Lignin Composites

Abstract

The present invention relates to compositions and methods for producing lignin composite materials. Composites of this invention have improved moisture resistance and mechanical properties that are desirable.

Description

This application claims the benefit of U.S. Provisional Application No. 62/315,731 filed on Mar. 31, 2016, and U.S. Provisional Application No. 62/315,722 filed on Mar. 31, 2016, and U.S. Provisional Application No. 62/315,737 filed on Mar. 31, 2016, and U.S. Provisional Application No. 62/315,744 filed on Mar. 31, 2016, the contents of each of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to composites and more specifically to composites comprising lignin, and methods for producing such composites.

BACKGROUND ART

There is increasing demand for cost effective composite materials derived from renewable materials. Lignin is ubiquitous in nature as a component in almost all cellulosic based plants, including trees. When trees or cellulosic feedstock are refined into pulp fiber, in many cases it is desirable to remove lignin from the pulp. This traditionally takes place during the Kraft process. The resulting lignin byproduct is contained within the black liquor which traditionally has been burnt to recover the energy as part of the economic balance of the pulp mill process. Besides the traditional kraft process, numerous other methods are known in the art to recover and purify lignin from chemical pulping and bio-refining processes, including dissolving, genetic, enzymatic and thermal pathways to lignin isolation. The properties of lignin can vary depending on the source and methods by which it is recovered and isolated. U.S. Pat. No. 8,771,464 describes a process for the recovery of high purity lignin.

Wood plastic composites (WPCs) have found application in a multitude of commercial products in recent years, and the overall market for WPCs is estimated to be billions of dollars annually. By and large, the leading uses for WPCs are in construction and automotive applications. When compared to conventional mineral and/or glass filled composites, WPCs have lower specific gravity and are often more cost effective. They also generally have the look of natural wood, which can be desirable. However, WPCs typically have poorer mechanical properties and moisture resistance compared to mineral and/or glass filled composites.

Lignin can be incorporated into composites that include a polymeric matrix. However, the lignin in such composites typically exhibits hydrophilic characteristics, which can in turn adversely affect the moisture resistance properties of the composites. It is therefore desirable to form lignin-based composites having improved moisture resistance and other properties.

SUMMARY OF INVENTION

According to an aspect of the invention, there is provided a composite that includes hydrophobic lignin and a polymeric matrix. The hydrophobic lignin is 0.1% to 90% by weight of the composite.

According to another aspect of the invention, there is provided a process for for making a composite that includes melt processing a mixture of hydrophobic lignin and a polymeric matrix.

According to another aspect of the invention, there is provided a process for making a composite that includes the step of melt processing a mixture that contains hydrophobic lignin and a polymeric matrix. The process may also include further melt processing a masterbatch from the first melt processing step, to form the composite.

According to another aspect of the invention, there is provided a process for making an article of manufacture. The process includes melt processing a mixture comprising hydrophobic lignin and a thermoplastic polymeric matrix and extruding the melt processed mixture into an article.

BRIEF DESCRIPTION OF DRAWINGS

In the figures which illustrate by way of example only, embodiments of the present invention,

FIG. 1 is a simplified flowchart depicting steps in an exemplary process for making hydrophobic lignin composites and articles manufactured therefrom; and

FIG. 2 is a flowchart diagram depicting steps involved in a process, exemplary of an embodiment of the present invention, for preparing hydrophobic lignin composites.

DESCRIPTION OF EMBODIMENTS

The following terms found in this disclosure are used as follows:

“Composite” is used to refer to a composite material comprising a polymeric matrix and a filler.

“Coupling Agent” is used to refer to an additive that improves the interfacial adhesion between a polymeric matrix and a cellulosic filler.

“Hydrophobic Lignin” is used to refer to lignin material that has an average molecular weight greater than 5,000 g/mol, reduced salt content with lower water absorption characteristics and an appropriate level of reactivity to bind with polymeric matrix.

“Hydrophobic Lignin Composite” is used to refer to a composite material that comprises hydrophobic lignin and a polymeric matrix.

“Lignin Composite” is used to refer to a composite material that comprises lignin and a polymeric matrix.

“Melt Processable Composition” is used to refer to a formulation that is capable of being melt processed, typically at elevated temperatures, by means of conventional polymer melt processing techniques such as extrusion or injection molding.

