WO2008030969A2

WO2008030969A2 - Composite materials

Info

Publication number: WO2008030969A2
Application number: PCT/US2007/077768
Authority: WO
Inventors: Jeffrey Jacob Cernohous; Neil Robert Granlund; William L. Hickey
Original assignee: Phillips Plastics Corporation
Priority date: 2006-09-07
Filing date: 2007-09-06
Publication date: 2008-03-13
Also published as: WO2008030969A3

Abstract

A variety of composite material compositions and methods for making the same are described. The composite materials may include a variety of fillers that provide improved mechanical properties. Fillers that may be included in the composite materials include naturally occurring cellulosic materials such as agricultural meals and the like. In one embodiment, the filler may have a relatively high protein content. The composite materials may be prepared by melt processing the filler with a polymeric matrix.

Description

COMPOSITE MATERIALS

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This patent application claims priority to U.S. Provisional Patent Application No. 60/824,873, entitled "Composite Materials," filed on 7 September 2006, which is hereby incorporated herein by reference in its entirety.

BACKGROUND

[0002] Wood plastic composites (WPCs) have become increasingly popular over the years as a substitute for wood and plastic products. WPCs have a number of advantages over wood products. One of the primary benefits of WPCs is that they are much more resistant to weathering and rot than wood. This has made WPCs especially useful in outdoor applications such as decks, railings, and the like. WPCs typically require significantly less maintenance in the form of staining, cleaning, etc. than a comparable item made from wood.

[0003] In certain situations, WPCs also have a number of advantages over plastic. For example, WPCs tend to be more cost effective because the filler used in WPCs typically costs less than the plastic. WPCs may also be foamed which makes them lighter and even less costly. Unfortunately, the physical properties of WPCs are often very different than the wood or plastic items that they replace. WPCs may not be as strong as plastic or wood. Also, WPCs may tend to break when a tensile force is exerted on them when a material such as plastic would only be deformed. These disadvantages have kept WPCs from being used in a number of applications.

[0004] It would be desirable to provide a composite material that has improved physical properties. It would also be desirable to provide a composite material that is economical to make and can be used as a substitute for plastic and/or wood materials.

SUMMARY

[0005] A number of composite materials are described herein that have improved physical properties (e.g., mechanical properties, etc.), unique compositions, and/or other benefits and advantages. For example, some of the composite materials may be improved to better withstand tensile forces. The composite materials include a filler and a polymeric matrix that includes one or more polymeric materials. The composite materials may be prepared by melt processing a mixture that includes the filler and the polymeric matrix. The composite materials may be used in a wide variety of products such as decking, fences, shingles, telephone poles, automobiles, heavy equipment (e.g., agricultural equipment such as tractors and the like, military and civilian heavy equipment, etc.), lawn and garden equipment, and the like.

[0006] In general, the filler refers to an organic or inorganic material that does not possess viscoelastic characteristics under the conditions utilized to melt process the melt processable composition. In many situations, the filler includes all of the materials in the composite material other than the one or more polymeric materials that make up the polymeric matrix. Due to the low cost of the filler relative to the polymeric matrix, it is usually desirable to include as much filler as possible in the composite material without compromising the desired physical and aesthetic properties of the finished product. In one embodiment, the filler may include a naturally-occurring cellulosic material. In another embodiment, the filler may include an agricultural material such as an agricultural by-product, agricultural meal, an oilseed by-product, and/or an oilseed meal. The agricultural material may include at least approximately 20 wt% protein or desirably at least approximately 25 wt% protein.

[0007] The polymeric matrix may include any of a number of suitable polymeric materials. In one embodiment, the polymeric matrix may include any suitable melt processable polymeric material that allows the composite material to be prepared using melt-processing techniques. In one embodiment, the polymeric matrix may include one or more polyolefms such as polyethylene and/or polypropylene.

[0008] The composite materials may be made by melt processing a mixture that includes the filler and the polymeric matrix. Suitable melt processes that may be used to make the composite material include extrusion, injection molding, thermo forming, batch mixing, blow molding and rotomolding.

[0009] As used herein the term "elongation value" refers to the elongation at break measured according to ASTM D638 at a test rate of 5 inches/minute. DETAILED DESCRIPTION

[0010] A number of composite materials and methods for producing the same are described herein. In general, the composite materials include a filler and a polymeric matrix made up of one or more polymeric materials or resins. The composite material may be prepared by extruding or otherwise melt processing a mixture that includes the filler and the polymeric matrix. The filler may be at least substantially uniformly dispersed throughout the polymeric matrix in both the melt processable composition and the composite material. It should be appreciated, however, that the filler may also be concentrated in certain areas of the polymeric matrix as long as all or substantially all of the polymeric matrix includes some amount of filler.

