiment, the siding product may be provided in the form of battens resembling wood, aluminum or vinyl siding. For example, FIG. 8 illustrates a siding product that includes longitudinal members 800 . 9 and 10 also show wall panel members 900,1000. In one embodiment, the biopolymer can be formed into longitudinal members having mating structures to connect adjacent members. For example, a tongue 810 and groove 820 arrangement may be used to connect a longitudinal member to a similar member located above or below. One embodiment of the longitudinal member may include reinforcing braces 930 or bracing webs 940 for added stiffness, as shown in FIG. 9 .

One embodiment of the wall panel member may include foam or hollow sections. FIG. 10 shows an embodiment 1000 with a foamed or hollow interior 1010 . Embodiments with hollow portions may also include webs for structural support, such as shown in FIG. 8 . Embodiments of foam or hollow sections can increase the R-value of the siding. Embodiments with foam or hollow sections can also make the panel members stiffer and exhibit less creep. A combination of at least two of foam, hollow portion, and mesh portion may also be included.

One embodiment of the wall plate assembly may include wall plate members that may be joined end-to-end by heat welding. The exposed surfaces of the siding components may be printed, coated, covered, or otherwise treated to improve weatherability and/or appearance, as described below.

Post and Railing Systems

Specific embodiments of structural members comprising biopolymer materials can be used to construct a wide variety of structures, including columns, rails, and decking systems, for use in a variety of settings, including porches, patios, entryways, gardens, Lawn, or as a key part (accent). In one embodiment, the posts and rails may be part of a trim system.

In a preferred embodiment of the post and railing system, the post consists of a base, corners, panels, and a cap. In one embodiment, the base may be configured to slide on a post coupled or secured to the ground or another structure. While a strut is not required, it provides beneficial structural support. In one embodiment, a plurality of panels may be interconnected by a plurality of corners to form a column. In one embodiment, four panels and four columns may be used to form a rectangular column. In other embodiments, other cylinder shapes can be formed, such as triangles, pentagons, hexagons, heptagons, and octagons, among others. Irregular columns are also OK: neither the panels nor the corners that shape the column need to be the same size.

In one embodiment, the posts may be configured to slide over or otherwise couple to the posts. The cylinder may also be coupled with the base. The column can also be fixed to the post, or the base can be fixed to the post. The canopy may then be mounted or otherwise coupled to the posts and/or columns. Caps can be in a variety of different forms, including functionally or aesthetically required forms. In one embodiment, the top cover is shaped as a substantially horizontal member having an inner body and first and second outer ends, and first and second first and second ends spaced from and inwardly disposed from said first and second ends of the horizontal member. two substantially vertical members.

Columns can be hollow, filled, partially filled, or foamed inside. In one embodiment, the post may have a hollow interior. In another embodiment, the columns have a partially filled interior, such as when the columns are secured to the roof but there is a distance or void between one or more panels and the columns. In a third embodiment, the uprights may have completely filled interiors, as when the uprights are secured to the roof and contact the panels. In other embodiments, the posts may have dense shells and foam, mesh, or supported interiors, or combinations thereof. The invention is not limited to these possible embodiments.

The panel may be a trim, desired color, material, or texture, and the like. In one embodiment, the panels may be of a transparent or translucent material such as stained glass or printed glass or plastic to give the appearance of stained glass. In one embodiment, a light source may be located within the column or column and may be configured to illuminate the transparent or translucent panels. In one embodiment, the light source is in the space between the column and the strut. In one embodiment, the corner pieces may constitute the frame of the trim panel.

In a preferred embodiment, the railing is formed from railing posts and rails. Multiple railing posts are placed between the upper and lower rails and then secured to the upper and lower rails. The rail cover is then secured to the upper rail to form a railing.

Structural members can be constructed in whole or in part from a variety of materials including biopolymers, wood, glass, and composites, and can be plated with brass, bronze, chrome, or gunmetal for unique looks and styles . The top cover can also be constructed of glass or other transparent or translucent material and be illuminated from the inside. Other lighting arrangements are also possible. The structural members may have various shapes. For example, the structural member may have rounded or sharp edges and may be circular or polygonal. The structural members can be produced in various ways, including injection molding or extrusion. The structural members may also be secured in various ways, including screwing, nailing, gluing, snapping, or snapping. Biopolymer parts can be heat welded together. The heat weld can be smoothed or otherwise featured with a knife, profiler, or other tool to provide an attractive appearance.

Illustrated embodiment of the post and railing system

Figures 13-26 illustrate examples of structural embodiments that may be formed from or comprise biopolymers of the invention.

