KR101450627B1 - Forming products using natural ingredients forming method and Forming products by same the methods - Google Patents

Abstract

Disclosed are a method for forming a foamed product using a natural ingredient and a foamed product manufactured by the forming method. The forming method according to an embodiment of the present invention is a method for forming a foamed product manufacturing by extrusion or injection forming of a material mixing a dry preventing agent of 0.1-30 phr with a complex material mixing 20-80 wt% of a natural ingredient and 20-80 wt% of a high molecular resin, which sets the temperature of a barrel on the transferring side of the extruder or an injection mold and the temperature of a nozzle die of the discharging side to a predetermined temperature respectively to evaporate the dry preventing agent included in the mixed material, and has the pressure of the nozzle die of discharging side of the extruder or the injection mold is maintained to be a predetermined pressure to perform foaming of a product by expansion of evaporated dry preventing agent when the mixed material is discharged through a discharge nozzle of the extruder or the injection mold.

Description

TECHNICAL FIELD [0001] The present invention relates to a foaming product molding method using a natural material and a foaming product produced by the foaming product using the natural material,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a foamed product using a natural material and more particularly to a method for molding a foamed product using natural materials such as rice bran, rice bran, And a foamed product produced by the molding method.

In addition to being lightweight and relatively inexpensive, plastics have a variety of excellent functions such as durability, processability, and chemical resistance, and are widely used in various forms throughout the industrial field. However, plastic waste does not decompose spontaneously. Therefore, in proportion to the increase in the use thereof, a large amount of waste is generated, thereby causing a serious damage to the environment such as soil, air and water pollution.

In addition, in the case of foamed plastic, styrofoam, since it is large in volume per unit weight and lightweight, it easily blows air. Therefore, the adverse effects on environmental pollution can be considered to be greater. As a result, products using natural species or pulp molds have been put to practical use as substitutes for conventional styrofoam for buffer packing materials. However, considering the fact that pulp is imported all over the country, there is a drawback that it is economically inferior in terms of cost.

In order to solve such a problem, research and development on a biodegradable or environmentally friendly packing material for packaging using a raw material obtained from natural materials is under way. Among them, starch has been used as a substitute material for plastics because of its various advantages such as abundance of resources, ease of supply, and low price. In some cases, commercialization has been made in some cases.

To date, research and manufacturing methods for biodegradable or environmentally friendly packaging cushioning materials have included a method in which a plasticizer is added to high amylose starch (amylose content 45% or more) or derivatives thereof, followed by foam molding using an extruder (US Patent No. 4,863,655) (Japanese Patent Application Laid-open No. Hei-136168), a method of producing a starch-containing starch by adding an alcohol derivative to the starch (Japanese Patent Laid-Open No. 1316168) And a manufacturing method using the above-mentioned method.

The above methods are generally environmentally friendly compared to conventional expanded polystyrene or urethane, and the manufacturing method is relatively simple and advantageous in that no foaming gas is used. However, in the methods disclosed in the prior art, in order to facilitate high-temperature molding workability, a separate plasticizer may be added using starch as a base material or a separate foaming agent such as limestone powder or calcium chloride may be added to ensure uniformity of foaming. The cost is high and the high expansion ratio of 30 times or more can not be achieved.

Korean Patent Publication No. 2004-76149 U.S. Patent No. 7,364,788

The technical problem to be solved by the present invention is to provide a process for producing a high-expansion foam having a high expansion rate of 30 times or more by extrusion or injection molding, using a raw material such as rice husk, rice bran, horsehair, wheat bran, starch, wood flour, wood by- And to provide a method capable of molding a foamable product and a foamed product by the method.

