Patent AU-2013203469-B2 (AU)
Title: Fibrous materials and composites
Inventor: MEDOFF MARSHALL
IPC: B29D99/00
Filed: 2013-04-10
Granted: 2015-01-22
Abstract: PEnarish European Patent Office Euro pean 80298 MUNICH Patent Office GERMANY Office europeen Tel: +49 89 2399 0 des brevets Fax: +49 89 2399 4465 Annex to EPO Form 2004, Communication pursuant to Rule 71(3) EPC Bibliographical data of European patent application No. 12 170 613.9 For the intended grant of the European patent, the bibliographical data are set out below, for information: Title of invention: - Verfahren zur Herstellung eines Fasermaterials - Method of making fibrous material - Procede de fabrication d'un materiau fibreux Classification: INV. B02C18/14 B02C18/00 D21C9/00 B02C1 3/284 Date of filing: 23.03.2006 Priority claimed: US / 24.03.2005 / USP664832 US / 07.06.2005 / USP688002 US /24.08.2005 /USP711057 US / 09.09.2005 / USP71 5822 US /12.10.2005 / USP725674 US /12.10.2005 / USP726102 US /13.12.2005 / USP750205 Contracting States* for which fees have been paid: AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LI LT LU LV MC NL PL PT RO SE SI SK TR Extension States* for which fees have been paid: Applicant(s)**: Xyleco, Inc. 271 Salem Street, Unit L Woburn MA 01801 Inventor(s): Medoff, Marshall 90 Addington Road Brookline, MA Massachusetts 02146 *) If the time limit for the payment of designation fees according to Rule 39(1) EPC has not yet expired and the applicant has not withdrawn any designation, all Contracting States/Extension States are currently still deemed to be designated. See also Rule 71(8) EPC and, if applicable, the above Note to users of the automatic debiting procedure. **) If two or more applicants have designated different Contracting States, this is indicated here. )) Europa sches Patentamt European Patent Office European80298 MUNICH Patent Office GER+ 8 2 9 Office europeen Fax: +49 89 2399 4465 J) ) des brevetsFa:+9823946 Application No.: 12170 613.9 IV.2. Patent classification The classification has been changed. It now is as follows: INV. B02C18/14 B02C18/00 D21C9/00 B02C1 3/284 IV.3. Title of the invention The title has been changed. It now is as follows: Verfahren zur Herstellung eines Fasermaterials Method of making fibrous material Proc6d6 de fabrication d'un mat6riau fibreux IV.4. Documentation 1 8. 10. 13 Date Kopp, Christian Kujat, Christian Muller, Gerard Chairman 1st examiner 2nd examiner Enclosure(s): PO Form 2035.4 (Sheet 1) 12.07TRI CLAIMS: 1. A method of making fibrous material, the method comprising: shearing a fiber source (10) to provide a first fibrous material (12); and 5 passing the first fibrous material (12) through a first screen (16) to provide a second fibrous material (14), wherein the average opening size of the first screen (16) is 1.59 mm or less, wherein the method further comprises shearing the second fibrous material (14) to form a third fibrous material (62), and further comprising cutting the fiber source (10) 10 prior to shearing the fiber source (10). 2. The method of claim 1, wherein the average opening size of the first screen (16) is less than 0.79 mm, or less than 0.51 mm, or less than 0.40 mm, or less than 0.20 mm, or less than 0.10 mm. 3. The method of claim 1, wherein the shearing is performed with a rotary knife cutter (20). 4. The method of claim 1, wherein the second fibrous material (14) is collected in a 20 bin (30) having a pressure below nominal atmospheric pressure, preferably wherein the pressure is at least 10 percent below nominal atmospheric pressure or at least 50 percent below nominal atmospheric pressure. 5. The method of claim 4, wherein the pressure is at least 75 percent below nominal 25 atmospheric pressure. 6. The method of claim 1, further comprising shearing the second fibrous material (14) and passing the resulting fibrous material through the first screen (16). 30 7. The method of claim 1, further comprising shearing the second fibrous material (14), and passing the resulting fibrous material through a second screen (60) having an average opening size less than the first screen (16) to provide a third fibrous material (62), preferably wherein a ratio of an average length-to-diameter ratio of the second fibrous material to an average length-to-diameter ratio of the third fibrous material is less 35 than 1.5 or less than 1.4 or less than 1.25 or less than 1.1. 8. The method of claim 1, further comprising passing the second fibrous material (14) through a second screen (60) having an average opening size less than the first screen (16) or wherein the shearing and passing are performed concurrently. 9. The method of claim 1, wherein an average length-to-diameter ratio of the second 5 fibrous material (14) is greater than 10/1 or greater than 25/1 or greater than 50/1 or wherein an average length of the second fibrous material (14) is between 0.5 mm and 2.5 mm, preferably wherein the average length is between 0.75 mm and 1.0 mm or wherein an average width of the second fibrous material (14) is between 5 pm and 50 pm, optionally wherein the average width is between 10 pm and 30 pm. 10. The method of claim 1, wherein a standard deviation of a length of the second fibrous material (14) is less than 60 percent of an average length of the second fibrous material (14), optionally wherein the standard deviation is less than 50 percent. 