13 is a front perspective view of an embodiment of a trim system, which may be composed of a corner 1 , a panel 2 , a railing post 3 , a rail 4 , a rail cover 5 , a base 6 , and a top cover 7 . The column body may include a corner 1, a panel 2, a base 6, and a top cover 7, and may be fixed on a railing, which may consist of a railing post 3, a rail 4, and a rail cover 5, as shown in Figure 13 .

FIG. 14 shows a front view of the base part, where the base 6 is slidable on the uprights 8 . Fasteners such as screws 9 can secure the base 6 to the posts 8 . A plurality of panels 2 can be connected to each other through a plurality of corners 1 to form a rectangular column. The column is slidable on the post 8 and can be mounted on the base 6 as shown in FIG. 15 . The top cover 7 can be mounted on the pillar 8 to form a column, as shown in FIG. 16 .

Figure 17 is a front view of the railing assembly. A plurality of baluster posts 3 may be placed between the upper rail 4 and the lower rail 4 as shown in FIG. 5 . The railing post 3 can be connected with the upper rail 4 and the lower rail 4 by eg screws 10, as shown in FIG. 18 . Cross bar cover 5 can be installed on the upper cross bar 4 of assembled railing to make railing, as shown in Figure 19.

Embodiments of structural components that may be used to form the structures of Figures 13-19 are shown in Figures 20-26. FIG. 20 is a perspective view of the base 6 . FIG. 21 is a top view of the panel part 2 . FIG. 22 is a cross-sectional view of the corner portion 1 . FIG. 23 is a perspective view of the top cover 7 . FIG. 24 is a top view of the railing post 3 . FIG. 25 is a side view of the lower cross bar 4 . FIG. 26 is a side view of the cross bar cover 5 .

Coating, Texture, and Appearance

The appearance of the biopolymer can be treated during or after molding. For example, a die or other surface used in molding may create a textured surface on the biopolymer article. Extrusion can coextrude an outer layer of polymer or other material with a biopolymer core. After shaping, the shaped biopolymer can be treated with multi-roll printing to impart the appearance of real wood or other desired printed textures or colors. After shaping, the shaped biopolymer can be treated with a thermosetting powder. The thermoset powder can be, for example, transparent, translucent, or fully colored. The powder can be thermally cured to form a coating suitable for interior or exterior use. The powder can also be textured to give, for example, the appearance and texture of natural wood.

In one embodiment, the biopolymer product can be powder coated, embossed, and/or printed to provide desired surface properties such as weather and UV resistance and/or surface effects such as wood grain color and texture.

In one embodiment, a protected biopolymer product can be formed. In one embodiment, the biopolymer product can be coated with a thermosetting powder that is baked to cure the powder into a high performance coating. The powder can be, for example, polyester, epoxy, acrylate, or other polymer or thermally active material, or combinations thereof. The coating can be clear, translucent, or fully pigmented. In one embodiment, the powder coated biopolymer product can be baked in an infrared or IR/UV oven. The coated product may be suitable for internal and external use.

In one embodiment, a thin layer of resin or other material may be applied to the surface. For example, one embodiment of the siding material can be fabricated with a resin overcoat for enhanced weather resistance. Adding a surface layer may also be suitable for other applications including, for example, interior applications where cleaning agents may come into contact (eg, tub or shower areas), and exterior applications such as architectural trim, shutters, lawn and garden equipment, decorative panels and signage, or yard furniture.

In one embodiment, the biopolymer product may be vinyl-coated or metal-coated.

The biopolymer product can be given the appearance and/or texture of wood (or other texture/appearance) by methods such as embossing or printing, or coextruding an outer layer with the biopolymer. For example, a siding assembly can be finished with a woodgrain look or texture. Sheet products may also be patterned and coated to provide a wood grain or other appearance. Other wood substitute products can also be processed to resemble specific woods (or stained woods) in grain and color.

In one embodiment, the biopolymer product may be passed through a multi-roll printing process to impart the appearance of real wood or other desired printed textures or colors, such as stucco, concrete, brick, stone, tile, clay, or metal. In other embodiments, the extrudates can be printed directly with gravure printing or embossing wheels. Color and grain combinations create the look and feel of natural wood. Other printing methods can also be used, including direct computer imaging. In one embodiment, printing or other methods can produce realistic wood textures such as maple, oak, cherry, fir, or other desired prints and textures. In one embodiment, the biopolymer material can be placed in a hot plate press during the curing process to both cure faster and imprint texture on the surface of the final product.

In one embodiment, the fermented solids are used together with a powder coating for the topical product to form a topical product. In one embodiment, the desired appearance can be printed on the topical product and/or textured in a stamper with a textured board to form a topical grade textured surface. In another embodiment, a durable product can be produced in a similar manner.

In another embodiment, the biopolymer can be printed and then coated to protect the printed surface. The biopolymer can be digitally printed, for example to impart a desired appearance such as the grain of a particular wood such as cherry. The biopolymer can then be powder coated to protect the printing surface. In one embodiment, a clear layer can be powder coated on the biopolymer to make the printed side visible.

