Biobased compositions from distillers' dried grains with solubles and methods of making those

Abstract

A composition and process of making the composition having a dried particulate by-product of starch fermentation of a grain to produce ethanol such as DDGS, and a polymerized polyurethane binder derived from a polyurethane prepolymer that is a reaction product of at least one polyol and at least one isocyanate. The by-product is present in the composition in an amount between about 20 and 90% by weight of the composition.

1 . A composition which comprises: 
 (a) a dried particulate by-product of starch fermentation of a grain to produce ethanol; and    (b) a polymerized polyurethane binder derived from a polyurethane prepolymer comprising a reaction product of at least one polyol and at least one isocyanate, the by-product being present in an amount between about 20 and 90% by weight of the composition.    
     
     
         2 . The composition of  claim 1 , wherein the polyol is a plant oil-based polyol.  
     
     
         3 . The composition of  claim 2 , wherein the plant oil-based polyol is selected from the group consisting of castor oil, soybean oil, rapeseed oil and mixtures thereof.  
     
     
         4 . The composition of  claim 1 , wherein the isocyanate is a diisocyanate selected from the group consisting of 4, 4′-methylenedi-p-phenyl diisocyanate (MDI), naphthalene 1,5-diisocyanate (NDI), toluene diisocyanate (TDI), hexamethylene diisocyanate (HDI), IPDI, H 12 -MDI, tetramethylene diisocyanate, and mixtures thereof.  
     
     
         5 . The composition of  claim 1 , wherein the by-product is derived from corn.  
     
     
         6 . The composition of  claim 5 , wherein the by-product is distiller's dried grains with solubles (DDGS ).  
     
     
         7 . The composition of  claim 1 , wherein the polyurethane prepolymer was formed in the presence of an organometallic or amine catalyst.  
     
     
         8 . The composition of  claim 1 , wherein the organometallic catalyst is selected from the group consisting of tin (II) 2-ethylhexanoate, tinbutyltin dilaurate, and stannous octoate.  
     
     
         9 . The composition of claims  1 ,  2  or  5 , wherein the composition was extruded.  
     
     
         10 . The composition of claims  1 ,  2  or  5 , wherein the composition was rapidly extruded and then molded under pressure at elevated temperatures.  
     
     
         11 . The composition of claims  1 ,  2  or  5 , further comprising natural fibers and organo-clay.  
     
     
         12 . The composition of  claim 11 , wherein the natural fibers are corn fibers.  
     
     
         13 . A process for producing the composition as set forth in claims  1 ,  2  or  5 , which comprises extruding a mixture of the prepolymer and the by-product at a temperature between about 25° C. and 80° C.  
     
     
         14 . The process of  claim 13  wherein in addition the composition is molded under pressure at elevated temperatures between 80° C. and 150° C.  
     
     
         15 . A process for producing a composition comprising: 
 (a) providing a polyurethane prepolymer comprising a reaction product of at least one polyol and at least one isocyanate;    (b) extruding a mixture of the polyurethane prepolymer and a dried particulate by-product of starch fermentation of a grain to provide an extrudate; and    (c) molding the extrudate of step (b) to form the composition, wherein the by-product is present in an amount between about 20 and 90% by weight of the composition.    
     
     
         16 . The process of  claim 15 , wherein the extrudate of step (b) is compression molded in step (d).  
     
     
         17 . A composition produced by the process of  claim 15 .  
     
     
         18 . The composition of  claim 17 , wherein the composition is formed as a product selected from the group consisting of a piece of furniture, a tray, a sheet, and a container.  
     
     
         19 . A process for producing a composition comprising: 
 (a) providing a polyurethane prepolymer comprising a reaction product of at least one polyol and at least one isocyanate;    (b) providing natural fibers;    (c) extruding a mixture of the polyurethane prepolymer, the natural fibers, and a dried particulate by-product of starch fermentation of a grain to provide an extrudate; and    (d) molding the extrudate of step (b) to form the composition, wherein the by-product is present in an amount between about 20 and 90% by weight of the composition.    
     
     
         20 . The process of  claim 19 , wherein the extrudate of step (b) is compression molded in step (d).  
     
     
         21 . The process of  claim 19 , wherein the extrudate of step (b) is injection molded in step (d).  
     
     
         22 . A composition produced by the process of  claim 19 .  
     
     
         23 . The composition of  claim 22 , wherein the composition is formed as a product selected from the group consisting of a piece of furniture, a tray, a sheet, and a container.