Field of the Invention The present invention relates to a composition, which can be referred to as a biopolymer, including fermentation solid and thermoactive material. The present invention also includes methods of making the biopolymer, which can include compounding fermentation solid and thermoactive material. The present biopolymer can be formed into an article of manufacture. Methods of making such articles of manufacture include for example extruding, injection molding, or compounding fermentation solid and thermoactive material. Structures formed from biopolymer can include lumber replacements, window components, door components, siding assemblies, and other structures.

Background of the Invention A variety of products may be formed from filled plastics. For example, plastics may be formed into lumber replacements, components of window and door assemblies, or siding for building structures.

Fillers have been used in the plastic industry for almost 90 years. The reason most manufacturers use filled plastic is to reduce the price of the high cost of polypropylene and other plastics with lower cost fillers, such as wood flour, talc, mica, and fiberglass. Filling plastic with fiberglass can improve its characteristics by creating higher thermal stability and higher bending and rupture strengths.

However, low cost fillers like wood flour can degrade some of the qualities of plastics and make it harder to process. Talc and mica provide some increase in strength to plastic, but also add weight and decrease the life of the extruder due to abrasion. Fiberglass adds considerable strength of the product, but at a substantial cost.

There are many disadvantages associated with existing plastics filled with plant material, such, such as wood or straw. A principal problem associated with the extrusion and injection of such plastics is that the particle size of the plant material used in this process is very small and is primarily ground wood. Otherwise, the viscosity of the mixture is too high to be extruded or molded efficiently. Moreover, extrusion or injection processes are further limited by the ratio of filler materials, such as wood, to the plastic that can be used. This puts undesirable constraints on the products that can be produced. Wood plastic composites typically use between 30% to 65% wood flour or fine wood saw dust mixed with simple plastics. Ratios higher than this cause both processing problems and overall performance degradation in areas of moisture absorption, rot, decay, moisture stability, and so on.

There remains a need for an inexpensive, biologically derived material that can reduce the cost and consumption of thermoactive materials and that performs better than a filler for products such as window and door assemblies, lumber replacements, siding for buildings, and other goods.

Summary of the Invention The present invention relates to a composition, which can be referred to as a biopolymer, including fermentation solid and thermoactive material. The present invention also includes methods of making the biopolymer, which can include compounding fermentation solid and thermoactive material. The present biopolymer can be formed into an article of manufacture.

The present invention relates to a composition including fermentation solid and thermoactive material. The composition can include wide ranges of amounts of these ingredients. For example, in an embodiment, the composition can include about 5 to about 95 wt-% fermentation solid and about 1 to about 95 wt-% thermoactive material. The fermentation solid can include, in an embodiment, distiller's dried grain or distiller's dried grain with solubles, which can be derived from fermentation of plant material such as grain (e. g., corn). The thermoactive material can include, for example, at least one of thermoplastic, thermoset material, and resin and adhesive polymer. The present composition can be employed in any of a variety of articles. The article can include the composition including fermentation solid and thermoactive material.

The present invention relates to a method of making a composition including fermentation solid and thermoactive material. The method includes compounding ingredients of the composition including but not limited to fermentation solid and thermoactive material. Compounding can include thermal kinetic compounding.

The composition can be made as a foamed composition. Producing a foamed composition can include extruding material comprising fermentation solid and thermoactive material; the foamed material need not include blowing or foaming agent.

The present composition can be employed in a method of making an article.

This method can include forming the article from a composition including fermentation solid and thermoactive material.

Structures can be formed from a composition, which can be referred to as a biopolymer, that includes fermentation solids and thermoactive material. Methods of making biopolymer products include for example extruding, injection molding, or compounding fermentation solid and thermoactive material. Structures formed from biopolymer can include lumber replacements, window components, door components, siding assemblies, and other structures.

In an embodiment, an article includes a biopolymer material which includes thermoactive material and fermentation solid. In an embodiment, the biopolymer can include about 5 to about 95 wt-% fermentation solid and about 1 to about 95 wt- % thermoactive material. In an embodiment the fermentation solid includes at least one of : distiller's dried grain, distiller's dried starchy root crop, distiller's dried tuber, and distiller's dried root.

In an embodiment, the fermentation solid includes at least one of distiller's dried cereal grain and distiller's dried legume. In an embodiment, the fermentation solid includes distiller's dried corn, distiller's dried sorghum (milo), distiller's dried barley, distiller's dried wheat, distiller's dried rye, distiller's dried rice, distiller's dried millet, distiller's dried oats, and distiller's dried soybean.

In an embodiment, an article including biopolymer can be configured as a part of a window, a part of a door, a part of a piece of furniture. For example, the article may be configured for assembly into at least one of a window assembly, door assembly, and furniture assembly.

In an embodiment, an article including biopolymer can be configured as a lumber replacement member. The lumber replacement member can include a solid

shell and a foamed core. The lumber replacement member can also include a textured surface on the solid shell.

In another embodiment, an article including biopolymer can be configured as an ornamental article.

In an embodiment, an article including biopolymer can include a foamed core. In an embodiment, an article including biopolymer can be configured to be assembled with another article through thermal welding.

In an embodiment, an article including biopolymer can be configured to include an interior surface defining a cavity, a strut extending into the cavity, and an anchor portion extending into the cavity, the anchor portion being configured to receive a fastener.

In an embodiment, an article including biopolymer can include at least one of a compression molded article, an extruded article, and an injection molded article.

In an embodiment, an article including biopolymer can include a layer of a second material on the biopolymer. In an embodiment, the layer of second material can include impression-formed features, a coextruded material, or a powder coating.

In an embodiment, an article including biopolymer can be configured as a component of a siding assembly for a building. In an embodiment, the component of a siding assembly for a building can include a longitudinal member having a longitudinal body extending between first and second ends, the longitudinal member comprising biopolymer material, at least one of the first and second ends being configured to couple to a second component of a siding assembly. In an embodiment, the second component includes biopolymer material and is configured to be coupled to one of the ends of the longitudinal member by thermal welding. In an embodiment, the longitudinal member includes an altered surface having an altered appearance, the altered surface including at least one of a powdered coating, a textured surface, a printed surface. In an embodiment, a siding product can include hollow portions, foamed portions, webbed portions, or a combination thereof.

In an embodiment, the fermentation solid includes fermented protein solid.

In an embodiment, the fermentation solid includes distiller's dried grain. In an embodiment, the distiller's dried grain further includes solubles, dried grain-200, and/or distiller's dried corn.

In an embodiment, an article including biopolymer includes about 50 to about 70 wt-% fermentation solid; and about 20 to about 50 wt-% thermoactive material.

In an embodiment, an article including biopolymer includes thermoactive material including at least one of thermoplastic, thermoset material, and resin, adhesive polymer, polyethylene, polypropylene, polyvinyl chloride, epoxy material melamine, polyester, phenolic polymer, and urea containing polymer.

In an embodiment, an article including biopolymer is in the form of an integral biopolymer, a composite biopolymer, or an aggregate biopolymer.

In an embodiment, an article including biopolymer is in the form of a composite biopolymer and the composite biopolymer has a granite-like appearance.

In an embodiment, an article including biopolymer includes at least one of dye, pigment, hydrolyzing agent, plasticizer, filler, preservative, antioxidants, nucleating agent, antistatic agent, biocide, fungicide, fire retardant, flame retardant, heat stabilizer, light stabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, crosslinking agent, blowing or foaming agent, and reclaimed or recycled plastic.

In an embodiment, an article including biopolymer includes at least one of plasticizer, light stabilizer, and coupling agent.

One method of making an article includes forming the article from a composition including about 5 to about 95 wt-% fermentation solid; and about 0.1 to about 95 wt-% thermoactive material. A method may further include one or more of extrusion molding, injection molding, blow molding, compression molding, transfer molding, thermoforming, casting, calendering, low-pressure molding, high-pressure laminating, reaction injection molding, foam molding, and coating.

A method of fabricating a biopolymer lumber replacement article, window or door component, or siding component, can include heating the biopolymer; applying pressure to the heated biopolymer; shaping the heated biopolymer; and cooling the biopolymer to preserve an article shape. A method can further include applying a surface texture to the article. Shaping the biopolymer can include injection molding, extruding the biopolymer through a die to produce an extrusion, or other processes.

Applying can includes pressing the article, which can include extraction of water from the biopolymer. In an embodiment, the method can include forming at a hollow and/or foamed portion in the he lumber replacement article, window, door,

siding component, the hollow or foamed portion acting to increase the R value of the article or component.

Brief Description of the Drawings Fig. 1 shows a window assembly.

Fig. 2 shows a cross section of a window assembly.

Fig. 3 shows a foamed extrusion product.

Fig. 4 shows a door assembly.

Fig. 5 shows a partially hollow extrusion.

Fig. 6 shows a lumber replacement member with a wood-like appearance.

Fig. 7 shows a sheet product.

Fig. 8 shows a siding product for a building structure.

Fig. 9 shows a back perspective view of the siding product of Fig. 8.

Fig. 10 shows a siding product including an interior region that can be foamed or hollow.

Fig. 11 illustrates a method for processing a biopolymer composition.

Fig. 12 illustrates a method for forming an article from a biopolymer.

Fig. 13 is a front perspective view of a decking system.

Fig. 14 is a front perspective view of a base component and a post.

Fig. 15 is a front perspective view of a pillar and a base component.

Fig. 16 is a front perspective view of a pillar, a base component, and a top cap.

Fig. 17 is a front perspective view of components of a railing assembly.

Fig. 18 is a side view of components a railing assembly.

Fig. 19 is a side view of a railing assembly with a railing cover.

Fig. 20 is a perspective view of a base.

Fig. 21 is a top view of a panel component.

Fig. 22 is a cross-sectional view of a corner.

Fig. 23 is a perspective view of a top cap.

Fig. 24 is a top view of a baluster.

Fig. 25 is a side view of a bottom rail.

Fig. 26 is a side view of a rail cover.

Detailed Description of the Invention

Definitions As used herein, the term"biopolymer"refers to a material including a thermoactive material and a fermentation solid.

As used herein, the phrase"fermentation solid"refers to solid material recovered from a fermentation process, such as alcohol (e. g. , ethanol) production.

As used herein, the phrase"fermented protein solid"refers to fermentation solid recovered from fermenting a material including protein. The fermented protein solid also includes protein.

As used herein, the phrase"distiller's dried grain" (DDG) refers to the dried residue remaining after the starch in grain (e. g., corn) has been fermented with selected yeasts and enzymes to produce products including ethanol and carbon dioxide. DDG can include residual amounts of solubles, for example, about 2 wt-%.

Distiller's dried grain includes compositions known as brewer's grain and spent solids.

As used herein, the phrase"distiller's dried grain with solubles" (DDGS) refers to a dried preparation of the coarse material remaining after the starch in grain (e. g., corn) has been fermented plus the soluble portion of the residue remaining after fermentation, which has been condensed by evaporation to produce solubles.

The solubles can be added to the DDG to form DDGS.

As used herein, the phrase"wet cake"or"wet distiller's grain"refers to the coarse, wet residue remaining after the starch in grain (e. g., corn) has been fermented with selected yeasts and enzymes to produce products including ethanol and carbon dioxide.

As used herein, the phrase"solvent washed wet cake"refers to wet cake that has been washed with a solvent such as, water, alcohol, or hexane.

As used herein, the phrase"gluten meal"refers to a by-product of the wet milling of plant material (e. g., corn, wheat, or potato) for starch. Corn gluten meal can also be a by-product of the conversion of the starch in whole or various fractions of dry milled corn to corn syrups. Gluten meal includes prolamin protein and gluten (a mixture of water-insoluble proteins that occurs in most cereal grains) and also smaller amounts of fat and fiber.

