HK1047013A1 - Texturized cellulosic and lignocellulosic materials and compositions and composities made therefrom - Google Patents

Description

CRUCIBLE DEFORMED CELLULOSE AND GLYCOLINIC MATERIALS AND COMPOSITIONS AND COMPOSITE-RELATED APPLICATIONS MADE THEREFROM

The present application claims priority from USSN 09/337,580 entitled "texturized cellulosic and lignocellulosic materials and compositions and composites made therefrom" filed on 22.6.1999, a continuation-in-part application entitled USSN 08/961,863 entitled "cellulosic fiber composites" filed on 31.10.1997; and claimed priority from USSN 09/338,209 entitled "texturized fibrous material derived from polymer-coated paper and compositions and composites made therefrom" filed on 22/6 1999, which is a partial continuation of USSN08/921,807 entitled "composites of polymer-coated paper" filed on 2/9/1997. Background

The present invention relates to texturized cellulosic or lignocellulosic material (e.g., texturized polymer-coated paper) and compositions and composites made from such texturized material.

Cellulosic and lignocellulosic materials are produced, processed, and used in large quantities in a number of applications. For example, polymer-coated paper (i.e., polymer-coated paper) is used to manufacture a variety of food containers, including single-serving size juice cartons and frozen food cartons. Once used, these cellulosic and lignocellulosic materials are typically discarded. Thus, the amount of waste cellulosic and lignocellulosic material is increasing.

Summary of The Invention

Broadly, the invention features texturized cellulosic or lignocellulosic material (e.g., texturized polymer-coated paper) and compositions and composites made therefrom.

In one embodiment, the invention features a method of making a texturized fibrous material. The method comprises shearing cellulosic or lignocellulosic material having internal fibers (e.g., flax, hemp, cotton, jute, rags, finished and unfinished paper, polymer coated paper, paper products or paper by-products such as pulp board, or synthetic cellulosic or lignocellulosic material such as rayon) to the extent that the internal fibers are substantially exposed, to obtain a texturized fibrous material. The cellulosic or lignocellulosic material may be, for example, a fabric such as a textile, or a non-fabric such as paper or strawboard. The length/diameter (L/D) ratio of exposed fibers of the texturized fibrous material is at least about 5 (e.g., at least about 5, 10, 25, 50, or more). For example, at least about 50% of the fibers may have an L/D ratio on this order of magnitude.

In another embodiment, the invention features texturized fibrous material including a cellulosic or lignocellulosic material (e.g., a polymer coated paper) having internal fibers, wherein the cellulosic or lignocellulosic material is sheared to the extent that the internal fibers are substantially exposed.

The texturized fibrous material can, for example, be incorporated into (e.g., associated with, mixed with, adjacent to, enclosed within, or within) a structure or a carrier (e.g., a mesh, film, flotation device, bag, shell, or biodegradable substance). The structure or carrier itself may alternatively be made from a texturized fibrous material (e.g., the texturized fibrous material of the invention), or from a composition or composite of texturized fibrous materials.

The crimped fiberThe bulk density of the fiber material may be less than about 0.5 grams per cubic centimeter (g/cm)³) Or even less than about 0.2g/cm³。

As with compositions comprising the texturized fibrous material and other liquid or solid ingredients (e.g., particulate, powdered or granular solids such as plant seeds, food or bacteria), compositions comprising the texturized fibrous material and a chemical or chemical formulation (e.g., a medicament such as an antibiotic or contraceptive optionally together with an excipient; an agricultural compound such as a fertilizer, herbicide or pesticide; or an enzyme-containing formulation) are also within the scope of the invention.

Composites comprising a thermoplastic resin and the texturized fibrous material are also contemplated. The resin may be, for example, polyethylene, polypropylene, polystyrene, polycarbonate, polybutylene, thermoplastic polyester, polyether, thermoplastic polyurethane, polyvinyl chloride, or polyamide, or a combination of two or more resins.

