CN102307723B - 利用离聚物面料的木塑复合物及其制造方法 - Google Patents

利用离聚物面料的木塑复合物及其制造方法 Download PDF

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CN102307723B
CN102307723B CN200980156095.3A CN200980156095A CN102307723B CN 102307723 B CN102307723 B CN 102307723B CN 200980156095 A CN200980156095 A CN 200980156095A CN 102307723 B CN102307723 B CN 102307723B
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fabric
coextrusion
approximately
polymer
weight
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CN102307723A (zh
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J·P·普兹比林斯基
D·G·曼柯什
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Fiber Composites LLC
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  • Extrusion Moulding Of Plastics Or The Like (AREA)
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Abstract

一种适用作建筑材料的挤出复合物，包括具有以基本上均匀混合物形式存在的基础聚合物和天然纤维的芯以及离聚物面料。为了提高所述离聚物对基础聚合物的粘合性，可以在与所述芯共挤出之前，将所述离聚物与相似或基本相似的基础聚合物混合。另外，可以将各种添加剂与面料材料混合以改善产品的视觉美感和建筑材料的性能，特别随着时间的推移。

Description

利用离聚物面料的木塑复合物及其制造方法
相关申请的交叉引用
本申请要求于2008年12月19日提交的序号为61/139,205的美国临时申请的优先权，其公开内容整体并入此处作为参考。
技术领域
本发明涉及制造挤出木塑复合物的系统和方法，更具体地，涉及利用离聚物面料制造挤出木塑复合物的系统。
背景技术
在过去的25年中，新型材料已经进入塑料产品市场。通常作为木塑复合物(WPC)、纤维-塑料复合物、或塑料复合物(PC)提及的新材料已经被建筑产品市场接纳，应用于例如户外装饰和栏杆、墙板、屋顶和各种其它产品。木塑复合物的市场已经壮大，木塑复合物目前用于汽车应用以及经济结构的建筑产品部门中。
木塑复合物是木材、或其它天然纤维和热塑性材料的共混产品。该产品可以用传统的塑料工艺例如挤出或注塑成型生产。例如，许多建筑产品采用类似于传统塑料工艺的挤出加工来生产。木材和塑料材料在挤出过程前或挤出过程中共混。在建筑产品市场中，木塑复合物通常与木材竞争。目前WPC材料是最常见的木材或天然纤维与聚乙烯、聚丙烯或聚氯乙烯(PVC)的化合物。但是，目前可用的WPC有某些缺陷。例如，如果复合物含有过高或过低的塑料对木材的比率，成品可能不具有预期的视觉外观或结构性能特点。这种产品在市场上是较为不理想的。另外，由于热塑性材料和用于制造的其它添加剂成本高，制备WPC可能是昂贵的。
讽刺的是，许多消费者希望WPC看起来与木材类似，但也希望WPC表现为强大的塑料化合物。为了提高性能，生产商通常在WPC配方中加入UV稳定剂、抗氧剂、杀菌剂、颜料、阻燃剂、或其它添加剂。但是，这些添加剂可能增加产品的制造成本，即使某些添加剂只在产品上有限位置有值得关注的好处(例如，在UV稳定剂的情况下，只对暴露在阳光下的产品外部有好处)。为了降低加入产品中的添加剂的用量，通常使用面料包覆。一般而言，面料与芯材料共挤出在芯挤出材料上形成聚合物薄层。可以在面料中加入各种添加剂，从而降低了每线英尺产品中添加剂的总量。但是，这些面料可能从基础WPC上脱落，可能破裂或其它方式的失效，导致外观难看、性能受损以及消费者不满意。
对于某些面料，为了提高粘合性，通常在芯材料和面料之间放置分离的束缚层，但是该束缚层可能存在许多问题。例如，随着时间的推移，由所述束缚层形成的结合可能从面料和芯材料之一或两者上分离，导致产品失效。这可能发生，因为由于材料性能的不同，面料和芯材料可能以不同的比率膨胀和收缩，其可能导致结合失效。另外，水、冰或安装环境条件相关的其它有害物仍然可以穿透面料层，例如，通过分离的面料部分的边缘空隙。此外，利用分离的束缚层的面料产品的制造成本往往很高，因为所述束缚层必须应用到成品面料和芯材料。
发明内容
在一个方面，本发明涉及一种适用作建筑材料的挤出复合物，所述挤出复合物包括具有以基本上均匀混合物形式存在的基础聚合物和天然纤维的芯以及具有离聚物的面料。在一个实施方案中，所述基础聚合物选自由聚丙烯、聚乙烯、HDPE、MDPE、LDPE、LLDPE、及其组合组成的组。在另一个实施方案中，所述天然纤维选自由木屑、木粉、薄木片、锯木屑、亚麻、黄麻、大麻、洋麻、稻壳、蕉麻、及其组合组成的组。在又一个实施方案中，所述面料进一步包括面料聚合物，其中所述离聚物和所述面料聚合物是基本上均匀混合物。在另外又一个实施方案中，所述基础聚合物是第一聚合物，同时所述面料聚合物也是第一聚合物，其可以是HDPE。