“Melt Processing Techniques” is used to refer to various melt processing techniques that may include, for example, extrusion, injection molding, blow molding, rotomolding, or batch mixing.

“Polymeric Matrix” is used to refer to a melt processable polymeric material.

“wt %” is used to denote percentage by weight as is commonly used in chemistry to express the relative composition of a mixture.

The above summary and the detailed description that follows are not intended to describe all embodiments or every possible implementation of the present technology. The detailed description is intended to provide some illustrative embodiments.

Exemplary embodiments of the present invention include composites based on hydrophobic lignin that in at least some specific embodiments, are more cost effective, have improved moisture resistance, antifungal properties or improved mechanical properties when compared to known lignin composites.

Some of the exemplary lignin composites described herein include a polymeric matrix and a hydrophobic lignin material. Other embodiments may further include natural fiber such as wood fiber.

In some embodiments, specific types of lignin added to a thermoplastic matrix, such as for example a wood plastic composite (WPC), the resulting composite exhibits improved moisture resistance, better antifungal and antimicrobial properties or higher oxidative performance compared to lignin composites known in the art.

The hydrophobic lignin used in the composites described herein may have a molecular weight greater than 5,000 g/mol. Particular exemplary embodiments of composites may be made using lignin manufactured according to a method described U.S. Pat. No. 8,771,464, which is incorporated herein by reference, in its entirety.

The above incorporated reference describes, a process for removing lignin from black liquor by oxidizing and acidifying the black liquor and filtering the acidified black liquor. The above incorporated reference also describes a process for separating lignin from black liquor. The process involves oxidizing black liquor containing lignin to destroy total reduced sulphur (IRS) compounds in the black liquor; acidifying the oxidized black liquor to precipitate lignin from the black liquor; and extracting lignin particles from the acidified liquor.

The above incorporated reference also describes a process for separating lignin from black liquor which includes the steps of a) oxidizing black liquor containing lignin to destroy total reduced sulphur compounds in the black liquor as well as oxidize certain organics to organic acids, b) acidifying the oxidized black liquor to precipitate lignin from the black liquor, c) filtering precipitated lignin particles from the acidified liquor, and d) treating the precipitated lignin particles with sulphuric acid and water.

Hydrophobic lignin can be incorporated into any suitable polymeric matrix to form a composite with enhanced mechanical and chemical properties. In some embodiments, the level of lignin in the polymeric matrix is in the range of about 0.1-90 wt %; in other embodiments the lignin level is in the range of about 0.5-50 wt %; and in particularly yet other embodiments the lignin level is in the range of about 1-20 wt %. These are weight percentages of hydrophobic lignin in the final composite.

The polymeric matrix may comprise one or more polymers. Non-limiting examples of polymers include: high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), functional polyolefin copolymers including polyolefin-based ionomers, polypropylene (PP), polyolefin copolymers (e.g., ethylene-butene, ethylene-octene, ethylene vinyl alcohol), polystyrene, polystyrene copolymers (e.g., high impact polystyrene, acrylonitrile butadiene styrene copolymer), polyacrylates, polymethacrylates, polyesters, polyvinylchloride (PVC), fluoropolymers, polylactic acid (PLA), polyamides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers (e.g., SIS, SEBS, SBS), or combinations thereof. For some end-use applications, polyolefins are well-suited to serve as polymeric matrices, for example, in articles useful as automotive components.

Bioplastics polymers useful in this invention include, biobased, biodegradable or compostable polyesters, polyamides, polyurethanes, polyacrylates, polyolefins, thermoplastic starches and cellulosics. Bioplastics of particular interest include biobased, biodegradable or compostable polyesters. Non limiting examples of biobased or biodegradable or compostable polyesters include: PLA (Polylactic acid), PHA (Polyhydroxyalkanoates), PBAT (polybutyrate adipate terephthalate), PBS (polybutylene succinate), PCL (polycaprolactones), PGA (Polygycolic acid).

Polylactic acid is increasingly proving to be a viable alternative to petrochemical-based plastics in many applications. PLA is produced from renewable resources and is biodegradable. This makes it well suited for green or environmentally sensitive applications. In addition, PLA has unique physical properties that make it useful in several industrial applications including paper coating, fibers, films, packaging materials and the like.