As a means for solving the problem, an aspect of the present invention is to provide a polyolefin polymer composite material comprising 50.1 to 80 wt% of a polyolefin resin and 20 to 49.9 wt% of a natural material in an amount of 0.1 to 30 phr of a drying agent, Wherein the temperature of the transfer-side barrel and the temperature of the discharge-side nozzle die are set so that the temperature of the extruder or the injection-molding machine transfer-side barrel is 150 And the pressure of the nozzle die on the extruder or the injection-molding machine on the discharge side is set so that the foamed product can be foamed by the expansion of the dry or wetted material when the compounded raw material is discharged to the discharge nozzle of the extruder or the injection molding machine Wherein said polyolefin is maintained in the range of 5 to 20 MPa and said polyolefin is selected from polyethylene or polypropylene. It provides the law.

The unit 'phr' referred to herein is an abbreviation of per hundred resin or parts per hundreds of rubber, and means the weight of the additive added to 100 parts by weight of the polymer. That is, when 1 kg of the additive is mixed with 100 kg of the polymer, it becomes 1 phr.

In one aspect, the natural material is a bio-by-product, a starch, a wood by-product or a cellulosic material,

By-product, starch, wood by-product, or a mixture of cellulosic materials and cellulose-based natural fibers.

In addition, the natural material may be a blend of two or more selected from the group consisting of bio-by-products, starch, wood by-products, cellulose-based materials, and natural fibers.

As the biocide by-products, it is preferable that the by-product obtained by extracting the edible oil from the by-product or grain from the cereal crop and the remaining by-products are used singly or in a mixture of two or more kinds. The cellulosic natural fiber may be kenaf, May be used alone or as a mixture of two or more species, such as jute, flax, hemp, ramie, sisal, henequen, pineapple or banana leaves .

In addition, the wood by-

Each of the byproducts that can be produced from wood such as wood flour, wood chips, or the like

Or a mixture of two or more of the by-products.

In one aspect, the starch may be one or more selected from the group consisting of corn, potato, sweet potato, arrow root, and pulverized into a powder form.

In one aspect, the compounded raw material may further comprise 0 to 10 wt% of a coupling agent (compatibilizer).

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In one aspect, the drying agent is a liquid having a boiling point at or above room temperature, and may be selected from the group consisting of water, ethanol, and glycerin, or may be a liquid mixed with two or more selected.

In one aspect, the compounded raw material may further contain 0.1 to 40.0 wt% of an inorganic substance, and the inorganic substance may be calcium carbonate (CaCO ₃ ).

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The product manufactured by the molding method according to the embodiment of the present invention can be molded without addition of any additional plasticizer in order to facilitate molding workability at a high temperature and a foaming ratio of 30 times or more can be achieved, Of course, the molding process is not complicated, and the productivity and workability can be greatly improved.

In addition, it is very effective in functional aspects such as environment friendliness because it is decomposed by microorganisms and is reduced to nature, and it is recyclable as compost after use compared to conventional synthetic resin foam products.

1 and 2 are process conceptual diagrams schematically showing a foamed product molding process according to one aspect of the present invention.
3 is a photograph of a foamed product manufactured by the foamed product molding method according to one aspect of the present invention.
4 is a photograph of foamed products manufactured by the molding method according to one aspect of the present invention.
Fig. 5 is a photograph showing the appearance of the foamed product according to the mixing ratio of the natural material, the polymer resin and the paper-making agent.
6 is a photograph showing a foamed product manufactured by a molding method according to an aspect of the present invention and a utilization thereof.

Hereinafter, preferred embodiments of the present invention will be described in detail.

1 and 2 show a process conceptual diagram schematically showing a foaming product molding process according to an aspect of the present invention. Fig. 3 shows a photograph of a foam product manufactured by the molding method according to one aspect of the present invention, .

Referring to these drawings, a foamed product according to an embodiment of the present invention is obtained by mixing a natural material, a polymer resin, and a mortar with a basic composition of a by-product of biocide at a predetermined composition ratio. Further, the foamed product according to the embodiment of the present invention can be obtained through the foam molding method using the extruder of Fig. 1, which maintains a predetermined operating condition. 1, the foamed product according to the embodiment of the present invention can also be obtained through an injection molding machine.

