Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D7/00—Producing flat articles, e.g. films or sheets
  • B29D7/01—Films or sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
  • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
  • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
  • B29K2105/0044—Stabilisers, e.g. against oxydation, light or heat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0264—Polyester
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
  • B32B2307/102—Insulating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/304—Insulating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/306—Resistant to heat
  • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/54—Yield strength; Tensile strength
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/71—Resistive to light or to UV
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/712—Weather resistant
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/726—Permeability to liquids, absorption
  • B32B2307/7265—Non-permeable
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof

Definitions

• the present invention relates to outdoor building materials in general
• the main requirements for outdoor building materials can be any type of materials.
• temperature is the temperature range in which the material is stable
• wood board is corrosive, water-sensitive, and has
• wood is not considered environmentally friendly
• Anti-corrosive coatings used on steel are impact- and
• Fiberglass sheets are brittle, and have low impact resistance, bad UV
• Asbestos cement sheets are brittle, corrosive and biodegradable (i.e.
• PVC sheets are generally only suitable for use in light colors and in medium temperature climates. Clear PVC sheets suffer from low impact resistance and low UV resistance unless special modifiers are used.
• Japanese Patent 8,183,054 assigned to JSP Corp. of Japan describes a flat, foamed polycarbonate sheet. Furthermore, commercially available sheets of PC laminated with acrylic are produced by Tsutsunaka Plastic of Tokyo, Japan.
• PC polycarbonate
• PC polycarbonate
• the second PC layer includes UV-resistant material.
• the sheet is one of a group including: a flat sheet, a corrugated sheet and a multi-wall sheet.
• the rigid PC sheet further includes a third PC layer co-extruded with the foamed PC layer on the side opposite to the second PC layer.
• the third PC layer includes UV-resistant material.
• the rigid PC sheet further includes a third PC layer co-extruded with the second PC layer on the side opposite to the foamed PC layer.
• the third PC layer includes UV-resistant material.
• present invention a method for production of a rigid polycarbonate (PC) sheet, the
• the second PC material forms a layer on the first PC material.
• the step of foaming includes adding a chemical blowing agent to the
• the step of foaming includes adding a liquid blowing agent to the first
• the step of foaming includes injecting liquefied gases at sufficiently high
• the step of foaming includes adding a chemical blowing agent to the
• the method includes at least one additional step of thermoforming the
• thermoforming is performed on-line or off-line.
• a sheet material for outdoor building use comprising a foamed PC layer, and a second PC layer co-extruded with the foamed PC layer.
• the second PC layer includes UV-resistant material.
• the sheet is one of a group including: a flat sheet, a corrugated sheet and a multi-wall sheet.
• the thickness of the foamed PC layer is 1 - 10 millimeters, and the thickness of the second PC layer is 25 - 100 microns.
• Fig. 1 A is a schematic cross-section illustration of a flat polycarbonate
• Fig. 1 B is a schematic cross-section illustration of a corrugated polycarbonate (PC) sheet, according to a further preferred embodiment of the present invention
• Fig. 2 is a block diagram illustration of a system for the production of a polycarbonate (PC) sheet, according to a preferred embodiment of the present invention
• Fig. 3 is a schematic flowchart of the operation of the system of Fig. 2;
• Figs. 4 and 5 are graphs of results of an accelerated weathering test on a PC sheet, according to a preferred embodiment of the present invention.
• Fig. 6 is a table of results of a heat insulation test on a PC sheet, according to a preferred embodiment of the present invention.
• Fig. 1A is a schematic illustration of a cross-section of a flat polycarbonate (PC) sheet 10, according to a preferred embodiment of the present invention.
• the polycarbonate (PC) sheet 10 comprises a rigid bulk foamed PC sheet 12 and a rigid skin layer 14 of UV protective PC.
• the skin layer 14 is applied via co-extrusion, but it will be apparent to those skilled in the art that any other suitable method for applying the skin layer may be utilized.
• the skin layer 14 of UV protective PC has a thickness of 30 microns.
• a PC sheet for outdoor building is preferably composed of a 30-micron layer of UV protective PC and a 2-mm layer of foamed PC.