The polymeric matrix may optionally contain one or more additives. Non-limiting examples of additives include antioxidants, light stabilizers, fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, antimicrobial additives, compatibilizers, plasticizers, tackifiers, processing aids, lubricants, coupling agents, flame retardants and colorants. The additives may be incorporated into the melt processable composition in the form of powders, pellets, granules, or in other extrudable forms. The amount and type of additives incorporated in the melt processable composition can be suitably chosen, depending upon the polymeric matrix and the desired physical properties of the finished composition. Those skilled in the art of melt processing are capable of selecting appropriate amounts and types of additives for a specific polymeric matrix and hydrophobic lignin in order to achieve desired physical properties of the finished composite material.

Some embodiments of the present hydrophobic lignin composites comprise one or more additional fillers. These can be incorporated in the melt processable composition, and can be used to adjust the mechanical properties of the final composite material or articles made therefrom. For example, fillers can function to improve mechanical and thermal properties of the composite. Fillers can also be utilized to adjust the coefficient of thermal expansion (CTE) of the composite, to make it more compatible with other materials with which it is to be used, for example. Non-limiting examples of fillers include mineral and organic fillers (e.g., talc, mica, clay, silica, alumina, carbon fiber, carbon black, glass fiber) and conventional cellulosic materials (e.g., wood flour, wood fibers, non-wood plant fibers, sawdust, wood shavings, newsprint, paper, flax, hemp, wheat straw, rice hulls, kenaf, jute, sisal, peanut shells, soy hulls, or other cellulose containing materials). The amount and type of filler in the melt processable composition can be suitably chosen depending upon the polymeric matrix and the desired physical properties of the finished composition. Fillers such as calcium carbonate, talc, clay and cellulosic fiber are well-suited for many applications. In some embodiments, the additional filler makes up 1 wt % to 90 wt % of the composite; in some other embodiments, 5 wt % to 75 wt % of the composite; and in yet some embodiments 1 wt % to 60 wt % of the composite. In some embodiments, a natural fiber is used as filler in the hydrophobic lignin composite. In some embodiments, the natural fiber is wood fiber.

Hydrophobic lignin composites, incorporating optional additives and/or additional fillers, can be prepared by blending the components into the polymeric matrix. Depending on the type and nature of polymeric matrix, this can be done using a variety of conventional mixing processes. For melt processable thermoplastic compositions, the polymeric matrix and additives can be combined by any suitable blending technique commonly employed in the plastics industry, such as with a compounding mill, a Banbury mixer, or a mixing extruder. The mixing operation is most conveniently carried out at a temperature above the melting point or softening point of the polymeric matrix. In some cases melt processing of the mixture is performed at a temperature from 80° C. to 400° C., although suitable operating temperatures are selected depending upon the melting point, melt viscosity, and thermal stability of the composite formulation. Different types of melt processing equipment, such as extruders, may be used to process the melt processable compositions described.

The resulting melt-blended mixture can be either extruded directly into the form of the final product shape or can be pelletized or otherwise comminuted into a desired particulate size or size distribution, and then fed to an extruder, such as a twin-screw extruder, that melt-processes the blended mixture to form the final product shape.

A flowchart depicted in FIG. 1 illustrates the above process. An exemplary process S100 starts with mixing hydrophobic lignin and polymer matrix in step S102. If the optional use of additives is desired in step S104 then additives are added to the mixture (step S106), but otherwise the step S106 is bypassed. Similarly, if the optional use of additional fillers is desired (step S108) then additional fillers are added to the mixture (step S110), but otherwise step S110 is bypassed. As noted above, for melt processable thermoplastic compositions, the polymeric matrix and additives can be combined by any suitable blending technique such as with a compounding mill, a Banbury mixer, or a mixing extruder. In Step S112 melt processing is used, which in this embodiment may be at a temperature from 80° C. to 400° C. Depending on the decision on whether to pelletize/comminute at step S114, the output of step S112 is either extruded directly into the form of the final product shape (step S120) or can be pelletized or otherwise comminuted (S116) into a desired particulate size or size distribution, and then fed to an extruder, such as a twin-screw extruder, that melt-processes the blended mixture to form the final product shape (step S120).