The product molding method according to one aspect of the present invention and the manufactured product, which is another aspect, will now be described in more detail.

The raw material including the natural material can be subjected to a pre-treatment process before full blow molding by the extruder as shown in FIG. The pretreatment process includes a process of finely grinding a natural material into an appropriate size to obtain a powder form, and a process of making a raw material having a predetermined viscosity by mixing water and a small amount of physical property reinforcement in a predetermined composition ratio to pulverized powder- Mixing processes may be included.

Cellulose contained in the bio-by-products used in the present invention is a main component forming the cell wall skeleton of the cell. Specifically, D-glucose accounts for almost half of the straight-chain polysaccharide linked with? -1,4 bonds, and is the most abundant in all organic substances. It is present with hemicelluloses such as xylan, mannan and galactan, and it is tightly bound with lignin. In addition to plants, bacteria (Acetobacter xylinum) and mucus are also found in small amounts on the outer membrane.

In this embodiment, the natural material may be a bio-by-product, or a mixture of the bio-by-product and the cellulose-based natural fiber in an appropriate ratio. The by-product of bio-products may be a by-product produced in the process of cropping rice such as rice, wheat or barley, or a mixture obtained by extracting edible oil from cereals such as soybeans, and remaining by-products alone or in a mixture of two or more kinds.

Preferable examples of the biocide by-products include rice hull, rice bran, horse chestnut, wheat bran, soybean meal, and the like. And cellulosic natural fibers include kenaf, jute, flax, hemp, ramie, sisal, henequen, pineapple or banana leaves. Or a mixture of two or more of them may be adopted as the cellulose-based natural fiber.

When a raw material of a product is prepared by mixing a natural material, a polymer resin and a paper-making agent at a predetermined composition ratio, a mixture of 20 to 80 wt% of a natural material and 20 to 80 wt% of a polymer resin It is preferable that the raw material is produced by mixing the raw material in an amount of 0.1 to 30 phr with a drying agent so that the mixture is homogeneously mixed or by mixing through a mixer.

In general, as the content of the polymer resin constituting the raw material is larger, the content of the paper-making agent becomes smaller and the foaming rate of the foamed product may be reduced in a specific range, but the physical functionality such as buffering properties can be improved. Also, when a material such as PLA (poly (lactic acid)) is selected as the polymer resin, the starch can be mixed due to the low melt tension of the material, and the content of the late agent can be further reduced due to the characteristics of PLA, Therefore, the content of the natural material, the polymer resin and the paper-making agent can be variously changed depending on the desired characteristics of the foamed product and the kind of the selected polymer resin.

The polymer resin may be a polyolefin, polystyrene, or polyester based material alone or blended with two or more materials.

In another aspect, the polymer resin may be selected from the group consisting of PCL (polycaprolactone), PLA (polylactic acid), PHA (polyhydroxyalkanoate) and PBS (polybutylene succinate) Selected and blended biodegradable material.

The drying agent is not particularly limited as long as the blended raw material is a liquid material that can be foamed when the raw material is discharged to the discharge nozzle of an extruder or an injection molding machine to foam the foamed product, And glycerin, or may be a liquid mixture of two or more selected.

In another aspect, the blended raw material may further comprise 0 to 10 wt% of a coupling agent (compatibilizer) for smooth mixing of the blended raw materials.