[0011] The composite materials described herein may have a wide variety of uses. For example, the composite materials may be used in any suitable outdoor or indoor application. The composite material may also be used to as a substitute for any existing wood or metal product. Due to the improved physical properties of the composite materials, they may also be used as a substitute for existing WPCs. In one embodiment, the composite materials may be used for decking, fencing, shingles, siding, posts, telephone poles, and the like.

[0012] The composite materials may also be used as a substitute for plastic components where conventional WPCs were not suitable. For example, conventional WPCs may not have been suitable to replace plastic components because conventional WPCs have undesirable physical properties such as a low elongation at break. However, certain embodiments of the composite materials have a higher elongation at break that make the composite materials suitable to use in these applications. Also, the composite materials may have a higher amount of filler than other WPCs making the composite materials more economical relative to solid plastic or WPCs. Composite materials may be used to replace plastic components in automotive parts and components, farming equipment such as tractors, heavy equipment such as earth working machinery and material handling equipment, as well as decking, fencing, siding, shingles, poles, railings, and so forth.

[0013] In general, the filler refers to an organic or inorganic material that does not possess viscoelastic characteristics under the conditions utilized to melt process the melt processable composition. In many situations, the filler includes all of the materials in the composite material other than the one or more polymeric materials that make up the polymeric matrix. In one embodiment, the filler may include a naturally-occurring cellulosic material. In another embodiment, the filler may include an agricultural material. The filler may include approximately 85 wt% to 100 wt% agricultural material. In another embodiment, the filler may include at least approximately 85 wt% agricultural material, at least approximately 90 wt% agricultural material, or, desirably, at least approximately 95 wt% agricultural material, or, suitably, at least approximately 100 wt% agricultural material.

[0014] The agricultural material may include an agricultural by-product. Agricultural byproducts are produced when agricultural materials such as corn are processed in a manner that produces a low value by-product. For example, oilseed by-products are produced from a low value by-product obtained when oil is extracted from oilseeds such as linseed, rapeseed, canola, soybeans, cottonseed, peanuts, sunflower seeds, safflower seeds, and the like. Some of these low value by-products may be referred to as "meals" and have little utility outside of animal feed. Agricultural meals that may be used include oilseed meals such as rapeseed meal, canola meal (canola is a low erucic acid rapeseed ("LEAR"), low erucic acid rapeseed produces oil having no more than 2 wt% erucic acid content), linseed meal (or flaxseed meal), crambe meal, soybean meal, sunflower meal, safflower meal, peanut meal, cottonseed meal, and/or Northstar meal. Agricultural meals may also include non-oilseed meals such as oat meal, corn gluten meal, and the like. It should be appreciated that oilseed by-products and oilseed meals may encompass other by-products and meals that may not qualify as agricultural by-products or agricultural meals.

[0015] Additional agricultural by-products include grain by-products such as brewers grains, distillers grains, barley screenings, wheat middlings, oat hulls, wheat chaff, wheat straw, wheat bran, and the like; corn by-products such as corn gluten feed, shelled corn, ear corn, ground corn cobs, and the like; soybean by-products such as soybean hulls, soybean screenings, and the like; field peas; oat hulls screenings; potato wastes; sunflower hulls; beet pulp; malt sprouts; dehydrated alfalfa; flax; hemp; rice hulls; kenaf; jute; sisal; and/or peanut hulls. [0016] In one embodiment, the agricultural material may include canola meal, corn meal, linseed meal, soybean meal, oat hulls, malt sprouts, sunflower meal, barley screenings, soy hulls, dehydrated alfalfa, beet pulp, oat meal, wheat middlings, Northstar meal, and/or distillers' grains. In another embodiment, the agricultural material may include rapeseed meal, canola meal, linseed meal, soybean meal, sunflower meal, cottonseed meal, and/or safflower meal. In another embodiment, the agricultural material may include canola meal, linseed meal, soy hulls, and/or oat hulls.

[0017] Composite materials that include agricultural materials, especially agricultural meals, may have improved physical properties such a greater elongation value. These properties allow the composite materials to be used in applications where composite have been unsuitable in the past. Also, composite materials having higher levels of filler (compared to wood fiber composites) can be formed using the agricultural material. Thus, composite materials may be formed from agricultural waste streams that are high performance and low cost.

