BE1026532B1 - METHOD FOR MANUFACTURING RECYCLED PLASTIC COMPOSITE MATERIAL - Google Patents

Abstract

The present invention in a first aspect describes a method of manufacturing a plastic composite material comprising the steps of: (a) providing a woven or nonwoven structure; (b) evenly distributing one or more granular components over the surface of the structure resulting in a layered structure, said granular components comprising one or more thermoplastic polymer components having a glass transition temperature and a melting temperature; (c) optionally providing a second structure over the granular components; (d) optionally repeating steps b and c; and (e) heating the layered structure; wherein the layered structure is heated to a temperature higher than the average glass transition temperature of the thermoplastic components, thereby obtaining a bond between the granular components and the structure. A second, third and fourth aspects include a nonwoven composite material, a composite composite material and a load carrier made from this composite material, respectively.

Description

METHOD FOR MANUFACTURING RECYCLED PLASTIC COMPOSITE MATERIAL

TECHNICAL DOMAIN

The present invention generally relates to methods of manufacturing a plastic composite. More specifically, the present invention relates to methods of manufacturing a plastic composite comprising a structure bonded in a thermoplastic matrix.

STATE OF THE ART

Plastic has become the most widely used material in the entire industry for forming a variety of products for both household and commercial purposes. Accordingly, there has been a significant increase in plastic production over the years and this has contributed significantly to the increased burden of solid waste. Due to their properties, plastics are a particularly difficult form of waste because they do not decay quickly.

In order to reduce the costs associated with obtaining raw materials, wasting natural resources for the manufacture of disposable products and minimizing potential negative effects on the environment, continuous efforts have been made to develop methods for recycling used thermoplastic materials that would otherwise be incinerated or landfilled. Such methods include injection molding, rotational molding, calendering and various extrusion techniques.

In such an application of recycled thermoplastic materials, a variety of thermoplastic composite sheets / panels have been developed. Such thermoplastic composites, generally made by nonwoven methods, include fiber materials reinforced in the recycled thermoplastic materials. These thermoplastic composites offer a number of advantages, for example they can be molded and molded into a variety of suitable products, both structural and non-structural, including, among other things, parking boards, billboards, car panels, load carriers (crates, boxes, pallets, etc.). ) and many others.

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However, the use of recycled materials for the production of thermoplastic composites has its own drawbacks. For example, recycling various lightweight thermoplastic products, e.g. disposable gloves, aprons, air filters, protective covers, plastic covers, polythene, etc., is generally not preferred because their use often results in products with physical properties that are generally less acceptable than products made of strong thermoplastic materials. Accordingly, these types of products remain 'waste', and thus continue to be landfilled or incinerated, and thus have harmful effects on the environment.

In some recent endeavors, such shortcoming with the lightweight thermoplastic material is resolved using a method in which lightweight plastic materials such as polypropylene (PP) or polyethylene bags, films, rags, or the like are first washed in a centrifuge process, then shredded and then melted and reprocessed into a raw pellet form. While this process is generally effective in providing desirable properties to the output products, it requires the individual melting processes to form pellets, which inevitably adds cost to the process and thus to the final recycled product.

As a result, there is a need in the art for a time-efficient as well as a cost-efficient method of forming thermoplastic composites made from recycled materials, with properties of impact strength, brittleness, swelling, heat resistance, heat retardancy, dimensional stability, abrasion resistance at least comparable to products made with new materials.

Moreover, in view of a continuously increasing complexity of packaging material, in particular multilayer bags, e.g. shrink bags, and hybrid bags and foils, and consequently increasing difficulties for recycling these materials, the object of the present invention is to provide a process to provide efficient recycling thereof.

The present invention aims at least to solve some of the above-mentioned problems or disadvantages.

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SUMMARY OF THE INVENTION

To this end, a first aspect of the present invention provides a method of manufacturing a plastic composite material according to claim 1. The method comprises the steps of (a) providing a woven or nonwoven structure; (b) uniformly spreading one or more granular components over the surface of the structure resulting in a layered structure, said granular components comprising one or more thermoplastic polymer components having a glass transition temperature and a melting temperature; (c) optionally providing a second structure over the granular components; (d) optionally repeating steps b and c; and (e) heating the layered structure. The layered structure is heated to a temperature higher than the average glass transition temperature of the thermoplastic components, thereby obtaining a bond between the granular components and the structure.

A particular advantage of this method is that it provides a very efficient process that allows the recycling of normally difficult to non-recyclable composite materials, including the recycling of increasingly complex packaging material, in particular multilayer bags (e.g.

shrink bags) and hybrid bags and foils. This usually requires an additional step, which is melting and shaping into granules or pellets.

Preferred forms of the method are set out in claims 2 to 21.

A specific preferred form concerns the method according to claim 2, wherein the layered structure is heated to a temperature lower than the average melting temperature of the thermoplastic components. Heating between the average glass transition temperature and the average melting temperature of the thermoplastic components provides a flexible composite material with the thermoplastic polymer components adhered together. Such a flexible composite material is easily foldable and transportable, and is a valuable semi-finished product that can be divided for subsequent thermoforming.

A further or other preferred form relates to the method according to claim 5, wherein the granular components are regrind, flakes, granulate and / or agglomerate

BE2018 / 5567 includes with a diameter included between 3 and 25 mm. The adhesion between the thermoplastic components is optimal within this diameter range and a wide variety of thermoplastic components is possible. The distribution of the granular components over the fabric is very uniform.