In another embodiment, an outer layer is applied to the product. The outer layer may be, for example, a veneer, a wood grain overlay, a colored overlay, or other type of coextruded layer. The outer layer can provide a desired color, appearance, texture, weather resistance, or other properties.

In another embodiment, the biopolymer can be made to resemble granite in appearance. In one embodiment, the biopolymer may comprise visible particles of residual fermentation solids. Such complex biopolymers can result in a matrix of one appearance surrounded by particles of a different appearance, resulting in a granite appearance. In such complex biopolymers, a larger proportion of the fermentation solids may be blended in and/or associated with the thermally active material.

In another embodiment, particulate matter may be added to the biopolymer. Embodiments comprising particulate matter may be shaped to simulate the appearance of granite or other stone materials, or natural wood textures such as deknotted wood. In one embodiment, the particles can be fused into the biopolymer product, for example by mixing the particles during extrusion or compression molding. In one embodiment, the particles are insoluble in the polymer and remain separated such that the particulate material can be seen with the naked eye. In one embodiment, the particles are mixed in a polymer to obtain the desired aggregate appearance. In one embodiment, aggregated biopolymers can be machined, cut, drilled, or otherwise processed.

FIG. 11 shows a flowchart 1100 illustrating a method of producing an article. At 1110 a composition comprising about 5 to about 95 wt% fermentation solids and about 0.1 to about 95 wt% thermally active material is prepared. The composition is formed into 1120 articles by molding, injection molding, blow molding, compression molding, transfer molding, thermoforming, casting, calendering, low pressure molding, high pressure lamination, reaction injection molding, foam molding, and coating. In one embodiment, a coating 1130 may be applied to the article after shaping.

Figure 12 shows a flow diagram illustrating a method by which the biopolymers of the present invention can be made into wood substitutes, window or door components, or siding components. The biopolymer is heated 1210. Pressure is applied 1220 to the heated biopolymer. In one embodiment, heating and pressure can be applied simultaneously or pressure can be initiated first. The heated biopolymer is shaped 1230 to form an article or part. In one embodiment, the biopolymer can be shaped by extrusion or injection molding 1240 . In one embodiment, the article can be pressed by pressing 1260 the article or part. In one embodiment, pressing the biopolymer expels water 1270 therefrom. For example, pressing can produce sheet products or other products or can prepare biopolymers for subsequent extrusion or injection molding. In one embodiment, other processing may be performed during and after shaping, including, for example, further shaping, cutting, machining, or surface modification. In one embodiment, a surface texture 1250 may be applied to an article or part. Surface textures can be applied by, for example, coextrusion or embossing the surface with a die. Other techniques for creating surface textures may also be used. The biopolymer is cooled 1280 to maintain the shape of the part or article.

Example

Example 1 Production of biopolymers by thermodynamic compounding

This example describes the preparation of a biopolymer of the invention comprising fermentation solids (eg, DDG, a specific fermented protein solid), polypropylene, and maleated acid. For example, measure out these components in a 60/38/2 ratio and compound with a Gelimate G1 thermodynamic compounder. Compound the other ratios listed in the table in the same way. Compounding was performed at 4400 RPM; the material was discharged from the compounder at a temperature of 190°C. The polypropylene is commercially available as SB 642 supplied by the Basell Corporation. The biopolymer leaves the compounder as a dough mass, similar to bread dough (soft or raw biopolymer). Soft or raw biopolymers are pelletized in a conventional knife milling system to form pellets.

The biopolymer pellets of the invention were injection molded in a standard "dog bone" mold on a Toshiba Electric injection molding press at a temperature of 320 degrees Fahrenheit in all three zones. As a control, commercially available polypropylene alone was also molded in the same manner.

The tensile strength, flexural modulus, and rupture modulus of the obtained dog-bone-shaped material were tested according to ASTM plastic testing standards to determine the mechanical strength. and get the following result: polymer Tensile strength (1bs, ASTM) Flexural strength (psi, ASTM) Displacement (elongation) tensile test (inch, ASTM) 100% polypropylene 130 61,000 0.22 Biopolymer Embodiment 1 (50 wt% fermented protein solids and 50 wt% polypropylene) 140 140,000 0.11 Biopolymer Embodiment 2 (70 wt% fermented protein solids and 30 wt% polypropylene) 130 210,000 0.061 Biopolymer Embodiment 3 (60 wt% fermented protein solids, 38 wt% polypropylene, 2 wt% maleated polypropylene) 140 220,000 0.071

Surprisingly, the addition of fermented solids, such as fermented protein solids, to plastics increased the strength of the plastics. The biopolymer of the present invention is stronger than the thermally active material used to make it. Three strength measurements for each polymer illustrate this result.

