CN104070662A - 发泡生态包装材料的制造方法 - Google Patents

发泡生态包装材料的制造方法 Download PDF

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CN104070662A
CN104070662A CN201310098097.XA CN201310098097A CN104070662A CN 104070662 A CN104070662 A CN 104070662A CN 201310098097 A CN201310098097 A CN 201310098097A CN 104070662 A CN104070662 A CN 104070662A
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foaming
ecological
raw material
blend step
extrusion
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李吉祥
杨奉儒
谢森芳
谢仁豪
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TRICAN CO Ltd
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    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种发泡生态包装材料的制造方法，包含原料混合步骤、混炼步骤、制粒步骤，及押出发泡步骤，原料混合步骤是将用多个原料充份混合成混合原料，混炼步骤将混合原料置于进行混炼而得到混炼材料，制粒步骤将混炼材料放入制粒机中得到多个胶粒，押出发泡步骤是将胶粒置入押出发泡机进行整形及发泡制程，在押出发泡机中将胶粒熔融，并以非化学发泡方式使熔融态胶材发泡，再押出形成发泡板材，经冷却后得到发泡生态包装材料，将可分解性高分子以降解酵素进行改质，更可与工业淀粉或生态纤维素混合，而得到具有堆肥特性的生物可分解的包装材料。