在上述方面的另一实施方案中，所述面料进一步包括添加剂。在一个实施方案中，其中所述添加剂包括着色剂、UV稳定剂、抗氧剂、杀菌剂和阻燃剂中的至少一种。在另一个实施方案中，所述着色剂是杂色着色剂。在又一个实施方案中，所述芯包括约1重量％至约100重量％的基础聚合物。在另外又一个实施方案中，所述芯包括约46重量％的基础聚合物。
在上述方面的另一个实施方案中，所述面料包括约1重量％至约100重量％的离聚物、约20重量％至约80重量％的离聚物、或约27.5重量％的离聚物。在另一个实施方案中，所述面料包括约0重量％至约99重量％的面料聚合物、约20重量％至约80重量％的面料聚合物、或约72.5重量％的面料聚合物。在又一个实施方案中，所述面料的厚度为约0.012英寸至0.040英寸、或约0.015英寸至约0.020英寸。在另外又一个实施方案中，所述面料通过共挤出与所述芯的至少一侧直接结合。
在另一个方面，本发明涉及一种适用作建筑材料的挤出复合物的制造方法，所述方法包括以下步骤：提供基础共聚物，提供天然纤维，混合并加热所述基础共聚物和天然纤维以生产包括基本上均匀熔融共混物的基础混合物，提供离聚物，以及通过模具共挤出离聚物到至少部分基础混合物上以形成型材。在一个实施方案中，所述方法进一步包括提供面料聚合物以及混合并加热所述离聚物和面料聚合物以生产具有基本上均匀熔融共混物的面料混合物的步骤。在另一个实施方案中，所述基础聚合物是第一聚合物，所述面料聚合物是该第一聚合物，其可以选自由聚丙烯、聚乙烯、HDPE、MDPE、LDPE、LLDPE、及其组合组成的组。在一个实施方案中，所述第一聚合物是HDPE。在又一个实施方案中，所述方法进一步包括提供添加剂以及混合并加热所述离聚物、面料聚合物和添加剂生产具有基本上均匀熔融共混物的面料混合物的步骤。在另外又一个实施方案中，所述添加剂是着色剂、UV稳定剂、抗氧剂、杀菌剂和阻燃剂中的至少一种。在另一个实施方案中，所述方法进一步包括冷却所述型材的步骤，其可以包括将所述型材通过一种液体，该液体可以是水和冷却剂中的至少一种。
此处，除非另有说明，当描述特定应用、工艺或实施方案时一种材料的使用不是将所述应用、工艺或实施方案限定到该特定的已知材料。根据此处所述的教导，所述材料可以互换使用。此外，除非另有说明，术语WPC、PC、纤维-塑料复合物、以及其变种可以互换使用。
附图简要说明
当结合附图阅读时，从下列各实施方案的描述中将更全面地理解本发明的其它特点和优点、以及本发明本身，其中：
图1是根据本发明一个实施方案制备的面料包覆的纤维-塑料复合挤出物的立体图；
图2是根据本发明一个实施方案形成面料包覆的纤维-塑料复合挤出物的系统的立体图；
图3是根据本发明另一个实施方案形成面料包覆的纤维-塑料复合挤出物的系统的横截面示意图；
图4是根据本发明另一个实施方案形成面料包覆的纤维-塑料复合挤出物的生产线的示意图；
图5是用在根据本发明另一个实施方案形成面料包覆的纤维-塑料复合挤出物的系统中的共旋转双螺杆挤出机的侧视图；
图6是用在根据本发明另一个实施方案形成面料包覆的纤维-塑料复合挤出物的系统中的Y形块适配器和挤出模具组件的立体图；
图7A描绘了用在根据本发明另一个实施方案形成面料包覆的纤维-塑料复合挤出物的系统中的共挤出模具组件的侧面剖视图和前视图；
图7B描绘了图7A中共挤出模具组件的板的入口图、侧面剖视图和出口图；
图7C描绘了图7A中共挤出模具组件的局部放大的侧面剖视图；以及
图8描绘了面料包覆的离聚物/聚合物配方与粘合强度的关系。
具体实施方式
图1显示了根据本发明的面料包覆的挤出的纤维-塑料复合物10的一种实施方案。所述挤出的木塑复合物(WPC)10一般包括由包括一种或多种基础聚合物和天然纤维的混合物形成的三维复合体或芯12。所述基础聚合物可以包括聚丙烯、聚乙烯、HDPE、MDPE、聚丙烯、LDPE、LLDPE、PVC、类似材料、及其组合。所述天然纤维或填充材料有助于给挤出的芯12提供天然木材产品的外观和感觉。天然纤维的类型，例如木材填料或类似材料，包括木屑、木粉、薄木片、锯木屑、亚麻、黄麻、蕉麻、大麻、洋麻、稻壳、类似材料、及其组合。这种填料的使用可以降低芯12的重量和成本。另外，所述芯12可以包括添加剂，例如着色剂、润滑剂、阻燃剂、防霉剂、相容剂、偶联剂、杀菌剂、UV稳定剂、抗氧剂、其它材料、及其组合。
在一个实施方案中，所述芯12至少在一侧用包括离聚物和面料聚合物的面料14涂覆。在一个实施方案中，在具有HDPE基础聚合物的芯上的HDPE和离聚物的面料已经显示出令人满意的结果。所述基础聚合物的一个目的是促进所述离聚物和所述含有相同聚合物的挤出WPC10之间的粘结。由于聚合物例如聚乙烯在特定条件下会迅速风化，离聚物的加入也可能改善外部风化性能。通常情况下，单独的离聚物对底层复合芯12表现出有限的粘合性。所述离聚物是能改善未涂覆挤出WPC表面性能的保护组分。大量控制性试验表明，所述挤出WPC 10表面上的离子化合物增强了抗划伤性、抗褪色性和抗污染性。所述离聚物/聚合物面料也降低了极高和极低温度下水对所述WPC 10的损伤。因此，通常希望在WPC的所有面上提供面料。但是，WPC不需要用面料完全包围来获得与其相关的优点。在一些实施方案中，可能希望将面料共挤出到芯型材的部分表面上，例如，只在那些环境暴露最严重的表面上(例如朝上的水平表面和可选的挤出面板的垂直边缘)。