An embodiment according to claim 6 relates to the method, wherein the granular components comprise a micronizate, which has a diameter between 0.1 and 300 µm.

A second aspect of the present invention relates to a nonwoven composite material according to claim 22, wherein a nonwoven or woven structure is contained in a thermoplastic matrix which binds the structure. The composite material includes a layered structure comprising between 5.0 and 50.0 m% per layer of structure and between 50.0 and 95.0 m% per layer of thermoplastic matrix.

Preferred shapes of the composite material are set out in claims 23 to 32.

In a third and fourth aspect, the present invention describes a composite composite material according to claim 33 and a charge carrier according to claim 36, respectively. Preferred forms of the composite composite material and the charge carrier are shown in claims 34-35 and 37-40, respectively.

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DETAILED DESCRIPTION

In a first aspect, the present application describes a method for forming a plastic composite from recycled thermoplastic materials using a simple, cost-efficient method. The method uses lightweight plastic materials such as, but not limited to, plastic films, foils, plastic bags, etc. to form a plastic composite with suitable mechanical properties, high heat resistance, high impact strength, load resistance, and very good dimensional stability. The constructed plastic composite is useful for forming varieties of panel plates, such as a construction fence board, billboards, plastic road plates, load carriers such as boxes, crates, pallets, or the like. It will be understood that although the present disclosure is only explained for lightweight recycled thermoplastic materials such as films, bags, films, etc., the current method can be used for generally all types of thermoplastic materials.

Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning generally understood by those skilled in the art of the invention. For a better assessment of the description of the invention, the following terms are explicitly explained.

One, de and in this document refer to both the singular and the plural unless the context clearly assumes otherwise. For example, a segment means one or more than a segment.

When around or around this document is used with a measurable quantity, a parameter, a duration or moment, and the like, variations of +/- 20% or less, preferably +/- 10% or less, more at preferably +/- 5% or less, even more preferably +/- 1% or less, and even more preferably +/- 0.1% or less than and of the quoted value, insofar as such variations apply in the described invention. However, this should be understood to mean that the value of the quantity by which the term is used approximately or round is itself specifically disclosed.

The terms include, comprising, consisting of, comprising, containing, containing, containing, contents, containing are synonyms and are inclusive or open terms which indicate the presence of what follows, and which

BE2018 / 5567 does not exclude or prevent the presence of other components, features, elements, members, steps, known from or described in the prior art.

Quoting numerical intervals through the endpoints includes all integers, fractions, and / or real numbers between the endpoints, including these endpoints.

The term granular components ”covers a wide range of products occurring as a group of loose pieces or particles. Different terms are used depending on the size of these particles and / or the shape in which they occur. Grinding material ”refers to particles obtained after, for example, a grinding process. According to a more or less decreasing particle size, the terms flakes "or flakes", granulate ", powder" and micronisate "are used. Flakes or flakes have a rather irregular shape and can be obtained, inter alia, after a breaking or tearing process, while a granulate mainly consists of particles of a substantially spherical shape. Once the dimensions of the granulate or powder are in the micrometer range, this granulate is also referred to as micronizate ”. By extension, multiple adhered or bonded particles are designated by the term agglomerate ”. Agglomerates are therefore more irregular in shape.

The term "melting temperature" refers to the minimum temperature required to melt a substance, or to switch it from a solid to a liquid form. With some materials, especially polymers and especially thermoplastic polymers, the boundary between solid and liquid form is a gradual transition. The term glass transition temperature ”in such cases denotes the temperature at which this substance softens, or alternatively, at which the substance softens. Between the glass transition temperature and the melting temperature, a polymer is still solid, not liquid, or soft and tacky.

The term natural fibers, "as used herein, refers to any continuous filament derived from natural, renewable resources such as plants or animals. The words "fiber" and "fiber" are used interchangeably. Natural fibers can include, but are not limited to, seed fibers such as cotton and kapok; leaf fibers such as sisal and agave; bast or skin fibers such as flax, jute, kenaf, hemp, ramie, rattan, soy fiber, vine fiber, and banana fiber; fruit fibers such as coconut fibers; stem fibers such as wheat straw, rice, barley, bamboo, grass, and tree wood; animal-like

BE2018 / 5567 hair fibers such as sheep's wool, goat hair (cashmere, mohair), alpaca hair, horse hair; silk fiber; bird fibers such as feathers.

A first aspect of the present invention involves a method of manufacturing a plastic composite material comprising the steps of: (a) providing a woven or nonwoven structure; (b) uniformly spreading one or more granular components over the surface of the structure resulting in a layered structure, said granular components comprising one or more thermoplastic polymer components having a glass transition temperature and a melting temperature; (c) optionally providing a second structure over the granular components; (d) optionally repeating steps b and c; and (e) heating the layered structure. The layered structure is heated to a temperature higher than the average glass transition temperature of the thermoplastic components, thereby obtaining a bond between the granular components and the structure. The bonded granular components are also referred to as a thermoplastic matrix ”.