In some cases, at least about 5% by weight (e.g., 5%, 10%, 25%, 50%, 75%, 90%, 95%, 99%, or about 100%) of the fibrous material included in the composite is texturized.

The properties of the texturized fibrous material of the invention make it suitable for a variety of uses. The texturized fibrous material has, for example, absorbent properties, which properties can be applied, for example, for pollution control. The fibers are generally biodegradable, which makes the fibers suitable for use in, for example, drug or chemical delivery (e.g., in human therapy, animal therapy, or agricultural applications). The texturized fibrous material may also be used to reinforce polymeric resins.

Those composites comprising texturized fibrous material and resin are strong, lightweight, and inexpensive. The raw materials used to make these composites are virgin or recycled materials; for example, they may include waste containers constructed of resin, and waste cellulosic or lignocellulosic fibers (e.g., waste containers constructed of polymer coated paper).

Polymer coated papers are difficult to recycle because the paper and polymer layers are generally not separable. In the present invention, both paper and polymer fractions are utilized, so there is no need to separate the two. Polymer coated papers comprising one or more aluminum layers may also be used. The present invention thus facilitates the recycling of discarded used containers while at the same time producing a useful product.

Other features and advantages of the invention will become apparent from the following detailed description, and from the claims.

Brief description of the drawings

FIG. 1 is a photograph of a texturized newspaper at 50 times magnification;

FIG. 2 is a photograph of a texturized, polymer coated paper at 50 times magnification;

FIG. 3 is a photograph of a half gallon polymer cardboard juice carton;

FIG. 4 is a photograph of a shredded half-gallon polymer cardboard juice carton;

fig. 5 is a photograph of texturized fibrous material prepared by cutting the comminuted half-gallon polymer paperboard juice carton of fig. 4.

Detailed description of the invention

Examples of cellulosic raw materials include paper and paper products such as newsprint and paper waste, and polymer coated paper. Examples of lignocellulosic raw materials include wood, wood fibers and wood-related materials, as well as from kenaf, grasses, rice hulls, bagasse, cotton, jute, other stem plants (e.g., hemp, flax, bamboo; bast and core fibers), leaf plants (e.g., sisal, abaca) and agricultural fibers (e.g., cereal grass, corn cobs, rice hulls, and coconut hair). In addition to virgin raw materials, post-use waste, industrial waste (e.g., scrap), and processing waste (e.g., waste liquid) may also be used as a fiber source.

Polymer coated papers are available in a variety of forms. For example, a full sheet of virgin polymer-coated Paper is available from International Paper, New York. Alternatively, unused scrap polymer coated Paper (e.g., trim scrap, and misprints inventory) may be obtained from International Paper or other Paper makers. Used polymer coated paper in the form of discarded food or beverage containers can be collected from a variety of sources, including waste products and recycling routes. Polymer coated paper can be made from polymer (e.g., polyethylene) and paper, and in some cases one or more layers of aluminum. Polymer coated papers comprising one or more layers of aluminium foil are commonly used for airtight liquid storage. Used polymer coated paper, waste polymer coated paper, or polymer coated paper scrap (e.g., post-consumer waste, industrial scrap) may also be purchased from intermediate merchants of these materials. Preparation of texturized fibrous materials

If cellulosic or lignocellulosic material chips are used, the chips should be cleaned and dried. The stock material may be texturized using any one or combination of a variety of mechanical methods. One method of texturizing involves first cutting the cellulosic or lignocellulosic material into 1/4 to 1/2 inch pieces, if necessary, using standard cutting equipment. Reverse rotating screw shredders and segmented rotating screw shredders such as those manufactured by Munson (Utica, NY) can also be used, as can standard document shredders found in many offices.

