Thermoset composite having thermoplastic characteristics

Abstract

A composite composition includes a thermoset resin and about 3 wt. % to about 35 wt. % of at least one material selected from the group consisting of cellulose nanofibrils (CNF), micro-sized cellulose fibers (MFC), and cellulose nanocrystals (CNC) dispersed therein as measured with respect to the overall weight of the composite composition. The cellulose nanofibrils and/or nanocrystals have an average diameter of about 5 nm to about 500 nm and an average aspect ratio in the range of about 5:1 to about 500:1. The cellulose micro-sized fibers have an average diameter of about 5 μm to about 100 μm and an average aspect ratio in the range of about 5:1 to about 250:1.

What is claimed is: 
     
         1 . A composite composition comprising a thermoset resin and about 3 wt. % to about 35 wt. % of at least one material selected from the group consisting of cellulose nanofibrils (CNF), micro-sized cellulose fibers (MFC), and cellulose nanocrystals (CNC) dispersed therein as measured with respect to the overall weight of the composite composition;
 wherein the cellulose nanofibrils and/or nanocrystals having an average diameter of about 5 nm to about 500 nm and an average aspect ratio in the range of about 5:1 to about 500:1;   wherein the cellulose micro-sized fibers have an average diameter of about 5 μm to about 100 μm and an average aspect ratio in the range of about 5:1 to about 250:1.   
     
     
         2 . A composite composition in accordance with  claim 1 , wherein the thermoset resin is selected from the group consisting of epoxy resins, vinyl ester resins, and polyester resins. 
     
     
         3 . A composite composition in accordance with  claim 2 , wherein the composite composition further comprises a curing agent. 
     
     
         4 . A composite composition in accordance with  claim 3  wherein the composite composition comprises a mixture of an epoxy resin and a curing agent. 
     
     
         5 . A composite composition in accordance with  claim 3 , wherein the curing agent is selected from the group consisting of a polyamide, an amidoamine, an aliphatic amine, a cycloaliphatic amine, or a mixture thereof. 
     
     
         6 . A composite composition in accordance with  claim 1 , wherein the thermoset resin is uncured. 
     
     
         7 . A composite composition in accordance with  claim 1 , wherein the thermoset resin is at least partially cured. 
     
     
         8 . A composite composition in accordance with  claim 7 , wherein the cure of the thermoset resin includes allowing the thermoset resin to remain at ambient temperature or heating the thermoset resin until the thermoset resin is substantially cured. 
     
     
         9 . A composite composition in accordance with  claim 1 , wherein the thermoset resin in the composite composition is a water-based thermoset resin. 
     
     
         10 . A composite composition in accordance with  claim 1 , wherein the composite composition further comprise one or more additional additives;
 wherein the additional additive is selected from the group consisting of solvents, cure accelerators, cure inhibitors, additional polymers, pigments or colorants, fillers, dispersants or surfactants, coalescent agents, pH neutralizing agents, plasticizers, defoamers, thickeners, biocides, co-solvents, rheology modifiers, wetting or spreading agents, leveling agents, conductive additives, adhesion promoters, anti-blocking agents, anti-cratering agents or anti-crawling agents, antifreezing agents, corrosion inhibitors, anti-static agents, flame retardants, optical brighteners, UV absorbers or other light stabilizers, chelating agents, flattening agents, flocculants, humectants, insecticides, lubricants, odorants, oils, waxes or anti-slip aids, soil repellants, and stain resistant agents.   
     
     
         11 . A method of making an article comprising the steps of:
 forming a composite composition comprising an uncured thermoset resin and about 3 wt. % to about 35 wt. % of at least one material selected from the group consisting of cellulose nanofibrils (CNF), micro-sized cellulose fibers (MFC), and cellulose nanocrystals (CNC) dispersed therein as measured with respect to the overall weight of the composite composition; wherein the cellulose nanofibrils and/or nanocrystals having an average diameter of about 5 nm to about 500 nm and an average aspect ratio in the range of about 5:1 to about 500:1; wherein the cellulose micro-sized fibers have an average diameter of about 5 μm to about 100 μm and an average aspect ratio in the range of about 5:1 to about 250:1.   depositing the composite composition to fabricate a green article; and   allowing the green article to remain at ambient temperature or be heated to a predetermined temperature and for a predetermined time, such that the thermoset resin is at least partially cured, thereby, making the article.   
     
     
         12 . The method according to  claim 11 , wherein forming a composite composition comprises the steps of:
 providing the uncured thermoset resin;   providing the cellulose nanofibrils (CNF), micro-sized cellulose fibers (MFC), and/or cellulose nanocrystals (CNC);   optionally, providing a curing agent; and   mixing the thermoset resin and the optional curing agent when present with the CNF, MFC, and/or CNC to form the composite composition.   
     
     
         13 . The method according to  claim 11 , wherein depositing the composite composition to fabricate a green article comprises a 3-D printing process. 
     
     
         14 . The method in accordance with  claim 11  wherein the composite composition comprises a thermoset resin selected from the group consisting of epoxy resins, vinyl ester resins, and polyester resins. 
     
     
         15 . The method in accordance with  claim 14 , wherein the composite composition comprises a mixture of an epoxy resin and the curing agent. 
     
     
         16 . An article of manufacture comprising a composite composition that is at least partially cured; the composite composition including a thermoset resin and about 3 wt. % to about 35 wt. % of at least one material selected from the group consisting of cellulose nanofibrils (CNF), micro-sized cellulose fibers (MFC), and cellulose nanocrystals (CNC) dispersed therein as measured with respect to the overall weight of the composite composition;
 wherein the cellulose nanofibrils and/or nanocrystals having an average diameter of about 5 nm to about 500 nm and an average aspect ratio in the range of about 5:1 to about 500:1;   wherein the cellulose micro-sized fibers have an average diameter of about 5 μm to about 100 μm and an average aspect ratio in the range of about 5:1 to about 250:1.   
     
     
         17 . The article in accordance with  claim 16 , wherein the composite composition is substantially cured. 
     
     
         18 . The article in accordance with  claim 16 , wherein the thermoset resin is selected from the group consisting of epoxy resins, vinyl ester resins, and polyester resins. 
     
     
         19 . The article in accordance with  claim 18 , wherein the composite composition comprises a mixture of an epoxy resin and a curing agent. 
     
     
         20 . The article in accordance with  claim 19 , wherein the curing agent is selected as one from the group consisting of a polyamide, an amidoamine, an aliphatic amine, a cycloaliphatic amine, or a mixture thereof.