The process is generally a simple, cost-effective, time-saving process for forming a high-quality thermoplastic composite using generally unused lightweight plastic waste such as, inter alia, plastic films, plastic bags, gloves, or the like, and / or combinations thereof. Usually, the use of such lightweight plastic materials requires an additional step of melting and molding in granules or pellets before they can be used to make thermoplastic composites. However, by using the method in accordance with the present invention, the recycling process can be considerably and considerably shortened. While recycling by melting plastics gives rise to a recycled product of inferior quality and reduced strength, the method of the present invention produces a high quality product. In addition, the product can be recycled several times, making the product increasingly stronger. The granular component may additionally also comprise thermosetting polymers, whereby the present method also offers a solution for recycling these normally difficult to non-recyclable components.

In one embodiment, the layered structure is heated to a maximum of 10 ° C above the average melting temperature of the thermoplastic

BE2018 / 5567 components. More preferably, a maximum of 5 ° C above the average melting temperature is heated.

In a preferred embodiment, steps b and c can be repeated up to 7, 10 or times before the structure is reinforced by heat.

The granular components generally include lightweight thermoplastic (generally having a lower specific gravity or lower bulk density than water) such as plastic films, plastic bags, plastic gloves, films, other polymer materials including polypropylene (PP), polystyrene (PS), polyamide (PA), polycarbonate (PC), polymethyl methacrylate (PMMA) or the like. Preferably, its melting temperature is less than 200 ° C, or more preferably less than 190 ° C.

According to a further or other embodiment, the layered structure is heated to a temperature lower than the average melting temperature of the thermoplastic components. Where in the conventional recycling process of thermoplastic materials, a heating temperature higher than the average melting temperature is always intended to form pellets, the temperatures used in the present process are considerably lower. After all, according to this method, it is not the melting of the thermoplastic components that is intended, but the adhesion thereof. This produces a flexible composite material. Such a flexible composite material is easily foldable, rollable and transportable, and is a valuable semi-finished product that can be divided for subsequent thermoforming. Not only allows the handling of this temperature to process a variety of thermoplastic components simultaneously, the process is also extremely cost efficient. In contrast to higher temperature recycling processes, where polymer melting is contemplated, the process of the present invention maintains the structure and quality of the plastic material, and in addition, the quality of the final product is even improved upon multiple recycling. In addition, potential hazards, such as the release of chlorine from PVC processing, are minimized at these low temperatures.

In one embodiment, the melting temperature of the thermoplastic components is at least 10 ° C higher than its glass transition temperature. A

BE2018 / 5567 temperature difference of at least 10 ° C allows the method to be carried out efficiently. The larger this temperature difference, the less stringent the requirements imposed on heating temperature are, and the greater the possibilities for the diversity of the thermoplastic components used. Preferably, the melting temperature of the thermoplastic components is at least 20 ° C higher than their glass transition temperature, more preferably at least 30 ° C higher, even more preferably at least 40 ° C, most preferably at least 50 ° C higher.

According to a further or other embodiment, the layered structure is heated to a temperature comprised between 90 and 140 ° C for 1 to 15 minutes. Preferably, the temperature is comprised between 100 and 130 ° C.

In an embodiment of the present invention, a plastic panel can be constructed from a thermoplastic composite in accordance with one aspect of the present invention. The thermoplastic composite is constructed, at least in part, from used, recyclable, thermoplastic material. The thermoplastic material generally includes granular components that include one or more lightweight (i.e., having a specific gravity and / or bulk density less than water), thermoplastic materials in the form of regrind, pellets, agglomerate and / or granulate. The diameter of the granular components is, according to an embodiment, included between 3 mm and 25 mm, which range gives optimum properties to the composite material. The adhesion of the thermoplastic components is optimal within this diameter range and the use of a wide variety of thermoplastic components is possible. The distribution of the granular components over the structure is very uniform. Within this range, properties such as impact strength, swelling, heat resistance, heat retardation, dimensional stability and wear resistance of the resulting composite material are obtained, which are at least comparable to commonly used composite materials. Preferably, the diameter is comprised between 3 mm and 15 mm, most preferably between 5 mm and 10 mm.

The granular components, according to an embodiment of the method, comprise micronisate with a diameter comprised between 0.1 and 300 µm. The use of a micronisate makes it possible to apply the method at lower temperatures and shorter heating times, so that the thermoplastic matrix optimally retains its structure and loses minimum strength. For this purpose, the diameter of the micronisate

BE2018 / 5567 preferably included between 30 and 300 μm. Granular components with a smaller diameter usually give rise to a final composite material of greater strength. Alternatively, especially for forming very thin and strong composite materials, the micronizate diameter is preferably comprised between 0.1 and 1.5 µm.

An embodiment includes the method wherein the granular components are present in the layered structure in a density comprised between 100 and 500 g / m ² per layer. Higher density gives rise to a composite material that contains more recycled material. This composite material is usually somewhat heavier and stiffer and has better sound-insulating properties. Lower density yields a composite material that is lighter and more open in texture, resulting in better heat insulation. This material is often a lot more flexible than material in which a high density of granular components is incorporated. Preferably, the density of the granular components in the layered structure is comprised between 200 and 400 g / m2 per layer, most preferably between 250 and 350 g / m2 per layer. With a density within this range, an optimal balance is achieved between the amount of recycled material and the desired properties of the flexible composite material.

Another or further embodiment describes the spreading of the granular components over the surface of the structure by means of a sprinkler and / or vibrating table, which ensures a homogeneous distribution of granular components and can be applied in a continuous production process.