The cellulosic or lignocellulosic material is then shredded using a rotary cutter, such as the cutter manufactured by Sprout, waldron companies, as described in the handbook of chemicals, pory's chem.eng.handbook, 6 th edition, pages 8-29 (1984). The spacing between the rotating and stationary knives of a rotary cutting machine is typically set to 0.020 inches or less and the rotational speed of the blades is set to 750 revolutions per minute (rpm) or more, although other settings may be used. In this process, the rotary cutter may be cooled to 100 ℃ or less using, for example, a water jacket.

The texturized material is passed through a discharge screen. Larger screens (e.g. up to 6 mm) may be used in large scale production. The cellulosic or lignocellulosic feedstock is typically held in contact with the blades of a rotary cutter until the fibers are torn apart; smaller screens (e.g., 2 mm mesh) provide longer retention times and more complete crimping, but can result in lower length/diameter (L/D) aspect ratios. A vacuum extractor may be attached to the screen to maximize and maintain the length/diameter aspect ratio of the fibers.

The texturized fibrous material may be stored directly in a sealed bag or may be dried at about 105 c for 4-18 hours (e.g., until the moisture content is less than about 0.5%) immediately prior to use. Fig. 1 is an SEM photograph of a texturized newspaper. Use of texturized fibrous material

Texturized fibrous materials and compositions and composites of such fibers with other chemicals and chemicals can be prepared to take advantage of the properties of the materials. The material may be used to absorb chemicals, for example, possibly many times its weight. Thus, the material may, for example, be used to absorb spills of oil, or to remove environmental contaminants, for example in water, in air or on land. Likewise, the absorbent properties of the material, together with its biodegradability, make it useful for the delivery of chemicals or chemical agents. For example, the material may be treated with a solution of an enzyme or a drug such as an antibiotic, nutrient or contraceptive, and any necessary excipients, for drug delivery (e.g. for treatment of humans or animals, or for use as or in animal feed and/or bedding), and with a solution of a fertiliser, herbicide or pesticide. The material may optionally be chemically treated to enhance specific absorption properties. For example, the material may be treated with a silane to render it lipophilic.

Compositions comprising texturizing material combined with a liquid or particulate, powder or granular solid may also be prepared. For example, the texturized fibrous material may be mixed with seeds (i.e., treated with or without a solution of fertilizer, pesticide, etc.), food products, or bacteria (e.g., bacteria that digest toxins). The ratio of fibrous material to the other components of the composition will depend on the nature of the component and can be readily adjusted to suit a particular product application.

In some cases, it may be advantageous to combine texturized fibrous materials or a combination or composite of these materials with a structure or carrier such as a mesh, film, flotation device, bag, shell or biodegradable substance. The structure or carrier itself may optionally be made of texturized fibrous material (e.g., the material of the present invention) or a combination or composite of texturized fibrous materials. Composite of texturized fibrous material and resin

Texturized fibrous materials may also be combined with resins to form a strong, lightweight composite. Also, materials treated with chemicals or chemical agents as described above may be combined with biodegradable or non-biodegradable resins to form complexes that incorporate, for example, hydrophilic species into an otherwise hydrophobic polymer matrix. Alternatively, the composite comprising the texturized fibrous material and the resin may be treated with chemicals or chemicals.

The texturized cellulosic or lignocellulosic material provides strength to the composite. The composite may include from about 10 wt% to about 90 wt%, for example from about 30 wt% to about 70 wt%, of texturized cellulosic or lignocellulosic material. Combinations of texturized fibrous materials may also be used (e.g., texturized polymer-coated paper mixed with texturized wood-related materials or other cellulosic or lignocellulosic fibers).

In composites, the resin encapsulates the texturized cellulosic or lignocellulosic material, helping to control the shape of the composite. The resin also transfers external loads to the fiber material, protecting the fiber from environmental and structural damage. The composite may include, for example, from about 10% to about 90% by weight, more preferably from about 30% to about 70% by weight, of the resin.