如上所述，在某些实施方案中，所述面料聚合物与芯12中采用的基础聚合物基本相同或相同。例如，面料聚合物和基础聚合物都可以是聚乙烯。或者，可以将聚乙烯面料聚合物和聚丙烯基础聚合物结合使用。也可以考虑聚丙烯面料聚合物和聚乙烯基础聚合物的结合使用以及其它不同聚合物的组合。这有助于确保所述芯12与面料14之间的粘合性。此外，所述面料14可以包括天然纤维和添加剂，例如上面列出的与芯12相关的那些。与直接将天然纤维和添加剂加入其中的复合物相比，通过将添加剂加入面料14而不是芯12的方式，可以明显降低每线英尺挤出复合物中添加剂的总量。
在某些实施方式中，本发明包括形成具有共挤出的离聚物/聚合物面料的塑料复合挤出物的系统和方法。如图2和3所示，挤出系统100包括至少四个主站：分配基础聚合物(例如，粉末和/或颗粒形式)和其它添加剂的供料站或主要喂料器150；用来接收基础聚合物的共旋转双螺杆挤出机102；分配到挤出机102中与基础聚合物混合的其它材料(例如，填充材料如木材或天然纤维、添加剂如着色剂等)的二次侧喂料器160；以及形成复合挤出物的具有预定配置的挤出模具140。图4，在下面更详细地描述，描述了图2和3的挤出系统100，具有两个共挤出站和制造成品面料包覆的WPC相关的下游组件。
在图2描述的挤出系统100中，挤出机102包括挤出筒120和一对共旋转挤出螺杆110、112。所述挤出筒120定义出一个内部腔122(图5)，材料(例如，基础聚合物、填充材料、添加剂等)在该内部腔中混合、加热和输送。所述挤出筒120是包括大量离散筒节128的组件。所述筒节128顺序排列一起形成内部腔122，其作为供料站150和挤出模具140之间的流动通道(即用于输送各种材料)。挤出螺杆110、112每个包含大量离散的螺杆段116，其密封在内部腔122中并从上游进料区130延伸到挤出模具140。所述螺杆段116是可拆卸、可更换和可互换的，螺杆螺纹可以被设计为当材料沿着挤出筒120的内部腔122通过所述挤出机时完成所需的进料、输送、揉捏和混合工序。
所述挤出螺杆110、112在平行位置上排列并且相对于彼此共旋转运动。挤出螺杆110、112的共旋转运动混合材料，例如基础聚合物、木纤维、添加剂等，并通过挤出筒120输送这些材料。所述挤出筒120和挤出螺杆110、112可以由市售零件制成。该工艺也可以采用螺杆相对于彼此反向旋转的相似类型的双螺杆挤出机。在反向旋转的设计中，所述工艺与上述共旋转配置不同，混合和分散往往是更不剧烈的。因此，更依赖于热量的加入，而不是剪切混合，以在通过挤出模具140之前完成所有成分的复合。
如图2和3所示，所述挤出系统100包括至少四个主站：供料站150；共旋转双螺杆挤出机102；第二侧喂料器160；以及挤出模具140。所述供料站150可以包括单个和/或两个螺杆(即双螺杆)失重式喂料器用于将固体材料，通常是纤维、粉末和/或颗粒形式，通入挤出机102的进料区130。典型的商业规模系统可以采用最大进料率在约50磅/小时和2000磅/小时之间的一个或多个失重式喂料器。所述喂料器也可以在所述工艺最初启动时直接将材料输送到挤出机中。
仍然参照图2和3，所述双螺杆挤出机102包括挤出筒120和一对共旋转螺杆110、112。所述挤出筒120是形成基本连续的筒的离散筒节128的组合。当与反旋转挤出机相比时，这样的排列提供了灵活性，可以移动、移除、和/或更换单个筒节128以提供不同的筒结构，例如顾及不同的供料(例如进料点)、真空、或注射位置。另外，所述分节的筒结构为进入挤出机102的多个进料点(例如，如示出的在132a、132b)之间的选择提供了灵活性。例如可以使用一个以上进料点来获得在复合成分、产品性能和外观方面更复杂的挤出产品。每一筒节128定义出一个筒孔，组装后，沿着挤出筒120的长度方向(即从进料区130向挤出模具140延伸)形成基本上连续的内部腔122。每一筒节128包括电加热元件，例如加热筒壳和用于逆流液体冷却的冷却孔，两者一起对温度进行可优化动态调整和控制。
单个筒节128选自开放筒(即具有用于喂料区的进料口)、具有嵌入件(用于脱气、计量或注射区)的开放筒、封闭筒和/或用于结合了喂料(例如，纤维或添加剂的侧向喂料)和排气功能的组合筒，每一个的长度在大约4英寸至20英寸之间。如图3所示，挤出筒120包括两个开放筒节128a、128b，其分别与第一喂料器150和第二侧喂料器160成流体连通。在相邻的筒节128之间的结合部形成堵漏密封。如图2所示，相邻筒节128可以与栓结法兰127连接，或者，可选地，与C形夹钳筒连接器连接。
参考图2，就分散和分布熔融挤出物基质内的添加物和其它材料的能力而言，共旋转挤出螺杆110、112提供相对有效的挤出机类型。如图所示，每个挤出螺杆110、112包含分段的螺杆排列，其中每个挤出螺杆110、112包括一系列适合于轴117的离散的元件或阶梯角度(即螺杆段116)。齿状物或齿条124(见图5)使得单个段116固定在轴117上。合适的螺杆段可购自黎巴嫩的俄勒冈州的ENTEK制造公司。单个螺杆段116每个是可拆卸和可更换的，并且可以选择不同的螺杆配置，从而允许针对具体应用和/或工艺要求的多种螺杆配置的排列。
在各种类型的螺杆段配置中，单个段可以选自输送元件、混合元件、捏合元件和/或特殊元件。以各种长度、螺距和倾伏向设计混合元件和捏合元件。采用几个相同或不同宽度且彼此间距相等的分段组成捏合块。排列捏合、混合、输送和其它段的顺序以控制剪切、熔融的程度和能量的添加。另外，这种混合工艺提供了基础聚合物和其它添加剂的均匀熔体和可控分散-分布。分段螺杆110、112允许螺杆配置的修改，例如修改工艺参数、改变物理性能和/或挤出产品的表面外观。通常，螺杆段的整个直径保持不变；然而，步级的形状(例如步级间的螺距和距离)可以改变。