The inventive biopolymer exhibits greater tensile strength than the control plastic. This is unexpected. Conventional filled plastics (eg, filled with inert fillers) generally have a lower tensile strength than the plastic from which it is made. Specifically, conventional filled plastics with as much as 50 wt% or 70 wt% inert fillers have lower tensile strength than the plastic from which they are made. In this example, biopolymers with 50 wt% or 70 wt% fermented solids (eg, fermented protein solids) both exhibited greater tensile strength than the control plastic. In this example, the biopolymers of the invention acquire additional tensile strength when a crosslinking agent is added.

The biopolymers of the invention exhibit greater flexural modulus than the control plastics. In this example, biopolymers with 50 wt% or 70 wt% fermented solids (eg, fermented protein solids) both exhibited greater flexural modulus than the control plastic. In this example, the biopolymers of the present invention acquire additional flexural modulus when a cross-linking agent is added.

The inventive biopolymers exhibit reduced displacement (less "stretch") than the control plastic. In this example, biopolymers with 50 wt% or 70 wt% fermented solids (eg, fermented protein solids) both showed reduced displacement compared to the control plastic. It is generally believed that reduced elongation correlates with increased thermal, processing, and structural stability.

Example 2 Production of biopolymers by extrusion

The following extrusion parameters were used to produce the biopolymers of the present invention.

·Conical reverse extruder

RT (resin temperature) 178℃

RP (resin pressure) 11.9

·Main motor (%) 32.3%

RPM 3.7

D2 (die temperature zone 2) 163

D1 (die temperature zone 1) 180

AD(die) 180

C4 (barrel heating zone 4)                                                              

C3 181

C2 194

C1 208

·Screw temperature 149

(temperature in °C)

(equipment TC85 milicron CCRE)

A mixture of 15% polypropylene ("PP") and 85% DDG blended with 7% MC was compounded with a high shear compounding system and then extruded through a hollow die system at the above process parameters. Note that DDG contains protein, fiber, fat, and ash. The second test adopts 15% PP and 85% cellulose fiber (wheat), and uses exactly the same process, equipment and the above process parameters as a comparison.

In the initial comparison of the tests of this particular embodiment, there were a number of differences between the biopolymer extrudate embodiments of the invention and the comparative fiber/PP extrudates. The fiber/PP extrudate closely mimics existing wood plastic fiber technology and overall performance. The fiber/PP extrudate was very different in color besides having a very dark overall color, showing individual fibers and particles. The conventional material also exhibits inferior mechanical strength properties and brittleness, whereas the biopolymer has higher overall fracture strength and stiffness.

The biopolymer embodiments of the present invention retain their lighter color and are generally uniform in appearance. This indicates that the biopolymers of the present invention bonded or melted together under the extruder conditions employed.

It should be noted that as used in this specification and the appended claims, the singular forms "a" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a composition comprising "a compound" includes a mixture of two or more compounds. It should also be noted that the term "or" includes "and/or" unless expressly stated otherwise.

It should also be noted that the terms "adapted and configured" as used in this specification and the appended claims describe a system, device, or other structure that is configured for a particular task or in a particular configuration. The terms "adopt and configure" are used interchangeably with other similar terms such as arrange and configure, construct and arrange, adopt, construct, manufacture and arrange, and the like.

The invention has been described in conjunction with various specific and preferred embodiments and techniques. It should be understood, however, that many modifications and changes can be made within the spirit and scope of the invention.

Claims (147)

1. composition comprises:

About 5 to about 95wt% fermentation solid; With

About 1 to about 95wt% hot active material.

2. the composition of claim 1, wherein said fermentation solid comprises the protein solid of fermentation.

3. the composition of claim 2, wherein said fermentation solid comprises the dried grains vinasse.

4. the composition of claim 2, wherein said dried grains vinasse also comprise solvend.

5. the composition of claim 2, wherein said dried grains vinasse comprise dried grains vinasse-200.

6. the composition of claim 2, wherein said dried grains vinasse comprise dried maize alcohol stillage.

7. the composition of claim 6, wherein said dried maize alcohol stillage comprise does the classification maize alcohol stillage.

8. in the wet cake that the composition of claim 1, wherein said fermentation solid comprise the dried grains vinasse, the dried grains vinasse of solvend are arranged, wet cake and solvent were washed one of at least.

9. the composition of claim 1, wherein said fermentation solid comprise the dried grains vinasse, do in amyloid root crop vinasse, dried stem tuber vinasse and the dried piece root vinasse one of at least.

10. the composition of claim 9, wherein said fermentation solid comprise in the poor and dried leguminous plants vinasse of solid food cereal wine one of at least.