The compatibilizing agent means a multi-component system containing two or more kinds of polymers in a broad sense, but narrowly means a mixture of heterogeneous polymers with or without a covalent bond. Phase structure contributes greatly to the development of properties for compatibilizers. The phase structure of the compatibilizing agent is generally classified into (1) complete commercial system, (2) partial commercial system, and (3) non commercial system. The important point for the characterization of the compatibilizing agent is that a heterogeneous polymer phase is dispersed to form a micro-phase separation structure. On the other hand, in the non-aqueous system, the phases are phase-separated in a macro state in the equilibrium state, the characteristics are not stable, and the effects expected in the compatibilizing agent can not be obtained in many cases. In commercialization, it is important to separate the heteropolymer phase of the non-commercial system into a micro-phase, and it is necessary to easily realize the micro-phase-separated structure and to manifest its characteristics stably. This role is a commercialization. That is, a compatibilizer can be said to be a substance capable of forming and stabilizing a microphase separation structure by alleviating the difference in dissimilar polymer properties in a blend. Thus, the ability of the compatibilizer to change the phase-separating structure is the same as the role of the surfactant when mixing oil and water, and acts on the interface of the polymer to lower the interfacial tension between the two polymers. The role of the compatibilizer in commercialization is important in the sense that it can effectively exhibit properties from a simple blend without adding special processing conditions by adding a compatibilizing agent to a non-commercial heteropolymer blend system. Further, it can be expected that the phase structure is controlled by the compatibilizing agent and the properties are synergistically expressed. Polymers commonly used as compatibilizers are known as block-copolymers or graft copolymers. These polymers are composed of two components having affinity (compatibility) with the dissimilar polymer, and play a role of a surfactant which reduces the interfacial tension between both polymers.

In another aspect, the compounded raw material may further contain 0.1 to 40.0 wt% of an inorganic substance, and as a specific example, the inorganic substance may be calcium carbonate (CaCO ₃ ). Calcium carbonate is a material capable of improving the physical properties of the foamed product manufactured by the molding method according to the present invention and can lower the composition ratio of the polymer resin added to the blended raw material and improve the physical properties of the foamed product and improve the environment- Effect can be achieved at the same time.

Injection molding using an injection machine that maintains predetermined operating conditions may be employed for foam molding of the raw material blended at the above-mentioned predetermined ratio through the pretreatment process.

1, the extruder 500 includes a hopper 210 for feeding the blended raw material 10 and a screw 221 for feeding the blended raw material 10 to the discharge side nozzle die 230 A transfer side barrel 220, and a nozzle die 230 through which the molten raw material 20 is discharged.

The extruder 500 may further include a motor 401 for transmitting a driving force to the screw 221, pulleys 402 and 404 and a belt 403, and the outer surface of the barrel 220 The heating band 311, 312, 313 and 314 controlled by the temperature control device 320 can be positioned and the discharge side nozzle die 230 can be positioned with respect to the nozzle die 230 A pressure sensor 330 and a pressure display device 340 may be additionally provided.

The temperature of the transfer side barrel 220 of the extruder 500 is a temperature condition in which the temperature increases from the hopper 210 to the discharge side nozzle die 230. The temperature of the transfer side barrel 220 is 150 Lt; RTI ID = 0.0 > 250 C. < / RTI > Specifically, the temperature control of the transfer-side barrel 220 can be controlled by the heating bands 311, 312, 313, and 314 located on the outer surface of the transfer-side barrel 220. For example, in the direction from the hopper 210 to the discharge side nozzle die 230, the heating band 311 is 150 ° C, the heating band 312 is 180 ° C, the heating band 313 is 210 ° C, and the heating band 314 is 250 < 0 > C. The temperature setting can be finely adjusted by increasing the number of heating bands 311, 312, 313, and 314 located on the outer surface of the transfer-side barrel 220 for setting a finer temperature condition.

The raw material 20 melted by the transfer side barrel 220 can be injected into the discharge side nozzle die 230 by the screw 221. The discharge-side nozzle die 230 maintains a high-pressure and high-temperature condition. Specifically, the pressure of the discharge-side nozzle die 230 may be 5 to 20 MPa, and the temperature may be 150 to 250 ° C.

1 and 3, the molten raw material 20 injected into the discharge-side nozzle die 230 can be foam-molded while being discharged to the nozzle die discharge port 231. Specifically, the dried raw material 20 is vaporized by the high temperature / high pressure inside the discharge side nozzle die 230, and the molten raw material 20 is discharged into the nozzle die discharge port 231 The foam molding of the product can be achieved due to the rapid vaporization of the paper-making agent 13 due to decompression while being discharged.