As used herein, the phrase"plant material"refers to all or part of any plant (e. g. , cereal grain), typically a material including starch. Suitable plant material includes grains such as maize (corn, e. g. , whole ground corn), sorghum (milo),

barley, wheat, rye, rice, millet, oats, soybeans, and other cereal or leguminous grain crops ; and starchy root crops, tubers, or roots such as sweet potato and cassava. The plant material can be a mixture of such materials and byproducts of such materials, e. g., corn fiber, corn cobs, stover, or other cellulose and hemicellulose containing materials such as wood or plant residues. Preferred plant materials include corn, either standard corn or waxy corn. Preferred plant materials can be fermented to produced fermentation solid.

As used herein, the term"prolamin"refers to any of a group of globular proteins which are found in plants, such as cereals. Prolamin proteins are generally soluble in 70-80 per cent alcohol but insoluble in water and absolute alcohol. These proteins contain high levels of glutamic acid and proline. Suitable prolamin proteins include gliadin (wheat and rye), zein (corn), and kafirin (sorghum and millet).

Suitable gliadin proteins include oe-, ß-, y, and co-gliadins.

As used herein, the term"zein"refers to a prolamin protein found in corn, with a molecular weight of about 40,000 (e. g., 38, 000), and not containing tryptophan and lysine.

As used herein, the phrase"glass transition point"or"Tg"refers to the temperature at which a particle of a material (such as a fermentation solid or thermoactive material) reaches a"softening point"so that it has a viscoelastic nature and can be more readily compacted. Below Tg a material is in its"glass state"and has a form that can not be as readily deformed under simple pressure. As used herein, the phrase"melting point"or"Tm"refers to the temperature at which a material (such as a fermentation solid or thermoactive material) melts and begins to flow. Suitable methods for measuring these temperatures include differential scanning calorimetry (DSC), dynamic mechanical thermal analysis (DTMA), and thermal mechanical analysis (TMA).

As used herein, weight percent (wt-%), percent by weight, % by weight, and the like are synonyms that refer to the concentration of a substance as the weight of that substance divided by the weight of the composition and multiplied by 100.

Unless otherwise specified, the quantity of an ingredient refers to the quantity of active ingredient.

As used herein, the term"about"modifying any amount refers to the variation in that amount encountered in real world conditions of producing materials

such as polymers or composite materials, e. g. , in the lab, pilot plant, or production facility. For example, an amount of an ingredient employed in a mixture when modified by about includes the variation and degree of care typically employed in measuring in a plant or lab producing a material or polymer. For example, the amount of a component of a product when modified by about includes the variation between batches in a plant or lab and the variation inherent in the analytical method.

Whether or not modified by about, the amounts include equivalents to those amounts. Any quantity stated herein and modified by"about"can also be employed in the present invention as the amount not modified by about.

The Biopolymer The present invention relates to a biopolymer that includes one or more fermentation solids and one or more thermoactive materials. The present biopolymer can exhibit properties typical of plastic materials, properties advantageous compared to conventional plastic materials, and/or properties advantageous compared to aggregates including plastic and, for example, wood or cellulosic materials. The present biopolymer can be formed into useful articles using any of a variety of conventional methods for forming items from plastic. The present biopolymer can take any of a variety of forms.

In an embodiment, the present biopolymer includes fermentation solid integrated with the thermoactive material. A biopolymer including fermentation solid integrated into the thermoactive material is referred to herein as an"integrated biopolymer". An integrated biopolymer can include covalent bonding between the thermoactive material and the fermentation solid. In an embodiment, the integrated biopolymer forms a uniform mass in which the fermentation solid has been blended into the thermoactive material.

In an embodiment, the present biopolymer includes visible particles of remaining fermentation solid. A biopolymer including visible particles of remaining fermentation solid is referred to herein as a"composite biopolymer". A composite biopolymer can have the appearance of granite, a matrix of thermoactive material with a first appearance surrounding particles of fermentation solid with a second appearance. In an embodiment, even in a composite biopolymer, a significant fraction of the fermentation solid can be blended into and/or bond with the thermoactive material. In an embodiment, a composite biopolymer with the

appearance of granite can form a single substance from which the particles of fermentation solid can not be removed.

In yet another embodiment, the present biopolymer includes a significant portion of fermentation solid present as discrete particles surrounded by or embedded in the thermoactive material. A biopolymer including discrete particles of fermentation solid surrounded by or embedded in the thermoactive material is referred to herein as an"aggregate biopolymer". In such an aggregate biopolymer, the significant portion of fermentation solid present as discrete particles can be considered an extender or a filler. Nonetheless, a minor portion of the fermentation solid can be blended into and/or bond with the thermoactive material.

In an embodiment, the compounded fermentation solid and thermoactive material (i. e. , the soft or raw biopolymer), before hardening, takes the form of a dough, which can be largely homogeneous. As used herein, "largely homogeneous" dough refers to a material with a consistency similar to baking dough (e. g. , bread or cookie dough) with a major proportion of the fermentation solid blended into the thermoactive material and no longer appearing as distinct particles. In an embodiment, the soft or raw biopolymer includes no detectable particles of fermentation solid, e. g. , it is a homogeneous dough. In an embodiment, the soft or raw biopolymer can include up to 95 wt-% (e. g. , 90 wt-%) fermentation solid and take the form of a largely homogeneous or homogeneous dough. In an embodiment, the soft or raw biopolymer can include about 50 to about 70 wt-% fermentation solid and take the form of a largely homogeneous or homogeneous dough.

In an embodiment, the raw or soft biopolymer includes visible amounts of fermentation solid. As used herein, visible amounts of fermentation solid refers to particles that are clearly visible to the naked eye and that provide a granite-like appearance to the cured biopolymer. Such visible fermentation solid can be colored for decorative effect in the cured biopolymer. The granite-like appearance can be produced by employing larger particles of fermentation solid than used to produce a homogeneous or largely homogeneous dough.

In certain embodiments, the biopolymer can include fermentation solid at about 0.01 to about 95 wt-%, about 1 to about 95 wt-%, about 5 to about 95 wt-%, about 5 to about 80 wt-%, about 5 to about 70 wt-%, about 5 to about 20 wt-%, about 50 to about 95 wt-%, about 50 to about 80 wt-%, about 50 to about 70 wt-%, about 50 to about 60 wt-%, about 60 to about 80 wt-%, or about 60 to about 70 wt-

%. In certain embodiments, the biopolymer can include fermentation solid at about 5 wt-%, about 10 wt-%, about 20 wt-%, about 50 wt-%, about 60 wt-%, about 70 wt-%, or about 75 wt-%. The present biopolymer can include any of these amounts or ranges not modified by about.

In certain embodiments, the biopolymer can include thermoactive material at about 0.01 to about 95 wt-%, about 1 to about 95 wt-%, about 5 to about 30 wt-%, about 5 to about 40 wt-%, about 5 to about 50 wt-%, about 5 to about 85 wt-%, about 5 to about 95 wt-%, about 10 to about 30 wt-%, about 10 to about 40 wt-%, about 10 to about 50 wt-%, or about 10 to about 95 wt-%. In certain embodiments, the biopolymer can include thermoactive material at about 95 wt-%, about 75 wt-%, about 50 wt-%, about 45 wt-%, about 40 wt-%, about 35 wt-%, about 30 wt-%, about 25 wt-%, about 20 wt-%, about 15 wt-%, about 10 wt-%, or about 5 wt. The present biopolymer can include any of these amounts or ranges not modified by about.

In certain embodiments, the biopolymer can include fermentation solid at about 5 to about 95 wt-% and thermoactive material at about 5 to about 95 wt-%, can include fermentation solid at about 50 to about 70 wt-% and thermoactive material at about 30 to about 70 wt-%, can include fermentation solid at about 50 to about 70 wt-% and thermoactive material at about 20 to about 70 wt-%, can include fermentation solid at about 50 to about 60 wt-% and thermoactive material at about 30 to about 50 wt-%, or can include fermentation solid at about 60 to about 70 wt-% and thermoactive material at about 20 to about 40 wt-%. In certain embodiments, the biopolymer can include about 5 wt-% fermentation solid and about 70 to about 95 wt-% thermoactive material, about 10 wt-% fermentation solid and about 70 to about 90 wt-% thermoactive material, about 50 wt-% fermentation solid and about 30 to about 50 wt-% thermoactive material, about 55 wt-% fermentation solid and about 30 to about 45 wt-% thermoactive material, about 60 wt-% fermentation solid and about 20 to about 40 wt-% thermoactive material, about 65 wt-% fermentation solid and about 20 to about 40 wt-% thermoactive material, about 70 wt-% fermentation solid and about 10 to about 30 wt-% thermoactive material, about 90 wt-% fermentation solid and about 5 to about 10 wt-% thermoactive material. The present biopolymer can include any of these amounts or ranges not modified by about.

Embodiments of Biopolymers In an embodiment, the present biopolymer can have higher thermal conductivity than conventional thermoplastics. For example, in an embodiment, the present biopolymer can cool or heat faster than the thermoactive material without fermentation solid. In an embodiment, the present biopolymer can cool as rapidly as the apparatus forming it can operate. Although not limiting to the present invention, it is believed that such increased thermal conductivity can be due to the nature of the fermentation solid. For example, the increased thermal conductivity may be due to integration of the fermentation solid into the thermoactive material. For example, increased thermal conductivity employing fermented protein solid may be due to the interaction of the protein with the thermoactive material.

In an embodiment, the present biopolymer has a granite-like appearance.

Biopolymer with a granite-like appearance can include larger particles of fermentation solid than an integrated biopolymer. For example, fermentation solid of a size of about 2 to about 10 mesh can be employed to form biopolymer with a granite-like appearance. In an embodiment, a biopolymer including such larger fermentation solid as flow characteristics suitable or even advantageous for compounding and forming, In an embodiment, a biopolymer including such a larger fermentation solid takes the form of a composite biopolymer.

Fermentation Solids The present biopolymer can include any of a variety of fermentation solids.

Fermentation solid can be recovered from any of a variety of fermentation processes, such as alcohol (e. g. , ethanol) production. A fermentation solid can be recovered from, for example, fermentation of plant material. In an embodiment, the fermentation solid can be recovered from fermentation of plant material containing starch, such as grain (e. g. , cereal grain or legume), starchy root crop, tuber, or root.

In an embodiment, the fermentation solid (e. g. , fermented protein solid) can be recovered from fermentation of plant material containing starch and protein, such as grain (e. g. , cereal grain or legume), starchy root crop, tuber, or root. In an embodiment, the fermentation solid is recovered from fermentation of grain. For example, the fermentation solid known as"distiller's dried grain"can be recovered from fermentation processes that convert grain to ethanol.

Fermentation consumes carbohydrate, such as starch, in the plant material and can provide a material with starch levels that have been reduced compared to the plant material. In an embodiment, fermentation solid includes a reduced wt-% starch compared to the plant material used in the fermentation. In certain embodiments, the fermentation solid includes less than or equal to about 10 wt-% carbohydrate, less than or equal to about 5 wt-% carbohydrate, or less than or equal to about 2 wt-% carbohydrate. Fermentation solid with more than 10 wt-% carbohydrate can be employed in the present biopolymer.

Numerous fermentation solids have been characterized, primarily as animal feed. The fermentation solids that have been characterized include those known as distiller's dried grain (DDG), distiller's dried grain with solubles (DDGS), wet cake (WC), solvent washed wet cake (WWC), fractionated distiller's dried grain (FDDG), and gluten meal. Fermentation solid can include, for example, protein, fiber, and, optionally, fat. Fermentation solid can also include residual starch.