可以排列螺杆段116以便挤出机102的约前半部分提供比较高的剪切和捏合(即基础材料和任意添加剂的分散混合)以及挤出机102的约后半部分提供比较低的剪切(即复合材料和着色剂或其它添加剂的分布混合)。可以使用这种排列抑制形成复合材料聚合部分的一种或多种聚合物和添加剂的过度混合。
图3和4描述了制造设备的示例性实施方案。每一个挤出螺杆110、112包括52个离散的螺杆段116，每一个螺杆段的长度为约60mm至约120mm。这种特殊的结构定义出了12个加工区Z1-Z12，每一个加工区展现了由一个或多个离散的螺杆段定义的螺杆配置的变化(例如见图3、4和表A-1)。在该实施方案中，排列螺杆段116以便前五个区域(Z1-Z5)形成用于分散混合(即比较高的捏合和剪切)的第一混合区域170，以及后七个区域(Z6-Z12)形成用于分布混合(即比较低的剪切)的第二混合区域172。在分散混合中，可以克服颗粒间的黏合强度以达到更精细水平的分散；分散混合也被称为充分混合。换句话说，分散混合包括化合物内的离散颗粒的混合和破坏。分布混合的目的是在黏合强度不起作用的情况下提高组分的空间分布；它也被称为简单混合或粗混合。分布混合允许在基本不影响颗粒的尺寸和/或形状(即不破坏颗粒)的情况下将离散颗粒分开和散开成混合物。
图4是根据本发明的一个实施方案形成面料包覆的WPC的加工线250的示意图。描述了挤出机102以及一对面料挤出机300a、300b和图2和3中的描述的配置挤出系统100下游的各种组件。每一个面料挤出系统300包括面料喂料器302和杂色着色剂喂料器304，每一个喂料器将所需数量的组分运送到共挤出料斗306。用离聚物和基础面料聚合物的混合物以特殊应用所需或要求的任意比例填满面料喂料器302。这种混合物可以预混合运送至喂料器302或者通过两个料斗引入喂料器302。可以通过一个或多个添加剂喂料器308将其它添加剂引入料斗306。所述添加剂可以包括着色剂、杀虫剂、阻燃剂、UV抑制剂等。
在描述的实施方案中，每个挤出机主体310包括四个区(Z1-Z4)，并在芯挤出模具140的出口处连接到共挤出模具312。所述挤出机310可以是单螺杆或双螺杆结构。面料挤出机300的相关工艺参数列于表A-1中。在描述的实施方案中，所述挤出机主体310与挤出机102不同，螺杆和机筒是不分段的。此外，所述螺杆配置不是用来混合的，而是用来熔化和输送。在其它的技术方案中，可以采用具有分段的机筒或螺杆的不同类型的挤出机。在某些实施方案中，每个共挤出主体310的输出量为约1251b/hr至约1751b/hr。如果采用单个面料挤出机，输出量可以在约2501b/hr至约4001b/hr之间。根据特定生产线的配置、面料层的表面积和厚度等，考虑其它输出量。一般来说，共挤出机的输出量约占体系100总输出量的5％。挤出后，如果需要，所述挤出的面料包覆的复合物可以用轧花机314装饰，并通过一个或多个冷却罐316，该冷却罐316可以用如水和/或冷却液的液体填充以加快冷却。在冷却的过程中可以采用可选的真空型或其它类型的校正模具来保持复合物的尺寸要求。采用钳子318从冷却罐316和校正模具中拉出所述挤出复合物以保持冷却后产品的尺寸一致性。在最后的空气冷却站322和包装站324之前，用一个或多个锯320切割挤出复合物成品。
图4中描绘的生产线250的其它技术方案也在考虑范围。例如，可以采用一个共挤出机310将熔融面料材料喂料到两个共挤出模具312a、312b中。所描绘的共挤出系统可能是特别理想的，但是，允许不同配方的面料应用到挤出的WPC的不同表面，或者允许应用到同一批芯材料的面料材料快速转换。这允许例如生产不同颜色的面料包覆的WPC。
表A-1确定了本发明各实施方案中采用的代表性的区域温度和挤出机工艺系统相关的其它细节。以高/低范围的形式列出了每个区温度。值得注意的是，可以利用所列的范围制备面料包覆的WPC和没有面料包覆的WPC。此外，也可以利用所列的范围制备根本没有采用木材或天然纤维而纯粹由添加剂和基础聚合物制成的复合物。根据表A-1中显示的范围制造面料包覆的WPC和没有面料包覆的WPC的实例如下所述。温度和那些描绘的以外的其它工艺参数也在考虑范围内。
Figure BDA0000080961650000111
表A-1：共挤出面料包覆的复合物的工艺参数
关于主挤出机，一般来说，输送和进料元件(例如Z1、Z2、Z4、Z6、Z8、Z10和Z12)用来将材料通过挤出机筒120，从第一进料口132a向挤出模具140转移。捏合块(例如参见Z3和Z6)提供(例如基础材料的)高剪切和分散。混合元件(例如参见Z7、Z9和Z11)提供比较高的粒度分布(例如纤维材料的高分布)。阶梯角度小于90°的区域用于压缩材料。阶梯角度约为90°的区域提供材料的摩擦热，而对材料的输送即使有也很小。阶梯角度超过90°的区域提供比较高效率的输送。
参考图3-5和表A-1，Z0区是室温。Z1和Z2区用来从挤出机102的咽喉部移动材料并在材料被引入Z3区前加热它。更具体地，第一加工区Z1用来在室温下将冷料，例如粒状基础聚合物，从进料点即主进料口132a移到第二加工区Z2。当材料向第三加工区Z3移动时，第二加工区Z2用来增加材料上的压力。前8-24段组成了阶梯角度约90°的第二加工区Z2。在这一部分，主要通过从第一加工区Z1引入其它材料来完成输送，其导致第二加工区Z2中压力增大，其转而迫使材料通过第二加工区Z2。