4 shows photographs of the foamed products manufactured by the above-mentioned molding method, and Table 1 below shows the expansion ratio of the foamed products shown in FIG.

Referring to FIG. 4 and Table 1, the foamed product that can be produced by the molding method according to the present invention can be manufactured in various forms by different kinds of natural materials and polymer resins. (A), (b), (b), (PP), (PP), and (PP) (c) a mixture of bran and recycled PP, (d) a mixture of bran and ABS, (e) a mixture of bran and LDPE, or (f) a mixture of starch and PP. At this time, the mixture ratio of the natural material and the polymer mixed with the raw material is 5: 5, and the content of water used as the gypsum is 10% of the natural material.

As shown in Table 1, (a) in the case of mixing bran and PP, the density is 0.017 g / cm ³ and 62 times the highest expansion ratio. (f) a mixture of starch and PP, (d) a mixture of wheat bran and ABS, and (c) a mixture of wheat bran and recycled PP were also 50 times, 42 times and 32 times, respectively, And shows the foaming efficiency. Such a foaming efficiency can be said to be a remarkably improved result as compared with the conventional foaming product having a foaming efficiency of less than 30 times.

<Table 1>

FIG. 5 is a photograph showing a comparison of appearance of foaming products according to mixing ratios of a natural material, a polymer resin and a mortar, and Table 2 below shows specific expansion ratios thereof.

5 and Table 2, when the natural material is selected as bran and the polymer resin is selected as PP, when the blending ratio of PP and wheat bran is 3: 7 (b) is 22 times and when the ratio is 4: 6 the expansion ratio is 40 times for 40 times, 50 times for 5: 5, and 24 times for 6: 4, respectively. As shown in Table 2, when the ratio of PP to wheat bran is 5: 5, the best expansion ratio is shown in (d), and in the case of 4: 6, (c) .

<Table 2>

In Table 3 below, the expansion ratio according to the water content (in contrast to wheat bran) in the 5: 5 blend of P.P and wheat bran is disclosed.

Referring to Table 3, it is possible to achieve an expansion ratio of 42 times or more when the water content is maintained at 20 to 40%. Specifically, 18 times for a water content of 15%, 50 times for a water content of 20%, 62 times for a water content of 25%, 44 times for a water content of 30%, and a water content of 35% 44 times, and the water content of 40%, the expansion ratio is 42 times.

<Table 3>

Table 4 below shows the specific expansion ratio of the foamed products according to the mixing ratio of the natural materials, the polymer resin and the paper-making agent.

As shown in Table 4, when the natural material was selected as starch and the polymer resin was selected as PP, the ratio of PP to starch was 42: 2, 62: 5: 5: 5, 70 times, 70 times in the case of 4: 6, and 90 times in the case of 3: 7, respectively. As shown in Table 4, the best foaming magnification is obtained when the mixing ratio of PP to starch is 3: 7, and the mixing ratios of all the blending ratios are remarkably improved compared with the conventional ones.

<Table 4>

Table 5 below shows the expansion ratio according to the water content (in terms of starch) in the 5: 5 blend of P.P and starch.

Referring to Table 5, when the water content is maintained at 25%, the highest expansion ratio of 85 times can be achieved. Specifically, the expansion ratio is 50 times for a water content of 10%, 65 times for a water content of 15%, 65 times for a water content of 20%, and 60 times for a water content of 30%.

<Table 5>

As described above, the foamed product which can be produced by the molding method according to the present invention can be manufactured in various forms by different kinds of natural materials and polymeric resins. However, it is most preferable that starch or wheat bran is selected as a natural material, PP is selected as a polymer resin, and a 5: 5 ratio is mixed to obtain 25% water as a paper making agent to achieve the most preferable expansion ratio . It can be interpreted that the limitation of the mixing ratio proposed in the present invention has a sufficiently critical meaning.