Other exemplary embodiments of the process for the preparation of composites comprising hydrophobic lignin may involve, melt processing the polymeric matrix with lignin having a relatively high moisture content. In one such embodiment, the moisture content of the hydrophobic lignin prior to melt processing is greater than 10 wt %; while in another embodiment, the moisture content is greater than 20 wt %; and in yet another embodiment the moisture content may be greater than 40 wt %. In some embodiments, the moisture content of the hydrophobic lignin prior to melt processing is in the range of 40 wt % to 60 wt %.

In some exemplary processes for preparing hydrophobic lignin composites and articles made therefrom, hydrophobic lignin composites are produced in a two major steps. First, a masterbatch of the hydrophobic lignin composite is produced by melt processing hydrophobic lignin with a thermoplastic polymeric matrix, and optionally other additives or fillers. As noted above, the lignin may have a high moisture content. The resulting masterbatch has a high concentration of hydrophobic lignin, and can be subsequently letdown (or diluted) to a more suitable loading level for the final application using a second melt processing step (e.g., compounding, injection molding or extrusion). In some embodiments, the masterbatch may have a hydrophobic lignin content in the range of about 50 wt % to 99 wt %, and the letdown has a hydrophobic lignin content in the range of about 5wt % to 50 wt %.

A flowchart depicted in FIG. 2 illustrates one such exemplary process having two melt processing steps. As shown, an exemplary process S200 starts with mixing hydrophobic lignin and thermoplastic polymer matrix in step S202.

If the optional use of additives is desired in step S204 then additives are added to the mixture (step S206), but otherwise the step S206 is bypassed. Similarly, if the optional use of fillers is desired (step S208) then fillers are added to the mixture (step S210), but otherwise step S210 is bypassed.

In Step S212 melt processing is used to form a masterbatch. The resulting masterbatch may have high concentration of hydrophobic lignin. In some embodiments, the resulting masterbatch from step S212 may contain hydrophobic lignin that is in the range of about 50wt % to 99wt %.

This masterbatch from step S212 is subsequently let down or diluted in step S214. The diluted masterbatch from step S214 may contain hydrophobic lignin that is in the range of about 5wt % to 50wt %.

A second melt processing step S116 is subsequently employed to obtain the desired hydrophobic lignin composite. The melt processing in step S116 may include compounding, injection or extrusion.

The hydrophobic lignin composites described herein can be converted into articles using extrusion and molding techniques.

Embodiments of the hydrophobic lignin composites described herein have broad utility in packaging, building and construction markets. Non-limiting examples of potential uses of the hydrophobic lignin composites of this disclosure include decking, fencing, railing, roofing, siding and agricultural containers and films.

Articles produced by melt processing the lignin composites described herein can exhibit certain desirable characteristics. For example, they may have improved mechanical properties and moisture resistance.

TABLE 1
MATERIALS
Material           Supplier
High density       Ineos TS-440 119 HDPE, commercially available
polyethylene       from Bamberger Polymers, Inc, Jericho, NY
(HDPE1)
High density       Bapolene 2035 HDPE, commercially available
polyethylene       from Bamberger Polymers, Inc, Jericho, NY
(HDPE2)
Low density        Exxon LL 1 002 LLDPE, commercially
polyethylene       available from Exxon Mobil Chemical Inc.,
(LDPE)             Spring, TX
Lignin A -         Hydrophobic Lignin, commercially available from
hydrophobic lignin West Fraser Mills Inc., Quesnel, BC, Canada
Lignin B           Lignin, commercially available from West Fraser
                   Mills Inc., Quesnel, BC, Canada
Lube               Struktol TPW113 lubricant, commercially available
                   from Struktol Inc., Stow, OH
Wood Fiber         40 mesh maple, commercially available from
                   American Wood Fibers Inc., Schoefield, WI
Anti-oxidant (AO)  Hostanox PEPQ, commercially available from
                   Clariant Inc., Muttenz, Switzerland

TABLE 2
EXPERIMENTAL COMPOSITE SAMPLE FORMULATIONS
						Lig-	Lig-
Sam-	HDPEl	HDPE2	LDPE	Wood	Lube	nin A	nin B	AO
ple	wt %	wt %	wt %	wt %	wt %	wt %	wt %	wt %
1	—	39	—	57	3	1	—	—
2	—	39	—	56	3	2	—	—
3	—	39	—	53	3	5	—	—
4	—	39	—	48	3	10	—	—
5	—	39	—	38	3	20	—	—
6	—	—	39	57	3	1	—	—
7	—	—	39	56	3	2	—	—
8	—	—	39	53	3	5	—	—
9	—	—	39	48	3	10	—	—
10	—	—	39	38	3	20	—	—
11	99	—	—	—	—	1	—	—
CEl	100	—	—	—	—	—	—	—
CE2	99	—	—	—	—	—	—	1
CE3	—	—	40	57	3	—	—	—
CE4	—	40	—	57	3	—	—	—
CE5	—	39	—	53	3	—	5	—
CE6	—	—	39	53	3	—	5	—