加工区Z3-Z5定义了高剪切部分。在该部分基础材料彻底分散到熔融复合物混合物中。Z6区标志着向分布混合区域172的过渡。在该区中木材或其它天然纤维(作为填料)和一些添加剂被加入到熔融复合物混合物。该区中120°的更大的阶梯角度增大了沿Z6区或在Z6区附近的输送能力，即该区材料快速向前移动，从而抑制了材料的冷却。Z7-Z9区是用来提供纤维填料和熔融复合物混合物的高分布混合。第十加工区Z10包括6-12个离散的螺杆段。这些段定义了比较高压力的第一部分Z10a，接着是比较低输送能力的部分Z10b，其允许材料膨胀，水分上升到外表面，在外表面上蒸发并从挤出机筒120排出。接着是比较高压力的第二部分Z10c。
第十一加工区Z11是具有比较高的阶梯角度的混合区，其增加了输送能力并提供精细混合。第十二加工区Z12从具有比较高的输送能力的第一部分(即该区材料以比较高的流速/进料速度移动，在进入模具前抑制冷却)向具有高压力的第二部分过渡，其使挤出机102的末端126附近的压力增大，迫使材料通过挤出模具140。
再参考图2-4，提供了一个或多个第二侧喂料器160用于将一种或多种其它材料(例如填充材料或天然纤维、着色剂、和/或其它添加剂)分配到挤出机筒中与基础聚合物混合。如本文所述，在面料材料中而不是芯材料中提供这些添加剂是理想的并降低了每线英尺挤出复合物中加入的添加剂的总量。为了满足特定的需求，在芯材料中包括添加剂可能是理想的或需要的(例如加入如阻燃剂的添加剂以满足特殊的产品安全规定)。第二侧喂料器160使用单螺杆或双螺杆结构将材料通过第二侧进料口132b移入挤出机120中。如图3所示，第二侧喂料器160可以包括一个或多个用于分配木纤维的失重式喂料器166和用于将多种着色剂(或其它添加剂)分配到挤出机中的并联的喂料器组162，例如容积式螺旋喂料器。因此，可以在挤出过程中从独立的料斗164中加入两种、三种、四种或更多种添加剂。
第二侧喂料器160可以安装在第一喂料器150(基本聚合物引入其中)和第一混合区170的下游位置，这样将填充材料和添加剂分配到挤出机102中，在第二(比较低的捏合和剪切)混合区172与基础聚合物混合。在共同的区域引入填充材料和添加剂可能存在特别的优势。例如，挤出螺杆110、112对纤维和添加剂的下游剪切和捏合效果不如对基础聚合物的上游效果，从而提供了充分混合的复合材料(即包括基础聚合物和填充材料)。
如图4和6所示，所述系统可以包括安装在挤出机102末端126的Y形块适配器200。Y形块适配器200包括两个适配器段202、204，分为三个温度区，大概定义为位置T1、T2、T3。由加热筒壳完成加热。Y形块适配器200定义出了一个流动通道206，其从挤出机筒120的内部腔122分流入两个离散的流动通道208、209。
如图6所示，系统100还包括安装在适配器200末端210的挤出模具140。挤出模具140可以定义一对挤出通道142a、142b，每个对应连接流动通道208、209，用于共同形成一对具有预定的配置或形状(即对应挤出通道142a、142b的形状)的挤出产品(即挤出物)。挤出通道142a、142b的每一个包括多达3个(或更多)对应通道142a的离散段L1-L3以及对应通道142b的R1-R3。这些离散段L1-L3、R1-R3沿挤出通道142a、142b平滑地过渡圆柱形流动通道208、209的几何形状以防止引入气泡、造成低流量或高压区等。L1-L3和R1-R3每一段包含离散的温度区并用独立的加热器加热。
再参考图3，基础混合物190包括基础聚合物(在一个实施方案中，聚乙烯混合物包括，例如纯高密度聚乙烯(HDPE)、再生HDPE、和/或再加工HDPE)和其它添加剂(例如碱着色剂、内部加工润滑剂、阻燃剂等)，一般是固体颗粒形式，例如粉末和/或颗粒。在一个实施方案中，将基础聚合物190以约4001b/hr至约20001b/hr的总进料速率从主挤出机料斗156经进料站150分配到挤出机102的进料区130中。当使用反旋转双螺杆挤出机时，其它合适的基础聚合物包括聚丙烯、中密度聚乙烯、低密度聚乙烯、线性低密度聚乙烯、和PVC。在其它实施方案中，再研磨聚合物、再加工聚合物、和回收聚合物(例如地毯废料)可以与基础聚合物一起加入，或者作为纯基础聚合物的替代品。基础混合物190由电加热元件加热，在其通过挤出机筒120从进料区130向挤出模具140用挤出螺杆110、112以约4001b/hr至约20001b/hr的进料速率输送时分散(即混合聚合物颗粒和添加剂颗粒并捣碎)。
如上所述，挤出螺杆110、112定义了十二个离散的加工区Z1-Z12，其中配置第一混合区170(用于比较高的捏合和剪切)的前六个加工区Z1-Z6和第二混合区172的后六个加工区Z7-Z12用于比较低的剪切和混合。本发明各实施方案中使用的高温和低温列于表A-1中，虽然比所列的那些更高或更低的温度是在考虑范围内的。如表A-1中所述，基础聚合物190在沿这些加工区的前四个(即Z1-Z4)输送时被加热到约30℃至约240℃的温度，并在退出第一混合区170之前逐渐冷却，从而形成充分混合的熔融塑料材料。在工艺中的该点时，熔融材料是基础聚合物即高密度聚乙烯和添加剂的复合物。
还可以添加其它材料，如填充材料(木材或天然纤维)和着色剂以达到所需的物理性能和外观效果。木材或天然纤维给予所得的WPC所需的硬度、刚性、外观或商业化成功的产品所需的其它性能。颜色是为了外观效果。