Description

发泡生态包装材料的制造方法
技术领域
本发明涉及一种包装材料，尤其是具有生物可分解，具可堆肥特性的发泡生态包装材料的制造方法。
背景技术
随着世界经济的发展，合理使用地球资源和保护生存环境日益受到全球的关注。以前在食品包装方面使用许多发泡聚苯乙烯(Expandable Polystyrene，EPS)类发泡一次性餐具，比目前大量运用的纸制品更有更好的保温保冷效果，目前在家用电器、精密仪器、电子计算机及电子组件等包装中也使用聚苯乙烯(EPS)类发泡缓冲包装材料，它是一种高分子化学合成物，其包装废弃物，不能自然降解和完全回收。随着全球贸易的一体化及各国对环境问题的高度重视，这些不能自然降解和回收利用的缓冲包装材料的应用将受到越来越大的限制，最终将被淘汰。EPS对环境会造成严重的污染且EPS的主要来源是石油，而石油是不可再生资源，所以原料的来源也有所限制。
EPS发泡塑料制品是污染环境的主要产品之一，面临淘汰大势所趋。目前主要的替代产品是纸浆模塑防震内衬包装制品，但由于其制品过于致密，抗震耐冲击性能大大低于EPS材料，该产品的抗震耐冲击性能主要是藉由制品的几何结构，由于受到模具结构及加工的影响，制品的发展受到很大的限制，只能制作小型包装衬垫，而目前大型家电产品的包装衬垫及填充仍然采用EPS发泡塑料制品。同时，由于纸浆模塑成本比EPS制品的成本要高，因而也极大地限制了纸浆模塑制品的发展。
此外，如台湾专利证书号I318996、公开号200716708的前案中，虽然涉及生物可分解的聚乳酸树脂，但都未涉及发泡的领域，而使得在做为缓冲材料尚不能取代EPS，而台湾专利证书号I280869虽然涉及发泡领域，但未说明自然纤维及非化学的发泡方式，在制程上仍有环境污染的疑虑。
因此，研发与应用具有良好的环境兼容性的绿色缓冲包装材料，同时在制程中使用无污染的制程方式以取代EPS，来进行保护环境和节约资源己成为21世纪的必然趋势。
发明内容
发明的主要目的在于提供一种发泡生态包装材料的制造方法，该方法包含原料混合步骤、混炼步骤、制粒步骤，以及押出发泡步骤，原料混合步骤是将用多个原料充份混合而得到一混合原料，混炼步骤是将混合原料置于捏合机以80～100℃，进行混炼一至三小时，而得到一混炼材料，制粒步骤将该混炼材料放入一制粒机，而得到多个胶粒，而押出发泡步骤是将所述胶粒置入一押出发泡机进行整形及发泡制程，在该押出发泡机中将所述胶粒熔融成一熔融态胶材，并通入二氧化碳或氮气，以非化学发泡方式使得熔融态胶材发泡，并押出而形成一发泡板材，经冷却后就得到一发泡生态包装材料。
其中所述原料包含至少可分解性高分子、降解酵素、界面兼容剂，以及添加剂，更进一步还可添加生态纤维素及/或工业淀粉。
利用将可分解性高分子以降解酵素进行改质，更可藉由与工业淀粉或生态纤维素进行混合，而能够得到具有堆肥特性的生物可分解的包装材料，且具有良好的机械性质，可作为包装缓冲材料、包装容器、包装支撑材料等用途，提供了环境的友善、永续的包装材料。
附图说明
图1为本发明发泡生态包装材料的制造方法的流程图。
其中，附图标记说明如下：
S1发泡生态包装材料
S10原料混合步骤
S11第一混合步骤
S13第二混合步骤
S20混炼步骤
S30制粒步骤
S40押出发泡步骤
具体实施方式
以下配合图式及组件符号对本发明的实施方式做更详细的说明，使熟习本领域的技术人员在研读本说明书后能据以实施。
参阅图1，本发明发泡生态包装材料的制造方法的流程图。如图1所示，本发明发泡生态包装材料的制造方法S1包含原料混合步骤S10、混炼步骤S20、制粒步骤S30以及押出发泡步骤S40。原料混合步骤S10是将用以制备生态包装材料的原料充份混合，该原料包含可分解性高分子、生态纤维素、降解酵素、工业淀粉，进一步地该原料还包含如界面相容剂、发泡成核剂等添加剂。
原料混合步骤S10进一步包含第一混合步骤S11以及第二混合步骤S13，第一混合步骤S11将可分解性高分子80～120phr、生态纤维素0-50phr、降解酵素15～25unit/g加入一混合机以250～350rpm混合30分钟，而到一前处理混合材料，第二混合步骤S13将该前处理混合材料改置于一搅拌槽，并依序加入工业淀粉0-50phr、界面兼容剂15～25phr以及添加剂以15～30rpm搅拌100分钟，而得到一混合原料，其中该可分解性高分子至少包含聚乳酸树脂，该界面兼容剂至少包含聚乙烯醇，该添加剂至少包含硅酸盐类3phr及碳酸盐类5phr，而生态纤维素是指产自纸浆的纤维素(cellulose from pulp)，或其它的生态纤维，如甘蔗渣、棕梠渣、木屑等。而降解酵素包含淀粉支切酵素(Isoamylase)以及支链淀粉酶(Pullulanase)的至少其中之一。
混炼步骤S20是将该混合原料，置于一捏合机进行原料混炼程序，该混炼的温度为80～100℃，进行时间为一至三小时，而得到一混炼材料。制粒步骤S30是将该混炼材料放入一制粒机，而得到多个胶粒，该制粒过程的是将该混炼材料以ψ160mm单轴押出，并以五段温度不同料筒，例如80℃/90℃/150℃/160℃/160℃，在以15～30rpm的转速使得混炼材料形成平均粒径3～6mm的胶粒。
押出发泡步骤S40是将所述胶粒置入一押出发泡机进行整形及发泡制程，押出发泡机中是以两支排列直角型螺杆进行，第一支螺杆以高温，而使得胶粒均匀熔融成一熔融态胶材，而第二支螺杆进行搅拌时，通入二氧化碳或氮气，以非化学发泡方式使得熔融态胶材发泡，并藉由押出使得发泡后的胶材成形成一发泡板材，该发泡板材冷却后就得到所需的发泡生态包装材料。
以下以表1中的实例1-6来说明本发明发泡生态包装材料的制造方法所制作出的生态包装材料，而表2显示传统EPS与实例1-6物性测试的比较结果。
[表1]
[表2]
由表2可知，实例1-6的发泡生态包装材料板材经过23℃*55%RH标准条件静置3天后，进行物性测试分析，与商用EPS发泡体比较，所有生态材料发泡体可堆肥性皆可达到ASTM D6400-99标准，远胜于EPS；所有生态材料发泡体尺寸变化率皆可达到CNS10132标准，优于EPS；压缩强度符合CNS10132标准。
本发明的技术特点在于，利用将可分解性高分子以降解酵素进行改质，在藉由与工业淀粉或生态纤维素进行混合，而能够得到具有堆肥特性的生物可分解的包装材料，且具有良好的机械性质，可作为包装缓冲材料、包装容器、包装支撑材料等用途。由于本发明所用的聚乳酸来自非食用的基因改良玉米作物，以及已有百年运用历史的工业淀粉和生态纤维素，都是资源最为丰富的天然高分子，自然循环生生不息，没有与民争食的议题，而能替代石油为基质的传统塑料，并可导入环保型包装材料，降低我国消费性电子产品外销的环保压力在生产过程中，制程中不使用化学类发泡剂，不会对大气及环境造成污染，因而在制程及最后终端的产品具有不污染环境、制作工艺简单、成本低廉、原料来源广与性能佳等优点。更可达到降低全球温室效应气体排放以及资源永续利用的目的。
以上所述仅为用以解释本发明的较佳实施例，并非企图据以对本发明做任何形式上的限制，是以，凡有在相同的发明精神下所作有关本发明的任何修饰或变更，皆仍应包括在本发明意图保护的范畴。