15 11. The method of claim 1, wherein a BET surface area of the second fibrous material (14) is greater than 0.5 m2/g or greater than 1.0 m2/g or greater than 1.5 m2/g or greater than 1.75 m2/g or wherein a porosity of the second fibrous material (14) is greater than 70 percent or greater than 85 percent or greater than 90 percent. 20 12. The method of claim 1, wherein a ratio of an average length-to-diameter ratio of the first fibrous material (12) to an average length-to-diameter ratio of the second fibrous material (14) is less than 1.5 or less than 1.4 or less than 1.25 or less than 1.1. 13. The method of claim 1, wherein the screen (16) is formed by interweaving 25 monofilaments (52). 14. The method of claim 1, wherein the fiber source (10) comprises: a cellulosic material or a lignocellulosic material; or comprises a blend of fibers, e.g., fibers derived from a paper source and fibers derived from a textile source, e.g., cotton; or wherein the 30 fiber source (10) is derived from a paper source; or wherein the fiber source (10) comprises a textile fiber, preferably wherein the textile fiber comprises cotton, or wherein the fiber source (10) is a natural fiber source selected from grasses, rice hulls, bagasse, cotton, jute, hemp, flax, bamboo, sisal, abaca, straw, corn cobs, rice hulls or coconut hair. CLAIMS: 1. A method of making fit rus material, the method comp s g: shearing a fiber soure provide a first fibrous mate and 5 passing the first fibrous materialthrough a first screento provide a second fibrous wherein th method further comprises shearing the second fibrous materials) 2. The method of claim 1, wherein the average opening size of the first screeris 10 .59 mm- OF 86, less than 0.79 mm, or less than 0.51 mm, or less than 0.40 mm, or less than 0.20 mm, or less than 0.10 mm. I. The method, of dajfl urther comprising cutting the fiber sourcelprior to shearing the fiber source( to) > X. The method of claim 1, wherein the shearing is performed with a rotary knife cutter(Zo). X. The method of claim 1, wherein the second fibrous materials collected in a binL 20 having a pressure below nominal atmospheric pressure, preferably wherein the pressure is at least 10 percent below nominal atmospheric pressure or at least 50 percent below nominal atmospheric pressure. The method of Claims, wherein the pressure is at least 75 percent below nominal 25 atmospheric pressure. 4of C 14 ; - (iq) The methodA, further comprising shearing the second fibrous materialLand passing the resulting fibrous material through the first screen(If), 30 A. The method of claim 1, further comprising shearing the sec fibrous materiaL and passing the resulting fibrous mater al through a second screenhavin an average opening size less than the first screento provide a third fibrous material preferably wherein a ratio of an average length-to-diameter ratio of the second fibrous material to an average length-to-diameter ratio of the third fibrous material is less than 1.5 or less 35 than 1.4 or less than 1.25 or less than 1.1. The method of claim 1, further comprising passing the second fibrous material 160) (Ii0 through a second screen~having an average opening size less than the first screenkor wherein the shearing and passing are performed concurrently. )4d The method of claim 1, wherein an average length-to-diameter ratio of the second (9 1 5 fibrous materials greater than 10/1 or greater than 25/1 or greater than 50/1 or wherein an average length of the second fibrous materialtis between 0.5 mm and 2.5 mm, preferably wherein the average length is between 0.75 mm and 1.0 mm or wherein an average width of the second fibrous materialLis between 5 pm and 50 pm, optionally wherein the average width is between 10 pm and 30 pm. t. The method of claim 1, wherein a standard deviation of a length of the second fibrous materialLiS less than 60 percent of an average length of the second fibrous material optionally wherein the standard deviation is less than 50 percent. 15 W. The method of claim 1, wherein a BET surface area of the second fibrous material 000 is greater than 0.5 m2/g or greater than 1.0 m2/g or greater than 1.5 m 2/g or greater than 1.75 m2/g or wherein a porosity of the second fibrous materials greater than 70 percent or greater than 85 percent or greater than 90 percent. 20 >3. The method of clir 1, wherein a ratio of an average length-to-diameter ratio of the first fibrous materialkto an average length-to-diameter ratio of the second fibrous materials less than 1.5 or less than 1.4 or less than 1.25 or less than 1.1. )4. The method of claim 1, wherein the screen kis formed by interweaving 25 monofilaments(%2) >5. The method of claim 1, wherein the fiber sourceLcomprises: a cellulosic material or a