Examples of resins suitable for bonding with the texturized fibers include polyethylene (including, for example, low density polyethylene and high density polyethylene), polypropylene, polystyrene, polycarbonate, polybutylene, thermoplastic polyesters (e.g., PET), polyethers, thermoplastic polyurethanes, PVC, polyamides (e.g., nylon), and other resins. Preferably the resin has a low melt flow index. Preferred resins include polyethylene and polypropylene having a melt flow index of less than 3 g/10 min, more preferably less than 1 g/10 min.

The resin may be virgin material purchased, or scrap obtained, and may be purchased in pellet or pellet form. One source of waste resin is used polyethylene baby bottles. However, if there is surface moisture on the pelletized or granulated resin, the resin should be dried prior to use.

The complex may also comprise a coupling agent. The coupling agent helps to bond the hydrophilic fibers to the hydrophobic resin. Examples of coupling agents include maleic anhydride modified polyethylenes, such as the FUSABOND  (available from DuPont, Delaware) and POLYBOND  (available from Uniroyal Chemical, Connecticut) series. One suitable coupling agent is a maleic anhydride modified high density polyethylene such as FUSABOND  MB 100D.

The composite may also contain additives known to those skilled in the art of compounding such as plasticizers, lubricants, antioxidants, opacifiers, heat stabilizers, colorants, flame retardants, biocides, impact modifiers, light stabilizers, and antistatic agents.

The composite may also contain inorganic additives such as calcium carbonate, graphite, asbestos, wollastonite, mica, glass, fiber glass, chalk, silica, talc, ceramics, ground construction waste, tire rubber powder, carbon fiber, or metal fiber (e.g., aluminum, stainless steel). When included, such additives are typically present in amounts of from about 0.5 wt% up to about 20-30 wt%. For example, submicron calcium carbonate may be added to the composite of texturized fibrous material and resin to improve impact modifying properties or to enhance composite strength. Preparation of the composition

Compositions comprising texturized cellulosic or lignocellulosic material and a chemical, chemical or other solid can be prepared, for example, in various immersion devices, spray devices, or mixing devices including, but not limited to, ribbon mixers, conical mixers, double conical mixers, and Patterson-Kelly "V" mixers.

For example, a composition containing 90 wt% texturized cellulosic or lignocellulosic material and 10 wt% ammonium phosphate or sodium bicarbonate can be prepared in a conical mixer to produce a flame retardant material for absorbing oil. Preparation of composites of texturized fibers and resins

Composites of texturized fibrous material and resin can be prepared as follows. A standard rubber/plastic hybrid two-roll mill was heated to 325-400 ° F. The resin (usually in pellet or pellet form) is fed to a heated roll mill. After about 5-10 minutes, the coupling agent is added to the roll mill. After a further 5 minutes, the texturized cellulosic or lignocellulosic material is added to the molten resin/coupling agent mixture. The process of adding the texturizing material lasts approximately 10 minutes.

The composite was removed from the roll mill, cut into pieces and cooled to room temperature. It is then compression molded into plaques using standard compression molding techniques.

Alternatively, the components are dispensed into a mixer, such as a Banbury internal mixer. The components are mixed while maintaining the temperature below about 190 ℃. The mixture was then compression molded.

In another embodiment, the components may be mixed in an extruder mixer, such as a twin screw extruder equipped with co-rotating screws. Introducing a resin and a coupling agent at the feed throat of the extruder; texturized cellulosic or lignocellulosic material is introduced into the molten resin at about 1/3 of the length of the extruder. The internal temperature of the extruder was maintained below about 190 ℃. At the outlet, the composite may be pelletized, for example, by cold strand pelletizing.

Alternatively, the mixture may be first prepared in a mixer and then transferred to an extruder.