6 shows a foamed product manufactured by the molding method according to an aspect of the present invention and a photograph showing a state in which the foamed product is utilized.

As shown in FIG. 6, the foamed product (a) produced by the molding method according to the present invention can be utilized as a buffer for protection of impact sensitive products. (B, c, d) Although it is not shown, it can be used for industrial cushioning packing material, courier packing material, warm / cold material, gift packing material, agricultural and marine packing material, and electronic device packing material.

As shown in Fig. 6 (a), the foamed product (a) produced by the molding method according to the present invention can exhibit light brown or green owing to the inclusion of a cellulose-based natural material. Therefore, the consumer can visually recognize that the foamed product (a) produced by the molding method according to the present invention is an environment-friendly product.

In the foregoing detailed description of the present invention, only specific embodiments thereof have been described. It is to be understood, however, that the invention is not to be limited to the specific embodiments thereof which are to be considered as illustrative, but rather is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. .

10: raw material 11: natural material
12: polymer resin 13: ground drying agent
20: molten raw material 100: foamed product
210: Hopper 220: Feed side barrel
221: screw 230: discharge side nozzle die
231: nozzle die outlet 311-315: heating band
320: Temperature control device 330: Pressure sensor
340: pressure display 401: motor
402, 404: pulley 403: belt
500: extruder

Claims (17)

A raw material in which 0.1 to 30 phr of a drying agent is blended with a polyolefin polymer composite material containing 50.1 to 80 wt% of a polyolefin resin and 20 to 49.9 wt% of a natural material is prepared by extrusion or injection molding A method of forming a foamed product,
The temperature of the extruder or the injection molding machine transfer side barrel and the temperature of the discharge side nozzle die are set to be in the range of 150 to 250 DEG C respectively so that the materials contained in the blended raw materials can be vaporized,
The pressure of the extruder or injection-molding nozzle die is maintained in the range of 5 to 20 MPa so that the foamed product can be foamed due to the expansion of the agglomerated dry agent to be discharged to the discharge nozzle of the extruder or the injection molding machine,
Characterized in that the polyolefin is selected from polyethylene or polypropylene. The method according to claim 1,
The natural material may be,
By-product, starch, wood by-product or cellulose-based material, or
A mixture of cellulose by-products, starch, wood by-products or cellulose-based natural fibers
Wherein the foamed product is a foamed product.
The method according to claim 1,
The natural material may be,
Wherein the material is a material blended with at least two selected from the group consisting of bio-by-products, starch, wood by-products, cellulose-based materials, and natural fibers.
3. The method of claim 2,
Wherein the bio-by-product is a mixture obtained by extracting edible oil from by-products or grains that are generated when the grain is harvested and by-products remaining alone or by mixing two or more kinds of by-products.
3. The method of claim 2,
The wood by-
Wood chips, wood chips, or by-products that may be produced from wood, respectively, or
Wherein the mixture is a mixture of at least two kinds of by-products.
3. The method of claim 2,
Wherein the starch is one or more selected from the group consisting of corn, potato, sweet potato, and arrow root, and is ground to a powder form.
3. The method of claim 2,
The cellulosic natural fibers may be used alone or in combination with other fibers such as kenaf, jute, flax, hemp, ramie, sisal, henequen, pineapple or banana leaves Or a mixture of two or more thereof.
delete delete delete The method according to claim 1,
Wherein the blended raw material further comprises 0 to 10 wt% of a coupling agent (compatibilizer).
The method according to claim 1,
The above-mentioned drying agent is a liquid having a boiling point of not lower than room temperature,
Wherein the liquid is a liquid selected from the group consisting of water, ethanol, and glycerin, or a mixture of two or more selected.
The method according to claim 1,
Wherein the blended raw material further comprises 0.1 to 40.0 wt% of an inorganic material.
14. The method of claim 13,
Wherein the inorganic material is calcium carbonate (CaCO ₃ ).
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