Lignocellulose fiber-resin composite material
A method of making a formed, dried lignocellulose fiber material comprising (a) providing an aqueous lignocellulose fiber pulp slurry having an effective consistency; (b) de-watering the slurry to provide a de-watered material at an effective de-watering rate under an effective pressure to prevent or reduce the formation of fissures and voids within the material; (c) drying an effective amount of the de-watered material at an effective temperature and period of time to provide the formed, dried lignocellulose fiber material having a thickness of at least 5 mm. The formed, dried lignocellulose material may be used to make a lignocellulose fiber-resin composite material of use as a cost effective structural member, as a substitute for steel, in, for example, bridges, processing equipment, and the like.
1. A rigid 3-Dimensional form comprising:
a plurality of dried, lignocellulose fibers formed from a dewatered aqueous lignocellulose slurry, the fibers having random fiber orientation and maximal fiber entanglement, the form having a thickness of at least 1 mm.
2. The 3-Dimensional form, according to claim 1 , is minimally flawed.
3. The 3-Dimensional form, according to claim 1 , in which the dried lignocellulose fibers have a length of less than 1.0 cm.
4. The 3-Dimensional form, according to claim 3 , in which the dried lignocellulose fibers have a length of from about 0.5 mm to 1.0 mm.
5. The 3-Dimensional form, according to claim 4 , in which the fibers are hardwood fibers.
6. The 3-Dimensional form, according to claim 1 , in which the dried lignocellulose fibers have a length of less than 1.0 mm.
7. The 3-Dimensional form, according to claim 6 , in which the fibers are softwood fibers.
8. The 3-Dimensional form, according to claim 1 , in which the dried lignocellulose fibers have a length of from about 0.5 mm to 10 mm.
9. The 3-Dimensional form, according to claim 8 , in which the fibers are non-wood fibers.
10. The 3-Dimensional form, according to claim 1 , has a thickness of at least 2 cm.
11. The 3-Dimensional form, according to claim 1 , has a length of and/or width of greater than 5 cm.
12. The 3-Dimensional form, according to claim 1 , in which the lignocellulose fibers are impregnated with a thermoset resin.
13. The 3-Dimensional form, according to claim 1 , in which the lignocellulose fibers are cured.
14. The 3-Dimensional form, according to claim 1 , in which the lignocellulose fibers are selected from the group consisting of: bleached, unbleached, dried, undried, refined, unrefined kraft, sulfite, mechanical, recycled, virgin wood and non-wood fibers.
15. The 3-Dimensional form, according to claim 14 , in which the non-wood fibers include agricultural waste, cotton linters, bagasse, hemp, jute, and grasses.
16. The 3-Dimensional form, according to claim 1 , is a rectangular brick.
17. A rigid 3-Dimensional form comprising:
a plurality of dried, lignocellulose fibers formed from a dewatered aqueous lignocellulose slurry, the fibers having random fiber orientation and maximal fiber entanglement, the form having a thickness of at least 1 mm; and
a resin impregnated into the fibers.
18. The 3-Dimensional form, according to claim 17 , is minimally flawed.
19. The 3-Dimensional form, according to claim 17 , in which the dried lignocellulose fibers have a length of less than 1.0 cm.
20. The 3-Dimensional form, according to claim 17 , in which the dried lignocellulose fibers have a length of from about 0.5 mm to 1.0 mm.
21. The 3-Dimensional form, according to claim 20 , in which the fibers are hardwood fibers.
22. The 3-Dimensional form, according to claim 17 , in which the dried lignocellulose fibers have a length of less than 1.0 mm.
23. The 3-Dimensional form, according to claim 22 , in which the fibers are softwood fibers.
24. The 3-Dimensional form, according to claim 17 , in which the dried lignocellulose fibers have a length of from about 0.5 mm to 10 mm.
25. The 3-Dimensional form, according to claim 24 , in which the fibers are non-wood fibers.
26. The 3-Dimensional form, according to claim 17 , has a thickness of at least 2 cm.
27. The 3-Dimensional form, according to claim 17 , has a length of and/or width of greater than 5 cm.
28. The 3-Dimensional form, according to claim 17 , in which the lignocellulose fibers are cured.
29. The 3-Dimensional form, according to claim 17 , in which the lignocellulose fibers are selected from the group consisting of: bleached, unbleached, dried, undried, refined, unrefined kraft, sulfite, mechanical, recycled, virgin wood and non-wood fibers.
30. The 3-Dimensional form, according to claim 29 , in which the non-wood fibers include agricultural waste, cotton linters, bagasse, hemp, jute, and grasses.
31. The 3-Dimensional form, according to claim 17 , is a rectangular brick.
32. The 3-Dimensional form, according to claim 17 , in which the resin is a thermoset resin.