In another embodiment, the composite may be formed into filaments for use in knitting, warping, weaving, knitting, or in the manufacture of nonwovens. In a further embodiment, the composite may be formed into a film. Properties of composites of texturized fibrous Material and resin

The resulting composite comprises a web of fibers encapsulated in a resin matrix. The fibers form a lattice network that provides strength to the composite. Because the cellulosic or lignocellulosic material is texturized, the surface area available for bonding to the resin is increased as compared to composites made with non-texturized cellulosic or lignocellulosic material. The resin bonds to the surface of the exposed fibers, creating an intimate mixture of the fiber network and the resin matrix. The intimate mixing of the fibers with the resin matrix further strengthens the composite. Use of composites of texturized fibrous material and resin

The resin/fiber material composite may be used in a variety of applications. The composite is strong and lightweight; they can be used, for example, as wood substitutes. The resin coating makes the composite water resistant, so it can be used for outdoor use. For example, the composite can be used to make pallets, wine staves, canoes, furniture, sleds, and mortars that are often left outdoors for extended periods of time. Other uses are also contemplated, including instrument panels, pipes, deck panels, boards, housings, sheets, rods, belts, fences, components, doors, shutters, awnings, light covers, signs, frames, window frames, tailgates, wall panels, floors, tiles, railroad ties, models, trays, tool handles, stalls, cushions, dispensers, barrel panels, films, wraps, totes, buckets, boxes, packaging, baskets, belts, docks, racks, enclosures, clips, screens, walls, indoor and outdoor carpet, carpets, woven fabrics, and mats, frames, bookshelves, sculptures, chairs, tables, desks, artwork, toys, games, spindle disks, docks, boats, masts, pollution control products, septic tanks, automotive panels, base layers, computer housings, above and below ground wire covers, furniture, picnic tables, tents, electrical wiring harnesses, electrical wiring, Playgrounds, benches, shelters, sporting goods, beds, bed pans, threads, filaments, cloths, decking, trays, hangers, trays, pools, insulation, jewelry boxes, book covers, clothing, canes, and other building, agriculture, material handling, transportation, automotive, industrial, environmental, marine, electrical, electronic, entertainment, medical, textile, and consumer products. A wide variety of other applications are also envisioned. The composite may be used, for example, as a base layer or a framework for a decorative article. Additionally, the composite may, for example, be surface treated, grooved, milled, shaped, imprinted, texturized, compressed, punched or colored. The surface of the composite may be smooth or rough.

The following examples are intended to illustrate certain embodiments and aspects of the invention, and are not intended as limitations on the scope of the invention.

Examples

Example 1

1500 pounds of virgin, half gallon juice carton material made of polymer coated white kraft Paper was obtained from International Paper. Figure 3 shows one such carton. Each carton is folded flat.

The cartons were fed into a 3 horsepower (hp) Flinch Baugh shredder at a feed rate of approximately 15-20 pounds per hour. The shredder was fitted with two 12 inch wide rotary blades each, two fixed blades and a 0.3 inch discharge screen. The spacing between the rotating blade and the fixed blade was 0.10 inches.

As shown in FIG. 4, the sample obtained at the exit of the shredder consisted primarily of pieces of confetti ranging from about 0.1 inch to about 0.5 inch wide by about 0.25 inch to about 1 inch long. The output of the Mill was fed to a Thomas Wiley Mill Model 2D5 rotary cutter. The rotary cutter had 4 rotating blades, 4 fixed blades and a 2 mm discharge screen. Each blade is about 2 inches long. The blade gap was set at 0.020 inches.

The rotary cutter cuts confetti-like pieces on a knife edge, shredding the pieces and discharging finely crimped fibers at a rate of about 1 lb/hr. The fibers have an average minimum L/D ratio of between 5 and 100 or more. The bulk density of the texturized fiber is about 0.1 grams per cubic centimeter (g/cc). Fig. 5 shows a sample of a crimped fiber at one normal magnification, and fig. 2 is a sample at 50 times magnification.

