PROCESS FOR MANUFACTURING BIOPLASTIC AND DERIVED BIOPLASTIC PRODUCT

Description

1 / 7 PROCESS FOR MANUFACTURING BIOPLASTIC AND DERIVED BIOPLASTIC PRODUCT DESCRIPTIVE REPORT FIELD OF THE INVENTION

[0001] Process for the production of bioplastic and resulting product where the process is characterized by the use of Brazil nut shells from which lignin and cellulose are extracted and which are combined with lignocellulose from other biomasses such as cocoa, açaí, coconut, tucumã, among others. Other polymeric matrices, such as potato, latex or recycled plastic, may be added to this mixture. The result, the product, is a bioplastic with a maximum of 70% of these polymeric matrices. PREVIOUS EDITIONS

[0002] The increasing pollution from conventional plastics, which take centuries to degrade, represents a major environmental challenge. These materials accumulate in ecosystems, contaminate waterways, and affect wildlife. Furthermore, the reliance on fossil fuels for their production exacerbates the problem of carbon emissions, contributing to global warming. On the other hand, there is a growing demand for sustainable materials that maintain high durability and mechanical strength without compromising biodegradability. Another challenge is the development of materials that can replace traditional plastics in industrial and commercial applications without losing functionality or economic viability. The search for innovative solutions that combine renewable materials, UV resistance, and flexibility is crucial to meet increasingly stringent environmental regulations and promote a sustainable circular economy. Some relevant inventions in this context are listed below.

[0003] US2024317977A1 ​​materials and systems of composite biomass and methods for Petition 870250000937, dated 06 / 01 / 2025, page 9 / 16 2 / 7 do the same.

[0004] This application claims the benefit of priority under U.S. Provisional Patent Application No. 63 / 492,175, filed March 24, 2023, entitled SUPERWOOD.

[0005] The invention described herein is directed to wood products that are comparable in strength to steel, non-corrosive, fire-resistant, lightweight, and pest-resistant with long-term stability that far exceeds current building materials.

[0006] EP3266810A1 Lignin composite material and method for its production.

[0007] The invention described herein relates to the use of lignin-based composite material according to the present invention for the preparation of adhesives, membranes, water-retaining materials, fire-retardant materials, fire-extinguishing materials, biomass-derived materials, medium-density fiberboard, particleboard, foams, insulators, and packaging materials. The present invention further relates to wood-based material or wood-like material composed of lignin-based composite material according to the present invention or obtained by a process according to the present invention. The wood-based material is, in particular, fiberboard and chipboard.

[0008] KR102519620B1 Bioplastic composite composed of wet torrefied lignocellulosic biomass and biodegradable polymer and method of preparation thereof.

[0009] The present invention aims to reinforce biodegradable polymers through the torrefaction of hemicellulose. Thus, unlike inorganic additives, such as conventional calcium carbonate, the wet torrefied lignocellulosic biomass of the present invention is an environmentally friendly organic additive, and its hydrophilicity is also reduced to improve interfacial compatibility with biodegradable polymers.

[0010] CN114874472A Production and application method for biodegradable lignocellulosic bioplastic.

[0011] Preferably, the molds can be used to prepare gel materials. Petition 870250000937, dated 06 / 01 / 2025, page 10 / 16 3 / 7 of cellulose / lignin is molded into specific shapes, such as cups, lunchboxes, and straws, and then dried to obtain corresponding lignin / cellulose bioplastic cups, lunchboxes, and straws.

[0012] US2019255817A1 Method for manufacturing lignin-based polymer systems.

[0013] The above invention description mentions the use of lignin as a layer additive to improve PLA, a compostable and bio-based polyester that has the disadvantages of:

[0014] The low melting point makes PLA unsuitable for high-temperature applications. PLA may even show signs of softening or warping on a hot summer day. PLA has a higher permeability than other plastics. Moisture and oxygen will pass through it more easily than other plastics. This will result in faster food spoilage. PLA is not recommended for long-term food storage applications. PLA is not the hardest or most durable plastic. PLA is not suitable for applications where toughness and impact resistance are critical.

[0015] US10173353B2 Biocomposite and / or biomaterial with sunflower seed husks / shells.

[0016] This invention relates to a biomaterial and / or a biocomposite based on sunflower seed husks / shells. According to the invention, it is proposed that sunflower seed husks / shells be used instead of wood, bamboo, or other wood-like fiber products as the source material for biocomposite products. In reference to this invention, the fact that it incorporates a small amount of lignin restricts the result to a less resistant plastic. The invention, although mentioning the use of chestnut shells, does not mention the use of Brazil nuts.