11. the composition of claim 10, wherein said fermentation solid comprise dried maize alcohol stillage, dried Chinese sorghum (chinese sorghum) vinasse, dried barley vinasse, do little spent grains, dried rye vinasse, dried rice vinasse, dried millet vinasse, dried oat vinasse and dried soybean vinasse.

12. the composition of claim 9, wherein said fermentation solid comprise dried piece root vinasse, described dried piece root vinasse comprise in dried sweet potato vinasse, dried Chinese yam vinasse and the dried cassava grain stillage one of at least.

13. the composition of claim 9, wherein said fermentation solid comprise dried stem tuber vinasse, described dried stem tuber vinasse comprise the dried potato vinasse.

14. the composition of claim 1 comprises:

About 50 to about 70wt% fermentation solid; With

About 20 to about 50wt% hot active materials.

15. the composition of claim 1, wherein said hot active material comprise thermoplastic material, thermosetting material, and resin and adhesive polymer in one of at least.

16. the composition of claim 1, wherein said hot active material comprise in polyethylene, polypropylene and the polyvinyl chloride one of at least.

17. the composition of claim 1, wherein said hot active material comprise in epoxy material and the melamine one of at least.

18. the composition of claim 1, wherein said hot active material comprise polyester, phenol polymer and contain in the polymkeric substance of urea one of at least.

19. the composition of claim 1, wherein said composition are the forms of whole biopolymer, compound bio superpolymer or gathering biopolymer.

20. the composition of claim 1, wherein said composition are the forms of compound bio superpolymer, the outward appearance of described compound bio superpolymer is like grouan.

21. the composition of claim 1, wherein said composition be ball sheet, particle, extrude the form of solid, injection moulding solid, rigid foam, sheet material, dough or its combination.

22. being macroscopic views, the composition of claim 1, wherein said composition go up uniformly.

23. the composition of claim 1 comprises the covalent bonding of described fermentation solid and described hot active material.

24. the composition of claim 1 comprises the melt of described fermentation solid and described hot active material.

25. the composition of claim 1, also comprise in dyestuff, pigment, hydrolytic reagent, softening agent, filler, sanitas, antioxidant, nucleator, static inhibitor, biocide, mycocide, fireproofing agent, fire retardant, thermo-stabilizer, photostabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, linking agent, whipping agent and the reprocessed plastic(s) one of at least.

26. the composition of claim 1, also comprise in softening agent, photostabilizer and the coupling agent one of at least.

27. goods that comprise composition, described composition comprises:

About 5 to about 95wt% fermentation solid; With

About 1 to about 95wt% hot active material.

28. a preparation of compositions method, this method comprise that to make the material that comprises fermentation solid and hot active material compound.

29. the method for claim 28 wherein compoundly comprises that heat power is compound.

30. the method for claim 28, the wherein compound twin screw that comprises is extruded.

31. the method for claim 30, wherein twin screw is extruded and is comprised and make the foaming of described composition.

32. the method for claim 28 also comprises making described composition sclerosis.

33. the method for claim 32 also comprises described hardened composition is ground.

34. the method for claim 33 comprises described composition is ground to form particle.

35. the method for claim 32 also comprises described composition is configured as the ball sheet.

36. the method for claim 32 also comprises described composition is configured as sheet material.

37. the method for claim 28 comprises that to make the mixture that comprises following component compound:

About 5 to about 95wt% fermentation solid; With

About 0.1 to about 95wt% hot active material.

38. the method for claim 37 comprises that to make the mixture that comprises following component compound:

About 50 to about 70wt% fermentation solid; With

About 20 to about 50wt% hot active materials.

39. the method for claim 28 comprises that to make dried grains vinasse and hot active material compound.

40. the method for claim 39 comprises that to make dried maize alcohol stillage and hot active material compound.

41. the method for claim 28 comprises making hot active material and dried grains vinasse, doing one of at least compound in amyloid root crop vinasse, dried stem tuber vinasse and the dried piece root vinasse.

42. the method for claim 28 comprises making hot active material and dried maize alcohol stillage, dried Chinese sorghum (chinese sorghum) vinasse, dried barley vinasse, doing one of at least compound in little spent grains, dried rye vinasse, dried rice vinasse, dried millet vinasse, dried oat vinasse, dried soybean vinasse, dried sweet potato vinasse, dried Chinese yam vinasse, dried cassava grain stillage and the dried potato vinasse.

43. the method for claim 28, comprise make fermentation solid and thermoplastic material, thermosetting material, and resin and adhesive polymer in one of at least compound.

44. the method for claim 28 comprises one of at least compound in the polymkeric substance that makes fermentation solid and polyethylene, polypropylene, polyvinyl chloride, epoxy material, melamine, polyester, phenol polymer and contain urea.

45. the method for claim 28, uniform composition on the wherein compound generation macroscopic view.