Example 2

Composites of texturized fibers and resin were prepared as follows. A standard rubber/plastic mixing two roll mill was heated to 325-400F. The resin (usually in pellet or pellet form) is fed to a heated roll mill. After about 5-10 minutes, the resin was coated onto the roll (i.e., the resin melted and fused on the roll). The coupling agent is then added to the roll mill. After a further 5 minutes, the texturized cellulosic or lignocellulosic material is added to the molten resin/coupling agent mixture. The feeding process of the cellulose or lignocellulose fibers lasts about 10 minutes.

The composite was then removed from the roll mill, cut into pieces and cooled to room temperature. Using standard compression molding techniques, about 80g of each batch was compression molded into 6 inch by 1/8 inch plaques.

One composite comprises the following components:

composition No. 1

Component amounts (g)

High density polyethylene¹ 160

Old newspaper² 240

Coupling agent³ 8

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

The panels were machined into appropriate test pieces and tested according to the procedure outlined in the method specified. Three different test pieces were tested for each property and the average value for each test was calculated. The properties of composition No. 1 are as follows:

flexural strength (10)³psi (pounds per square inch)) 9.81(ASTM D790)

Flexural modulus (10)⁵psi) 6.27(ASTM D790)

The second complex comprises the following components:

composition No. 2

Component amounts (g)

High density polyethylene¹ 160

Old magazine² 240

Coupling agent³ 8

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

The properties of composition No. 2 are as follows:

flexural strength (10)³psi) 9.06(ASTM D790)

Flexural modulus (10)⁵psi) 6.78(ASTM D790)

The third complex contains the following components:

composition No. 3

Component amounts (g)

HDPE¹ 160

Fiber paper² 240

Kenaf fiber 24 with 3.1mm crimp deformation

Coupling agent³ 8

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

The properties of composition No. 3 are as follows:

flexural strength (10)³psi) 11.4(ASTM D790)

Flexural modulus (10)⁵psi) 6.41(ASTM D790)

The fourth complex contains the following components:

composition No. 4

Component amounts (g)

SUPERFLEXCaCO₃ 33

Fiber^2，4 67

HDPE (weight/3% compatibilizer)^1，3 100

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

⁴Unused polymer-coated milk carton

The properties of composition No. 4 are as follows:

flexural strength (10)⁵psi) 8.29(ASTM D790)

Ultimate elongation (%) < 5(ASTM D638)

Flexural modulus (10)⁵psi) 10.1(ASTM D790)

Eszo Notch test (Notch Izod) (foot pounds/inch) 1.39(ASTM D256-97)

The fifth complex contains the following components:

composition No. 5

Component amounts (g)

SUPERFLEXCaCO₃ 22

Fiber^2，4 67

HDPE (weight/3% compatibilizer)^1，3 100

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

⁴Unused polymer-coated milk carton

The properties of composition No. 5 are as follows:

flexural strength (10)⁵psi) 8.38(ASTM D790)

Ultimate elongation (%) < 5(ASTM D638)

Flexural modulus (10)⁵psi) 9.86(ASTM D790)

Eszo Notch test (Notch Izod) (foot pounds/inch) 1.37(ASTM D256-97)

The sixth complex contains the following components:

no. 6 composition

Component amounts (g)

ULTRAFLEXCaCO₃ 33

Fiber^2，4 67

HDPE/compatibilizer^1，3 100

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

⁴Unused polymer-coated milk carton

The properties of composition No. 6 are as follows:

flexural strength (10)⁵psi) 7.43(ASTM D790)

Ultimate elongation (%) < 5(ASTM D638)

Flexural modulus (10)⁵psi) 11.6(ASTM D790)

Eszo Notch test (Notch Izod) (foot pounds/inch) 1.27(ASTM D256-97)

The seventh complex contains the following components:

composition No. 7

Component amounts (g)

HDPE (weight/3% compatibilizer)^3，5 60

Kraft paper board² 40

¹Marlex 16007

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND100D

⁴Unused polymer-coated milk carton

⁵HDPE with melt flow index < 1

The properties of composition No. 7 are as follows:

flexural strength (10)⁵psi) 7.79(ASTM D790)