Samples 1-11 containing various amounts of hydrophobic lignin (Lignin A) as indicated in TABLE 2. Samples CE1-4 contained no hydrophobic lignin, and were used as comparative examples. Samples CE5-6 contained a more hydrophilic lignin with a lower molecular weight (Lignin B).

Samples 1-10 and CE3-6 were prepared using the following procedure. The HDPE or LDPE and Lube were dry blended in a plastic bag and gravimetrically fed into the throat of a 27 mm twin screw extruder (52:1 L:D, commercially available from Entek Extruders, Lebanon, OR). The wood and lignin (if present) were dry blended and added to the side feed in zone 6. The compounding was performed using the following temperature profile in zones 1-13 (° F.): 170, 390, 400, 400, 400, 400, 360, 350, 340, 320, 300, 300, 300. The die was at 330° F. The compounds were extruded into strands and pelletized into pellets approximately 1-2 mm in length. The resulting composite was injection molded into test specimens and their properties tested following ASTM D790 (flexural properties) and ASTM D638 (tensile properties). Specific Gravity was determined using Archimedes Method. Impact testing (Izod impact) was performed following ASTM D256. Moisture uptake was determined by gravimetric analysis after 96 hour submersion in water. Results of this testing are given in TABLE 3 below.

Samples 11, CEI and CE2, having compositions as indicated in TABLE 2, were prepared using the following procedure. The HDPE, lignin and AO (if present) were dry blended in a plastic bag and gravimetrically fed into a 27 mm twin screw extruder (52:1 L:D, commercially available from Entek Extruders, Lebanon, Oreg.). The compounding was performed using the following temperature profile in zones 1-13 (° F.): 180, 360, 360, 360, 360, 360, 360, 360, 360, 360, 360, 360, 360. The die temperature was set to 380° F. The compounds were extruded into strands and pelletized into pellets approximately 1-2 mm in length and tested for Oxidative-Induction Time (01T) following ASTM D3895-07. Results of this testing are given in TABLE 3 below.

TABLE 3
EXPERIMENTAL RESULTS
	Flexural	Flexural	Specific	Izod Impact	Moisture
Sam-	Modulus	Strength	Gravity	Unnotched	Uptake	OIT
ple	(kpsi)	(kpsi)	(g/cm3)	(ft-lbs/in)	96 hr (%)	(min)
1	508	4.3	1.12	1.01	3.93	—
2	492	4.2	1.12	0.99	3.90	—
3	418	3.6	1.10	0.87	3.83	—
4	409	3.6	1.10	0.81	3.56	—
5	374	3.2	1.10	0.80	4.01	—
6	354	3.2	1.15	1.29	2.49	—
7	349	3.0	1.15	1.77	2.43	—
8	328	3.0	1.15	1.39	2.19	—
9	302	2.7	1.15	1.24	1.58	—
10	236	2.4	1.13	1.48	1.27	—
11	—	—	—	—	—	35.6
CE1	—	—	—	—	—	32.63
CE2	—	—	—	—	—	52.68
CE3	303	2.3	1.12	1.98	5.76	—
CE4	559	4.8	1.12	1.03	5.02	—
CE5	452	4.2	1.10	1.57	7.31	—
CE6	192	1.9	1.09	1.88	14.43	—

Results for Samples CE1-CE4 demonstrate properties for HDPE, and wood-filled HDPE and LDPE. Results for Samples 1-13 demonstrate the mechanical properties of hydrophobic Lignin A composites according to certain embodiments of the present invention. The moisture uptake of Lignin A composites is considerably lower than for the wood-filled composites and very much lower than for composites comprising the Lignin B.