46. the method for claim 28, the wherein compound covalent bonding that impels described fermentation solid and described hot active material.

47. the method for claim 28, the wherein compound temperature that makes described fermentation solid rises to the temperature of the Tg that is higher than described fermentation solid.

48. the method for claim 28, the wherein compound temperature that makes described fermentation solid rises to the temperature of the Tm that is higher than described fermentation solid.

49. the method for claim 28 also comprises to described compound composition coating coating.

50. the preparation method of a foam composition, this method comprises:

The material that will comprise fermentation solid and hot active material is extruded; With

Production comprises the foam composition of fermentation solid and hot active material.

51. the method for claim 50 comprises and extruding not containing the composition that adds whipping agent.

52. the production method of goods, this method comprises:

Form described goods by composition, described composition comprises:

About 5 to about 95wt% fermentation solid; With

About 0.1 to about 95wt% hot active material.

53. the method for claim 52, the method that wherein forms goods comprise in extrusion molding, injection moulding, blowing, compression moulding, transfer molding, thermoforming, casting, calendering, low pressure molding, high-pressure laminating, reaction injection molding(RIM), the foam-formed and coating one or more.

54. the method for claim 52 also comprises to described goods coating coating.

55. the composition of claim 1 comprises dried grains vinasse and polypropylene, also comprises the maleinization polypropylene.

56. goods that comprise the biopolymer material, described biopolymer material comprises hot active material and fermentation solid.

57. the goods of claim 56, wherein said biopolymer comprises:

About 5 to about 95wt% fermentation solid; With

About 1 to about 95wt% hot active material.

58. the goods of claim 56, wherein said fermentation solid comprise the dried grains vinasse, do in amyloid root crop vinasse, dried stem tuber vinasse and the dried piece root vinasse one of at least.

59. the goods of claim 58, wherein said fermentation solid comprise in the poor and dried leguminous plants vinasse of solid food cereal wine one of at least.

60. the goods of claim 59, wherein said fermentation solid comprise dried maize alcohol stillage, dried Chinese sorghum (chinese sorghum) vinasse, dried barley vinasse, do little spent grains, dried rye vinasse, dried rice vinasse, dried millet vinasse, dried oat vinasse and dried soybean vinasse.

61. the goods of claim 56, goods described in being total to are the part of window, the part of door, the part of a piece of furniture.

62. the goods of claim 56, wherein said article configurations becomes the timber alternative means.

63. the goods of claim 62 also comprise fine and close shell and foam core.

64. the goods of claim 63 also are included in the grain surface on the fine and close shell.

65. the goods of claim 56, wherein said article configurations becomes decorated articles.

66. the goods of claim 56, at least a portion of wherein said goods comprises foam core.

67. the goods of claim 56 are configured to fit together by thermo-welding and another goods.

68. the goods of claim 56, assembled configuration become in window assembly, door assembly and the furniture assembly one of at least.

69. the goods of claim 56 also comprise the internal surface that limits the chamber, stretch into the support in the chamber and stretch into anchor portion in the chamber that described anchor portion is configured for receiving fastening piece.

70. the goods of claim 56, comprise in compression moulding goods, extruded product and the injection-molded item one of at least.

71. the goods of claim 56 also comprise second material layer that is positioned on the biopolymer.

72. the goods of claim 71, wherein said second material layer comprises the imprinting moulding feature.

73. the goods of claim 71, wherein said second material layer comprises the coextrusion material.

74. the goods of claim 71, wherein said second material layer comprises powder coating.

75. the goods of claim 56, wherein said article configurations becomes the parts of wall panel assembly for building.

76. the goods of claim 75, the parts of wherein said wall panel assembly for building comprise:

The longitudinal member that the vertical body that extends between first and second ends is arranged;

Described longitudinal member comprises the biopolymer material;

One of at least be configured to be connected in first and second ends with second parts of wall panel assembly.

77. the goods of claim 76, wherein said second parts comprise the biopolymer material, and described second unit architecture becomes to be connected with an end of longitudinal member by thermo-welding.

78. the goods of claim 76, wherein said longitudinal member include the surface variations that changes outward appearance, described surface variations comprise in powder coating, grain surface and the print surface one of at least.

79. the goods of claim 56, wherein said fermentation solid comprises the protein solid of fermentation.

80. the goods of claim 79, wherein said fermentation solid comprises the dried grains vinasse.

81. the goods of claim 80, wherein said dried grains vinasse also comprise solvend.

82. the goods of claim 80, wherein said dried grains vinasse comprise dried grains vinasse-200.

83. the goods of claim 80, wherein said dried grains vinasse comprise dried maize alcohol stillage.

84. the goods of claim 56 comprise:

About 50 to about 70wt% fermentation solid; With

About 20 to about 50wt% hot active materials.

