GB2288143A - Plastics extrusions and method of extrusion thereof - Google Patents

Plastics extrusions and method of extrusion thereof Download PDF

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Publication number
GB2288143A
GB2288143A GB9505826A GB9505826A GB2288143A GB 2288143 A GB2288143 A GB 2288143A GB 9505826 A GB9505826 A GB 9505826A GB 9505826 A GB9505826 A GB 9505826A GB 2288143 A GB2288143 A GB 2288143A
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GB
United Kingdom
Prior art keywords
extrusion
polyvinyl chloride
thermoplastics
polystyrene
stabilised
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB9505826A
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GB9505826D0 (en
Inventor
Julian Cubitt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Anglian Windows Ltd
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Anglian Windows Ltd
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Filing date
Publication date
Application filed by Anglian Windows Ltd filed Critical Anglian Windows Ltd
Publication of GB9505826D0 publication Critical patent/GB9505826D0/en
Publication of GB2288143A publication Critical patent/GB2288143A/en
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/17—Articles comprising two or more components, e.g. co-extruded layers the components having different colours
    • B29C48/175—Articles comprising two or more components, e.g. co-extruded layers the components having different colours comprising a multi-coloured single component, e.g. striated, marbled or wood-like patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/908—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article characterised by calibrator surface, e.g. structure or holes for lubrication, cooling or venting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/916—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means using vacuum
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C08J9/08—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04—Particle-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/904—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article using dry calibration, i.e. no quenching tank, e.g. with water spray for cooling or lubrication
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9115—Cooling of hollow articles
    • B29C48/912—Cooling of hollow articles of tubular films
    • B29C48/913—Cooling of hollow articles of tubular films externally
    • 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
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds 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
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • 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
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/043—Skinned foam
    • 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
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/065—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts containing impurities
    • 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
    • B29K2105/26—Scrap or recycled 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0016—Non-flammable or resistant to heat
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
    • C08J2325/02—Homopolymers or copolymers of hydrocarbons
    • C08J2325/04—Homopolymers or copolymers of styrene
    • C08J2325/06—Polystyrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2427/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Abstract

A thermoplastics product which can be used as a timber substitute comprises a mixture of polystyrene and pre-stabilised polyvinyl chloride, preferably recycled polyvinyl chloride, which has been die extruded and foamed to form a product of cross-section of predetermined size and shape, rendered fire retardant due to the presence of the chlorine in the polyvinyl chloride.