For example, the fermentation solid distiller's dried grain with solubles recovered from dry mill fermentation of corn can include 30 wt-% or more protein.

For example, the fermentation solid distiller's dried grain with solubles recovered from conventional dry mill fermentation of corn can include about 30 to about 35 wt-% protein, about 10 to about 15 wt-% fat, about 5 to about 10 wt-% fiber, and about 5 to about 10 wt-% ash. For example, the fermentation solid distiller's dried grain with solubles recovered from conventional dry mill fermentation of corn can include about 5 wt-% starch, about 35 wt-% protein, about 15 wt-% fat, about 25 wt- % fiber, and about 5 wt-% ash. In an embodiment, the fermentation solid includes or is a DDGS including about 30-38 wt-% protein, about 11-19 wt-% fat, and about 25-37 wt-% fiber. In an embodiment, the fermentation solid includes or is a DDGS including about 10 wt-% starch, about 35 wt-% protein, about 15 wt-% fat, about 30 wt-% fiber, and about 5 wt-% ash. Such as DDGS can be produced by raw starch fermentation of corn. The present fermentation solid can include any of these amounts or ranges not modified by about.

Distiller's dried grains or other distiller's dried plant materials can be derived from any of a variety of agricultural products. As used herein, "distiller's dried" followed by the name of a plant or type of plant refers to a fermentation solid derived from fermentation of that plant or type of plant. For example, distiller's dried grain refers to a fermentation solid derived from fermentation of grain. By

way of a more specific example, distiller's dried corn refers to a fermentation solid derived from fermentation of corn. Distiller's dried sorghum refers to a fermentation solid derived from fermentation of sorghum (milo). Distiller's dried wheat refers to a fermentation solid derived from fermentation of wheat. A distiller's dried plant material need not be exclusively derived from the named plant material. Rather, the named plant material is the predominant plant material or the only plant material in the fermentation solid.

The present biopolymer can include any of a variety of fermentation solids including, for example, distiller's dried grain, distiller's dried starchy root crop, distiller's dried tuber, distiller's dried root. Suitable distiller's dried grains include distiller's dried cereal grain and distiller's dried legume. Suitable distiller's dried grains include distiller's dried maize (distiller's dried corn, e. g. , distiller's dried whole ground corn or distiller's dried fractionated corn), distiller's dried sorghum (milo), distiller's dried barley, distiller's dried wheat, distiller's dried rye, distiller's dried rice, distiller's dried millet, distiller's dried oats, distiller's dried soybean.

Suitable distiller's dried roots include distiller's dried sweet potato and distiller's dried cassava. Suitable distiller's dried tubers include distiller's dried potato.

The plant material can include the entirety of a plant or a portion of a plant.

Alternatively, the plant or portion of a plant can be fractionated. A fermentation solid derived from fractionated plant material is referred to herein as distiller's dried fractionated plant material, e. g. , distiller's dried fractionated grain. The present biopolymer can include any of a variety of fractionated fermentation solids. For example, the present biopolymer can include distiller's dried fractionated corn. For example, the present biopolymer can include distiller's dried corn germ and/or distiller's dried corn endosperm.

Distiller's dried grains or other distiller's dried plant materials can be derived from any of a variety of fermentation processes. As the phrase suggests, distiller's dried plant materials have been dried. Drying can be accomplished at elevated temperatures in a fermentation plant or apparatus. Drying can include exposing the wet distiller's plant material with air, which can be a temperatures of 1,000 to 1,500 °F. Although mixed with hot air, the distiller's plant material does not reach temperatures as hot as the hot air. The distiller's plant material can be tumbled or circulated with the air. Thus, for example, after being exposed to air at temperatures

of 1,000 to 1,500 °F, the distiller's dried plant material can reach a temperature (e. g., at the exit of the drying apparatus) of only about 200 °F.

In certain embodiments, the present fermentation solid (e. g. , fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 500 °F, about 400 °F, about 300 °F, about 250 °F, about 200 °F, or about 180 °F. In an embodiment, the present fermentation solid (e. g., fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 500 °F. In an embodiment, the present fermentation solid (e. g. , fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 400 °F. In an embodiment, the present fermentation solid (e. g., fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 300 °F. In an embodiment, the present fermentation solid (e. g., fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 250 °F. In an embodiment, the present fermentation solid (e. g., fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 200 °F. In an embodiment, the present fermentation solid (e. g., fermented protein isolate) reached a temperature (e. g. , at the exit from the dryer) of no higher than about 180 °F. The present fermentation solid can include any of these temperatures not modified by about.

As used herein,"distiller's dried"followed by a number refers to a fermentation solid that reached a temperature (e. g. , at the exit from the dryer) at or below that temperature. For example, distiller's dried grain-200 refers to distiller's dried grain that reached a temperature (e. g. , at the exit from the dryer) at or below 200 °F. In certain distillation processes, the plant material can also be ground.

Grinding can subject plant material to elevated temperatures. As used herein, "distiller's dried"followed by a number with the suffix"gd"refers to a fermentation solid that was ground and dried reaching a temperature (e. g. , at the exit from the dryer) at or below that temperature. For example, distiller's dried grain-200gd refers to distiller's dried grain ground and dried and that reached a temperature (e. g. , at the exit from the dryer) at or below 200 °F. A fermentation solid that has been prepared by employing low temperature grinding and/or drying is referred to herein as"gently treated fermentation solid". A fermented protein solid that has been prepared by employing low temperature grinding and/or drying is referred to herein as "proteinaceous fermentation solid". Suitable gently treated fermentation solids

include gently treated DDG and gently treated DDGS. Gently treated fermentation solids include those derived from fermentation processes lacking a cooking stage.

Fermentation solid suitable for the present biopolymer can be have a wide range of moisture content. In an embodiment, the moisture content can be less than or equal to about 15 wt-%, for example about 1 to about 15 wt-%. In an embodiment, the moisture content can be about 5 to about 15 wt-%. In an embodiment, the moisture content can be about 5 to about 10 (e. g. , 12) wt-%. In an embodiment, the moisture content can be about 5 (e. g. , 6) wt-%.

The present biopolymer can include or can be made from a fermentation solid with any of broad range of sizes. In certain embodiments, the fermentation solid employed in the biopolymer has a particle size of about 2 mesh to less than about 1 micron (e. g. , to about 0.1 or about 0. 01 micron), about 2 to about 10 mesh, about 12 to about 500 mesh, about 60 mesh to less than about 1 micron, about 60 mesh to about 1 micron, about 60 to about 500 mesh. Biopolymers including fermentation solid with particle size less than about 1 micron (e. g. , to about 0.1 or about 0.01 micron) can be considered nano materials, or in certain circumstances nano-composites.

In certain embodiments, the fermentation solid employed in the biopolymer can be or has been treated before compounding by coloring, grinding and screening (e. g. , to a uniform range of sizes), drying, or any of a variety of procedures known for treating agricultural material before mixing with thermoactive material.

In certain embodiments, the biopolymer can include fermentation solid at about 0.01 to about 95 wt-%, about 1 to about 95 wt-%, about 5 to about 95 wt-%, about 5 to about 80 wt-%, about 5 to about 70 wt-%, about 50 to about 95 wt-%, about 50 to about 80 wt-%, about 50 to about 70 wt-%, about 50 to about 60 wt-%, about 60 to about 80 wt-%, or about 60 to about 70 wt-%. In certain embodiments, the biopolymer can include fermentation solid at about 5 wt-%, about 10 wt-%, about 50 wt-%, about 60 wt-%, about 70 wt-%, or about 75 wt-%. The present biopolymer can include any of these amounts or ranges not modified by about.

Fermentation solid suitable for the present biopolymer include those derived from dry milling processes known as"raw starch"processes. Raw starch processes producing suitable fermentation solid include those described in U. S. Patent Application No. 10/798,226 and U. S. Provisional Patent Application No.

60/552,108, each filed March 10,2004, and each entitled"METHOD FOR

PRODUCING ETHANOL USING RAW STARCH". Each of these applications is incorporated herein by reference.

Embodiments of Fermentation Solids Although not limiting to the present invention, in certain embodiments, it is believed that the present fermentation solid (e. g. , fermented protein solid) can be advantageously suited for forming biopolymers. For example, in an embodiment, the present fermentation solid (e. g. , fermented protein solid) can be characterized by or can have a glass transition point (Tg) and/or a melting point (Tm). For example, in an embodiment, the present fermentation solid (e. g. , fermented protein solid) can form an integral biopolymer. Although not limiting to the present invention, it is believed that an embodiment of an integral biopolymer can include covalent bonding between the fermentation solid (e. g. , fermented protein solid) and the thermoactive material. By way of further example, in an embodiment, it is believed that the present fermentation solid (e. g. , fermented protein solid) imparts desirable thermal conductivity (e. g. , advantageously rapid heating and cooling) to the biopolymer.

Although not limiting to the present invention, it is believed that, in certain embodiments, the present fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can be characterized with reference to two temperatures, a glass transition point (Tg) and a melting point (Tm). In an embodiment, the fermentation solid can be compounded at a temperature at which it exhibits viscoelastic properties, e. g. between Tg and Tm. In an embodiment, the fermentation solid can be compounded at a temperature at which it has melted or can melt, e. g. , at or above Tm. In an embodiment, the biopolymer includes a thermoactive material with a melting point less than about Tg for the fermentation solid. In an embodiment, the biopolymer includes a thermoactive material with a melting point less than about Tm for the fermentation solid. In an embodiment, the fermentation solid can have Tm approximately equal to that of the polymer.

Although not limiting to the present invention, it is believed that compounding the fermentation solid with the thermoactive material at a temperature below Tg and/or below Tm for the fermentation solid will not produce an integral biopolymer or a soft or raw biopolymer in the form of a dough. It is believed that DDG from raw starch hydrolysis ethanol processes has a Tm of about 150 °C.

The Tm of the fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can be related to its content of oil or syrup (e. g. , solubles) from the plant material or other additives. In an embodiment, the Tm of the fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can be selected by controlling the amount of oil or syrup (e. g. , solubles) in the material. For example, it is believed that higher oil or syrup (e. g. , solubles) content decreases Tm and Tg and lower oil or syrup (e. g. , solubles) content increases Tm.

The Tm of fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can be related to its content of plasticizer (e. g. , water, liquid polymer, liquid thermal plastic, fatty acid, or the like). In an embodiment, the Tm of the fermentation solid fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can be selected by controlling the amount of plasticizer in the material. For example, it is believed that higher plasticizer content decreases Tm and Tg and lower plasticizer content increases Tm.

Although not limiting to the present invention, it is believed that compounding the present biopolymer at temperatures between Tg and Tm of the fermentation solid provides advantageous interaction between the thermoactive material and the fermentation solid, which can result in a biopolymer with advantageous properties. In an embodiment, the selected temperature can be also above the melting point of the thermoactive material and suitable for compounding with the thermoactive material. In certain embodiments, the Tg and Tm of the fermentation solid allow compounding with polymers with a relatively high melting point, such as polyethylene terephthalate (PET), polycarbonate, and other engineered plastics.

Although not limiting to the present invention, it is believed that the present fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS) can include an advantageously processed plant material. Fermenting the plant material can remove a substantial portion of the starch and carbohydrate. It is believed that fermentation can hydrolyze protein. It is believed that hydrolyzing the protein can provide functional groups that can form covalent interactions with the thermoactive material, which can result in advantageous characteristics for the resulting biopolymer. Further, it is believed that, in certain embodiments, fermentation can render the protein less water soluble.