再参考图3和4，通过一个或多个第二侧喂料器160向挤出机102计量供给大多数天然纤维192，例如木纤维、大麻纤维、洋麻、蕉麻、黄麻、磨碎的稻壳以及一种或多种添加剂与熔融聚合物材料混合。在第六加工区Z6最近的一个区域将天然纤维192和任选的添加剂194引入到挤出机102中。然后，当通过第二(比较低的剪切)混合区域172运送熔融基础材料190时，纤维192和添加剂/着色剂194与熔融基础材料190混合。当沿着约第十加工区Z10运送熔融复合物时，首先在大约29英寸汞柱的真空下将其压缩。然后，允许材料膨胀，使水分上升至外表面蒸发。然后在大约25至大约29英寸汞柱的真空下再次压缩该材料。当向挤出模具运送材料时，该过渡区Z10移除水分。如上面更详细描述的选择螺杆段116以提供纤维192在复合材料190中的高分布，而同时抑制着色剂194与复合材料的过度混合。在该实施方案中，以约4001b/hr以下至约20001b/hr以上的速率向挤出机102计量供给天然纤维192。可以在这一点上引入到挤出机中的添加剂通常在数量上更小，在51b/hr至约501b/hr的范围内。例外的是成型机和/或刀具修剪，其可以以约501b/hr至约3001b/hr的速率添加以及回收的地毯废弃物，其可以以约501b/hr至约5001b/hr的速率添加。回收的地毯废弃物可以是颗粒的形式，如美国专利申请公开No.2008/0128933中描述的，其公开内容整体并入本文作为参考。
通过可编程逻辑控制器180控制所有用于主进料口和第二进料口的喂料器。此外，控制器180也控制共挤出机300和相关组件、以及下游组件(例如钳子318、锯320等)。控制每种添加材料的量以控制最佳配方，允许使用特定数量的特定材料来控制挤出复合产品的物理性能。
当沿着第二混合区域172向挤出模具140运送复合材料时，将复合材料从离开第一混合区域170时的温度逐渐冷却到约170℃至约180℃的温度。此冷却允许纤维192在不被加工温度烧毁或破坏的情况下与熔融复合材料190混合。为了迫使材料通过模具，当从Z11区向Z12区运送材料时，压缩材料，从而使得压力增长，例如在挤出机出口处为约7bar至约30bar之间，在熔体泵出口处增加至10bar至80bar。在一个实施方案中，适配器和熔体泵位于挤出系统100的末端126。熔体泵平衡系统100内的挤出材料的压力。表A-1也描述了熔体泵处材料的温度范围和压力范围。然后将复合材料喂入Y形块适配器(如果存在)，在那里将复合材料加热至165℃的温度并分成两种独立的流体，迫使其通过挤出模具140的相应挤出口142a、142b以形成一对将与面料共挤出的挤出复合型材。共挤出模具312位于每一个挤出模具140的出口面140a、140b(如图6中所示)上，下文将作更详细的描述。类似地，模具的内部压力取决于挤出是在一个模具还是排列的两个模具上完成。
图7A-7C是根据本发明的一个实施方案的共挤出模具312的多个视图。共挤出模具312是具有离散的A-D部分的层压四板模具。每一个模具部分的特定孔400调节螺栓和定位销以对齐各自的部分。模具312的每一部分定义了按一定尺寸制作以调节在F方向上流过模具312的挤出芯材料的通道402。使用两个共挤出模具。A部分的入口面固定到每一个挤出模具140的出口面140a、140b上。通过A部分的入口406将熔融面料材料引入模具312。熔融面料材料流过多个通道408。通常每一个通道408与模具312的相邻连接部分上的相应的通道408对应。例如，B部分的出口面上的通道结构基本与C部分的入口面上的通道结构对应。最终，在B和C部分之间的界面以及C和D部分之间的界面的位置410上将熔融面料材料引入挤出芯材料并且计量到通过的芯挤出物外表面上。图7C描述的扩大的局部图中更详细地显示这些位置410，如由图7A中的图7C指定的圆形透明区显示的。
制备许多可能的面料配方并测试以确定性能特点。表B-1A和表B-1B表示根据本发明制备的许多配方。以基于总配方每种组分的重量百分数的形式提供配方。由“ID#”表示具体的样品配方。样品FCI1000-FCI1013和FCI1008B利用三种酸共聚物前体中的一种和锌母料(MB)生产离聚物面料。与所有描述的配方一起使用的母料为CRYZNCON(Lot 4501)。这些样品配方中的两种是成品离聚物：样品FCI1000和Surlyn 9910，由DuPont制造。由Chevron Phillips制造的高密度聚乙烯作为产品6007HDPE/0760-01，以表中表示的百分数引入到某些离聚物样品中。也可以添加其它的添加剂，如硫酸钙、颜料和抗静电添加剂。已经观察到一些面料材料表现出吸尘的亲和性，其随后很难擦干净。相信在离聚物中可能存在未反应的酸。可以将硫酸钙(如石膏)添加到配方中以模仿灰尘与活性酸位结合。通过减少面料材料上的任何残余静电荷，抗静电添加剂也可以减少吸尘。
各样品配方的试验结果也列于表B-1A和B-1B中。为获得结果进行的ASTM标准测试如下：熔融指数测试(ASTM D-1238)、邵氏D硬度测试(ASTM D-2240)、加德纳冲击试验(ASTM D-5420)、拉伸强度试验(ASTM D-412)、伸长率试验(ASTM D-412)、和弯曲模量试验(ASTM D-790)。总之，利用成品离聚物(即Surlyn 9910和FCI 1000)的样品产生更理想的结果，可能是由于存在更少的添加剂。
Figure BDA0000080961650000181
Figure BDA0000080961650000191
Figure BDA0000080961650000201
Figure BDA0000080961650000211
表B-1B：示例性离聚物配方，Pt.2
表B-2描绘了采用百分数递增的HDPE的离聚物面料的示例性配方。也提供了(根据关于表B-1A和B-1B的上述ASTM标准测试的)性能数据。该性质指标等同于完成离子化反应的性质。一个值得关注的趋势是粘合性数据随着配方中HDPE百分数的增加而增加。