Description

Plastics Extrusions and Method Extrusion thereof This invention relates to plastics extrusions and to a method of production thereof.
It is a principal aim of the invention to provide a plastics extrusion which can be employed as a substitute for timber.
According to a first aspect of the invention, there is provided an extruded and foamed extrusion of ffiermoplastics materials which comprise polystyrene and prestabilised polyvinyl chloride, the extrusion having a cross-section of predetermined shape and size and being rendered fire-retardant, at least in part, by the presence of chlorine contained in the polyvinyl chloride.
According to a second aspect of the invention, there is provided a method of producing a thermoplastics extrusion having a cross-section of predetermind shape and size, according to which a blend of thermoplastics materials comprising polystyrene and pre-stabilised polyvinyl chloride present in a sufficient proportion to render the extrusion fire retardant, together with a blowing agent, is die extruded and then foamed, sized and shaped in a calibrating means.
The extrusion may comprise at least 50 per cent polystyrene by weigh. Up to about 40 per cent pre-stabilised polyvinyl chloride by weight may be employed to impart fire retardance. The amount of polyvinyl chloride incorporated may be dependent on the standard of fire performance required of the final product.
The pre-stabilised polyvinyl chloride is preferably recycled polyvinyl chloride obtained from waste in the manufacture of other PVC products. Recycled PVC powder or flake obtained from PVC bottle waste is especially suitable. The polystyrene employed in manufacture of the extrusion may also be recycled material, at least in part. It may also be possible to employ waste from polyvinyl chloride wall coverings, provided the residual wood fibre content is relatively small, i.e. less than 20 per cent.
An initial blend of polystyrene and pre-stabilised polyvinyl chloride may also include the blowing agent, which alternatively may be added later, andlor an ultraviolet stabiliser andlor colouring pigments, and additional fire retardant agent if a very high standard of fire performance is required.
Moreover, it is preferable for the product extrusion step to be preceded by a compatibilising step, wherein the polystyrene and pre-stabilised polyvinyl chloride are compafilised by combination with a suitable compaiibiliser. his is important to avoid laminating of the final product. The compatibilising step may comprise die extruding a blend of polystyrene, pre-stabilised polyvinyl chloride and compatibiliser to form pellets. The pellets will then be used as the starting material for the product extrusion step.
At a point downstream from entry of the raw material to the barrel of the product extruder, it may be convenient to add a streaker, intermittently andlor in varying amounts appropriately to "pattern" the final product. In this way, taken in conjunction with the colouring pigment or pigments, it is possible to produce an extrusion which will resemble natural timber. However, the invention is by no means restricted to tbe production of an extrusion which resembles natural timber in appearance. It may be deseed, for example, to produce an extrusion which resembles painted timber in nce.
In the method of production of the extrusion, the blend of polystyrene and pre stabilised polyvinyl chloride, which may have been first compatibilised, may be subject to beating and application of shear forces in the die unit. This may be achieved, in known manner, by driving the product through the actual die by use of a screw, whilst applying heat.
As the extrusion melt leaves the die it may have a hollow cross-section, the calibrating means being such as to enable inward foaming to take place. In most kaown foamed extrusion processes employing polystyrene, it is usual to employ outward foaming of the melt. The inward foaming results in a fiaished extrusion of cross-section which is slightly denser on the surface than in the centre.
However, the possibility of outward foaming is not exuded from the invention.
Especially but not only in the latter case, the crss-section of the product may be hollow. This may readily be achieved by use of a die having centalcoreor mandrel, extended into the region in which foaming takes place. A hollow cross- section permits interior reinforcement to incowred, ifdesired.
The calibrating means is subject to cooling, and beyond this calibrating means are provided means for pulling out the final product.
An extrusion and method of production thereof in accordance with the invention are exemplified in the following description, making reference to the accompanying drawing, the single figure of which sbows the production method diagrammatically.
Referring to the drawing, the actual step of foam extruding the timber substitute may be preceded by a step in which polystyrene, which may at least in part be recycled polystyrene, sod pre-stabilised polyvinyl chloride, for example recycled polyvinyl chloride obtained from waste, typically polyvinyl chloride bottle waste in the lorin of flakes or powder, are compatibilised at a compatibiliser 10. In this step, the polystyrene and pre-stabilised polyvinyl chloride, together with pigment and a suitable compatibiliser, are extruded into a pelletised form.
The blend of polystyrene and polyvinyl chloride, possibly ia the approximate proportions by weight of 60 : 40, and generally but not essentially first compatibilised as aforesaid, is supplied at 12 to the hopper 14 of an extruding unit 16, together with a blowing agent 18. Optiona- a streaker material 20 may be intermittently and variably added under the control of a timer 22, at an intermediate point of the cxtruder barrel.
In the extruding unit 16, the mixture of materials is subject to elevated tempo control by heating and cooling device 24 and shear forces applied by mass Of a rotating screw 26, generally in known manner.
The material in flowable form is thereby driven through the extruding die 28, which extrudes a cross-section of the material directly into a sizing unit or calibrator 30. In the calibrator, the extrusion foams inwardly owing to the presence of the blowing agent, such as sodium bicarbonate, in the mixture.
Additionlly, the calihrator 30 is subject to cooling 32 and, as the extrusion passes through the unit, it is externally sized and shaped, possibly with the aid of application of a vacuum, and hardens to emerge as a rigid product 34 which can be utilised as a substitute for timber. A pulling means applies tension to the finished product to haul it from the calibrator.
The timber substitute product 34 has a slightly greater density on the surface than at the centre, but a mean density and tensile strength can be achieved of the same order as that of some kinds of timber. By use of one ot ODe Orincreappropriate pigments and appropriate addition of the streaker, it is also possible to achieve a natural timber-like appearance of the finaö product, although this is not necessarily an essential requirement. Far emple, a product resembling painted timber may be required. Shaping and sizing in the calibrator enables a wide variety of timber substitute products to be produced. Although including polystyrene, the product is a fire-retardant matetrial owing to the presence of the chlorine in the pre stabilised polyvinyl chloride which has been foam extruded with the polystyrene.
If desird, the product may be extruded with a hollow centre, for which purpose the die is provided with a core mandrel which extends into the calibrator in which foaming takcs place. The final product may then include metal reinforcement inserted into the hollow extrusion.