Although not limiting to the present invention, it is believed that, in certain embodiments, the present biopolymer can include fermentation solid (e. g., fermented protein solid, such as DDG or DDGS) including advantageously high levels of the prolamin protein found in cereal grain. These prolamin proteins include zein (e. g., corn zein) and kafirin (e. g. , sorghum kafirin).

Although not limiting to the present invention, it is believed that in certain embodiments, the present biopolymer can include fermentation solid recovered from a fermentation process in which the material has been in the presence of relatively high alcohol concentrations. For example, in an embodiment, the present fermentation solid be recovered from a fermentation process in which the concentration of alcohol in the beer well reaches or exceeds about 60 wt-%. For example, in an embodiment, the present fermentation solid be recovered from a fermentation process in which the concentration of alcohol in the fermenter reaches or exceeds about 19, about 20, or about 21 vol-%. Although not limiting to the present invention, it is believed that such high alcohol concentrations can produce a fermentation solid including increased levels of prolamin protein.

In an embodiment, the present biopolymer can include a fermentation solid including diminished levels of fermentable materials, such as starch. In an embodiment, a fermentation solid can be produced by fermenting fractionated plant material. For example, removing the bran and/or germ fractions prior to fermentation can concentrate prolamin protein (e. g. , zein) in the plant material and resulting fermentation solid. Corn endosperm includes zein. Although not limiting to the present invention, it is believed that fermentation of corn endosperm can result in increased levels of zein in the fermentation solid.

In an embodiment, the present biopolymer can have advantageous flow characteristics compared to simple thermal plastics. The melt flow index represents the ability of a plastic material to flow. The higher the melt flow index the easier the material flows at a specified temperature. Melt flow index can be measured by a standard test known as MFR or MFI.

Briefly, the test includes a specific force, produced by an accurate weight, extruding a heated plastic material through a circular die of a fixed size, at a specified temperature. The amount of thermoactive material extruded in 10 minutes is called the MFR. This test is defined by standard plastics testing method ASTM D 3364.

Most olefin thermal plastics are tested at a temperature of 230 °C. The present biopolymer can achieve the melt index of a homogeneous thermoactive material but at a lower temperature. For example, consider a plastic with a melt index of 10 at 230 °C. This plastic can be employed as the thermoactive material in the present biopolymer at a level of only about 30 wt-% thermoactive material and about 70 wt-% of fermentation solid (e. g. , fermented protein solid, such as DDG or DDGS). The resulting biopolymer will have a melt index of about 10 at only about 160 °C, which is a much lower temperature than 230 °C. Similarly, the resulting biopolymer will have a melt flow index significantly lower than 10 at 230 °C. Such advantageous flow characteristics can allow processing present biopolymer at lower temperatures. Processing at lower temperatures can save energy and provide for faster cooling.

In contrast, filled plastics such as woodlplastic, fiber filled plastics, mineral filled plastics and other inert fillers typically decrease the melt index of the thermoactive material, which results in less flow or greater force required to induce flow. Thus, these conventional filled plastics are harder to process compared to the pure plastic and can require higher temperatures to process and maintain melt flow index.

Thermoactive Material The biopolymer can include any of a wide variety of thermoactive materials.

For example, the biopolymer can include any thermoactive material in which the fermentation solid can be embedded. In an embodiment, the thermoactive material can be selected for its ability to form a homogeneous or largely homogeneous dough including the fermentation solid. In an embodiment, the thermoactive material can be selected for its ability to covalently bond with the fermentation solid. In an embodiment, the thermoactive material can be selected for its ability to flow when mixed or compounded with fermentation solid. In an embodiment, the thermoactive material can set after being formed. Numerous such thermoactive materials are commercially available.

Suitable thermoactive materials include thermoplastic, thermoset material, a resin and adhesive polymer, or the like. As used herein, the term"thermoplastic" refers to a plastic that can once hardened be melted and reset. As used herein, the term"thermoset"material refers to a material (e. g. , plastic) that once hardened

cannot readily be melted and reset. As used herein, the phrase"resin and adhesive polymer"refers to more reactive or more highly polar polymers than thermoplastic and thermoset materials.

Suitable thermoplastics include polyamide, polyolefin (e. g. , polyethylene, polypropylene, poly (ethylene-copropylene), poly (ethylene-coalphaolefin), polybutene, polyvinyl chloride, acrylate, acetate, and the like), polystyrenes (e. g., polystyrene homopolymers, polystyrene copolymers, polystyrene terpolymers, and styrene acrylonitrile (SAN) polymers), polysulfone, halogenated polymers (e. g., polyvinyl chloride, polyvinylidene chloride, polycarbonate, or the like, copolymers and mixtures of these materials, and the like. Suitable vinyl polymers include those produced by homopolymerization, copolymerization, terpolymerization, and like methods. Suitable homopolymers include polyolefins such as polyethylene, polypropylene, poly-l-butene, etc. , polyvinylchloride, polyacrylate, substituted polyacrylate, polymethacrylate, polymethylmethacrylate, copolymers and mixtures of these materials, and the like. Suitable copolymers of alpha-olefins include ethylene-propylene copolymers, ethylene-hexylene copolymers, ethylene- methacrylate copolymers, ethylene-methacrylate copolymers, copolymers and mixtures of these materials, and the like. In certain embodiments, suitable thermoplastics include polypropylene (PP), polyethylene (PE), and polyvinyl chloride (PVC), copolymers and mixtures of these materials, and the like. In certain embodiments, suitable thermoplastics include polyethylene, polypropylene, polyvinyl chloride (PVC), low density polyethylene (LDPE), copoly-ethylene-vinyl acetate, copolymers and mixtures of these materials, and the like.

Suitable thermoset materials include epoxy materials, melamine materials, copolymers and mixtures of these materials, and the like. In certain embodiments, suitable thermoset materials include epoxy materials and melamine materials. In certain embodiments, suitable thermoset materials include epichlorohydrin, bisphenol A, diglycidyl ether of 1,4-butanediol, diglycidyl ether of neopentyl glycol, diglycidyl ether of cyclohexanedimethanol, aliphatic; aromatic amine hardening agents, such as triethylenetetraamine, ethylenediamine, N- cocoalkyltrimethylenediamine, isophoronediamine, diethyltoluenediamine, tris (dimethylaminomethylphe- nol) ; carboxylic acid anhydrides such as methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, maleic

anhydride, polyazelaic polyanhydride and phthalic anhydride, mixtures of these materials, and the like.

Suitable resin and adhesive polymer materials include resins such as condensation polymeric materials, vinyl polymeric materials, and alloys thereof.

Suitable resin and adhesive polymer materials include polyesters (e. g. , polyethylene terephthalate, polybutylene terephthalate, and the like), methyl diisocyanate (urethane or MDI), organic isocyanide, aromatic isocyanide, phenolic polymers, urea based polymers, copolymers and mixtures of these materials, and the like.

Suitable resin materials include acrylonitrile-butadiene-styrene (ABS), polyacetyl resins, polyacrylic resins, fluorocarbon resins, nylon, phenoxy resins, polybutylene resins, polyarylether such as polyphenylether, polyphenylsulfide materials, polycarbonate materials, chlorinated polyether resins, polyethersulfone resins, polyphenylene oxide resins, polysulfone resins, polyimide resins, thermoplastic urethane elastomers, copolymers and mixtures of these materials, and the like. In certain embodiments, suitable resin and adhesive polymer materials include polyester, methyl diisocyanate (urethane or MDI), phenolic polymers, urea based polymers, and the like.

Suitable thermoactive materials include polymers derived from renewable resources, such as polymers including polylactic acid (PLA) and a class of polymers known as polyhydroxyalkanoates (PHA). PHA polymers include polyhydroxybutyrates (PHB), polyhydroxyvalerates (PHV), and polyhydroxybutyrate-hydroxyvalerate copolymers (PHBV), polycaprolactone (PCL) (i. e. TONE), polyesteramides (i. e. BAK), a modified polyethylene terephthalate (PET) (i. e. BIOMAX), and"aliphatic-aromatic"copolymers (i. e. ECOFLEX and EASTAR BIO), mixtures of these materials and the like.

In certain embodiments, the biopolymer can include thermoactive material at about 0.01 to about 95 wt-%, about 1 to about 95 wt-%, about 5 to about 30 wt-%, about 5 to about 40 wt-%, about 5 to about 50 wt-%, about 5 to about 85 wt-%, about 5 to about 95 wt-%, about 10 to about 30 wt-%, about 10 to about 40 wt-%, about 10 to about 50 wt-%, or about 10 to about 95 wt-%. In certain embodiments, the biopolymer can include thermoactive material at about 95 wt-%, about 75 wt-%, about 50 wt-%, about 45 wt-%, about 40 wt-%, about 35 wt-%, about 30 wt-%, about 25 wt-%, about 20 wt-%, about 15 wt-%, about 10 wt-%, or about 5 wt. The

present biopolymer can include any of these amounts or ranges not modified by about.

Embodiments of Thermoactive Materials In an embodiment, the present biopolymer includes a thermoactive material supplied as a liquid (e. g., MDI). The liquid thermoactive material can provide advantageous characteristics to the biopolymer. MDI, organic isocyanide, aromatic isocyanide, phenol, melamine, and urea based polymers, and the like can be considered high moisture content polymers, which can be advantageous for extrusion. Such thermoactive materials can be employed to create a foamed extrusion for lower weight applications.

Additives The present biopolymer can also include one or more additives. Suitable additives include one or more of dye, pigment, other colorant, hydrolyzing agent, plasticizer, filler, extender, preservative, antioxidants, nucleating agent, antistatic agent, biocide, fungicide, fire retardant, flame retardant, heat stabilizer, light stabilizer, conductive material, water, oil, lubricant, impact modifier, coupling agent, crosslinking agent, blowing or foaming agent, reclaimed or recycled plastic, and the like, or mixtures thereof. Suitable additives include plasticizer, light stabilizer, coupling agent, and the like, or mixtures thereof. In certain embodiments, additives can tailor properties of the present biopolymer for end applications. In an embodiment, the present biopolymer can optionally include about 1 to about 20 wt- % additive.

Hydrolyzing Agent Hydrolyzing fermentation solid can be accomplished with a highly alkaline aqueous solution containing an alkaline dispersion agent, such as a strong inorganic or organic base. The base can be a strong inorganic base, such as: KOH, NaOH, CaOH, NH40H, hydrated lime or combination thereof. Hydrolyzing can be accomplished by mechanical methods of heat and pressure. Hydrolysis can be accomplished by lowering the pH of the admixture. Chemical compounds such as maleic acid or maleated polypropylene can be added to the fermentation solid.

Maleated polypropylenes such as G-3003 and G-3015 manufactured by Eastman

chemicals are examples of hydrolysis and/or coupling materials. The fermentation solid and thermoactive material can crosslink via the hydrolysis process and the molding process conditions (high temperature and high pressure). In an embodiment, the present biopolymer can optionally include about 0.01 to about 20 wt-% hydrolyzing agent.

Plasticizer Conventional plasticizers can be employed in the present biopolymer.