Ultimate elongation (%) < 5(ASTM D638)

Flexural modulus (10)⁵psi) 7.19(ASTM D790)

The eighth complex contains the following ingredients:

composition No. 8

Component amounts (g)

High density polyethylene¹ 160

Polymer coated paper² 240

Coupling agent³ 8

¹Marlex 6007, melt flow index 0.65 g/10 min, commercially available from Philips

²Rotary cutter crimp deformation using 2 mm mesh

³POLYBOND  3009 available from Uniroyal Chemical

The properties of composition No. 8 are as follows:

tensile modulus (10)⁵psi) 8.63(ASTM D638)

Tensile Strength at Break (psi) 6820(ASTM D638)

Ultimate elongation (%) < 5(ASTM D638)

Flexural Strength (psi) 12,200(ASTM D790)

Flexural modulus (10)⁵psi) 6.61(ASTM D790)

The ninth complex contains the following components:

composition No. 9

Component amounts (g)

High density polyethylene¹ 160

Polymer coated paper² 240

Coupling agent³ 8

¹A waste milk kettle having a melt flow index of 0.8 g/10 min,

²rotary cutter crimp deformation using 2 mm mesh

³POLYBOND3009

The properties of composition No. 9 are as follows:

tensile modulus (10)⁵psi) 7.38(ASTM D638)

Tensile Strength at Break (psi) 6500(ASTM D638)

Ultimate elongation (%) < 5(ASTM D638)

Flexural Strength (psi) 11,900(ASTM D790)

Flexural modulus (10)⁵psi) 6.50(ASTM D790)

The tenth complex contains the following components:

no. 10 composition

Component amounts (g)

High density polyethylene¹ 160

Polymer coated paper² 240

Coupling agent³ 8

¹Waste milk jug having melt flow index of 0.8 g/10 min

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABOND  MB100D, commercially available from DuPont

The properties of composition No. 10 are as follows:

tensile modulus (10)⁵psi) 7.08(ASTM D638)

Tensile Strength at Break (psi) 6480(ASTM D638)

Ultimate elongation (%) < 5(ASTM D638)

Flexural Strength (psi) 10,200(ASTM D790)

Flexural modulus (10)⁵psi) 5.73(ASTM D790)

The eleventh complex contains the following components:

composition No. 11

Component amounts (g)

High density polyethylene¹ 160

Polymer coated paper² 240

Coupling agent³ 8

¹Marlex 6007, melt flow index 0.65 g/10 min

²Rotary cutter crimp deformation using 2 mm mesh

³FUSABONDMB 100D

The properties of composition No. 11 are as follows:

tensile modulus (10)⁵psi) 7.17(ASTM D638)

Tensile Strength at Break (psi) 6860(ASTM D638)

Ultimate elongation (%) < 5(ASTM D638)

Flexural Strength (psi) 12,200(ASTM D790)

Flexural modulus (10)⁵psi) 7.50(ASTM D790)

Other embodiments are within the claims.

Claims (27)

1. A composite comprising (a) a texturized fibrous material comprising a cellulosic or lignocellulosic material having internal fibers, (b) a thermoplastic resin and (c) an inorganic additive, wherein said cellulosic or lignocellulosic material is sheared to the extent that the internal fibers thereof are substantially exposed.

2. The composite of claim 1, wherein the resin is selected from the group consisting of: polyethylene, polypropylene, polystyrene, polycarbonate, polybutylene, thermoplastic polyesters, polyethers, thermoplastic polyurethanes, polyvinyl chloride, and polyamides.

