Nanocellulose-dispersion concentrates and masterbatches, methods of making and using the same, and nanocellulose-containing composites

Abstract

The disclosed technology provides improved compositions and methods for dispersion and drying of nanocellulose, for polymer composites and other systems. Some variations provide a nanocellulose-dispersion concentrate comprising nanocellulose and a dispersion/drying agent selected for compatibility with the nanocellulose and with the nanocellulose-containing composite product, wherein the dispersion/drying agent is selected from the group consisting of waxes, polyolefins, olefinmaleic anhydride copolymers, olefinacrylic acid copolymers, polyols, fatty acids, fatty alcohols, polyolglyceride esters, polydimethylsiloxanes, polydimethylsiloxanealkyl esters, polyacrylamides, starches, cellulose derivatives, particulates, and combinations or reaction products thereof, and wherein the nanocellulose-dispersion concentrate is in solid form (e.g., a powder) or liquid form. Other variations provide a nanocellulose-dispersion masterbatch (e.g., pellets) comprising the nanocellulose-dispersion concentrate and a carrier material. Other variations provide a nanocellulose-containing composite including the nanocellulosedispersion masterbatch or concentrate and a matrix material. Processes of making and using the disclosed compositions are described.

1 . A nanocellulose-dispersion concentrate comprising:
 (a) from about 5 wt % to about 90 wt % nanocellulose; and   (b) from about 5 wt % to about 95 wt % dispersion/drying agent selected for compatibility with said nanocellulose,   wherein said dispersion/drying agent is selected from the group consisting of waxes, polyolefins, olefin-maleic anhydride copolymers, olefin-acrylic acid copolymers, polyols, fatty acids, fatty alcohols, polyol-glyceride esters, polydimethylsiloxanes, polydimethylsiloxane-alkyl esters, polyacrylamides, starches, cellulose derivatives, particulates, and combinations or reaction products thereof,   and wherein said nanocellulose-dispersion concentrate is in solid form or liquid form.   
     
     
         2 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose is present at a concentration of about 10 wt % to about 70 wt %, and wherein said dispersion/drying agent is present at a concentration of about 5 wt % to about 50 wt %. 
     
     
         3 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said weight ratio of said nanocellulose to said dispersion/drying agent is selected from about 0.5 to about 2. 
     
     
         4 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose-dispersion concentrate consists essentially of said nanocellulose and said dispersion/drying agent. 
     
     
         5 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose includes cellulose nanocrystals, cellulose nanofibrils, microfibrillated cellulose, or a combination thereof. 
     
     
         6 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose includes lignin-containing nanocellulose. 
     
     
         7 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose includes lignin-coated nanocellulose. 
     
     
         8 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent is a functionalized polyalkylene wax that is functionalized for compatibility with said nanocellulose. 
     
     
         9 . The nanocellulose-dispersion concentrate of  claim 8 , wherein said functionalized polyalkylene wax is a functionalized polyethylene wax, a functionalized polypropylene wax, a functionalized polybutylene wax, or a combination thereof. 
     
     
         10 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent is a low-molecular weight oligomer or polymer of ethylene or functionalized ethylene, with number-average degree of polymerization from 2 to 1000. 
     
     
         11 . The nanocellulose-dispersion concentrate of  claim 10 , wherein said number-average degree of polymerization is from 5 to 500. 
     
     
         12 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent is a copolymer of (a) one or more C 2 -C 4  olefins and (b) maleic anhydride. 
     
     
         13 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent is a copolymer of (a) one or more C 2 -C 4  olefins and (b) acrylic acid. 
     
     
         14 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent includes a polyol selected from ethylene glycol, polyethylene glycol, propylene glycol, polypropylene glycol, glycerol, butylene glycol, polybutylene glycol, or a combination thereof, wherein said polyol is optionally esterified with a fatty acid. 
     
     
         15 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent includes an alkyl ester polydimethylsiloxane emulsion. 
     
     
         16 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent includes cationic starch, amphoteric starch, thermoplastic starch, or a combination thereof. 
     
     
         17 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent includes a particulate selected from the group consisting of clay, nano-clay, talc, wollastonite, calcium carbonate, silica, mica, kaolin, nickel, glass fibers, bentonite, biotite, illite, kaolin, vermiculite, zeolite, carbon fibers, carbon nanotubes, graphene, or a combination thereof, and wherein said particulate optionally has a surface charge. 
     
     
         18 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said dispersion/drying agent includes at least one fatty acid and at least one particulate. 
     
     
         19 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose-dispersion concentrate further comprises a liquid solvent, and wherein said liquid solvent is optionally selected from the group consisting of water, C 1 -C 8  alcohols, C 2 -C 8  polyols, and combinations thereof. 
     
     
         20 . The nanocellulose-dispersion concentrate of  claim 1 , wherein said nanocellulose-dispersion concentrate further comprises from about 0.1 wt % to about 50 wt % of one or more elastomers. 
     
     
         21 - 96 . (canceled)