Plasticizers can modify the performance of the biopolymer, for example, by making it more flexible and/or changing flow characteristics. The present biopolymer can include plasticizer in amounts employed in conventional plastics. Suitable plasticizers include natural or synthetic compounds such as at least one of polyethylene glycol, polypropylene glycol, polyethylene-propylene glycol, triethylene glycol, diethylene glycol, dipropylene glycol, propylene glycol, ethylene glycol, glycerol, glycerol monoacetate, diglycerol, glycerol diacetate or triacetate, 1,4-butanediol, diacetin sorbitol, sorbitan, mannitol, maltitol, polyvinyl alcohol, sodium cellulose glycolate, urea, cellulose methyl ether, sodium alginate, oleic acid, lactic acid, citric acid, sodium diethylsuccinate, triethyl citrate, sodium diethylsuccinate, 1,2, 6-hexanetriol, triethanolamine, polyethylene glycol fatty acid esters, oils, expoxified oils, natural rubbers, other known plasticizers, mixtures or combinations thereof, and the like. In certain embodiments, the present biopolymer can optionally include about 1 to about 15 wt-% plasticizer, about 1 to about 30 wt- % plasticizer, or about 1 to about 50 wt-% plasticizer.

Crosslinking Agent Crosslinking agents have been found to decrease the creep observed with plastic composite products and/or can modify water resistance. Crosslinking agents also have the ability to increase the mechanical and physical performance of the present biopolymer. As used herein, crosslinking refers to linking the thermoactive material and the fermentation solid. Crosslinking can be distinguished from coupling agents which form bonds between plastic materials. Suitable crosslinking agents include one or more of metallic salts (e. g., NaCl or rock salt) and salt hydrates (which may improve mechanical properties), formaldehyhde, urea formaldehyde, phenol and phenolic resins, melamine, methyl diisocyanide (MDI),

other adhesive or resin systems, mixtures of combinations thereof, and the like. In an embodiment, the present biopolymer can optionally include about 1 to about 20 wt-% crosslinking agent.

Lubricant In an embodiment, the present biopolymer can include a lubricant. A lubricant can alter the fluxing (melting) point in a compounding, extrusion, or injection molding process to achieve desired processing characteristics and physical properties.

Lubricants can be categorized as external, internal, and external/internal.

These categories are based on the effect of the lubricant on the melt in a plasticizing screw or thermal kinetic compounding device as follows. External lubricants can provide good release from metal surfaces and lubricate between individual particles or surface of the particles and a metal part of the processing equipment. Internal lubricants can provide lubrication within the composition, for example, between resin particles, and can reduce the melt viscosity. Internal/external lubricants can provide both external and internal lubrication.

Suitable external lubricants include non-polar molecules or alkanes, such as at least one of paraffin wax, mineral oil, polyethylene, mixtures or combinations thereof, and the like. Such lubricants can help the present biopolymer (for example, those including PVC) slip over the hot melt surfaces of dies, barrel, and screws without sticking and contribute to the gloss on the end product surface. In addition an external lubricant can maintain the shear point and reduce overheating of the biopolymer.

Suitable internal lubricants include polar molecules, such as at least one of fatty acids, fatty acid esters, metal esters of fatty acids, mixtures or combinations thereof, and the like. Internal lubricants can be compatible with thermoactive materials such as olefins, PVC, and other thermally active materials and the fermentation solid. These lubricants can lower melt viscosity, reduce internal friction and related heat due to internal friction, and promote fusion.

Certain lubricants can also be natural plasticizers. Suitable natural plasticizer lubricants include at least one of oleic acid, linoleic acid, polyethylene glycol, glycerol,

steric acid, palmitic acid, lactic acid, sorbitol, wax, epoxified oil (e. g. , soybean), heat embodied oil, mixtures or combinations thereof, and the like.

In an embodiment, the present biopolymer can optionally include about 1 to about 10 wt-% lubricant.

Processing Aid In an embodiment, the present biopolymer includes a processing aid.

Suitable processing aids include acrylic polymers and alpha methylstyrene. These processing aids can be employed with a PVC polymer. A processing aid can reduce or increase melt viscosity and reduce uneven die flow. In a thermoactive material material, it promotes fluxing and acts like an internal lubricant. Increasing levels of processing aids normally allow lower compounding, extrusion, injection molding processing temperatures. In an embodiment, the present biopolymer can optionally include about 1 to about 10 wt-% processing aid.

Impact Modifier In an embodiment, the present biopolymer includes an impact modifier.

Certain applications require higher impact strength than a simple plastic. Suitable impact modifiers include acrylic, chlorinated polyethylene (CPE), methacryalate- butadiene-styrene (MBS), and the like. These impact modifiers can be employed with a PVC thermoactive material. In an embodiment, the present biopolymer can optionally include about 1 to about 10 wt-% impact modifier.

Filler The present biopolymer need not but can include a filler. Fillers can reduce the cost of the material and can, in certain embodiments, enhance properties such as hardness, stiffness, and impact strength. Filler can improve the characteristic of the biopolymer, for example, by increasing thermal stability, increasing flexibility or bending, and improving rupture strength. In an embodiment, the present biopolymer can be in the form of a cohesive substance that can bind inert filler (such as wood, fiber, fiberglass, etc. ) with petroleum based thermoactive materials. Fillers such as wood flour do not particularly enhance the qualities of filled plastic or biopolymer.

Conventional fillers such as talc and mica provide increased impact resistance to the present biopolymer, but add weight and decrease the life of an extruder. Fiberglass

as a filler adds considerable strength to the product, but at a relatively high cost. In an embodiment, the present biopolymer can optionally include about 1 to about 50 wt-% filler.

Wood flour and some other fillers used in plastics are not thermally stable.

Wood flour does not mix or crosslink with plastics and individual particles are surrounded with plastics under heat and pressure conditions. Mineral, fiberglass, and wood flour are called"inert"fillers due to the fact they can not crosslink or bond to the plastic. Also, wood or cellulose based fillers can not handle the heat requirements of most plastic processes (such as extrusion and injection molding).

Additionally, wood flour fillers degrade and retain moisture.

Fiber The present biopolymer can include a fiber additive. Suitable fibers include any of a variety of natural and synthetic fibers, such as at least one of wood; agricultural fibers including flax, hemp, kenaf, wheat, soybean, switchgrass, or grass; synthetic fibers including fiberglass, Kevlar, carbon fiber, nylon; mixtures or combinations thereof, and the like. The fiber can modify the performance of the biopolymer. For example, longer fibers can be added to biopolymer structural members to impart higher flexural and rupture modulus. In an embodiment, the present biopolymer can include about 1 to about 20 wt-% fiber.

Blowing Agent Even when produced in the form of a foam, the present biopolymer composition need not include or employ a blowing agent. However, for certain applications for producing the composition in the form of a foam, the biopolymer can include or the process employ a blowing agent. Suitable blowing agents include at least one of pentane, carbon dioxide, methyl isobutyl ketone (MIBK), acetone, and the like.

Methods of Making the Biopolymer The present biopolymer can be made by any of a variety of methods that can mix thermoactive material and fermentation solid. In an embodiment, the thermoactive material and fermentation solid are compounded. As used herein, the verb"compound"refers to putting together parts so as to form a whole and/or

forming by combining parts (e. g., thermoactive material and fermentation solid).

The fermentation solid can be compounded with any of a variety of thermoactive materials, such as thermoset and thermoplastic materials. Any of a variety of additives or other suitable materials can be mixed or compounded with the fermentation solid and thermoactive material to make the present biopolymer. In an embodiment, compounding fermentation solid and thermoactive material produces the dough-like material described hereinabove.

Compounding can include one or more of heating the fermentation solid and thermoactive material, mixing (e. g. , kneading) the fermentation solid and thermoactive material, and crosslinking the fermentation solid and thermoactive material. Compounding can include thermal kinetic compounding, extruding, high shear mixing compounding, or the like. In an embodiment, the fermentation solid and thermoactive material are compounded in the presence of hydrolyzing agent.

The biopolymer or biopolymer dough can be formed by melting together the fermentation solid and the thermoactive material. In contrast, thermal kinetic compounding of wood particles and thermoactive material produces a material in which wood particles are easily seen as individual particles suspended in the plastic matrix or as wood particles coated with plastic. Advantageously, the compounded fermentation solid and thermoactive material can be an integrated mass that is homogenous or nearly so.

The compounded, raw or soft biopolymer can be used directly or can be formed as pellets, granules, or another convenient form for converting to articles by molding or other processes.

Thermal Kinetic Compounding Thermal Kinetic Compounding ("TKC") can mix and compound employing high speed thermal kinetic principals. Thermal kinetic compounding includes mixing two or more components with high shear speeds using an impeller. Suitable thermal kinetic compounding apparatus are commercially available, for example, the Gelimat Gl (Draiswerke Company). Such a system can include a computer controlled metering and weight batch system.

An embodiment of a thermal kinetic compounding apparatus includes a horizontally positioned mixer and compounding chamber with a central rotating shaft. Several staggered mixing elements are mounted to the shaft at different

angles. The specific number and positions of the mixing blades varies with the size of the chamber. A pre-measured batch of thermoactive material and fermentation solid can be fed in to the compounder, for example, via an integrated screw which can be part of the rotor shaft. Alternatively, the thermoactive material and fermentation solid can be fed through a slide door, located on the mixer body. The apparatus can include an automatically operated discharge door at the bottom of the compounding chamber.

In the compounding chamber, the thermoactive material and fermentation solid is subject to extremely high turbulence, due to high tip-speed of the mixing element. The thermoactive material and fermentation solid are well mixed and also subjected to temperature increase from impact against the chamber wall, mixing blades, and the material particles themselves. The friction in the moving particles can rapidly increase temperature and remove moisture.

The mixture of thermoactive material and fermentation solid striking the interior of the chamber heats the material. For example, the material can be heated to about 140 °C to about 250 °C in times as short as about 5 to about 30 seconds.

The process cycle can be microprocessor controlled. The microprocessor can monitor parameters such as energy, input, temperature, and/or time. When the microprocessor determines that the process is complete, the apparatus can open the discharge door and discharge of the compounded thermoactive material and fermentation solid (the biopolymer). In an embodiment, the discharged compounded thermoactive material and fermentation solid is a uniformly blended, fluxed compound, which can immediately be processed.

Using the commercially available thermal kinetic compounding apparatus identified above, the energy consumed by blending, dispersing, and fluxing can be about 0.04 kilowatt per pound of product, which compares favorably to 0.06-0. 12 kilowatt per pound of product produced by standard twin-screw compounding systems.

The compounded thermoactive material and fermentation solid, the biopolymer, can then be run through a regrinding process to produce uniform granular materials. Such regrinding can employ a standard knife grinding system using a screen, which can create smaller uniform particles of a similar size and shape. Such granular materials can be used in, for example, extrusion, injection molding, and other plastic processing.

In an embodiment, TKC processes expose the thermoactive material and fermentation solid to high temperatures and shear stresses for only a short or reduced time. The duration of TKC can be selected to prevent or reduce thermal degradation.

In an embodiment, thermal kinetic compounding operates on a mixture of as little as 10 wt-% thermoactive material and as much as 90 wt-% fermentation solid.

Such high proportions of fermentation solid are difficult to compound with a conventional twin-screw compounding system. In an embodiment, using thermal kinetic compounding, product formulations can be changed rather quickly. The chamber of the apparatus can remain clean upon compounding the fermentation solid and thermoactive material. In an embodiment, quick startup and shut down procedures are also possible in the thermal kinetic compounding apparatus as compared to standard compounding systems that require long and extensive shutdown and cleanout processes.

Although not limiting to the present invention, thermal kinetic compounding can quickly raise the temperature of the material including fermentation solid to the boiling point of water, at which point vaporization of water slows the temperature rise. Once the moisture content of the material in the compounding chamber decreases below several tenths of a percent, a fast rise in temperature can occur until it reaches the Tm point of the admixture of the thermoactive material and the fermentation solid. Residence time in the chamber can be from about 10 to about 30 seconds. The residence time can be selected based on variables such as diffusion constant time of the particles, initial moisture content, and the like.