According to one embodiment, the structure comprises natural fibers and / or synthetic fibers with a glass transition temperature and a melting temperature. Preferably, the glass transition temperature of the fibers is higher than the glass transition temperature of the thermoplastic components and the melting temperature of the fibers is higher than its glass transition temperature. This makes it possible to produce a hard composite material by melting the thermoplastic components, whereby the fibers are only adhered without melting. This greatly increases the strength of the composite material.

According to one embodiment, the structure can be manufactured by providing carded, natural fibers and / or synthetic fibers, which are arbitrary

BE2018 / 5567 are oriented. This orientation is achieved by a fabric process, preferably a carding or needle punching process to form a homogeneously mixed fabric structure. Weaving or related textile production processes, or ultrasonic welding can also be used. A structure can also be provided just as well by purchasing a woven or non-woven cloth.

The carding process can be performed, for example, on a Rando machine or Laroche machine, or any other machine as already known in the art. Alternatively, the fabric is performed using any known mechanism such as a carding process, or the like. Carding is a mechanical process that detangles and mixes fibers to form a continuous fabric that is suitable for later processing. By using a carding process, a structure can be produced to a very thin predetermined thickness (up to 16 g / m ² ).

Ultrasonic welding is a technique for fabric manufacturing that does not require a weaving process. This technique may have an advantage in that the spacing between fibers can be variably selected such that flakes on either side of the fabric structure can contact each other, resulting in improved characteristics of the recycled plastic composite.

Once the structure has been formed, the process proceeds to a next step in which the lightweight thermoplastic matrix is uniformly spread, i.e., evenly distributed by uniformly spreading, on the structure. After spreading the thermoplastic matrix, a second structure can be positioned on the thermoplastic matrix, as such, with the lightweight thermoplastic matrix between two fabrics. The last two steps can be repeated a number of times, resulting in layers of spread lightweight thermoplastic matrix between fiber structures, resulting in very high volumes of thermoplastic matrix enclosed in the resulting plastic composite. Then, the layered structure is heated using known mechanisms such as a thermoforming process. The thermoforming process used preferably includes a thermobonding process in which the structure obtained from the previous step is heated by passing it through heated calendar rolls, or by other pressing techniques.

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In one embodiment, the structure has a density comprised between 20 and 150 g / m ² per layer. A density of the structure within this range provides improved characteristics to the composite material, mainly with regard to strength. More preferably, the density is comprised between 50 and 100 g / m2 per layer, even more preferably between 60 and 80 g / m2 per layer. Most preferably, the structure has a density of 70 g / m2 per layer.

In one embodiment, the granular components are obtained by providing one or more polymer materials, and shredding, grinding, comminuting, micronizing, and / or crushing them. This has the advantage that the structural or formal requirements of the polymer material to be recycled are very low. Polymer blends can be used, the form in which they exist is insignificant. The average glass transition and melting temperature of these materials are important. A method according to the present invention may comprise a number of steps for obtaining granular components of thermoplastic material to be recycled, however, the sequence of the method steps disclosed below is exemplary for the understanding of the invention to those skilled in the art.

Generally, the collection of thermoplastic granular components to be mixed to form the thermoplastic matrix can be obtained in a ready-to-use configuration from various sources (e.g. external suppliers) that provide the recycled thermoplastic granular components. However, in some embodiments of the present invention, the collection of the thermoplastic granular components is obtained from a collection of thermoplastic material to be recycled.

The thermoplastic material collection generally comprises a low specific gravity and / or low bulk density thermoplastic material which is mixed with high specific gravity and / or high bulk density thermoplastic materials. The collection of received thermoplastic material is sorted based on various factors such as type of material, color of material, or the like, and is then crushed to form regrind including flakes and granules. Standard reduction of plastics to regrind is usually carried out by shredders and pellet machines. These machines have industrial blades that perform rotary cutting to chop the plastic, which is passed through a sieve and then discharged to the

BE2018 / 5567 next phase in the process. In embodiments of the present invention, the grain machine screen may have a hole diameter that preferably ranges between 3mm and 25mm, or more preferably between 3mm and 15mm, and most preferably between 5mm and 10mm. Reduction of plastics is alternatively done by micronization to a particle diameter between 0.1 and 300 μm.

Thereafter, regrind with higher specific weight and / or higher bulk density is separated from regrind with lower specific weight and / or lower bulk density; preferably by a centrifugal process, or by a flotation technique such as separation in water, whereby the thermoplastic flakes with a density and / or bulk density lower than water are separated from the flakes with a density and / or bulk density higher than water.

In a next step, the regrind with a lower specific weight and / or lower bulk density is processed to separate flakes from grains, for example by wind shifting.

According to an embodiment, the regrind comes from, inter alia, plastic foils, plastic bags, plastic gloves, and all kinds of plastic foil or multilayer plate material with a specific weight and / or bulk density lower than water. The size of these particles is determined by passing through the screen of a pellet machine with a hole diameter that preferably varies between 3 mm and 25 mm, or more preferably between 3 mm and 15 mm, and most preferably between 5 mm and 10 mm. Alternatively, a micronized product with a particle diameter between 0.1 and 300 μm is contemplated. The thermoplastic composite further comprises a core of fibers, generally entangled and bonded in a three-dimensional structure with the thermoplastic matrix.