Claims (1)

  1. Claims 1. An extruded and foamed extrusion of thermoplastics materials which comprise polystyrene and pre-satbilised polyvinyl chloride, the extrusion having a crosssection of predetermined shape and size and being rendered fire retardant by the presence of the chlorine contained in the polyvinyl chloride.
    2. A thermoplastics extrusion according to claims 1, wherein the content of polystyrene is at least 50 per cent by weight 3. A thermoplastics extrusion according to claim 1 or claim 2, wherein the content of pre-stabilised polyvinyl chloride is ep to 40 per ctct by weight.
    4. A thermoplastics extrusion according to claim 3, wherein ttre pre-stabilised polyvinyl chloride is recycled waste polyvinyl dbloride.
    5. A thermoplastics extrusion according to claim 4, wherein the recycled polyvinyl chloride is a powder or flake obtained from polyvinyl chloride bottle waste.
    6. A thermoplastics extrusion according to any of claims 1 to 5, wherein the polystrene, at least in part, is recycled polystyrene.
    7. A thermoplastics extrusion according to any of claims I to 6, also including an ultra violet stabiliser.
    8. A thermoplastics extrusion according to any of claims 1 to 7, also including a colouring pigment or pigments.
    9. A thermoplastics extrusion according to any of claims 1 to 8, also including surface pattrning formed by a streaker material introduced at a point downstream of the entry of the raw material into the extruder barrel.
    10. A thermoplastics extnision according to any of claims 1 to 9, in which the melt leaves the die as a hollow cross-section and is inwardly foamed in a calibrating means which determines the cross-sectional size and shape of the extrusion.
    11. A thermoplastics extrusion according to claim 10, which constitutes a fire retardant timber substitute.
    12. A method of producing a Ihermopiastics extruion having a cross-section of predetermined shape and size, accoridng to which a blend of thermoplastics materials comprising polystyrene and pre-stabilised polyvinyl chloride present in a sufficient amount to render the extrusion fire retardant, together with a blowing agent, is die extruded and then foamed, sized and shaped in a calibrating means.
    13. A method according to claim 12, including a preliminaiy step in which the polystyrene and pre-stabilised polyvinyl chloride are compatibilised 14. A method according to claim 13, in which the polystyrene and pre-stabilised polyvinyl chloride are stabilised by mixing the thermoplastics materials with a compatibiliser and extruding the mixture through a pellet-forming die.
    13. A method according to any of claims 12 to 14, wherein, at a point downstream of entry to the barrel of the product extruding means, a streaker material is added to the mixture.
    16. A method according to claim 13, in which the addition of streaker material is intermittent.
    17. A method according to claim 16, in which the addition of streaker material is timer controlled.
    18. A method according to any of claims 12 to 17, in which the extrusion melt of thermoplastics materials leaves the die as a hollow cross-section and the thus extruded material is inwardly foamed in a calibrating means which shapes and sizes the extruded product.
    19. A method according to claim 18, in which, preceding the die, the blend of thermoplastics materials is subject to application of both beat and shear forces.
    20. A method according to claim 19, wherein the extruded material is cooled on passage through the calibrating means.
    21. A method according to any of claims 12 to 20, wherein the pre-stabilised polyvinyl chloride employed is recycled polyvinyl chloride.
    22. A hod according to claim 21, wherein the recycled polyvinyl chloride is recycled polyvinyl chloride bottle waste.
    23. A method according to any of claims 12 to 22, wherein the die has an extended mandrel such that the extension is formed with a hollow core.
    24. A method according to claim 23, wherein metal rtinforcement is inserted into the hollow extrusion.
    25. A method substantially as hereinbefore described with reference to the accompanying drawing.
    26. A thermoplastics extrusion produced by the method of any of claims 12 to 25.
GB9505826A 1994-03-24 1995-03-22 Plastics extrusions and method of extrusion thereof Withdrawn GB2288143A (en)