Thermal kinetic compounding of fermentation solid and thermoactive material can employ various processing parameters to produce a desirable biopolymer. In an embodiment, compounding continues until the material (s) have reached or exceeded their Tm points.

In an embodiment, thermal kinetic compounding of fermentation solid and thermoactive material produces a soft or raw biopolymer in the form of a dough, which can be largely homogeneous. For example, thermal kinetic compounding can produce a material with a consistency similar to baking dough (e. g. , bread or cookie dough) with a major proportion of the fermentation solid blended into the thermoactive material and no longer appearing as distinct particles. In an embodiment, thermal kinetic compounding can produce a soft or raw biopolymer

with greater than or equal to 70-90 wt-% of the fermentation solid homogenized into the dough. In an embodiment, thermal kinetic compounding can produce a soft or raw biopolymer including no detectable particles of fermentation solid.

In an embodiment, thermal kinetic compounding can melt together the fermentation solid and the thermoactive material. In contrast, thermal kinetic compounding of wood particles and thermoactive material produces a material in which wood particles are easily seen as individual particles suspended in the plastic matrix or as wood particles coated with plastic. Advantageously, in the an embodiment, thermal kinetic compounding can compound fermentation solid and thermoactive material to form an integrated mass that is homogenous or nearly so.

In an embodiment, thermal kinetic compounding can produce raw or soft biopolymer including visible amounts of fermentation solid. Such compounding can employ particles of fermentation solid with a size of about 2 to about 20 mesh.

Thermal kinetic compounding can include compounding the quantities or concentrations listed above for the fermentation solid and thermoactive materials in batch sized suitable for the apparatus. In an embodiment, thermal kinetic compounding can effectively compound fermentation solid with small amounts of thermoactive material (e. g. , about 5 to about 10 wt-% thermoactive material) and produce a raw or soft biopolymer. Such amounts of thermoactive material are small compared to those employed for conventional processes of compounding plant materials, such as wood, with thermoactive materials.

Compounding by Extruding The present biopolymer can be formed by any of a variety of extruding processes suitable for mixing or compounding fermentation solid and thermoactive material. For example, conventional extruding processes, such as twin screw compounding, can be employed to make the present biopolymer. Compounding by extruding can provide a higher internal temperature within the extruder and promote the interaction of thermoplastics with the fermentation solid. Twin screw compounding can employ co-or counter-rotating screws. The extruder can include vents that allow escape of moisture or volatiles from the mixture being compounded.

Using a die on the extruder can compound and form the biopolymer.

Removal of Water and Other Matter Processing machinery (such as an extruder) can be configured to remove water or other matter (gases, liquids, or solids) during processing of materials to form the biopolymer. Water may be extracted for example during twin screw extruding processes or during thermokinetic compounding processes. For clarity, reference hereinafter is made to extraction of water but it is understood that other liquids, gasses, or solids, such as impurities, decomposition products, gaseous by products, and the like, can be extracted as well.

In an embodiment, water can be extracted mechanically. For example, compression forces can be applied during extrusion processes to press water from the material. In an embodiment, compressing the material during extrusion can press water or other liquids or gases out of internal cells that can form in the material.

Heat can also be used to extract water and/or dry the material. In an embodiment, heat can be applied during the extrusion process or during other mechanical water-extraction processes. In an embodiment, after the extrusion or compression molding process, the biopolymer can be immediately processed through a microwave or hot air drying system to remove the balance of water to the equilibrium point of the material. This is typically between 3-8 percent moisture content. A higher addition rate of thermoactive material tends to lower the equilibrium point and further increase chemical bonding efficiencies which creates high degrees of water resistance and mechanical strength.

Vacuum or suction techniques can also be applied to extract water from the biopolymer as well as other impurities or gases. In an embodiment, heat, vacuum, and mechanical techniques can be employed together to extract water and other matter from the biopolymer. In an embodiment, closed cells can be ruptured through application of one or more of heat, compression, and vacuum suction.

Techniques for extraction of water from polymeric materials are further described in United States Patent No. 6, 280, 667, which is incorporated herein by reference. This patent discloses methods and apparatus employed for processing plastics with wood fillers. These methods and apparatus can also be employed to process and form embodiments of the present biopolymer.

Forming Biopolymer into Products The present invention relates to articles fabricated from or including biopolymers including fermentation solid and thermoactive material. The present biopolymer can exhibit properties typical of plastic materials, properties advantageous compared to conventional plastic materials, and/or properties advantageous compared to aggregates including plastic and, for example, wood or cellulosic materials. The present biopolymer can be formed into useful articles using any of a variety of conventional methods for forming items from plastic. The present biopolymer can take any of a variety of forms.

Biopolymer material can be formed into a variety of objects and structures.

In one embodiment, raw biopolymer can be formed into pellets which are fed into machinery configured to injection mold, extrude, or otherwise form or process the biopolymer. In an embodiment, pellets can be formed by first urging polymer and fermentation solids through a die to produce a linear extrusion and then cutting the extrusion into a pellet shape. In an embodiment, the pellets have a substantially uniform size and shape. The cross-section of the pellet can be any of a variety of shapes, such as square, circular, oval, rectangular, pentagonal, hexagonal, etc. , as determined by depending on the shape of the extrusion die. A circular cross section can be preferred in many applications, typically with a radius of several millimeters and length of about two to four time the radius.

While specific biopolymer products are described hereinbelow, other products are also possible. For example, biopolymer can be used in boat hulls, playground sets, storage containers, crown molding, and the like.

Injection Molding the Biopolymer Embodiments of the present biopolymer can be injection molded. In an embodiment, compounded biopolymer can be ground to form uniform pellets for use in an injection molding process. In an embodiment, the present polymer can be processed using less energy per pound than conventional thermoplastics. In an embodiment, the present biopolymer can exhibit faster heating and cooling times during injection molding compared to conventional thermoplastics. In an embodiment, the present biopolymer maintains the melt index of the plastic and allows flowability characteristics that allows high speed injection molding. For example, biopolymer including fermentation solid and polypropylene was observed to have higher thermal conductivity than pure polypropylene. Higher thermal conductivity provides faster heating and/or cooling, which can which can speed processes such as injection molding.

Injection molding techniques are known to those skilled in the art. In an embodiment, machinery can be configured to injection mold biopolymer into a desired shape. A mold defines a shape, into which heated thermoactive material is injected. The material is then allowed to cool and subsequently ejected from the mold.

Extruding the Biopolymer The present biopolymer can be extruded to form an article of manufacture employing any of a number of conventional extrusion processes. For example, the present biopolymer can be extruded by dry process extrusion. For example, the present biopolymer can be extruded using any of a variety of conventional die designs. In an embodiment, extruding the present biopolymer to form an article can include feeding the biopolymer into a material preparation auger and converting it to a size suitable for extruding. Extruding can employ any of a variety of conventional dies and any of a variety of conventional temperatures. Compounding by extruding can provide a higher internal temperature within the extruder and promote the interaction of thermoplastics with the fermentation solid.

An extruder having one or more dies can be configured to form the biopolymer into a shape. The biopolymer can be urged through a die to produce a desired cross section. The extruded biopolymer can then be cut to a desired length as necessary. The biopolymer can also be allowed to harden or otherwise cured to

preserve the cross-sectional shape. Extruded biopolymer can later be cut into shorter lengths as desired.

In an embodiment, the biopolymer material can be heated above the melting point. The biopolymer can then be moved through a converging die that is heated to reduce shear stress in the biopolymer near the wall and then through a forming section to provide a desired cross section. In an embodiment, the biopolymer can then be passed through a low-friction unheated or thermally insulated section that has a cross section that is the same or similar to the cross section of the forming section to establish a cross sectional memory in the polymer and reduce swelling after extrusion. The biopolymer material can then be quenched to form a shell below the melting point. In embodiments, the shell can substantially maintain the biopolymer in the desired shape.

In another embodiment, machinery can be configured to move biopolymer through a transition die and then through a stranding die to produce strands of biopolymer. Machinery can further be configured to move the strands through a molding die that combines the strands into a desired extrusion. In one embodiment, this stranding and re-bonding process can produce a product having a structure and/or appearance that is similar to the grain in wood.

Co-Extruding Materials with the Biopolymer Additional materials can be co-extruded with the biopolymer. In an embodiment, a layer or sheet of another material (e. g. , a coating or thermoactive material) can be co-extruded with the biopolymer. In an embodiment, the co- extruded layer or sheet can provide desired surface properties, structural properties, and/or appearance.

Foaming the Biopolymer In an embodiment, the present biopolymer can be foamed either from its soft, raw form or upon melting without addition of foaming or blowing agents.

Surprisingly, the present biopolymer can foam upon extruding even in the absence of foaming agents to produce a rigid, strong hardened foam. Although not limiting the present invention, it is believed that the present foam can result from foaming of protein in the fermentation solid.

The stiff or solid foam can exhibit greater strength (e. g. , flexural modulus) compared to conventional foamed plastics at the same density. Conventional plastics decrease in strength when foamed. Although not limiting to the present invention, it is believed that the present biopolymer foam may include denatured protein interacting with the thermoactive material to create an advantageously strong biopolymer foam.

The present biopolymer (e. g. , in the form of pellets) can be converted to a biopolymer foam by injection molding, extrusion, and like methods employed for forming plastics. Although not limiting to the present invention, it is believed that the heat and kinetic energy applied in these processes, such as by a mixing screw, is sufficient to foam the present biopolymer. In injection molding, the mold can be partially filled to allow the foaming action of the biopolymer to fill the cavity. This can decrease the density of the molded article without using chemical foaming or blowing agents. Extruding can also be employed to foam the present biopolymer.

The dies used in extruding can form the foamed biopolymer.

In an embodiment, a foamed biopolymer can be produced by mixing a foaming agent with fermentation solids and thermoactive material. In an embodiment, biopolymer can be foamed without pre-fabrication into pellets by mixing fermentation solids and thermoactive material with a powdered foaming agent, heating and compounding the mixture and then extruding the biopolymer. In an embodiment, vacuum can be used to remove vapors. In an embodiment, greater expansion occurs in the center of an extruded profile than at the perimeter of the profile, such that the extruded product has a higher density near the exterior than on the interior.

It may be desirable to process biopolymer ingredients into fine particulate to allow for effective foaming. In an embodiment, ingredients can first be processed into a biopolymer product and then the biopolymer can be re-ground into fine particles to facilitate foaming into a foamed product shape.

In an embodiment, foamed biopolymer can be created by creating discontinuities in a biopolymer material. The discontinuities are expanded and the biopolymer is then stabilized to preserve the discontinuities by cooling or crosslinking. In an embodiment biopolymer can be made using foaming agents such as an inert gases (e. g. nitrogen or carbon dioxide, hydrocarbons, chlorinated hydrocarbons, chlorofluorocarbons) or a decomposing chemical blowing agent that

dissolves or disperses into biopolymer in liquid form and which decomposes to an inert gas at elevated temperatures. The expansion associate with foaming agents or decomposing chemical blowing agents cause expansion of cell structures to develop a foamed biopolymer. The foaming process can be control through control of the extrusion temperature and other parameters.

An embodiment of a foamed component includes a solid outer layer or shell and an interior formed of foamed biopolymer. Foamed biopolymer components can be configured to offer relatively low weight and high stiffness compared to solid components. Foamed biopolymer can be formed for example into components such as sized lumber, posts, beams, trim, shaped structural members, furniture board, and trim components. It can be desirable to form components with a specific gravity lower than water, so the components float, or to approximate the density of wood lumber. Window or door components can also be formed from foamed biopolymer.

Components combining hollow and foamed cores are also possible.