The thermoplastic materials suitable for use in this invention generally consist of various types of lightweight plastic components derived from the recycled objects such as flexible films and / or plates obtained from commercial labels, and / or bags, and / or containers, and / or casings, preferably for use in the food and / or agricultural sector, preferably made of at least one material of polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polypropylene (PP), polystyrene (PS), which cannot normally be reused and which usually do

BE2018 / 5567 can be landfilled or incinerated due to costs, melting / gluing, or contamination problems.

Some other non-limiting examples of suitable thermoplastic materials include a product selected from the following group of resins: acrylonitrile butadiene styrene (ABS), acrylic, high density polyethylene (HDPE), low density polyethylene (LDPE), polyethylene terephthalate ( PET), polyvinyl chloride (PVC), polypropylene (PP) and polystyrene (PS). Current most readily available recycled plastics are products made from PET and HDPE and include plastic bottles, containers and packaging, plastic lumber, etc., all of which are identified with one of the acceptable recycling symbols including: 'high density white plastic' means holders and packages made of white or translucent plastics such as holders for white detergents, holders for wiper fluid, etc.

Other examples of thermoplastic materials include, the commercial plastic labels applied to containers, boxes, cans, bottles containing foodstuffs, etc .; transparent, semi-transparent and opaque bags containing fresh food and / or long-life food; bags for agricultural products, such as fertilizers, manure, seeds, etc .; transparent, semi-transparent and opaque impermeable tarpaulins; bags for waste, food, products and goods, etc .; thermoplastic packaging of mono and multi-product packaging, etc. and / or any suitable combination thereof.

Optionally, the regrind of plastic materials with higher density and / or higher bulk density than water (e.g. acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC)) is additionally evenly distributed over the structure (s) or can be part of the thermoplastic matrix to be distributed. This can result in a plastic composite with lower brittleness. This type of regrind can represent between 5 and 20 percent by weight, or between 10 and 20 percent by weight, of the total amount of regrind including granular components in the plastic composite.

An embodiment of the present method comprises a structure comprising fibers selected from the group consisting of glass fibers, polyester fibers, acrylonitrile butadiene-

BE2018 / 5567 styrene fibers (ABS), polystyrene fibers (PS), nylon fibers, polyamide fibers (PA), natural fibers, metal fibers, or combinations thereof.

Preferably, the natural fibers used in this invention have at least moderate strength and stiffness and good ductility. Fibers with larger diameters are also preferred because they offer greater fiber stiffness. Furthermore, optional glass fibers or natural fibers can also be evenly distributed over the structure. This can result in higher stiffness and / or lower thermal expansion.

In an embodiment of the present invention, the natural fibers include natural raw fibers such as jute, hemp, coconut, flax, sisal, etc. In a more preferred embodiment of the present invention, jute fibers are used as natural fibers. The jute fibers inherit properties such as low density, low abrasive properties, high strength and therefore good dimensional stability.

The fibers with a melting temperature higher than the melting point of the thermoplastic matrix for use in the manufacture of the plastic composite may include thermoplastic fibers having a melting point higher than the melting point of the thermoplastic matrix, and / or glass fibers, and / or metal fibers, and / or a matrix of natural fibers, preferably unraveled, obtained by working entangled natural raw fibers using conventionally available tools such as a bast fiber opening machine, or a ripping machine, or the like.

One embodiment includes the method wherein the structure and granular components are present in a ratio of less than 50:50 by weight. Smaller proportions yield structurally better composite materials. Preferably this ratio is less than 40:60 by weight, and most preferably the ratio is 30:70.

In one embodiment, fibers have a length which is comprised between 50 and 400 mm. Within this range, the method can be carried out efficiently and the addition of the fibers means an added value for the strength and other structural properties of the composite material. Their length is preferably included between 150 and 350 mm.

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An embodiment of the present method includes heating the layered structure by steam heating, steam injection heating, microwave heating, vacuum heating, or combinations thereof.

A further or other embodiment comprises thermoforming one or more composite materials by pressing, vacuum forming, gluing and / or welding, or combinations thereof. Two or more thermoplastic composites are joined together in this way in a layered structure to form a multilayer thermoplastic composite. Furthermore, each layer of the multilayer thermoplastic composite can be formed from a similar or different thermoplastic material according to the desired application and properties of the thermoplastic composite to be manufactured.

The one or more composite materials, according to one embodiment, are thermoformed at a temperature higher than the melting temperature of the thermoplastic components. A hard composite sheet material is hereby obtained.

The temperature of thermoforming may lie between the glass transition temperature of the fibers and their melting temperature, such that the thermoplastic matrix melts at least partially, and preferably substantially completely, and such that the fibers with a second melting temperature do not melt. The composite material obtained is hard and, moreover, reinforced by the presence of the fiber structure, which is still intact, but still adhered.

Alternatively, reinforcement can be performed in a two-step thermoforming process. In a first step, thermoforming is performed at a temperature lower than the melting temperature of the thermoplastic components (e.g., between 90 and 120 ° C) but higher than their glass transition temperature, such that the thermoplastic matrix absorbs sufficient heat energy for softening and sufficient bonding or bonding for bonding the fibers and thermoplastic matrix, resulting in part in a flexible semi-finished product, e.g. a flexible mat. In the second step, thermoforming is performed at a temperature between the melting temperature of the thermoplastic components and the glass transition temperature of the fibers to further solidify and form the finished plastic composite. Optionally, a number of flexible mats can be joined to be exposed to the second thermoforming step,

BE2018 / 5567 which results in a rigid composite panel, a rigid composite board, or a rigid composite board with higher thickness.