[0018] While not wishing to be bound by theory, it is believed that protein in the agricultural material may be a leading contributor to the improved physical properties of the composite materials. Table 1 shows the protein content and neutral detergent fiber content (NDF) of various agricultural materials that may be included in the composite materials. In one embodiment, the agricultural material may include approximately 20 wt% to 60 wt% protein. In another embodiment, the agricultural material may include at least approximately 20 wt% protein, at least approximately 25 wt% protein, at least approximately 30 wt% protein, at least approximately 35 wt% protein, at least approximately 40 wt% protein, at least approximately 45 wt% protein, or at least approximately 50 wt% protein.

Table 1 - Composition of Various Agricultural Materials

[0019] It should be appreciated that the filler may also include cellulosic materials other than agricultural materials. Typically, these additional cellulosic materials are wood based materials having various aspect ratios, chemical compositions, densities, and physical characteristics. Examples of such cellulosic materials include wood flour, wood fibers, sawdust, wood shavings, newsprint, and/or paper. These cellulosic materials have been utilized in composite materials to impart specific physical characteristics or to reduce the cost of the finished product. These cellulosic materials may be combined with the agricultural materials in the composite materials. For example, an agricultural material may be included in a composite material that already includes conventional cellulosic materials and a polymeric matrix to reduce melt defects and provide a smoother exterior surface.

[0020] It should be appreciated that additional non-cellulosic fillers may also be included in the composite materials. For example, non-cellulosic fillers may include minerals, inorganic material, and/or organic material such as talc, mica, clay, silica, alumina, carbon fiber, carbon black glass fiber may also be included.

[0021] Before melt processing the mixture of the filler and the polymeric matrix (the melt processable composition), additional additives may be included in the mixture that are useful in preparing the composite materials. Examples of suitable additives include antioxidants, light stabilizers, inorganic or organic fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, compatibilizers, flame retardants, plasticizers, tackifϊers, colorants, processing aids, lubricants, coupling agents, and pigments. The additives may be incorporated into the melt processable composition in the form of powders, pellets, granules, or in any other extrudable form. The amount and type of additives in the melt processable composition may vary depending upon the composition of the polymeric matrix and the desired physical properties of the finished composite material. [0022] The composite material may include any suitable amount of filler. The amount of filler in the composite material may vary depending upon the polymeric matrix and the desired physical properties of the finished product. Due to the low cost of the filler relative to the polymeric matrix, it is usually desirable to use as much filler as possible while still achieving the desired physical properties in the finished product. Since the physical and aesthetic requirements for the final product can vary significantly, it follows that the amount of filler in the composite material can vary just as much.

[0023] In one embodiment, the composite material may include approximately 5 wt% to 90 wt% filler, desirably, approximately 15 wt% to 80 wt% filler, or, suitably, approximately 25 wt% to 70 wt% filler. In another embodiment, the composite material may include at least approximately 15 wt% filler, at least approximately 20 wt% filler, at least approximately 25 wt% filler, at least approximately 30 wt% filler, at least approximately 35 wt% filler, at least approximately 40 wt% filler, at least approximately 45 wt% filler, at least approximately 50 wt% filler, at least approximately 55 wt% filler, desirably, at least approximately 60 wt% filler, or, suitably, at least approximately 70 wt% filler. The composite material may also include approximately 3 wt% to 35 wt% protein, or, desirably, approximately 5 wt% to 30 wt% protein. In another embodiment, the composite material may include at least approximately 2 wt% protein, at least approximately 3 wt% protein, at least approximately 5 wt% protein, at least approximately 7 wt% protein, at least approximately 10 wt% protein, at least approximately 12 wt% protein, desirably, at least approximately 15 wt% protein, or, suitably, at least approximately 20 wt% protein.

[0024] The filler may be provided in various forms depending on the specific polymeric matrices and requirements of the finished product. The filler may be provided as one component that includes all of the material that does not possess viscoelastic characteristics under the conditions utilized to melt process. In other embodiments, each component of the filler may be provided separately. Either way, the filler may be in the form of a pellet, powder, fiber, spheres, granules, and so forth.