85. the goods of claim 56, wherein said hot active material comprise thermoplastic material, thermosetting material, and resin and adhesive polymer in one of at least.

86. the goods of claim 56, wherein said hot active material comprise in polyethylene, polypropylene and the polyvinyl chloride one of at least.

87. the goods of claim 56, wherein said hot active material comprise in epoxy material and the melamine one of at least.

88. the goods of claim 56, wherein said hot active material comprise polyester, phenol polymer and contain in the polymkeric substance of urea one of at least.

89. the goods of claim 56, wherein said goods are forms of whole biopolymer, compound bio superpolymer or gathering biopolymer.

90. the goods of claim 56, wherein said goods are forms of compound bio superpolymer, the outward appearance of described compound bio superpolymer is like grouan.

91. the goods of claim 56, also comprise in dyestuff, pigment, hydrolytic reagent, softening agent, filler, sanitas, antioxidant, nucleator, static inhibitor, biocide, mycocide, fireproofing agent, fire retardant, thermo-stabilizer, photostabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, linking agent, whipping agent and the reprocessed plastic(s) one of at least.

92. the goods of claim 56, also comprise in softening agent, photostabilizer and the coupling agent one of at least.

93. a biopolymer timber substitutes the manufacture method of goods, window or door part or wall member, this method comprises:

With described biopolymer heating;

Exert pressure for the biopolymer of described heating;

Make the biopolymer moulding of described heating; With

Make described biopolymer cooling to keep article shape.

94. the method for claim 93 wherein makes described biopolymer moulding comprise and makes described biopolymer extrude the generation extrudate by die head.

95. the method for claim 93 also comprises to described goods or parts applying superficial makings.

96. the method for claim 95 wherein applies step and comprises described goods of compacting or parts.

97. the method for claim 96 is wherein suppressed described goods or parts and is impelled drainage water from described biopolymer.

98. the method for claim 93, wherein also be included in described window, door or the wall member form in foam segment or the hollow space one of at least, thereby exist described foam or hollow space to make the R value raising of described parts.

99. a hotmelt that comprises the biopolymer material, described biopolymer material comprises hot active material and fermentation solid.

100. the hotmelt of claim 99, wherein said fermentation solid comprises the protein solid of fermentation.

101. the hotmelt of claim 99, wherein said fermentation solid comprises the dried grains vinasse.

102. goods that comprise biopolymer, described biopolymer comprises hot active material and fermentation solid.

103. the goods of claim 102, wherein said biopolymer comprises:

About 5 to about 95wt% fermentation solid; With

About 1 to about 95wt% hot active material.

104. the goods of claim 102, wherein said fermentation solid comprise the dried grains vinasse, do in amyloid root crop vinasse, dried stem tuber vinasse and the dried piece root vinasse one of at least.

105. the goods of claim 104, wherein said fermentation solid comprise in the poor and dried leguminous plants vinasse of solid food cereal wine one of at least.

106. the goods of claim 105, wherein said fermentation solid comprise dried maize alcohol stillage, dried Chinese sorghum (chinese sorghum) vinasse, dried barley vinasse, do little spent grains, dried rye vinasse, dried rice vinasse, dried millet vinasse, dried oat vinasse and dried soybean vinasse.

107. the goods of claim 102, wherein said article configurations becomes the substitute as wood structures.

108. the goods of claim 102, wherein said goods comprise plate.

109. the goods of claim 102, wherein said goods comprise the capping slab.

110. the goods of claim 102, wherein said article configurations becomes column, and described column comprises:

Pedestal;

The cylinder that links to each other with pedestal, wherein said cylinder comprises:

A plurality of bights; With

A plurality of panels, wherein every side of each panel all links to each other with the bight; With

The top cover that links to each other with cylinder;

One of at least comprise the goods that comprise described biopolymer in wherein said pedestal, bight, panel and the top cover.

111. the goods of claim 102, wherein said article configurations becomes column, and described column comprises:

Pillar;

The pedestal that links to each other with pillar;

With pedestal, pillar or cylinder that the two links to each other, wherein said cylinder comprises:

A plurality of bights; With

A plurality of panels, wherein panel links to each other with the bight and forms cylinder; With

With cylinder, pillar or top cover that the two links to each other;

One of at least comprise the goods that comprise described biopolymer in wherein said pedestal, bight, panel and the top cover.

112. the goods of claim 102, wherein said article configurations becomes railing system, and described railing system comprises:

A plurality of stanchions, each stanchion all comprises top and bottom;

The cross tube that links to each other with the upper end of stanchion;

The sheer pole that links to each other with the lower end of stanchion; With

The cross bar lid that links to each other with cross tube;

One of at least comprise the goods that comprise described biopolymer in wherein said stanchion, cross tube, sheer pole, pedestal, bight, panel and the top cover.