Figure BDA0000080961650000221
表B-2：离聚物/HDPE面料配方
表C-1描述了根据本发明的面料包覆的复合物配方中可以利用的各组分的范围。表C-1和本文所有的表格中提供的数据是近似值；可接受的范围可能低于和高于实际列举的那些。表B-1A、B-1B和B-2中所述的任一种离聚物配方可以用于本文所述的面料包覆的木塑复合物或单独的塑料芯中。具体而言，通过第一喂料器引入的材料可以包括HDPE颗粒(作为基础聚合物)、润滑剂和着色剂。也可以通过第一喂料器引入其它组分，例如用来替代基础聚合物中使用的至少部分HDPE颗粒的再生聚合物(粉末状或片状)、清样(repro)聚合物、和/或回收聚合物。所述再生材料是工业应用后或消费者使用后的聚乙烯材料或两者的组合。所述清样是在挤出产品的生产中产生的再加工挤出材料。所述回收聚合物可以是回收地毯废料、塑料袋、瓶等。如果需要，可以利用位于第一喂料器下游的侧喂料器引入木粉填料和其它添加剂。
Figure BDA0000080961650000231
Figure BDA0000080961650000241
表C-1：具有共挤出面料的挤出复合物的配方
已经惊奇地发现，本文所述的离聚物面料可以与WPC共挤出以生产具有改善的性能和外观特征的挤出产品，而不需要改变标准的芯木塑复合物的配方，并且可以在使用相同螺杆配置和区域参数的挤出机中加工。此外，根据表C-1的组分范围和表A-1的工艺范围制造的面料包覆的WPC的具体实例列于表D-1、D-2A和D-2B中。
表C-1表示了可以用于生产可接受的面料包覆的WPC的各组分的范围。值得注意的是，离聚物面料可以包括约1重量％至约100重量％的离聚物。离聚物面料的其它实施方案可以包括约20重量％至约80重量％的离聚物、约50重量％至约70重量％的离聚物、和约60重量％至约68重量％的离聚物。HDPE颗粒(作为基础聚合物)可以包含面料的约0重量％至约99重量％、面料的约20重量％至约80重量％、面料的约30重量％至约60重量％、和面料的约30重量％至约50重量％。其它实施方案包含面料的约32重量％至约40重量％的HDPE颗粒。利用约27.5％离聚物和约72.5％HDPE的面料配方的实施方案已经显示了特别理想的商业性质。在该最后的配方中，粘合性很高，而抗划伤性和承受损坏的能力不受影响。
此外，不同类型的润滑剂在该工艺过程中表现得同样好。例如，无论润滑剂如何配制，本发明加工可接受的单组份或组合的特种润滑剂(例如Struktol 801)与更常用的单独润滑剂组(例如硬脂酸锌、EBS蜡等)使用方法相同。在表C-1中描述的组分范围内，某些配方已经证明对商业目的而言是特别理想的。一种这样的芯材料的实施方案是约47.5％聚合物、约5％润滑剂、约1％颜料、和约46.5％木粉填料。该实施方案的面料材料是约61.5％离聚物、约34.6％HDPE颗粒、和3.9％颜料。
也已经确定配方中使用的高百分数的面料聚合物导致了粘合性的增加，甚至在保持可接受的耐候性时。图8描述了配方中HDPE的百分数与粘合强度之间的关系。值得注意的是，当HDPE增加时粘合性稳步增强，面料配方中HDPE含量超过50％时，即使有，对粘合性的提高表现得也很小。
下游的机械操作，除了挤出机模具的排列，采用配方和工艺条件方面相同的模式，原因在于，相对于没有面料包覆的木塑复合物，共挤出的面料包覆的复合物对成品的加工影响最小。该挤出产品可以用常用的活动锯或其它设备切割。同样地，挤塑板可以用标准设备成型和/或压花。在成型的情况下，可以用刀片切割机将表面外观变成沟槽或磨光的外观。这些配方也能够被热表面压花。采用内部热油系统加热压花辊表面或远红外加热系统加热辊表面并对板进行压花、或采用室温辊表面的压花辊可以压在热的共挤出表面上。
共挤出复合物配方产生相当于标准的没有面料包覆的复合物的抗弯强度和刚度。挤出和冷却后，可以对成品复合材料进行测试和检查以确保可接受的外观和几何形状。可以评估多个参数，包括视觉外观、尺寸控制、物理性质、化学性质、吸水性等。
从外观上来说，检查复合物沿边缘的裂纹或材料内部的缝隙(例如可以对复合物切割、钻孔等，以确保材料的一致性分布、面料的粘合性等)。尺寸控制检查，静态和负载时，都确定复合物是否足以抵抗变形、弯曲、或扭曲。例如可以根据ASTM-D790测试样品，以确定具体的物理化学性质，例如应力、位移、弹性模量、和载荷。
实施例
表D-1描述了根据本发明制造的三种离聚物面料包覆的WPC。芯材料包括HDPE颗粒、再加工聚乙烯、再生料(回收聚乙烯)、Struktol801、和颜料。枫木粉加入到聚合物混合物中，然后其与面料共挤出。三种样品9318A、9318B和9318C每一个的芯配方相同。每个样品包括不同的面料。三种样品都利用杜邦公司制造的37％HDPE和63％Surlyn9910的基础面料。杜邦Fusabond A和B作为粘合促进剂分别加入样品9318B和9318C中。有趣的是，样品9318A的粘合力值高于加入粘合促进剂的其它样品。这可能因为由面料材料中HDPE成分形成的键强于由添加剂形成的键。其它测试结果根据ASTM D-198测定，列于表D-1中。
对样品进行热水暴露试验，其包括将面料包覆的WPC在沸水中放置24小时并评估外观上的任何变化。另外，对样品进行浸泡/冷冻/解冻试验，其包括将面料包覆的WPC室温下在水中浸泡3小时。此后，将样品冷冻3小时，然后室温解冻长达12小时。在该试验中，室温为约68°F至约78°F。该面料包覆的样品具有很低的吸水性能，尤其与没有面料包覆的WPC相比时。例如，面料包覆的WPC在一天的热水暴露试验后表现出明显更小的水的损坏。与面料包覆的WPC不同，没有面料包覆的WPC的末端和边缘退化、磨损、并吸收水分。浸泡/冷冻/解冻试验的视觉上的结果表现出类似的差异，其中没有面料包覆的WPC经历了明显的破裂、翘弯和退化。虽然面料包覆的WPC在相同的浸泡/冷冻/解冻试验后出现了一些裂纹，但明显减少。据预计没有面料包覆的WPC能够比面料包覆的WPC保持更好的形状，因为它能向所有方向自由扩展。因此，面料包覆的WPC能够更好地承受该测试程序是令人吃惊的。