[0025] The polymeric matrix functions as the host polymer and is a primary component of the melt processable composition. A wide variety of polymeric materials suitable for melt processing may be included in the polymeric matrix. Suitable polymeric materials may be either hydrocarbon or non-hydrocarbon polymers. Examples of polymeric materials include, but are not limited to, polyamides, polyimides, polyurethanes, polyolefϊns, polystyrenes, polyesters, polycarbonates, polyketones, polyureas, polyvinyl resins, polyacrylates and polymethylacrylates. In one embodiment, the polymeric matrix includes an olefm-based polymer.

[0026] Preferred polymeric materials matrices include, high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), polypropylene (PP), polyolefm copolymers (e.g., ethylene-butene, ethylene-octene, ethylene vinyl alcohol), polystyrene, polystyrene copolymers (e.g., high impact polystyrene, acrylonitrile butadiene styrene copolymer), polyacrylates, polymethacrylates, polyesters, polyvinylchloride (PVC), fluoropolymers, Liquid Crystal Polymers, polyamides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers (e.g., SIS, SEBS, SBS), epoxies, alkyds, melamines, phenolics, ureas, vinyl esters or combinations thereof. In one embodiment, the polymeric matrix includes polyolefϊns and/or thermoplastic elastomers. In another embodiment, the polymeric matrix includes polyethylene and/or polypropylene (e.g., HDPE, LDPE, LLDPE, and so forth).

[0027] The composite materials may include approximately 20 wt% to 99 wt% polymeric matrix, approximately 30wt% to 90 wt% polymeric matrix, or, desirably approximately 40 wt% to 80 wt% polymeric matrix. In another embodiment, the composite materials may include at least approximately 20 wt% polymeric matrix, at least approximately 25 wt% polymeric matrix, at least approximately 30 wt% polymeric matrix, at least approximately 35 wt% polymeric matrix, at least approximately 40 wt% polymeric matrix, at least approximately 45 wt% polymeric matrix, at least approximately 50 wt% polymeric matrix, at least approximately 55 wt% polymeric matrix, at least approximately 60 wt% polymeric matrix, at least approximately 65 wt% polymeric matrix, at least approximately 70 wt% polymeric matrix, at least approximately 75 wt% polymeric matrix, or at least approximately 80 wt% polymeric matrix.

[0028] The composite materials may also be foamed to reduce the density of the finished product. Foaming the composite material may reduce the cost of the finished product since less raw material is used. Also, the finished product may be easier to handle since it is lighter, which may be a significant consideration in applications such as decking and fencing.

[0029] The composite materials may be prepared using any of a number of suitable melt processing techniques. For example, the composite materials may be made using melt processes such as extrusion, injection molding, blow molding, rotomolding and batch mixing.

[0030] The melt processable composition can be prepared in any of a variety of ways. For example, the polymeric matrix and the filler can be combined together using any of the blending techniques usually employed in the plastics industry. For example, the polymeric matrix and the filler may be mixed together using a compounding mill, a Banbury mixer, or a mixing extruder. Typically, the melt processable composition is mixed until all of the filler and other additives are uniformly distributed throughout the polymeric matrix. The filler and the polymeric matrix may be provided in any suitable form in the mixture. For example, the filler and the polymeric matrix may be provided as powders, pellets, or granules that are mixed together. The mixing operation is typically carried out at a temperature above the melting point or softening point of the polymeric matrix. However, it is also feasible to dry- blend the components in the solid state as particulates and then cause uniform distribution of the components by feeding the dry blend to a twin-screw melt extruder. The resulting melt processable composition can be either extruded directly into the form of the final product shape or pelletized or otherwise comminuted into a desired particulate size or size distribution and fed to an extruder, which is typically a single-screw extruder, that melt- processes the intermediate particulates to form the final composite material product.

[0031] Melt-processing typically is performed at temperatures of 120° to 300° C, although optimum operating temperatures are selected depending upon the melting point; melt viscosity, and thermal stability of the composition. Different types of melt processing equipment, such as extruders, may be used to process the melt processable compositions of this invention. Extruders suitable for use with the present invention are described, for example, by Rauwendaal, C, "Polymer Extrusion," Hansen Publishers, p. 11 - 33, copyright 2001. [0032] The composite materials may have a number of advantageous physical properties. For example the elongation value of the composite materials may be higher than that of conventional WPCs. The elongation value of the composite materials changes depending on the ratio of filler to polymeric matrix. Composite materials that have a higher loading of polymeric material tend to have a higher elongation value than composite materials that have a higher loading of filler. The following equation provides a good approximation of the correlation between elongation value and the amount of filler in the composite material.