Processing Parameters and Structural Parameters In an embodiment, biopolymer admixture can provide a higher flow or lower viscosity compared to typical mixtures that use dried fibers with a thermoactive material. This can allow for processing with significantly lower pressures during extrusion or injection molding. For example, pressures of compression molding a conventional fiber/polymer material can typically fall in the 500-1000 psi range. In contrast, in an embodiment, the present biopolymer can reach maximum density at less than 150 psi. In an embodiment, motor load for processing the present biopolymer can be decreased from 50% for conventional polymer to 10% for the present polymer.

The lower compression pressure requirement of embodiments of the present biopolymer can allow for significant changes to the engineering and structure of pressing or extrusion equipment for the biopolymer and lower the costs of such equipment. In an embodiment, equipment for processing the biopolymer can also be configured with lower processing temperature. In an embodiment, processing temperature can be reduced from 400 degrees Fahrenheit for conventional polymer to 320 degrees Fahrenheit for an embodiment of the present biopolymer.

Mechanical properties for lumber replacements (or other structures) can be quantified and tested for a variety of parameters. Biopolymer ingredients and

manufacturing processes can be manipulated to achieve desired combinations of properties. Properties that can be considered include density, surface hardness, shear strength and bending properties, retention force (for retaining nails, screws, or other fasteners), strip-out properties, coefficient of thermal expansion, and Young's modulus. In an embodiment, structural parameters can be manipulated by altering the percentage of fermentation solids in the biopolymer.

Illustrated Embodiments Examples of structural embodiments that can be formed from biopolymer are shown in Figs. 1-8.

Sheet Products The present biopolymer can be formed into sheets. Fig. 7 shows an embodiment of a sheet product 700. An embodiment of a sheet product may be textured and/or or printed to simulate other materials.

Structural Members In one embodiment, biopolymer can be formed into a structural member. In one embodiment, a structural member can be fabricated to replicate the properties and/or appearance of other materials. For example, in one embodiment, the biopolymer can be used to fabricate structural members of assemblies conventionally made from wood, plastic, or metal, such assemblies are shown in Figs. 1 and 2. In an embodiment, biopolymer can be formed into a lumber replacement member, such as the member 600 shown in Fig. 6. The core 610 of member 600 can include solid biopolymer, foamed biopolymer, hollow voids, struts, webs, or a combination thereof. Lumber replacement members can be sized according to common industry parameters, e. g. 2x4,2x2, 2x6, and the like.

Lumber replacement sheets can also be formed from biopolymer. For example, biopolymer can be formed into a 4x8 sheet to replace standard plywood.

Other types of sheets can also be formed.

Biopolymer can also be formed into more specialized lumber replacement members or other structural members, including members having more complex shapes. An exemplary sheet is shown in Fig. 7.

Components for Window and Door Assemblies In one embodiment, the present biopolymer can be formed into components for doors and windows. Fig. 1 shows a window assembly, components of which can be constructed from biopolymer. Window assembly 100 includes a frame 25 which can be formed from a header 30, a sill 35, and jambs 40, all of which can be formed from the biopolymer material. Sash 45 can be formed from rails 50 and stiles 55. Rails 50 and stiles 55 can also be formed from the biopolymer. Muntins 60, casing 65, and trim components 70 (shown in Fig. 2) can also be formed from the biopolymer. While Fig. 1 shows a double-hung window, other types of window assemblies can be formed from the biopolymer, including but not limited to assemblies for casement windows, awning windows, fixed frame and circle head windows, transom windows, skylights, gliding windows, tilt-in windows, bowed windows, and bay windows.

In an embodiment, specifically designed cross-sectional shapes can be formed to allow the biopolymer window or door components to fit together and fit with glass, trim or other components. An example of a member with a complex shape is shown in Fig. 5. In an embodiment, biopolymer components can be assembled in a thermo weld process in which components are heated and fused together. In an embodiment, thermal welding can produce a welded joint having greater strength and rigidity than typical assemblies made from wooden members.

In an embodiment, a welded region can be finished using a tool to create a uniform transition and/or an attractive appearance. The tool can be for example a knife, a routing tool, or other shaper tools. In an embodiment, the tool can be heated to partially melt the biopolymer to promote a clean and attractive weld.

Fig. 2 shows a cross-section of a window. Solid components 80, hollow components 85, and sheet components 90 can all be formed from the biopolymer. In some embodiments, components are formed with a hollow cross-section and at least one structural web member to provide both light weight and sufficient strength and durability to withstand daily use. Embodiments of window assemblies can include into foamed components. An embodiment of a foamed component shown in Fig. 3 has a solid shell 95 with a foamed core 100. The core 97 shown in Fig. 3 could alternatively be hollow or webbed.

Fig. 4 shows a door assembly. Components for standard doors, French doors, sliding patio doors, and others types of doors can be formed from the

biopolymer. The door assembly in Fig. 4 includes frame 105 including header 110, door jamb 115 and sill 120. The door includes panels 125, sash 130, and muntins 135. All of these components can be formed from the biopolymer material. Non- structural trim elements and molding can also be formed from the biopolymer.

Biopolymer components can be formed in hollow or semi-hollow configurations. In one embodiment, a component formed from the biopolymer includes a shell or wall and one or more internal supports. Fig. 5 shows an exemplary semi-hollow component that can be formed from the biopolymer material. The component includes an outer wall 200 having internal surfaces 205 and external surface 210. Grooves 215 or other premolded paths or features can be formed in the exterior surfaces to accommodate interface with related components. One or more internal struts 220 can be provided. One or more anchors 225 can also be provided. Anchors can be configured to receive a fastener such as a screw or bolt. Bonding surfaces 230 can also be provided to accommodate thermal-welding of biopolymer components to other thermoactive material or biopolymer components.

Siding Products Siding products for building structures can also be formed from the biopolymer. In one embodiment, siding product can be provided in sheet form.

Siding product can for example replicate stone or marble.

In another embodiment, siding product can be provided in the form of slats, similar to wood, aluminum, or vinyl siding. Figures 8, for example, shows a siding product including a longitudinal member 800. Figures 9 and 10 also show a siding members 900,1000. In an embodiment, the biopolymer can be formed into longitudinal members having mating structures such that adjacent members can be connected. For example, a tongue 810 and groove 820 arrangement can be used to connect a longitudinal member to a like member situated above or below. An embodiment of a longitudinal members can include stiffening struts 930 or a supporting web 940 to add stiffness as shown in Fig. 9.

An embodiment of a siding member can include portions which are foamed or hollow. Fig. 10 show an embodiment 1000 having an internal portion 1010 that can be foamed or hollow. An embodiment having a hollow portions can also include a web of structural supports, as shown for example in Fig. 8. Embodiments

of foamed or hollow portions can increase the R value of the siding. Embodiments with foamed or hollow portions can also make the siding member more rigid and exhibit less creep. Embodiments may also include combinations of at least two of foam, hollow portions, and webbed portions.

An embodiment of a siding assembly can include siding members that can be connected end-to-end by thermal welding. The exposed surface of a siding member can be printed, coated, covered or otherwise processed to improve weatherability and/or appearance, as described below.

Column and Rail System Embodiments of structural members that include biopolymer material can be used to build a variety of structures, including pillars, rails, and decking systems, and can be used in a variety of places, including porches, patios, entryways, gardens, lawns, or as accents. In one embodiment, pillars and rails can be used as a component of a decking system.

In a preferred embodiment of a column and rail system, a pillar is made from a base, corners, panels, and a top cap. In an embodiment, a base can be configured to slide over a post that is coupled or secured to the ground or another structure.

Although a post'is not required, it can provide advantageous structural support. In an embodiment, a plurality of panels can be interconnected by a plurality of corners to form a pillar. In one embodiment, four panels and four pillars can be used to create a rectangular pillar. In other embodiments, other pillar shapes can be formed, such as triangles, pentagons, hexagons, heptagons, octagons, and so on. Irregular pillars are also possible: Neither the panels nor the corners that shape the pillar need to be the same size.

In an embodiment, a pillar can be configured to slide over or otherwise couple to a post. The pillar can further be coupled to the base. Alternatively, the pillar can be secured to the post, or the base can be secured to the post. A top cap can then be mounted or otherwise coupled to the post and/or to the pillar. The top cap can be in a variety of different forms, including functional or aesthetically pleasing forms. In one embodiment, the top cap is shaped as a generally horizontal member having an inner body portion and first and second outer ends and first and second generally vertical members that are spaced apart and disposed inwardly from said first and second ends of the horizontal member.

The column can be hollow, filled, partially filled, or internally foamed. In one embodiment, the column can have a hollow interior. In another embodiment, the column can have a partially filled interior, such as when the post is secured to the top cap but there is a distance or void between one or more panels and the post. In a third embodiment, the column can have an entirely filled interior, such as when the post is secured to the top cap and is also touching the panels. In other embodiments, the column can include a solid shell and a foamed, webbed, or strutted interior, or a combination thereof. The invention is not limited to these possible embodiments.

The panel can be a decorative element, with a desirable color, material, texture, or the like. In an embodiment, the panel can be a transparent or translucent material, such as stained glass or a printed glass or plastic material that gives the appearance of stained glass. In an embodiment, a light source can be positioned within the pillar or column and can be configured to illuminate the transparent or translucent panel. In an embodiment, the light source is in the space between the pillar and the post. In an embodiment, the corner component can form a frame for the decorative panel.

In a preferred embodiment, the railing is formed from balusters and rails. A plurality of balusters are placed between a top rail and a bottom rail and then secured to the top and bottom rails. A rail cover can then be secured to the top rail to make the railing.

The structural members can be made in whole or in part of a variety of materials, including biopolymer, wood, glass, and composite materials, and can be metalized with brass, bronze, chrome, or gun metal for unique looks and styles. The top caps can also made of glass or other transparent or translucent material and lighted from the inside. Other lighting arrangements are also possible. The structural members can take a variety of shapes. For example, the structural members can have rounded or sharp edges, and can be circular or polygons. The structural members can be made in a variety of ways, including injection molding or extrusion. The structural members can also be secured in a variety of ways, including by being screwed, nailed, glued, snapped, or fastened. Biopolymer components can be thermowelded together. Thermowelds can be smoothed or otherwise featured with a knife, router or other tool to provide a pleasing appearance.

Illustrated Embodiments of the Column and Rail System FIGS. 13-26 illustrate examples of structural embodiments that can be formed from or include the present biopolymer.

FIG. 13 is a front perspective view of an embodiment of a decking system that can be made of a corner 1, a panel 2, a baluster 3, a rail 4, a rail cover 5, a base 6, and a top cap 7. A pillar can include a corner 1, a panel 2, a base 6, and a top cap 7, and can be secured to a railing, which can be made up of a baluster 3, rail 4, and rail cover 5, as shown in FIG. 13.

FIG. 14 shows a front view of a base component where a base 6 can slide over a post 8. A fastener, such as screw 9, can secure a base 6 to a post 8. A plurality of panels 2 can be interconnected by a plurality of corners 1 to form a rectangular pillar. A pillar can slide over a post 8 and can be mounted on a base 6 as shown in FIG. 15. A top cap 7 can be mounted to a post 8 to form the pillar as shown in FIG. 16.

FIG. 17 is a front view of a railing assembly. A plurality of balusters 3 can be placed between a top rail 4 and a bottom rail 4 as shown in FIG. 5. A baluster 3 can be connected to a top rail 4 and a bottom rail 4 by, for example, a screw 10, as shown in FIG. 18. A rail cover 5 can be mounted on a top rail 4 of an assembling railing to make a railing as shown in FIG. 19.

Embodiments of structural components that can be used to form the structure in FIGS. 13-19 are shown in FIGS. 20-26. FIG. 20 is a perspective view of a base 6.