3. The composite of claim 1, wherein the cellulosic material comprises a polymer-coated paper.

4. The composite of claim 3, wherein the polymer coated paper comprises polyethylene and paper.

5. The composite of claim 4, wherein the polymer coated paper further comprises one or more layers of aluminum.

6. The composite of claim 1, wherein said cellulosic or lignocellulosic material is selected from the group consisting of: flax, hemp, cotton, jute, rags, paper products, and byproducts of paper manufacture.

7. The composite of claim 1, wherein the cellulosic or lignocellulosic material is pulp board.

8. The composite of claim 1, wherein the cellulosic or lignocellulosic material is a synthetic material.

9. The composite of claim 1, wherein the cellulosic or lignocellulosic material is a nonwoven material.

10. The composite of claim 1, wherein at least about 50% of the fibers have a length/diameter ratio of at least about 5.

11. The composite of claim 1, wherein at least about 50% of the fibers have a length/diameter ratio of at least about 25.

12. The composite of claim 1, wherein at least about 50% of the fibers have a length/diameter ratio of at least about 50.

13. The composite of claim 1, wherein the inorganic additive is selected from the group consisting of: calcium carbonate, graphite, asbestos, wollastonite, mica, glass, fiber glass, chalk, talc, silica, ceramics, ground construction waste, tire rubber powder, carbon fibers and metal fibers.

14. The composite of claim 1, wherein the inorganic additive comprises from about 0.5% to about 20% of the total weight of the composite.

15. The composite of claim 1, wherein said composite is in the form of pellets.

16. The composite of claim 15 wherein said pellets are injection molded.

17. The composite of claim 1, wherein said composite is in the form of an article selected from the group consisting of: instrument panels, pipes, deck panels, boards, housings, sheets, poles, belts, fences, members, doors, shutters, awnings, lightcovers, signs, frames, window frames, tailgates, wall panels, floors, tiles, railroad ties, models, trays, tool handles, stalls, cushions, feeders, tub panels, wraps, tote bags, drums, boxes, packaging materials, baskets, belts, docks, racks, enclosures, clips, screens, walls, indoor and outdoor carpet, carpets, woven fabrics, and mats, frames, bookshelves, sculptures, chairs, desks, tables, artwork, toys, games, spindle boards, docks, boats, boat, pollution control products, septic tanks, automotive panels, substrates, computer housings, above and below ground wire covers, furniture, picnic tables, tents, playgrounds, benches, shelters, sporting goods, electrical wiring harnesses, tents, electrical wiring harnesses, electrical wiring, Beds, bedpans, thread, cloth, plaques, trays, hangers, trays, pools, insulation, jewel cases, book covers, clothing, canes, crutches, and other building, agricultural, materials handling, transportation, automotive, industrial, environmental, marine, electrical, electronic, entertainment, medical, textile, and consumer products.

18. The composite of claim 1, wherein said composite is in the form of a fiber, filament or film.

19. A composition comprising texturized fibrous material comprising (a) a cellulosic or lignocellulosic material having internal fibers and (b) a chemical or chemical agent, wherein said cellulosic or lignocellulosic material is sheared to the extent that the internal fibers thereof are substantially exposed.

20. The composition of claim 19, wherein the chemical agent comprises a pharmaceutical composition.

21. The composition of claim 19, wherein the chemical agent is an agricultural compound.

22. The composition of claim 19, wherein the chemical comprises an enzyme.

23. A composition comprising (a) a texturized fibrous material comprising a cellulosic or lignocellulosic material having internal fibers and (b) a liquid, wherein said cellulosic or lignocellulosic material is sheared to the extent that the internal fibers thereof are substantially exposed.

24. A composition comprising (a) texturized fibrous material comprising a cellulosic or lignocellulosic material having internal fibers and (b) particulate, powdered or granular solid, wherein said cellulosic or lignocellulosic material is sheared to the extent that the internal fibers thereof are substantially exposed.

25. The composition of claim 24, wherein the solid comprises plant seeds.

26. The composition of claim 24, wherein the solid comprises a food product.

27. The composition of claim 24, wherein the solid comprises bacteria.