elongation value (%) = _m*e^{~α0474*(the amount of flller in the composite mateπal (%))}

The value of m in the preceding equation may be approximately 35 to 120, approximately 40 to 80, or approximately 45 to 55. In another embodiment, m may be at least approximately 35, at least approximately 37, at least approximately 40, at least approximately 43, at least approximately 45, at least approximately 47, at least approximately 48, at least approximately 49, at least approximately 50, at least approximately 52, at least approximately 54, at least approximately 60, at least approximately 80, at least approximately 100, or at least approximately 120. The flexural modulus of the composite materials may be at least approximately 1000 MPa, at least approximately 1250 MPa, or at least approximately 1500 MPa.

Example

[0033] The following example is provided to further illustrate the subject matter disclosed herein. The following example should not be considered as being limiting in any way.

[0034] In this example, a number of composite materials were prepared using various types and amounts of filler. Table 2 shows the materials used to prepare the composite materials, and Table 3 shows the composition of each sample. The mechanical properties of each composite material was tested and the results reported in Table 4.

[0035] The samples of composite materials shown in Table 3 were prepared and tested using the following protocol. The filler materials were predried for 4 hours at 93.3 ⁰C in a vacuum oven at a pressure of less than approximately 0.1 mmHg. The Resin (PP/HDPE) and the filler material(s) were combined and dry mixed in a plastic bag and gravity fed into a 27 mm co-rotating twin screw extruder fitted with a three strand die (commercially available from American Leistritz Extruder Corporation, Sommerville, NJ). All samples were processed at 150 rpm screw speed using the following temperature profile: Zone 1-2 = 150 ⁰C, Zone 3-4 = 160 ⁰C, Zone 5-6 = 180 ⁰C, Zone 7-8= 190 ⁰C. The resulting strands were subsequently cooled in a water bath and pelletized into approximately 6.35 mm pellets. The pellets were injection molded into test specimens following ASTM D638 (tensile) and ASTM D790 (flexural) specifications. Injection molding on composite formulations was performed using a 300-ton machine (commercially available from Engel Corporation, York, PA) having a barrel and nozzle temperature of 190 ⁰C. The flexural and tensile properties were subsequently tested as specified in the ASTM methods.

[0036] The results shown in Table 4 indicate that composite materials that include filler materials having high protein content (e.g., canola meal, linseed meal, soybean meal (48 % protein), malt sprouts, sunflower meal, Northstar meal) have a relatively high elongation value compared to composite materials that include filler materials having low or no protein content.

Table 2 - Materials

Table 4 - Mechanical Properties of Samples CE1-CE6 and 1-90

Illustrative Embodiments

[0037] Reference is made in the following to a number of illustrative embodiments of the subject matter described herein. The following embodiments illustrate only a few selected embodiments that may include the various features, characteristics, and advantages of the subject matter as presently described. Accordingly, the following embodiments should not be considered as being comprehensive of all of the possible embodiments. Also, features and characteristics of one embodiment may and should be interpreted to equally apply to other embodiments or be used in combination with any number of other features from the various embodiments to provide further additional embodiments, which may describe subject matter having a scope that varies (e.g., broader, etc.) from the particular embodiments explained below. Accordingly, any combination of any of the subject matter described herein is contemplated.

[0038] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries (e.g., definition of "plane" as a carpenter's tool would not be relevant to the use of the term "plane" when used to refer to an airplane, etc.) in dictionaries (e.g., widely used general reference dictionaries and/or relevant technical dictionaries), commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used herein in a manner more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase "as used herein shall mean" or similar language (e.g., "herein this term means," "as defined herein," "for the purposes of this disclosure [the term] shall mean," etc.). References to specific examples, use of "i.e.," use of the word "invention," etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained herein should be considered a disclaimer or disavowal of claim scope. Accordingly, the subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any particular embodiment, feature, or combination of features shown herein. This is true even if only a single embodiment of the particular feature or combination of features is illustrated and described herein. Thus, the appended claims should be read to be given their broadest interpretation in view of the prior art and the ordinary meaning of the claim terms.

[0039] As used herein (i.e., in the claims and the specification), articles such as "the," "a," and "an" can connote the singular or plural. Also, as used herein, the word "or" when used without a preceding "either" (or other similar language indicating that "or" is unequivocally meant to be exclusive - e.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., "x or y" means one or both x or y). Likewise, as used herein, the term "and/or" shall also be interpreted to be inclusive (e.g., "x and/or y" means one or both x or y). In situations where "and/or" or "or" are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all of the items together, or any combination or number of the items. Moreover, terms used in the specification and claims such as have, having, include, and including should be construed to be synonymous with the terms comprise and comprising.