The melting temperature of the fibers may be at least 10 ° C higher than the melting temperature of the thermoplastic components, or preferably at least 20 ° C higher, more preferably at least 30 ° C higher, and most preferably at least 50 ° C higher. In some embodiments, the melting temperature of the fibers may be at least 210 ° C, preferably at least 220 ° C, more preferably at least 240 ° C, and most preferably at least 260 ° C.

In some embodiments, the thermoforming processing temperature may be between 190 ° C and 250 ° C, preferably between 190 ° C and 230 ° C, more preferably between 190 ° C and 210 ° C, most preferably around 200 ° C. The resulting plastic composite is a rigid composite panel, a rigid composite board or a rigid composite board.

The thermoforming processing temperature here lies between the melting temperature of the thermoplastic components and the melting temperature of the fibers, such that the thermoplastic matrix melts at least partially, and preferably substantially completely, and such that the fibers do not melt. In some embodiments, the thermoforming processing temperature may be between 190 ° C and 250 ° C, preferably between 190 ° C and 230 ° C, more preferably between 190 ° C and 210 ° C, most preferably around 200 ° C.

According to a further or other embodiment, the method comprises treating the plastic composite with a finishing material and / or post-treatment to impart selected properties to the composite. For example, one or more surfaces of the thermoplastic composite can be treated with an antimicrobial agent, an antifungal agent, or the like. Alternatively and / or additionally, the thermoplastic composite can be treated with finishing materials such as wax, paint, or the like.

An embodiment comprises the method in which the resulting plastic composite material is reused as raw material for a subsequent implementation of the method. The recycling process hereby forms, as it were, an endless loop in which the composite material does not lose quality when it is repeated several times, but it just gains strength. In this way, the present method allows polymer materials to be recycled and recycled a large number of times

BE2018 / 5567 reuse. Any residual materials when going through the process can also be reused in a subsequent cycle, so that the process generates virtually no waste.

A second aspect of the present invention relates to a nonwoven composite material in which a woven or nonwoven structure is contained in a thermoplastic matrix which binds the structure. The composite material comprises a layered structure, which comprises between 5.0 and 50.0 m% per layer of structure, and between 50.0 and 95.0 m% per layer of thermoplastic matrix. The thermoplastic matrix hereby ensures good adhesion in the composite material, while the structure present therein improves the structural properties. Desired properties are good impact strength, low brittleness, low swelling, heat resistance, heat retardation, dimensional stability, wear resistance, at least comparable to products made with new materials. Preferably, the layered structure comprises between 10 and 40 m% per layer of structure and between 60 and 90 m% per layer of thermoplastic matrix, respectively. More preferably, these concentrations are between 20 and 40 m% per layer and 60 and 80 m% per layer, respectively. Most preferably, they are included between 25 and 35 m% per layer, and between 65 and 75 m% per layer, respectively.

A further or other embodiment describes the composite material wherein the structure comprises fibers selected from the group of glass fibers, polyester fibers, acrylonictrile-butadiene-styrene fibers (ABS), polystyrene fibers (PS), nylon fibers, polyamide fibers (PA), natural fibers, metal fibers, or combinations of them. Fibers contribute to the strength of the composite material. The thermoplastic matrix, in one embodiment, includes polymers selected from the group of acrylonitrile butadiene styrene (ABS), acrylic, high density polyethylene (HDPE), low density polyethylene (LDPE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polypropylene ( PP) and polystyrene (PS), or combinations thereof. The thermoplastic matrix adheres the various components in the composite material into a sturdy, cohesive whole.

An embodiment includes the composite material with a thickness comprised between 2 and 15 mm. The composite material can be used in this range in a wide range of applications. Moreover, thicknesses up to 15 mm remain deformable through a thermoforming process. Preferably, the thickness of the composite material is comprised between between 3 and 12 mm, most preferably between 4 and 10 mm.

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A further or other embodiment comprises the composite material comprising 70 to 90 m% polymers in the form of flakes and / or micronisate selected from the group consisting of polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC), polystyrene (PS), or combinations thereof. The particle size of the micronized polymers is preferably comprised between 0.1 and 1.5 microns. This composite material can be manufactured extremely thin, from a minimum thickness of 4 mm.

In one embodiment, the composite material of the present invention comprises 10.0 to 30.0 m% polyester fibers. Polyester fibers are readily available and have an ideal melt and glass transition temperature for use in the present invention. They provide the composite material with improved strength and rigidity.

An embodiment comprises a composite material deformable by means of a thermoforming process and / or a vacuum process. Deformability is an important aspect as forming a non-planar structure broadens the scope of this composite material.

In an embodiment of the present invention, a composite sheet can be formed from a multilayer thermoplastic composite. The multilayer composite comprises a first layer of thermoplastic composite attached and / or adhered to an adjacent second layer of thermoplastic composite. In some examples, the layers may be of equal thickness. In some other embodiments, the layers can be of different thickness. In some examples, the first layer and the second layer are both formed from the same thermoplastic materials in the same composition. In some other examples, the first layer and the second layer can be formed using different types of thermoplastic materials, thereby providing different properties to each.

Accordingly, by enclosing alternating layers of different materials, the multilayer composite can exhibit desirable properties, such as high chemical, thermal, and mechanical resistance, high strength, or the like.