Another study was carried out to evaluate antimicrobial properties of exemplary composites and in particular mold resistance of four panel groups in an AWPA E24-15 lab-based test. The samples included untreated southern pine (negative control) and a preservative-treated southern pine (positive control) group in accordance with AWPA E24-15 requirements. Samples were tested for resistance to collective mold fungi species as specified in AWPA E24-15. The test included 5 groups and an untreated and a treated southern pine control groups. Therefore, the test was performed with 7 groups and 4 replicates from each group for a total of 28 samples.

The tests were performed in accordance with American Wood Protection Association (AWPA) E24-15 Standard Method for Evaluating the Resistance of Wood

Product Surfaces to Mold Growth (AWPA 2015). All untreated southern pine control samples were milled and machined on a band saw.

Each sample had a zip tie connected to one end of it so it could be connected to a rod and suspended over soil that had been inoculated with known fungi. The samples were kept in a sealed chamber at 95% relative humidity and 25 C for 8 weeks. Samples were removed and evaluated on both faces for mold resistance every two weeks. Each sample was rated based on the following AWPA rating system:

TABLE 4
Rating Scale
Rating Mold Coverage
0      No visible growth
1      Mold growth covering up to 10% of surfaces providing growth
       that is not so intense or colored as to obscure the sample color
       on more than 5% of the surfaces
2      Mold growth between 10% and 30% of surfaces providing
       growth that is not so intense or colored as to obscure the
       sample color on more than 10% of the surfaces
3      Mold growth between 30% and 70% of surfaces providing
       growth that is not so intense or colored as to obscure the
       sample color on more than 30% of the surfaces
4      Mold on greater than 70% of surfaces providing growth that is
       not so intense or colored as to obscure the sample color
       on more than 70% of the surfaces
5      Mold on 100% of surfaces or with less than 100% coverage and
       with intense or colored growth obscuring greater than 70%
       of the sample cover

TABLE 5
Results - mold ratings of samples
	Week
	Sample	2	4	6	8
	1-1	0	0	0	0
	1-2	0	0	0	0
	1-3	0	0	0	0
	1-4	0	0	0	0
	Avg	0	0	0	0
	3-1	0	0	0	0
	3-2	0	0	0	0
	3-3	0	0	0	0
	3-4	0	0	0	0
	Avg	0	0	0	0
	4-1	0	0	0	0
	4-2	0	0	0	0
	4-3	0	0	0	0
	4-4	0	0	0	0
	Avg	0	0	0	0
	5-1	0	0	0	0
	5-2	0	0	0	0
	5-3	0	0	0	0
	5-4	0	0	0	0
	Avg	0	0	0	0
	6-1	0	0	0	0
	6-2	0	0	0	0
	6-3	0	0	0	0
	6-4	0	0	0	0
	Avg	0	0	0	0
	7-1	0	1	2	5
	7-2	0	1	3	5
	7-3	0	1	3	5
	7-4	0	1	2	5
	Avg	0	1	2.5	5
	8-1	0	0	0	1
	8-2	0	0	0	1
	8-3	0	0	0	0
	8-4	0	0	0	0
	Avg	0	0	0	0.5

As shown above, the untreated samples (Group 7) showed high attack by mold fungi which indicates good mold fungi vigor and thus the data are valid. As expected the positive control group (Group 6) provided excellent mold resistance. All groups of exemplary composites provided also showed excellent mold resistance.

Other useful properties of exemplary lignin composites disclosed herein include antioxidant characteristics. Lignin and its derivatives may exhibit antioxidant properties as characterized by, for example, radical scavenging index (RSI).

Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiments, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate embodiments or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.

The above-described embodiments are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention that is defined solely by the claims appended hereto.

Claims

1. A composite comprising hydrophobic lignin having an average molecular weight of greater than 5,000 g/mol and a polymeric matrix, wherein the hydrophobic lignin is 0.1% to 90% by weight of the composite.

2. The composite of claim 1, wherein said polymeric matrix is a thermoplastic polymeric matrix.

3. The composite of claim 2, wherein the hydrophobic lignin is 0.5% to 50% by weight of the composite.

4. The composite of claim 3, wherein the hydrophobic lignin is 1% to 20% by weight of the composite.

5. The composite of claim 1, wherein the hydrophobic lignin is 20% to 90% by weight of the composite.

6. The composite of claim 1, wherein the polymeric matrix comprises at least one of: high density polyethylene, low density polyethylene, linear low density polyethylene, functional polyolefin copolymers, polyolefin based ionomers, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polyacrylates, polymethacrylates, polyesters, polyvinylchloride (PVC), fluoropolymers, polyamides, polyether imides, polyphenylene sulfides, polysulfones, polylactic acid (PLA), polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, and thermoplastic elastomers.