• the PC sheet 10 is shown as being flat, having been extruded through a flat sheet die. It will be appreciated that any shape of sheet may be produced, depending on the die used.
• Fig. 1 B is a schematic illustration of a cross-section of a corrugated polycarbonate sheet.
• the flat polycarbonate sheet 10 of Fig. 1 has been thermoformed into a corrugated sheet.
• the foamed PC sheet 12 and the skin layer 14 are thermoformed together into a corrugated sheet.
• thermoforming may be used to transform the flat PC sheet 10 of Fig. 1 into complex or small size articles, such as, but not limited to, multi-wall sheets, roof ridges, roof tiles, flashings and accessories.
• Fig. 2 is a block diagram illustration of a system for the production of a polycarbonate (PC) sheet, according to a preferred embodiment of the present invention.
• the system comprises an extruder 20, a co-extruder 22, a flat sheet extrusion die 24, a thermoformer 26, an edge trimmer 28, a cross cutter 30 and a stacker 32.
• a polycarbonate (PC) material 34 is fed (step 100) into the extruder 20.
• a foaming agent 36 such as a chemical blowing agent
• step 102 is fed (step 102) with the PC material 34 into the extruder 20.
• foaming agents can be used, for example, but not limited to, liquid blowing agents, which are chemicals that decompose at the extrusion temperatures and release a gas that causes foaming.
• the foaming could be achieved by using "physical blowing", which is the injection of water or liquefied gases, such as, but not limited to, C0 2 and N 2 . In this embodiment, no chemical reaction is used to cause the foaming.
• the PC material already contains the chemical blowing agent, and the addition of a blowing agent on-line can be omitted.
• a special PC compound 38 with increased UV resistance properties is fed (step 104) into the co-extruder 22. Proximate the exit of extruder 20, the UV protective PC compound 38 is combined (step 106) with the PC material 34 into a melt. This process, known as skin layer UV co-extrusion, is well known in the art.
• the melt consisting of the PC material 34 and the UV protective PC compound 38 is forced (step 108) through the flat sheet extrusion die 24.
• the PC material 34 foams due to the expansion of the gas released by the foaming agent 36.
• the UV protective PC compound 38 does not foam.
• the melt is then solidified (step 110) into a flat sheet.
• the flat sheet can be used as is or can be further thermoformed either on-line or off-line.
• On-line thermoforming into corrugated sheets and multi-wall sheets is the preferred method for sheets for building.
• Off-line thermoforming of more complex or small size articles is the preferred method for producing roof ridges, roof tiles, flashings and accessories.
• the flat sheet is passed (step 112) through the thermoformer 26.
• the corrugated (or flat) sheet is trimmed (step 114) by the edge trimmer 28, cut (step 116) to its final size by the cross cutter 30 on-line and stacked (step 118) by the stacker 32 on pallets for shipment.
• PC sheet comprising foamed PC and a skin layer of UV protective PC make it suitable for use as an outdoor building material. It is well known in the art that PC is resistant to fungus, microorganisms, humic acids and termite attack. It is also known that PC is water-resistant and impermeable. PC can be colored internally, with no need to paint or coat. PC is suitable for contact with food. Furthermore, since no hazardous materials are used in the production or disposal of PC, and since it is fully recyclable, PC is an environmentally friendly material. Another advantage of PC is that its service
• the skin layer of UV protective PC provides UV and weathering
• the test exposes materials to alternating cycles of light
• the PC sheet retains its mechanical properties after 1500 hours of QUV exposure.
• PC being a plastic
• PC is non-corrosive
• present invention is ductile and resilient, as well as resistant to hail and wind.
• Fig. 6 is a table of results of a heat insulation test conducted by the Standards Institution of Israel on a PC sheet according to a preferred embodiment of the present invention.
• the standard test (ASTM-C 177-85) was conducted on two PC sheets of approximately 30x30x3 cm, and it was found that the PC sheet has good heat insulation due to its foam structure.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=22250096

Family Applications (1)

Country Status (5)

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Family Cites Families (3)

• 1999
  • 1999-07-27 WO PCT/IL1999/000411 patent/WO2000007812A1/en not_active Application Discontinuation
  • 1999-07-27 NZ NZ509906A patent/NZ509906A/en unknown
  • 1999-07-27 AU AU49280/99A patent/AU764956B2/en not_active Ceased
  • 1999-07-27 EP EP99933112A patent/EP1117525A1/de not_active Withdrawn
  • 1999-07-27 CA CA002339264A patent/CA2339264A1/en not_active Abandoned

Non-Patent Citations (1)

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