[0017] EP0864612A1 Composite Materials Thermoplastic and Lignin Composites and Production Process. Petition 870250000937, dated 06 / 01 / 2025, p. 11 / 16 4 / 7

[0018] This invention relates to a process and formulations for the production of composite materials consisting of thermoplastic and lignin, obtained in a thermokinetic mixer under conditions of minimal thermal degradation that ensure adequate dispersion of the lignin in the thermoplastic matrix and provide materials whose physical, mechanical and thermal properties make them suitable for various applications. The process is carried out in two stages: the first stage comprises heating and melting the thermoplastic material; in the second stage the polymer is mixed with the lignin. The present invention restricts lignin as an additive to make the polymeric matrix less polluting. It uses a pre-formulated lignin, does not use lignocellulose and regenerated cellulose, and does not use biomass as a filler in the polymer. GENERAL DESCRIPTION

[0019] In view of the gaps found in the state of the art, we have developed here a new technique for the construction of bioplastics with a maximum of 70% polymer matrices that can be seen as a manufacturing process and an automatically obtained product.

[0020] The Process

[0021] The process consists of eleven (11) steps:

[0022] 1 (a).: Grinding of Brazil nuts (Bertholletia excelsa) to a particle size of 0.25 - 2.00 mm

[0023] 2 (b).: Separate grinding of açaí biomass or other lignocellulosic biomass.

[0024] 3 (c).: Treatment of lignocellulosic material derived from (1) with pressure of 8-13 bar temperature between 120-200oC in an alcoholic solution in the range of 30-70%. In this step the soluble lignin is removed from the mixture and sent to step 5.

[0025] 4 (d). Bleaching in hydrogen peroxide under alkaline conditions with pH of 9 to 13.5 and temperature between 30-70oC. In this step, lignin is extracted. Petition 870250000937, dated 06 / 01 / 2025, page 12 / 16 5 / 7 soluble and regenerated cellulose is sent to be mixed with the cellulose derived from step 2. The insoluble lignin removed from this phase is taken to be mixed with the soluble lignin removed from the previous step. The two are mixed in step 5.

[0026] 5 (e). Mixture of lignins obtained in steps 3 and 4. These lignins are essential for the UV resistance of the final bioplastic.

[0027] 6 (f). Mixture of regenerated cellulose removed from steps 3 and 4 with cellulose from crushed lignocellulosic biomass obtained in step 2. Both are ground in an industrial blender.

[0028] 7 (g). Grinding of lignocellulosic biomass in a mill.

[0029] 8 (h). Sieving of the lignocellulosic biomass derived from step 7, until a particle size < 0.063 mm is achieved.

[0030] 9 (i). Addition of polymer matrix to the lignin resulting from step 5. This step can be omitted if a 100% plant-based bioplastic is desired. The percentage of polymer matrix to be added to the lignin depends on the desired bioplastic results.

[0031] 10 (j). Mixing and homogenizing the products from steps 8 and 9 in extruders capable of homogenizing the mixture, such as twin-screw extruders. Note that this process allows the construction of a bioplastic with lignin and lignocellulosic biomass values ​​equal to or greater than 30%.

[0032] 11 (k). Injection or compression molding

[0033] Result: Bioplastic with at least 30% of: lignin, regenerated cellulose and lignocellulosic biomass. Note that among the properties of this bioplastic is UV resistance, which is greater the higher the lignin component in the bioplastic.

[0034] The product:

[0035] The resulting product is a bioplastic with more than 30% biodegradable material (derived from biomass) and with resistance to ultraviolet (UV) rays and with traceability of lignin and its proportions to identify the raw material. Petition 870250000937, dated 06 / 01 / 2025, page 13 / 16 6 / 7 used and its origin. Note that depending on the desired properties of the final product, the amounts of polymer matrix may vary. The use of vegetable-derived latex or vegetable-derived potato can ensure that even with some polymer matrix component, the resulting bioplastic is still biodegradable.

[0036] The use of recyclable plastic as a polymer matrix, although the latter is not fully biodegradable, still provides a good solution from an environmental point of view.

[0037] The use of a polymer matrix in step 5 contributes to the plastic's strength.

[0038] The presence of lignocellulosic biomass and regenerated cellulose ensures good lignin distribution in the bioplastic.

[0039] In Figure 1, the Bioplastic Process consists of the following steps:

[0040] a. Grinding of Brazil nut biomass into a particle size of 0.25–2.00 mm

[0041] b. Crushing the Bark

[0042] c. Treatment of lignocellulosic material with pressure of 8-13 bar and temperature between 120-200°C in an alcoholic solution in the range of 30-70%

[0043] d. Hydrogen peroxide bleaching under alkaline conditions with pH 9 to 13.5. Temperature between 30-70°C.