7. The cellulosic composite of claim 1, wherein the polymeric matrix comprises bioplastics polymers comprising at least one of: biobased polyesters, biodegradable polyesters, compostable polyesters, polyamides, polyurethanes, polyacrylates, polyolefins, thermoplastic starches, cellulosics, PLA (Polylactic acid), PHA (Polyhydroxyalkanoates), PBAT (polybutyrate adipate terephthalate), PBS (polybutylene succinate), PCL (polycaprolactones), and PGA (Polygycolic acid).

8. The composite of claim 6, wherein said polyolefin copolymers comprise one of: ethylene-butene, ethylene-octene and ethylene vinyl alcohol; and wherein said polystyrene copolymers comprise one of: high impact polystyrene, and acrylonitrile butadiene styrene copolymer.

9. The composite of claim 1, further comprising an additional filler.

10. The composite of claim 9, wherein said additional filler comprises a natural fiber.

11. The composite of claim 10, wherein the natural fiber comprises wood fiber at a loading of 30% to 60% by weight.

12. The composite of claim 9, wherein said additional filler comprises one of: talc, mica, clay, silica, alumina, carbon fiber, carbon black, glass fiber, wood flour, wood fibers, non-wood plant fibers, sawdust, wood shavings, newsprint, paper, flax, hemp, wheat straw, rice hulls, kenaf, jute, sisal, peanut shells, and soy hulls.

13. The composite of claim 1, wherein said polymeric matrix comprises an additive selected from a group consisting of: antioxidants, light stabilizers, fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, antimicrobial additives, compatibilizers, plasticizers, tackifiers, processing aids, lubricants, coupling agents, flame retardants and colorants.

14. The composite of claim 1, wherein the composite has a moisture uptake of less than 5 wt % after 96 hours of immersion in water.

15. The composite of claim 1, wherein the composite has antimicrobial properties.

16. The composite of claim 15, wherein the composite has no visible mould growth after exposure to fungi for 8 weeks at 95% relative humidity and 25° C.

17. The composite of claim 16, having a mould coverage of 0 on a standardized mould rating scale of 0 to 5 after said exposure to fungi.

18. The composite of claim 1, wherein the composite is an antioxidant.

19. A process for making a composite, the process comprising: melt processing a mixture comprising hydrophobic lignin having an average molecular weight greater than 5,000 g/mol and a polymeric matrix.

20. A process for making a composite comprising:

a) melt processing a mixture comprising hydrophobic lignin having an average molecular weight greater than 5,000 g/mol and a thermoplastic polymeric matrix to form a masterbatch; and

b) further melt processing the masterbatch to form said composite.

21. The process of claim 20, further comprising: diluting said masterbatch prior to said further melt processing.

22. The process of claim 19, wherein the mixture comprises at least one of: an additive and a filler.

23. The process of claim 20, wherein each of the melt processing in (a) and said further melt processing in (b) is one of: compounding, injection molding and extrusion.

24. The process of claim 19, wherein said hydrophobic lignin is produced by:

a) oxidizing black liquor containing lignin to destroy total reduced sulphur compounds in the black liquor;

b) acidifying the oxidized black liquor to precipitate lignin from the black liquor; and

c) extracting lignin particles from the acidified liquor.

25. A process for making an article of manufacture comprising:

a) melt processing a mixture comprising hydrophobic lignin having an average molecular weight greater than 5,000 g/mol and a thermoplastic polymeric matrix; and

b) one of: extruding, compounding, and injection molding, the melt processed mixture into the article.

26. The process of claim 25, wherein said extruding is used, the process further comprising pelletizing the melt processed mixture prior to said extruding.

27. The process of claim 25, wherein said melt processing occurs at a temperature of 80° C. to 400° C.

28. The process of claim 20, wherein the mixture comprises at least one of: an additive and a filler.

29. The process of claim 20, wherein said hydrophobic lignin is produced by:

a) oxidizing black liquor containing lignin to destroy total reduced sulphur compounds in the black liquor;

b) acidifying the oxidized black liquor to precipitate lignin from the black liquor; and

c) extracting lignin particles from the acidified liquor.