FIG. 21 is a top view of a panel component 2. FIG. 22 is a cross-sectional view of a corner 1. FIG. 23 is a perspective view of a top cap 7. FIG. 24 is a top view of a baluster 3. FIG. 25 is a side view of a bottom rail 4. FIG. 26 is a side view of a rail cover 5.

Coatings, Textures, and Appearance The biopolymer can be treated for appearance during or after forming. For example, the die or other surface used in forming can form a textured surface on the biopolymer article. Extruding can co-extrude an appearance layer of polymer or other material with a biopolymer core. After forming, the formed biopolymer can be treated with a multi roller printing process to impart the look of real wood or other desired printed textures or colors. After forming, the formed biopolymer can be treated with a thermosetting powder. The thermosetting powder can be, for

example, clear, semi-transparent, or fully pigmented. The powder can be heat cured, which can form a coating suitable for interior or exterior uses. The powder can also be textured to provide, for example, a natural wood look and texture.

In an embodiment, the biopolymer products can be powder coated, embossed, and/or printed to provide desired surface properties such as weatherability and UV-resistance and/or surface effects such as wood grain colors and textures.

In an embodiment, a biopolymer product can be formed with a protective layer. In an embodiment, a biopolymer product can be coated with a thermosetting powder that is baked on to cure the powder into a high performance coating. The powder can for example be polyester, epoxy, acrylates, or other polymers or thermoactive material, or a combination thereof. The coating can be clear, semi- transparent, or fully pigmented. In one embodiment, the powder coated biopolymer product can be baked in an infrared or IR/UV oven. Such a coated product can be appropriate for both internal and exterior usage.

In an embodiment, a thin layer of resin or other material can be added to a surface. An embodiment of siding material, for example, can be fabricated with a protective resin layer to enhance weatherability. Addition of a surface layer can also be useful in other applications, including for example interior applications where exposure to cleaning agents can occur (e. g. tub or shower areas), and exterior applications such as building trim, shutters, lawn and garden equipment, decorative panels and signs, or patio furniture.

In an embodiment, a biopolymer product can be vinyl wrapped or metal wrapped.

Biopolymer products can be given a wood appearance and/or texture (or other texture/appearance) through processing such as embossing or printing, or by co-extruding an outer layer with the biopolymer. Siding assemblies, for example, can be patterned with a wood grain appearance or texture. Sheet products may also be patterned and coated to provide a wood grain appearance or other appearance.

Other wood-replacement products can similarly be processed to resemble particular woods (or stained woods) in texture and color.

In one embodiment, the biopolymer product can be run through a multiroller printing process to impart the look of real wood or other desired printed textures or colors, such as stucco, concrete, bricks, stone, tile, clay, or metal. In other

embodiments, an extrusion can be directly printed using a gravure printing process or an embossing wheel. The combination of color and texture can create a natural wood look and feel. Other printing process also can be used, including direct computer imagery. In an embodiment, printing or other methods can create realistic wood textures such as maple, oak, cherry, cedar or other desired prints and textures.

In one embodiment, the biopolymer material can be placed in a thermal plated press during the curing process both to impart faster curing and to impress a texture onto the surface of the end product.

In an embodiment, an exterior product can be formed using fermentation solids in conjunction with a powder coating for exterior products. In an embodiment, the exterior product can be printed with a desired appearance and/or textured in a press with a texture plate to form an exterior grade textured surface. In another embodiment, similar processes can be employed to generate a rough-service product.

In another embodiment, the biopolymer can be printed and then coated to protect the printed surface. The biopolymer may be digitally printed for example, to impart a desired appearance such as the grain of a particular wood, such as cherry.

The biopolymer may then be powder coated to protect the printed surface. In an embodiment, the biopolymer may be powder coated with a clear layer to allow the printed surface to show through.

In another embodiment, an outer layer is applied to the product. The outer layer can for example be a veneer, a wood grain covering, a pigmented covering, or another type of co-extruded layer. The outer layer can provide a desired color, appearance, texture, weatherability, or other property.

In another embodiment, the biopolymer can be made to look like granite. In an embodiment, the biopolymer can include visible particles of remaining fermentation solid. Such a composite biopolymer can result in a matrix of one appearance surrounding particles with a different appearance, giving the appearance of granite. In such a composite biopolymer, a significant fraction of the fermentation solid can be blended into and/or bonded with the thermoactive material.

In another embodiment, particulate matter can be added to the biopolymer.

Embodiments including particulate matter can be formed to simulate the appearance of granite or other stones, or natural wood grains such as burled wood. In an

embodiment, particulate can be fused into a biopolymer product for example by mixing in the particular during extrusion molding or compression molding. In an embodiment, particulate does not dissolve into the polymer but remains distinct, so that the particulate matter is visible to the naked eye. In an embodiment, particulate can be combined in a polymer to give a desired aggregate appearance. In an embodiment, the biopolymer with aggregate matter can be machined, cut, drilled, or otherwise processed.

Figure 11 shows a flow chart 1100 illustrating a process of making an article.

A composition is made at 1110 that includes about 5 to about 95 wt-% fermentation solid and about 0.1 to about 95 wt-% thermoactive material. The composition is formed 1120 into an article by molding, injection molding, blow molding, compression molding, transfer molding, thermoforming, casting, calendering, low- pressure molding, high-pressure laminating, reaction injection molding, foam molding and/or coating. In an embodiment, the article can be coated 1130 after forming.

Figure 12 shows a flow chart 1200 illustrating a process by which the present biopolymer can be fabricated into a lumber replacement article, window or door component, or siding component. A biopolymer is heated 1210. Pressure is applied 1220 to the heated biopolymer. In an embodiment, heating and application of pressure can occur simultaneously or application of pressure can begin first. Heated biopolymer can be shaped 1230 into an article or component. In an embodiment, the biopolymer can be shaped by extruding or injection molding 1240. In an embodiment, the article can be pressed by pressing 1260 the article or component.

In an embodiment, pressing the biopolymer extracts water 1270 from the biopolymer. Pressing for example can create a sheet product or other product or can prepare biopolymer for subsequent extruding or injection molding. In an embodiment, further processing can occur during or after shaping, including for example further shaping, cutting, machining, or surfacing. In an embodiment, a surface texture can be applied 1250 to the article or component. The surface texture can be applied for example by coextruding or by impressing the surface with a die.

Other techniques for creating a surface texture can also be used. The biopolymer is cooled 1280 to preserve the shape of the component or article.

EXAMPLES

Example 1-Biopolymer Production by Thermal Kinetic Compounding The present example describes preparation of a biopolymer according to the present invention and that included fermentation solid (e. g. , DDG, a particular fermented protein solid), polypropylene, and maleated acid. For example, these components were taken in a ratio of 60/38/2 and were compounded using a Gelimate Gl thermal kinetic compounder. The other ratios listed in the table were compounded according to the same procedure. Compounding was conducted at 4400 RPM ; the material was and ejected from the compounder at a temperature of 190 °C. The polypropylene was a commercial product called SB 642 and supplied by Basell Coproration. The biopolymer left the compounder as a dough like mass that resembled bread dough (soft or raw biopolymer). The soft or raw biopolymer was granulated in a conventional knife grinding system to create pellets.

Pellets of the present biopolymer were injection molded in a standard "dogbone"mold on an Toshiba Electric Injection molding press at a temperature in all three zones of 320 °F. As a control, the commercial polypropylene alone was also molded by the same procedure.

The resulting dogbones were tested in accordance to ASTM testing standards for plastic for tensile strength, flexural modulus, modulus of rupture to determine mechanical strengths. The following results were obtained: Displacement Tensile Flexural (Stretching) Polymer Strength Strength Tensile Testing (lbf, ASTM) (psi, ASTM) (inches, ASTM) 100% Polypropylene 130 61,000 0.22 Biopolymer Embodiment 1 (50 wt-% fermented protein solid and 50 140 140,000 0.11 wt-% polypropylene) Biopolymer Embodiment 2 (70 wt-% fermented protein solid and 30 130 210,000 0.061 wt-% polypropylene) Biopolymer Embodiment 3 (60 wt-% fermented protein solid, 38 wt- 140 220,000 0.071 % polypropylene, 2 wt-% maleated polypropylene)

Surprisingly, adding fermentation solid (e. g. , fermented protein solid) to a plastic increased the strength of the plastic. The present biopolymer was stronger than the thermoactive material from which it was made. This result is illustrated in each of the three measures of strength for each polymer.

The present biopolymer exhibited greater tensile strength than the plastic control. This was surprising. Conventional filled plastic materials (filled, for example with inert filler) typically have less tensile strength than the plastic material from which they are made. In particular, a conventional filled plastic material with as much as 50 wt-% or 70 wt-% inert filler would have less tensile strength than the plastic from which it was made. In this example, biopolymers with 50 wt-% or 70 wt-% fermentation solid (e. g. , fermented protein solid) each exhibited greater tensile strength than the plastic control. In this example, the present biopolymer gained additional tensile strength upon addition of a cross-linking agent.

The present biopolymer exhibited greater flexural modulus than the plastic control. In this example, biopolymers with 50 wt-% or 70 wt-% fermentation solid

(e. g. , fermented protein solid) each exhibited greater flexural modulus than the plastic control. In this example, the present biopolymer gained additional flexural modulus upon addition of a cross-linking agent.

The present biopolymer exhibited decreased displacement (less"stretch") compared to the plastic control. In this example, biopolymers with 50 wt-% or 70 wt-% fermentation solid (e. g. , fermented protein solid) each exhibited decreased displacement compared to the plastic control. Generally, decreased stretch can be considered to relate to increased thermal, process, and structural stability.

Example 2-Biopolymer Production by Extrusion The following extrusion parameters have been employed for producing a biopolymer according to the present invention.

Conical Counter Rotating Extruder RT (Resin Temperature) 178 C.

RP (Resin Pressures) 11.9 Main Motor (%) 32.3% RPM 3.7 . D2 (Die Temperature Zone 2) 163 D1 (Die Temperature Zone 1) 180 AD (Die) 180 C4 (Barrel Heating Zone 4) 177 C3 181 C2 194 ci 208 Screw Temperature 149 (Temperature in Degrees C) (Equipment TC85 milicron CCRE) An admixture of 15% polypropylene ("PP") and 85% DDG blended @ 7% MC was compounded using a high shear compounding system, then extruded at the above processing parameters through a hollow die system. Note that DDG contains protein, fiber, fat, and ash components. The second tests used 15% PP and 85% cellulose fiber (wheat) as a comparison in the exact same process, equipment and process parameters above.

In an initial comparison of the testing of this embodiment, there were many differences between the embodiment of the present biopolymer extrusion as compared to the fiber/PP extrusion. The fiber/PP extrusion closely simulates today's current wood plastic fiber technology and overall performance. The fiber/PP extrusion was a very different color showing the individual fibers and particles in addition in having an overall very dark color. This conventional material also showed poor mechanical strength characteristics and brittleness whereas the biopolymer has higher degrees of overall rupture and stiffness.

The embodiment of the present biopolymer maintained its lighter color and was very homogenous in appearance. This indicates that the present biopolymer intermeshed or melted together under the extruder condition employed.

It should be noted that, as used in this specification and the appended claims, the singular forms"a,""an,"and"the"include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing "a compound"includes a mixture of two or more compounds. It should also be noted that the term"or"is generally employed in its sense including"and/or"unless the content clearly dictates otherwise.

It should also be noted that, as used in this specification and the appended claims, the phrase"adapted and configured"describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase"adapted and configured"can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, adapted, constructed, manufactured and arranged, and the like.

The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.