[0044] e. Lignin

[0045] f. Grinding in an industrial blender

[0046] g. Benchtop milling

[0047] h. Sieving of samples with particle size < 0.063 mm

[0048] i. Lignin + polymer matrix

[0049] j. Homogenization: 30% lignocellulosic biomass + 70% lignin with polymer matrix; in a twin-screw extruder

[0050] k. Injection or compression Petition 870250000937, dated 06 / 01 / 2025, page 14 / 16 7 / 7 PREFERRED MODALITIES

[0051] A preferred first approach is the use of a biodegradable polymer matrix based on natural latex and / or batala, providing greater flexibility and handling to the bioplastic without compromising its biodegradability.

[0052] A second preferred option is the use of a recyclable polymer matrix derived from recycled PET plastics and / or other polymers, providing greater mechanical strength and contributing to environmental sustainability.

[0053] A third preferred application is the use of bioplastics in injection-molded products, enabling the manufacture of durable and environmentally friendly packaging for use in food and cosmetics.

[0054] A fourth preferred method is the incorporation of natural pigments and antioxidant additives during the homogenization step, increasing the thermal stability and durability of the bioplastic.

[0055] A fifth preferred application is the use of bioplastics in compostable materials for agriculture, such as soil covering films, promoting biodegradability in the agricultural environment.

[0056] A sixth preferred embodiment is the optimization of the extrusion process with twin-screw extruders to ensure ideal homogenization and improve the mechanical properties of the final product.

[0057] A seventh preferred method is the use of automated temperature and pressure control during the treatment and bleaching stages, ensuring greater efficiency and quality in the processing of materials.

[0058] An eighth preferred method is the addition of compatibilizing agents in the mixing stage, promoting greater integration between the lignocellulosic components and the polymer matrix, increasing the strength and flexibility of the final product. Petition 870250000937, dated 06 / 01 / 2025, page 15 / 16

Claims

1 / 2 CLAIMS 1. Process for the manufacture of bioplastic, characterized by comprising the following steps: (a) grinding of Brazil nuts (Bertholletia excelsa) to a particle size of 0.25 - 2.00 mm; (b) separate grinding of açaí biomass or other lignocellulosic biomass; (c) treatment of the lignocellulosic material derived from (a) with a pressure of 8-13 bar and a temperature between 120-200°C in an alcoholic solution in the range of 30-70%, removing soluble lignin; (d) bleaching in hydrogen peroxide under alkaline conditions with a pH of 9 to 13.5 and a temperature between 30-70°C, removing insoluble lignin and regenerating cellulose; (e) mixing of the lignins obtained in (c) and (d) for UV resistance; (f) mixing the regenerated celluloses from (c) and (d) with crushed lignocellulosic biomass from (b); (g) grinding the lignocellulosic biomass in a mill; (h) sieving the lignocellulosic biomass until it reaches a particle size < 0.063 mm;(i) addition of a polymer matrix to the lignin in (e), which may be omitted for 100% plant-based bioplastic; (j) mixing and homogenization of the products from (h) and (i) in extruders; (k) injection or compression molding, resulting in bioplastic with at least 30% lignin, regenerated cellulose and lignocellulosic biomass.

2. Bioplastic-derived product, characterized by containing more than 30% biodegradable material derived from biomass and possessing resistance to ultraviolet (UV) rays, and may include a polymer matrix in varying proportions.

3. Process for the manufacture of bioplastic, according to claim 1, characterized in that step (c) uses an alcoholic solution composed of ethanol or methanol.

4. Process for manufacturing bioplastic, according to claim 1, characterized by including in step (i) a recyclable polymer matrix to improve the mechanical strength of the bioplastic.

5. Process for the manufacture of bioplastic, according to claim 1, characterized in that step (j) uses twin-screw extruders for better homogenization of the mixture. Petition 870250000937, dated 06 / 01 / 2025, page 7 / 16 2 / 2 6. Process for manufacturing bioplastic, according to claim 1, characterized by allowing adjustment in the proportion of lignin and polymer matrix to modify the properties of the final product.

7. Bioplastic-derived product, according to claim 2, characterized by using a polymer matrix of vegetable origin, such as latex or potato, guaranteeing biodegradability above 30% even with polymer components.

8. Bioplastic-derived product, according to claim 2, characterized by including lignocellulosic biomass and regenerated cellulose to ensure good lignin distribution and UV resistance.

9. Bioplastic-derived product, as per claim 2, characterized by allowing the identification of the raw material used and its proportions and its origin through lignin traceability. Petition 870250000937, dated 06 / 01 / 2025, p. 8 / 16

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