The thermoplastic composite may further comprise one or more layers of finishing materials applied to an upper and / or lower surface of one or more

BE2018 / 5567 separate layers of the thermoplastic composite. In an embodiment of the present invention, the finishing material comprises one or more antimicrobial coatings of material such as antibacterial, antifungal, or the like. In another embodiment, the finishing material may include washing solutions, paint, or the like.

The present invention is mainly useful for various applications such as traffic management products such as billboards, parking boards, road plates, other structural components formed from thermoplastic materials and required desirable properties such as impact strength, swelling, heat resistance, heat retardation, dimensional stability, abrasion resistance, etc. at least comparable to conventional plastic plates, mats or panels. In addition, by spreading recycled thermoplastic matrices over thin fiber fabrics, very large volumes of recycled thermoplastic matrices can be included in the resulting plastic composite.

In one embodiment, the composite material is formed at least partially into a three-dimensional structure. Preferably, this three-dimensional structure comprises a honeycomb structure.

Previous embodiments of the composite material are preferably prepared by a method according to the first aspect of the present invention.

A third aspect of the present invention includes a composite composite material, consisting of at least two composite materials attached together according to the preceding aspect. Preferably, the composite material comprises a central composite material formed into a three-dimensional structure, which central composite material is surrounded by two flat composite plates which are glued on either side of the central composite material. More preferably, the three-dimensional structure of the central composite material comprises a honeycomb structure.

A final aspect of the present invention includes a charge carrier made of a composite material according to any of the above embodiments. The load carrier exhibits good strength, at least comparable to commonly used load carriers, and is a good alternative for

BE2018 / 5567 existing load carriers in the context of the recovery of polymer waste materials.

The composite material is preferably formed at least partially into a three-dimensional structure. The three-dimensional structure imparts improved structural properties to the composite material, such as increased strength, and increased resistance to bending and breaking, while keeping the load carrier extremely light. Due to the three-dimensional structure, the required amount of composite material per load carrier is rather limited. The three-dimensional structure may provide engagement points for fork lifts and / or carts, facilitating their use. Preferably, this three-dimensional structure is a honeycomb structure.

In one embodiment, the charge carrier comprises a plurality of composite materials attached together. This makes it possible to combine different material properties in the load carrier and also allows to manufacture more complex shapes.

Preferably, the charge carrier comprises a central composite material, which material is formed into a three-dimensional structure, and which material is surrounded by two flat composite plates which are glued on either side of the central composite material. The three-dimensional structure anchored between two flat composite plates is particularly rigid, light, and extremely suitable as a load carrier. The flat plates on both sides allow easy stacking of goods on the load carrier, as well as placing the load carrier on a surface or in a loading trolley. Load carriers assembled in this manner include, but are not limited to, pallets and trays.

In a preferred form, the three-dimensional structure comprises a honeycomb structure, which imparts optimal structural properties to the load carrier and simplifies gluing of surrounding composite plates.

In what follows, the invention is described by means of non-limiting examples or figures illustrating the invention, which are not intended or should be interpreted to limit the scope of the invention.

BE2018 / 5567

EXAMPLES

Example production of a pallet weight percent of recycled LDPE flakes from foils and bags shredded with a shredder with an 8 mm hole diameter sieve was mixed with 15 weight percent of a mixture of ABS, PS and PVC granules of approximately the same size.

About 300 g / m ² of the above mixture was evenly distributed on a carded fabric structure of 70 g / m 2 recycled PET fibers. This process was repeated 2 times and a finished fabric structure was placed on top, and ended up in a sandwich structure of 4 carded fabrics with the mixture of flakes and granules evenly distributed between them. As such, the total weight of the structure is about 1180 g / m2.

This structure was thermoformed under pressure into a 1 cm thick intermediate composite material. The intermediate is a flexible mat and can be rolled up into a roll of, for example, about 200 kg.

pieces of these flexible mats were superimposed and pressed at 200 ° C to a total thickness of 9 mm to form a pallet.

Claims (40)