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GB9405864A GB9405864D0 (en) 1994-03-24 1994-03-24 Plastics extrusions and method of extrusion thereof

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GB2288143A true GB2288143A (en) 1995-10-11

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WO2007024682A2 (en) * 2005-08-22 2007-03-01 Owens Corning Intellectual Capital, Llc Deformable, polystyrene, foam board
US8999279B2 (en) 2008-06-04 2015-04-07 Carbon Sink, Inc. Laminar flow air collector with solid sorbent materials for capturing ambient CO2
US9266052B2 (en) 2006-10-02 2016-02-23 Carbon Sink, Inc. Method and apparatus for extracting carbon dioxide from air
US9527747B2 (en) 2008-02-19 2016-12-27 Carbon Sink, Inc. Extraction and sequestration of carbon dioxide
US9616375B2 (en) 2007-04-17 2017-04-11 Carbon Sink, Inc. Capture of carbon dioxide (CO2) from air
US10010829B2 (en) 2005-07-28 2018-07-03 Carbon Sink, Inc. Removal of carbon dioxide from air
US10150112B2 (en) 2006-03-08 2018-12-11 Carbon Sink, Inc. Air collector with functionalized ion exchange membrane for capturing ambient CO2
US11737398B2 (en) 2018-02-16 2023-08-29 Carbon Sink, Inc. Fluidized bed extractors for capture of CO2 from ambient air

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Publication number Priority date Publication date Assignee Title
US10010829B2 (en) 2005-07-28 2018-07-03 Carbon Sink, Inc. Removal of carbon dioxide from air
WO2007024682A3 (en) * 2005-08-22 2007-11-15 Owens Corning Intellectual Cap Deformable, polystyrene, foam board
US8314161B2 (en) 2005-08-22 2012-11-20 Owens Corning Intellectual Capital, Llc Deformable, rigid polystyrene foam board
US8524792B2 (en) 2005-08-22 2013-09-03 Owens Corning Intellectual Capital, Llc Deformable, rigid polystyrene foam board
US9150719B2 (en) 2005-08-22 2015-10-06 Owens Corning Intellectual Capital, Llc Deformable, rigid polystyrene foam board
WO2007024682A2 (en) * 2005-08-22 2007-03-01 Owens Corning Intellectual Capital, Llc Deformable, polystyrene, foam board
US10150112B2 (en) 2006-03-08 2018-12-11 Carbon Sink, Inc. Air collector with functionalized ion exchange membrane for capturing ambient CO2
US9266052B2 (en) 2006-10-02 2016-02-23 Carbon Sink, Inc. Method and apparatus for extracting carbon dioxide from air
US9861933B2 (en) 2006-10-02 2018-01-09 Carbon Sink, Inc. Method and apparatus for extracting carbon dioxide from air
US9616375B2 (en) 2007-04-17 2017-04-11 Carbon Sink, Inc. Capture of carbon dioxide (CO2) from air
US9527747B2 (en) 2008-02-19 2016-12-27 Carbon Sink, Inc. Extraction and sequestration of carbon dioxide
US8999279B2 (en) 2008-06-04 2015-04-07 Carbon Sink, Inc. Laminar flow air collector with solid sorbent materials for capturing ambient CO2
US11737398B2 (en) 2018-02-16 2023-08-29 Carbon Sink, Inc. Fluidized bed extractors for capture of CO2 from ambient air

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GB9405864D0 (en) 1994-05-11

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