[0040] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term "approximately." At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term "approximately" should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).

Claims

WHAT IS CLAIMED IS:

1. A composite material comprising: an agricultural material; and a polymeric matrix.

2. The composite material of claim 1 wherein the agricultural material includes an agricultural by-product.

3. The composite material of claim 1 wherein the agricultural material includes an agricultural meal.

4. The composite material of claim 1 wherein the agricultural material includes an oilseed by-product.

5. The composite material of claim 1 wherein the agricultural material includes an oilseed meal.

6. The composite material of claim 1 wherein the agricultural material includes rapeseed meal, canola meal, corn meal, linseed meal, soybean meal, oat hulls, malt sprouts, sunflower meal, peanut meal, cottonseed meal, cottonseed hulls, barley screenings, soy hulls, dehydrated alfalfa, beet pulp, oat meal, wheat middlings, Northstar meal, and/or distillers grains.

7. The composite material of claim 1 wherein the agricultural material includes rapeseed meal, canola meal, linseed meal, and/or Northstar meal.

8. The composite material of claim 1 wherein the composite material comprises at least approximately 15 wt% of the agricultural material.

9. The composite material of claim 1 wherein the polymeric matrix includes a polyolefm.

10. The composite material of claim 1 wherein the composite material includes at least approximately 20 wt% polyolefms.

11. The composite material of claim 1 wherein the polymeric matrix includes polyethylene and/or polypropylene.

12. The composite material of claim 1 wherein the composite material comprises at least approximately 25 wt% of the polymeric matrix.

13. The composite material of claim 1 wherein the composite material includes at least approximately 3 wt% protein.

14. The composite material of claim 1 wherein the composite material has a flexural modulus of at least approximately 1000 MPa.

15. A compo site material comprising : at least approximately 2 wt% protein; at least approximately 30 wt% polymeric matrix.

16. The composite material of claim 15 wherein the composite material comprises at least approximately 3 wt% protein.

17. The composite material of claim 15 wherein the polymeric matrix includes a polyolefm.

18. The composite material of claim 15 wherein the polymeric material includes polyethylene and/or polypropylene.

19. The composite material of claim 15 wherein the composite material comprises at least approximately 40 wt% polymeric matrix.

20. The composite material of claim 15 wherein the composite material comprises at least approximately 20 wt% filler, the filler including the protein.

21. The composite material of claim 15 wherein the composite material comprises at least approximately 40 wt% filler, the filler including the protein.

22. A composite material comprising: a filler in an amount that forms at least approximately 15 wt% of the composite material; and a polymeric matrix in an amount that forms at least approximately 20 wt% of the composite material; wherein the composite material has an elongation value that is at least approximately equal to the elongation value obtained using the amount of the filler in the following equation elongation value (%) = _m*e^{~α0474*(the amount of flller in &e composite mateπal (%))}; wherein m is at least approximately 30.

23. The composite material of claim 22 wherein m is at least approximately 35.

24. A composite material comprising: at least approximately 15 wt% agricultural meal; at least approximately 30 wt% polymeric matrix.

25. The composite material of claim 24 wherein the agricultural meal includes rapeseed meal, linseed meal, peanut meal, cottonseed meal, soybean meal, corn meal, sunflower meal, oat meal, and/or Northstar meal.

26. The composite material of claim 24 wherein the agricultural meal includes rapeseed meal, linseed meal, and/or Northstar meal.

27. The composite material of claim 24 wherein the agricultural meal includes oilseed meal.

28. A composite material comprising: a filler that includes at least approximately 25 wt% protein; at least approximately 30 wt% polymeric matrix.

29. The composite material of claim 28 wherein the filler includes at least approximately 30 wt% protein.

30. A composite material comprising: a naturally-occurring cellulosic material; and a polymeric matrix.

31. The composite material of claim 30 wherein the polymeric matrix includes a polyolefm.

32. The composite material of claim 30 wherein the naturally-occurring cellulosic material includes canola meal, corn meal, linseed meal, soybean meal, oat hulls, malt sprouts, sunflower meal, barley screenings, soy hulls, dehydrated alfalfa, beet pulp, oat meal, wheat middlings, Northstar meal, and/or distillers grains.