Biopolymer structures and components including column and rail system
The present invention relates generally to structures formed from a biopolymer. The present invention more particularly relates to biopolymer structures and components formed from fermentation solids and thermoactive materials, including a column and rail system and the component parts of this system.
1 . An article of manufacture comprising a biopolymer, the biopolymer comprising thermoactive material and fermentation solid.
2 . The article of claim 1 , wherein the biopolymer comprises:
about 5 to about 95 wt-% fermentation solid; and
about 1 to about 95 wt-% thermoactive material.
3 . The article of claim 1 , wherein the fermentation solid comprises at least one of distiller's dried grain, distiller's dried starchy root crop, distiller's dried tuber, and distiller's dried root.
4 . The article of claim 3 , wherein the fermentation solid comprises at least one of distiller's dried cereal grain and distiller's dried legume.
5 . The article of claim 4 , wherein the fermentation solid comprises distiller's dried corn, distiller's dried sorghum (milo), distiller's dried barley, distiller's dried wheat, distiller's dried rye, distiller's dried rice, distiller's dried millet, distiller's dried oats, and distiller's dried soybean.
6 . The article of claim 1 , wherein the article is configured for use as a replacement for a wood structural member.
7 . The article of claim 1 wherein the article comprises a board.
8 . The article of claim 1 wherein the article comprises a deck plank.
9 . The article of claim 1 , wherein the article is configured as a column, the column comprising:
a base;
a pillar coupled to the base, wherein the pillar comprises:
plurality of corners; and
plurality of panels, wherein each panel is coupled to a corner on each side; and
a top cap coupled to the pillar;
wherein at least one of the base, the corners, the panels, and the top cap comprises an article comprising the biopolymer.
10 . The article of claim 1 , wherein the article is configured as a column, the column comprising:
a post;
a base coupled to the post;
a pillar coupled to the base, the post, or both, wherein the pillar comprises:
a plurality of corners; and
a plurality of panels, wherein the panels are coupled to the corners forming a pillar; and
a top cap, coupled to the pillar, the post, or both;
wherein at least one of the base, the corners, the panels, and the top cap comprises an article comprising biopolymer.
11 . The article of claim 1 , wherein the article is configured as a rail system, the rail system comprising:
a plurality of balusters, each baluster comprising a top end and a bottom end;
a top rail coupled to the top ends of the balusters;
a bottom rail coupled to the bottom ends of the balusters; and
a rail cover coupled to the top rail;
wherein at least one of the balusters, the top rail, the bottom rail, the base, the corners, the panels, and the top cap comprises an article comprising biopolymer.
12 . The article of claim 1 , wherein the article is configured as a column and rail system, the column and rail system comprising:
a plurality of columns, each of the columns comprising:
a post;
a base coupled to the post;
a pillar coupled to the base, the post, or both, wherein the pillar comprises:
a plurality of corners; and
a plurality of panels, wherein the panels are coupled to the corners forming a pillar; and
a top cap coupled to the pillar, the post, or both;
a railing segment comprising:
at least one baluster, each baluster a top end and a bottom end;
a top rail coupled to at least one baluster top end;
a bottom rail coupled to at least one baluster bottom end; and
a rail cover coupled to the top rail;
the railing segment extending between two of the columns;
wherein at least one of the baluster, the top rail, the bottom rail, the base, the corners, the panels, and the top cap comprises an article comprising biopolymer.
13 . The article of claim 1 , wherein the article comprises a corner configured for being a component of a column and rail system.
14 . The article of claim 1 , wherein the article comprises a panel configured for being a component of a column and rail system.
15 . The article of claim 1 , wherein the article comprises a column configured for being a configured for being a component of a column and rail system.
16 . The article of claim 1 , wherein the article comprises a baluster configured for being a component of a column and rail system.
17 . The article of claim 1 , wherein the article comprises a rail configured for being a component of a column and rail system.
18 . The article of claim 1 , wherein the article comprises a rail cover configured for being a component of a column and rail system.
19 . The article of claim 1 , wherein the article comprises a base configured for being a component of a column and rail system.
20 . The article of claim 1 , wherein the article comprises a top cap configured for being a component of a column and rail system.
21 . The article of claim 1 , wherein the article comprises a decorative cap configured for being a component of a column and rail system.
22 . The article of claim 1 , further comprising a layer of a second material on the biopolymer.
23 . The article of claim 22 , wherein the layer of second material comprises impression-formed features.
24 . The article of claim 22 , wherein the layer of second material comprises a coextruded material.
25 . The article of claim 22 , wherein the layer of second material comprises a powder coating.
26 . The article of claim 1 , wherein the fermentation solid comprises fermented protein solid.
27 . The article of claim 26 , wherein the fermentation solid comprises distiller's dried grain.
28 . The article of claim 27 , wherein the distiller's dried grain further comprises solubles.
29 . The article of claim 27 , wherein the distiller's dried grain comprises distiller's dried grain-200.
30 . The article of claim 27 , wherein the distiller's dried grain comprises distiller's dried corn.
31 . The article of claim 1 , wherein the biopolymer comprises:
about 50 to about 70 wt-% fermentation solid; and
about 20 to about 50 wt-% thermoactive material.
32 . The article of claim 1 , wherein the thermoactive material comprises at least one of thermoplastic, thermoset material, and resin and adhesive polymer.
33 . The article of claim 1 , wherein the thermoactive material comprises at least one of polyethylene, polypropylene, and polyvinyl chloride.
34 . The article of claim 1 , wherein the thermoactive material comprises at least one of epoxy material and melamine.
35 . The article of claim 1 , wherein the thermoactive material comprises at least one of polyester, phenolic polymer, and urea containing polymer.
36 . The article of claim 1 , wherein the article is in the form of an integral biopolymer, a composite biopolymer, or an aggregate biopolymer.
37 . The article of claim 1 , wherein the article is in the form of a composite biopolymer and the composite biopolymer has a granite-like appearance.
38 . The article of claim 1 , further comprising at least one of dye, pigment, hydrolyzing agent, plasticizer, filler, preservative, antioxidants, nucleating agent, antistatic agent, biocide, fungicide, fire retardant, flame retardant, heat stabilizer, light stabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, crosslinking agent, blowing or foaming agent, and reclaimed or recycled plastic.
39 . The article of claim 1 , further comprising at least one of plasticizer, light stabilizer, and coupling agent.
40 . A method of making an article, the method comprising:
forming the article from a composition comprising:
about 5 to about 95 wt-% fermentation solid; and
about 0.1 to about 95 wt-% thermoactive material.
41 . The method of claim 40 , wherein forming comprises one or more of extrusion molding, injection molding, blow molding, compression molding, transfer molding, thermoforming, casting, calendering, low-pressure molding, high-pressure laminating, reaction injection molding, foam molding, and coating.
42 . The method of claim 40 , further comprising coating the article.
43 . The method of claim 40 , wherein forming the composition comprises extruding the biopolymer through a die to produce an extrusion.
44 . The method of claim 43 , further comprising applying a surface texture to the article.
45 . The method of claim 44 , wherein applying comprises pressing the article.
46 . The method of claim 45 , wherein pressing the article promotes extraction of water from the mixture.