通过使用杀菌剂，在没有面料包覆的WPC的基础上改善了霉菌和霉病抗性，其只需要加入到复合物芯表面上的面料中。此外，可以使用紫外线稳定剂和氧稳定剂来保护面料化合物的染色，改善了面料包覆的WPC的老化性能。
Figure BDA0000080961650000271
表D-1：具有粘合促进剂和不具有粘合促进剂的共挤出面料包覆的材料
表D-2A和D-2B描述了根据本发明制造的六种离聚物面料包覆的WPC。除了上述表D-1相关的组分外，一些样品加入了其它组分。表D-2A和D-2B中描述的实施例使用杜邦Nucrel或杜邦Alvaloy(乙烯-乙烯醇)代替杜邦Fusabond作为粘合促进剂。此外，还列出了两个使用Struktol离聚物的实施例。值得注意的是，包括Struktol离聚物的两个配方表现出高粘合性，以至于发生面料和芯材料分离之前，面料材料开始撕裂和脱落。
Figure BDA0000080961650000281
Figure BDA0000080961650000291
表D-2A：具有粘合促进剂的共挤出面料包覆的材料
Figure BDA0000080961650000292
Figure BDA0000080961650000301
表D-2B：具有粘合促进剂的共挤出面料包覆的材料

Claims (29)

1.一种适用作建筑材料的共挤出复合物，所述共挤出复合物包含：
包含以基本上均匀的混合物形式存在的基础聚合物和天然纤维的芯；和
包含以基本上均匀的混合物形式存在的离聚物和面料聚合物的面料，
其中面料的特征在于不含天然纤维。
2.权利要求1所述的共挤出复合物，其中所述基础聚合物选自由聚丙烯、聚乙烯、HDPE、MDPE、LDPE、LLDPE、及其组合组成的组。
3.权利要求1所述的共挤出复合物，其中所述天然纤维选自由木屑、木粉、薄木片、锯木屑、亚麻、黄麻、大麻、洋麻、稻壳、蕉麻、及其组合组成的组。
4.权利要求1所述的共挤出复合物，其中所述基础聚合物包含第一聚合物，所述面料聚合物包含该第一聚合物。
5.权利要求4所述的共挤出复合物，其中所述第一聚合物是HDPE。
6.权利要求1所述的共挤出复合物，其中所述面料进一步包含添加剂。
7.权利要求6所述的共挤出复合物，其中所述添加剂包括着色剂、UV稳定剂、抗氧剂、杀菌剂和阻燃剂中的至少一种。
8.权利要求7所述的共挤出复合物，其中所述着色剂包括杂色着色剂。
9.权利要求1所述的共挤出复合物，其中所述芯包括约1重量％至约100重量％的基础聚合物。
10.权利要求9所述的共挤出复合物，其中所述芯包括约46重量％的基础聚合物。
11.权利要求1所述的共挤出复合物，其中所述面料包括约1重量％至约100重量％的离聚物。
12.权利要求1所述的共挤出复合物，其中所述面料包括约20重量％至约80重量％的离聚物。
13.权利要求1所述的共挤出复合物，其中所述面料包括约27.5重量％的离聚物。
14.权利要求1所述的共挤出复合物，其中所述面料包括约0重量％至约99重量％的HDPE。
15.权利要求1所述的共挤出复合物，其中所述面料包括约20重量％至约80重量％的HDPE。
16.权利要求1所述的共挤出复合物，其中所述面料包括约72.5重量％的HDPE。
17.权利要求1所述的共挤出复合物，其中所述面料包括大于约50重量％的HDPE。
18.权利要求1所述的共挤出复合物，其中所述面料的厚度为约0.012英寸至约0.040英寸。
19.权利要求18所述的共挤出复合物，其中所述面料的厚度为约0.015英寸至约0.020英寸。
20.权利要求1所述的共挤出复合物，其中所述面料与所述芯的至少一侧直接结合。
21.一种制造适用作建筑材料的共挤出复合物的方法，所述方法包括以下步骤：
提供基础聚合物；
提供天然纤维；
混合并加热所述基础聚合物和天然纤维以生产含基本上均匀熔融共混物的基础混合物；
提供离聚物；
提供面料聚合物；
混合和加热离聚物与面料聚合物以生产含基本上均匀的熔融共混物的面料混合物，其中面料混合物的特征在于不舍天然纤维；以及
通过模具将面料混合物共挤出到基础混合物的至少一部分上以形成共挤出型材。
22.权利要求21所述的方法，其中所述基础聚合物包含第一聚合物，所述面料聚合物包含该第一聚合物。
23.权利要求22所述的方法，其中所述第一聚合物选自由聚丙烯、聚乙烯、HDPE、MDPE、LDPE、LLDPE、及其组合组成的组。
24.权利要求22所述的方法，其中所述第一聚合物是HDPE。
25.权利要求21所述的方法，进一步包括以下步骤：
提供添加剂；以及
混合并加热所述离聚物、面料聚合物和添加剂以生产含基本上均匀熔融共混物的面料混合物。
26.权利要求25所述的方法，其中所述添加剂包括着色剂、UV稳定剂、抗氧剂、杀菌剂和阻燃剂中的至少一种。
27.权利要求21所述的方法，进一步包括冷却所述共挤出型材的步骤。
28.权利要求27所述的方法，其中冷却步骤包括将所述共挤出型材通过一种液体。
29.权利要求28所述的方法，其中所述液体包含水和冷却剂中的至少一种。
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