A method of manufacturing a plastic composite material comprising the steps of: a. Providing a woven or non-woven structure; b. uniformly distributing one or more granular components across the surface of the structure resulting in a layered structure, said granular components comprising one or more thermoplastic polymer components having a glass transition temperature and a melting temperature; c. optionally providing a second structure over the granular components; d. optionally repeating steps b and c; and e. heating the layered structure to a temperature higher than the glass transition temperature of the thermoplastic components, thereby obtaining a bond between the granular components and the structure; characterized in that said woven or nonwoven structure and the granular components of steps (a-d) are present in a ratio of less than 50:50 by weight, the granular components being evenly distributed over the woven or nonwoven structure. A method according to claim 1, characterized in that the layered structure is heated to a temperature lower than the melting temperature of the thermoplastic components. Method according to claim 1 or 2, characterized in that the melting temperature of the thermoplastic components is at least 10 ° C higher than its glass transition temperature. Method according to any one of the preceding claims 1-3, characterized in that the layered structure is heated to a temperature which is comprised between 90 and 140 ° C for 1 to 15 minutes. Method according to any one of the preceding claims 1-4, characterized in that the granular components comprise regrind, flakes, granulate and / or agglomerate with a diameter included between 3 and 25 mm. Method according to any one of the preceding claims 1-4, characterized in that the granular components comprise micronizate with a diameter included between 0.1 and 300 µm. 24 BE2018 / 5567 Method according to any one of the preceding claims 1-6, characterized in that the granular components are present in the layered structure in a density which is comprised between 100 and 500 g / m ² per layer. Method according to any one of the preceding claims 1-7, characterized in that the granular components are spread evenly over the surface of the structure by means of a sprinkler and / or vibrating table. Method according to any one of the preceding claims 1-8, characterized in that the structure comprises natural fibers and / or synthetic fibers with a glass transition temperature and a melting temperature. Method according to any one of the preceding claims 1-9, characterized in that the structure is manufactured by providing carded, natural fibers and / or synthetic fibers which are oriented randomly. Method according to any one of the preceding claims 1-10, characterized in that the structure has a density which is comprised between 20 and 150 g / m2 per layer. Method according to any one of the preceding claims 1-11, characterized in that the granular components are obtained by providing one or more polymer materials and shredding, grinding, comminuting, micronizing and / or crushing them. A method according to any one of the preceding claims 1-12, characterized in that the granular components are derived from materials selected from the group of plastic foils, plastic bags, single or multilayer plastic sheet materials, or combinations thereof. A method according to any one of the preceding claims 1 to 13, characterized in that the structure comprises fibers selected from the group of glass fibers, polyester fibers, ABS fibers, polystyrene fibers, nylon fibers, PA fibers, natural fibers, metal fibers, or combinations thereof . Method according to any one of the preceding claims 9-14, characterized in that the fibers have a length which is comprised between 50 and 400 mm. Method according to any one of the preceding claims 1-15, characterized in that the heating of the layered structure takes place by steam heating, steam injection heating, microwave heating, vacuum heating, or combinations thereof. Method according to any one of the preceding claims 1-16, characterized in that one or more composite materials subsequently become thermal BE2018 / 5567 formed by pressing, vacuum forming, gluing and / or welding, forming a composite plate. A method according to any one of the preceding claims 3-17, characterized in that the composite materials are thermoformed at a temperature higher than the melting temperature of the thermoplastic components. A method according to any one of the preceding claims 3-18, characterized in that the composite materials are thermoformed at a temperature higher than the glass transition temperature of the fibers and lower than their melting temperature. A method according to any one of the preceding claims 17-19, characterized in that the composite plate is subsequently provided with one or more finishing layers. A method according to any one of the preceding claims 1-20, characterized in that the resulting plastic composite material is reused as raw material for a subsequent implementation of the method. A nonwoven composite material in which a nonwoven or woven structure is contained in a thermoplastic matrix, which binds the structure, characterized in that the composite material comprises a layered structure, the layered structure comprising one or more layers, which layered structure comprises between 5.0 and 50.0 m% per layer of woven structure, and comprises between 50.0 and 95.0 m% per layer of thermoplastic matrix, and which thermoplastic matrix is homogeneous across the nonwoven or woven structure divided. Composite material according to claim 22, characterized in that the structure comprises fibers selected from the group consisting of glass fibers, polyester fibers, acrylonitrile-butadiene-styrene fibers (ABS), polystyrene fibers (PS), nylon fibers, polyamide fibers (PA), natural fibers, metal fibers , or combinations thereof. Composite material according to claim 22 or 23, characterized in that the thermoplastic matrix comprises polymers selected from the group of ABS, acrylic, high density polyethylene (HDPE), low density polyethylene (LDPE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polypropylene (PP) and polystyrene (PS), or combinations thereof. Composite material according to any one of the preceding claims 22-24, characterized in that the composite material has a thickness which is comprised between 2 and 15 mm. 26 BE2018 / 5567 Composite material according to any one of the preceding claims 22-25, characterized in that the composite material comprises 70 to 90 m% polymers in the form of flakes and / or micronisate selected from the group of, polypropylene (PP), high-density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC), polystyrene (PS) or combinations thereof. Composite material according to claim 26, characterized in that the micronisate has a particle size between 0.1 and 1.5 µm. Composite material according to any one of the preceding claims 22-27, characterized in that the composite material comprises 10.0 to 30.0 m% polyester fibers. Composite material according to any of the preceding claims 22-28, characterized in that the composite material is deformable by means of a thermoforming process and / or a vacuum process. Composite material according to any one of the preceding claims 22-29, characterized in that the composite material is formed at least partially into a three-dimensional structure. Composite material according to claim 30, characterized in that the three-dimensional structure comprises a honeycomb structure. Composite material according to claims 22-31, manufactured by a method according to any one of claims 1-21. A composite composite material, comprising at least two attached composite materials according to any one of the preceding claims 2232. Composite composite material according to claim 33, characterized in that the composite composite material comprises a central composite material formed into a three-dimensional structure, which material is surrounded by two flat composite plates which are glued on either side of the central composite material. Composite composite material according to claim 34, characterized in that the three-dimensional structure comprises a honeycomb structure. A load carrier made of a composite material according to any one of claims 22-32. Load carrier according to claim 36, characterized in that the composite material is formed at least partially into a three-dimensional structure. 27 BE2018 / 5567 Load carrier according to claim 36 or 37, characterized in that the load carrier comprises a number of composite materials fastened together. Load carrier according to any one of the preceding claims 36-38, characterized in that the load carrier comprises a central composite material, which The material is formed into a three-dimensional structure, and which material is surrounded by two flat composite plates which are glued on either side of the central composite material. Load carrier according to claim 39, characterized in that the three-dimensional structure comprises a honeycomb structure.