113. the goods of claim 102, wherein said article configurations becomes column and railing system, and described column and railing system comprise:

A plurality of columns, each column all comprises:

Pillar;

The pedestal that links to each other with pillar;

With pedestal, pillar or cylinder that the two links to each other, wherein said cylinder comprises:

A plurality of bights; With

A plurality of panels, wherein said panel link to each other with the bight and form cylinder; With

With cylinder, pillar or top cover that the two links to each other;

The railing section comprises:

At least one stanchion, each stanchion all comprises top and bottom;

The cross tube that links to each other with the upper end of at least one stanchion;

The sheer pole that links to each other with the lower end of at least one stanchion; With

The cross bar lid that links to each other with cross tube;

Described railing section is extended between two columns;

One of at least comprise the goods that comprise described biopolymer in wherein said stanchion, cross tube, sheer pole, pedestal, bight, panel and the top cover.

114. the goods of claim 102, wherein said goods comprise the bight as the unit architecture of column and railing system.

115. the goods of claim 102, wherein said goods comprise the panel as the unit architecture of column and railing system.

116. the goods of claim 102, wherein said goods comprise the column as the unit architecture of column and railing system.

117. the goods of claim 102, wherein said goods comprise the stanchion as the unit architecture of column and railing system.

118. the goods of claim 102, wherein said goods comprise the cross bar as the unit architecture of column and railing system.

119. the goods of claim 102, wherein said goods comprise the cross bar lid as the unit architecture of column and railing system.

120. the goods of claim 102, wherein said goods comprise the pedestal as the unit architecture of column and railing system.

121. the goods of claim 102, wherein said goods comprise the top cover as the unit architecture of column and railing system.

122. the goods of claim 102, wherein said goods comprise the trim as the unit architecture of column and railing system.

123. the goods of claim 102 also comprise second material layer that is positioned on the described biopolymer.

124. the goods of claim 123, wherein said second material layer comprises the imprinting moulding feature.

125. the goods of claim 123, wherein said second material layer comprises the coextrusion material.

126. the goods of claim 123, wherein said second material layer comprises powder coating.

127. the goods of claim 102, wherein said fermentation solid comprises the protein solid of fermentation.

128. the goods of claim 127, wherein said fermentation solid comprises the dried grains vinasse.

129. the goods of claim 128, wherein said dried grains vinasse also comprise solvend.

130. the goods of claim 128, wherein said dried grains vinasse comprise dried grains vinasse-200.

131. the goods of claim 128, wherein said dried grains vinasse comprise dried maize alcohol stillage.

132. the goods of claim 102, wherein said biopolymer comprises:

About 50 to about 70wt% fermentation solid; With

About 20 to about 50wt% hot active materials.

133. the goods of claim 102, wherein said hot active material comprise thermoplastic material, thermosetting material, and resin and adhesive polymer in one of at least.

134. the goods of claim 102, wherein said hot active material comprise in polyethylene, polypropylene and the polyvinyl chloride one of at least.

135. the goods of claim 102, wherein said hot active material comprise in epoxy material and the melamine one of at least.

136. the goods of claim 102, wherein said hot active material comprise polyester, phenol polymer and contain in the polymkeric substance of urea one of at least.

137. the goods of claim 102, wherein said goods are forms of whole biopolymer, compound bio superpolymer or gathering biopolymer.

138. the goods of claim 102, wherein said goods are forms of compound bio superpolymer, the outward appearance of described compound bio superpolymer is like grouan.

139. the goods of claim 102, also comprise in dyestuff, pigment, hydrolytic reagent, softening agent, filler, sanitas, antioxidant, nucleator, static inhibitor, biocide, mycocide, fireproofing agent, fire retardant, thermo-stabilizer, photostabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, linking agent, whipping agent and the reprocessed plastic(s) one of at least.

140. the goods of claim 102, also comprise in softening agent, photostabilizer and the coupling agent one of at least.

141. the production method of goods, this method comprises:

Form described goods by composition, described composition comprises:

About 5 to about 95wt% fermentation solid; With

About 0.1 to about 95wt% hot active material.

142. the method for claim 141, the method that wherein forms goods comprise in extrusion molding, injection moulding, blowing, compression moulding, transfer molding, thermoforming, casting, calendering, low pressure molding, high-pressure laminating, reaction injection molding(RIM), the foam-formed and coating one or more.

143. the method for claim 141 also comprises to described goods coating coating.

144. the method for claim 141 wherein makes described composition molding comprise and makes described biopolymer extrude the generation extrudate by die head.

145. the method for claim 144 also comprises to described goods applying superficial makings.

146. the method for claim 145 wherein applies step and comprises the described goods of compacting.

147. the method for claim 146 is wherein suppressed described goods and is impelled drainage water from described composition.

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