Patent ID: 7582241

Claim:
A process for producing an article from a temperature sensitive natural fibers-reinforced thermoplastic polymer composition which comprises: (a) extrusion melt-forming through a die in a first extruder a first mixture to form first strands, the first mixture consisting essentially of a high melting temperature thermoplastic polymer with a first melting temperature of 200° C. or above, which has been pre-dried to remove moisture, and at least one metal salt selected from the group consisting of lithium chloride, lithium bromide, lithium iodide, copper chloride, zinc chloride, aluminum chloride, gallium chloride, and mixtures thereof, wherein (i) the salt reduces the melting point of the first mixture to a second lower melting temperature of less than 200° C., (ii) the metal salt is added to the melted thermoplastic polymer in the first extruder as a water solution comprising the metal salt, and (iii) the metal in the metal salt forms a reaction product with the thermoplastic polymer in the melt; (b) pelletizing the first strands to form pellets; (c) extruding a second mixture of one or more temperature sensitive natural fibers and the pellets in a second extruder, at the second lower melting temperature of less than 200° C. without degrading the natural fibers to form second strands of the temperature sensitive natural fibers-reinforced thermoplastic polymer composition, wherein the temperature sensitive natural fibers consist essentially of cut fibers selected from the group consisting of a plant leaf, seed, stalk and combinations thereof; and (d) melt-forming an article from the composition of step (c), wherein the extruding and melt forming without the metal salt degrades the temperature sensitive natural fibers.