Claims (8)

1.一种发泡生态包装材料的制造方法，其特征在于，包含：
一原料混合步骤，是将用多个原料充份混合而得到一混合原料；
一混炼步骤，将该混合原料置于一捏合机以80～100℃，进行混炼一至三小时，而得到一混炼材料；
一制粒步骤，将该混炼材料放入一制粒机，而得到多个胶粒；以及
一押出发泡步骤，将所述胶粒置入一押出发泡机进行整形及发泡制程，在该押出发泡机中将所述胶粒熔融成一熔融态胶材，并通入二氧化碳或氮气，以非化学发泡方式使得熔融态胶材发泡，并押出而形成一发泡板材，经冷却后就得到一发泡生态包装材料，
其中所述原料包含至少可分解性高分子80～120phr、降解酵素15～25unit/g、界面兼容剂15～25phr、以及添加剂1～10phr。
2.如权利要求1所述的方法，其特征在于，所述原料还包含一生态纤维素0～50phr及一工业淀粉0～50phr。
3.如权利要求2所述的方法，其特征在于，该可分解性高分子至少包含聚乳酸树脂，该界面兼容剂至少包含聚乙烯醇，该生态纤维素包含产自纸浆的纤维素、甘蔗渣、棕梠渣、木屑的至少其中之一，该降解酵素包含淀粉支切酵素(Isoamylase)以及支链淀粉酶(Pullulanase)的至少其中之一，以及该添加剂至少包含硅酸盐类3phr及碳酸盐类5phr。
4.如权利要求1所述的方法，其特征在于，该原料混合步骤包含一第一混合步骤以及一第二混合步骤，该第一混合步骤将该可分解性高分子及该降解酵素加入一混合机以250～350rpm混合30分钟，而到一前处理混合材料，而该第二混合步骤将该前处理混合材料改置于一搅拌槽，加入该面兼容剂以及该添加剂以搅拌100分钟。
5.如权利要求4所述的方法，其特征在于，在第一混合步骤中还包含一生态纤维素0-50phr，而在该第二混合步骤中还包含一工业淀粉0-50phr。
6.如权利要求1所述的方法，其特征在于，所述胶粒的平均粒径为3～6mm。
7.如权利要求1所述的方法，其特征在于，该制粒步骤将该混炼材料以ψ160mm单轴押出，并以80℃/90℃/150℃/160℃/160℃五段温度不同料筒，以15～30rpm使得该混炼材料形成所述胶粒。
8.如权利要求1所述的方法，其特征在于，该押出发泡机是以一第一支螺杆以高温将所述胶粒均匀熔融成该熔融态胶材，并以一第二支螺杆搅拌，同时通入二氧化碳或氮气，以非化学发泡方式使得该熔融态胶材发泡。
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