WO2000073037A1 - Carton comportant une ame alveolaire et une proportion elevee d'une charge cellulosique - Google Patents

Carton comportant une ame alveolaire et une proportion elevee d'une charge cellulosique Download PDF

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Publication number
WO2000073037A1
WO2000073037A1 PCT/NL2000/000287 NL0000287W WO0073037A1 WO 2000073037 A1 WO2000073037 A1 WO 2000073037A1 NL 0000287 W NL0000287 W NL 0000287W WO 0073037 A1 WO0073037 A1 WO 0073037A1
Authority
WO
WIPO (PCT)
Prior art keywords
cellulose
board
based filler
board according
thermoplastic polymer
Prior art date
Application number
PCT/NL2000/000287
Other languages
English (en)
Inventor
Jaap Stuiver
Original Assignee
Jaap Stuiver
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Jaap Stuiver filed Critical Jaap Stuiver
Priority to EP00927949A priority Critical patent/EP1094924A1/fr
Priority to AU46252/00A priority patent/AU4625200A/en
Publication of WO2000073037A1 publication Critical patent/WO2000073037A1/fr

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Classifications

    • 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
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/10—Applying counter-pressure during expanding

Definitions

  • the invention relates to a board provided with a foam core having a substantially solid skin on both sides, in which the foam core and the skin are made of the same synthetic compound which comprises a thermoplastic polymer and cellulose-based filler.
  • such foamed polymer products are described of thermoplastic polymers and 5-75% by weight of fibre material having a fibre length of 0.05-1 .25cm.
  • the fibre material can be chosen from amongst others asbestos, wood and nylon.
  • Such products are generally unsuitable as wood substitutes.
  • Said fillers such as for instance talcum, chalk, glass fibre and asbestos make the product difficult to process, for instance by gluing or painting.
  • the watertightness and the specific gravity is not optimal as a result of the particle size.
  • a board described in the patent is not suitable for use in construction because of the limited mechanic properties.
  • the invention now intends to provide a board which at least partially overcomes said disadvantages.
  • the invention consists in the board being provided with a foam core having a substantially solid skin on both sides, in which the foam core and the skin are made of the same synthetic compound which comprises a thermoplastic polymer and cellulose-based filler, the cellulose-based filler being in powder form.
  • the invention also consists of a process for the manufacturing of a board according to the invention using low pressure injection moulding in a gasproof mould at a mould pressure of 60 bar at a maximum and in which a gas counter pressure prevails, sufficient to prevent premature expansion of the injection mixture which comprises thermoplastic polymer, cellulose- based filler and blowing agent or water or inert gas, in which after the mould has been partially or entirely filled the injection mixture is allowed to expand, the mould providing counter pressure.
  • the board By using a cellulose-based powdered filler, it is possible to combine the positive properties of the used filler with the positive properties of thermoplastic polymers, namely, simple processing, easy mouldability and good resistance against the action of moisture.
  • wood flour or sawdust or agro-fibre are used as filler the board can very well be used as a substitute for a wooden board, especially as construction material for exterior uses.
  • the board according to the invention has such properties that it complies with NEN-standard 3278 interior 1 , exterior 1 and exterior 2.
  • the board can be worked on very well with conventional wood processing equipment and can be glued, lacquered and/or painted well. To that end the board has to be sanded lightly.
  • the filler here ensures optimal mechanic properties. Additionally exact sizes are possible as a result of the manner of manufacturing and the material used.
  • the board according to the invention comprises a thermoplastic polymer.
  • a polymer which can be processed in an injection moulding process.
  • the processing temperature of such a polymer then has to be such that its filler is not adversely affected by it.
  • the polymer therefore has to processable at a temperature up to approximately 200 degrees Celsius.
  • Suitable polymers according to the invention are polypropylene, polyethylene, polyvinyl chloride, polystyrene, styrene-butadienes, styrene- acrylonitrile, acrylonitrile butadiene styrene, acrylonitrile styrene acrylate, polyamide, polyoxymethylene, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide and thermoplastic polyutherane.
  • thermoplastic polymers preferably polystyrene, polypropylene or polyethylene are used. Said polymers result in a product with little to no swelling when exposed to moisture. As a result the product is able to comply with the above-mentioned standards.
  • re-used plastic is used in the form of industrial production waste.
  • Said material could possibly be used in combination with new material of the above-mentioned polymers.
  • biologically degradable polymers are preferred such as starch-based polymers and poly lactic acid. Examples of such polymers are amongst others described in US 5827905.
  • the board apart from thermoplastic polymer consists of at least 45% by weight of cellulose-based filler.
  • the content of said filler is at least 50% by weight and more preferably at least 60% by weight.
  • Optimal results are obtained with a content of cellulose- based filler of at least 80% by weight. A higher content has a positive effect on the cost price of the board.
  • the board will comprise a maximum of 95% by weight of said filler.
  • a powdered cellulose-based filler a very good wood substitute was obtained at a content of cellulose-based filler of 45-65% by weight, preferably 45-60% by weight.
  • An optimal result as wood substitute was obtained at a content of cellulose-based filler of approximately 50% by weight.
  • a combination of cellulose-based filler with poly olefin preferably polyethylene or polypropylene, turned out to give good results at 40-60% by weight of poly olefin.
  • poly olefin preferably polyethylene or polypropylene
  • the moisture resistance turned out to deteriorate, and the board became too heavy.
  • poly olefin With a higher content of poly olefin the procesability turned out to deteriorate: the product could be glued and painted less well.
  • Polymers such as polyethylene in solid have a large linear expansion coefficient: approximately 1 ,8.1 0 "4 K '1 .
  • the product has a low linear expansion coefficient when polyethylene is used. Ad- ditionally particularly polyethylene and polypropylene do not give harmful waste products.
  • the cellulose-based filler suitable according to the invention will preferably consist of sawdust, possibly pulverized, wood flour, wood pulp, agro-fibres from flax, hemp or jute, or pulp thereof, paper or paper pulp.
  • Said material is preferably used having a particle size of approximately 20 mesh, in order to prevent too large particles being present.
  • the particle size is approximately 35-60 mesh (a particle size of 0-0.5 mm to -.25mm) .
  • Such a particle size is cellulose powder.
  • said material is used in the form of residue material or material made suitable for re-use.
  • the board may comprise additives such as stabilisers, colorants compatibility improvers or fire retardants. Additionally if so desired, small quantities of other fillers can be used. The use of such additives and the suitable kinds are known to the expert however.
  • the board according to the invention can be manufactured in various ways. Preferably, however, the board is manufactured by means of low pressure injection. Said technology is based on the injection moulding process, in which the viscosity of the material to be treated is lowered by adding blowing agents, water or inert gas such as nitrogen. As a result it is possible to make the board from thermoplastic polymer having a high content of cellulose-based filler. The board can be manufactured without tension because of the low pressure. As a result the board will not twist during further processing.
  • An additional advantage is that fluctuations in the supplied raw material, such as for instance the water contents of the filler, will be easy to compensate in the production process.
  • the synthetic compound is injected into a preferably gas proof mould under the already mentioned relative low pressure of 60 bar (mould pressure) at the most.
  • a gas proof mould a relatively smooth surface will be obtained and jetting is prevented.
  • a gas counter pressure system is used. In a gas proof mould a counter pressure is created which is larger than the vapour pressure of the blowing agent. As a result premature expansion of the melt is then prevented. When the mould cavity is entirely filled, the counter pressure is relieved and volume expansion can take place. Optimal results are achieved when the melt is brought directly from the extruder to the plunger, and directly injected from the plunger into the mould.
  • a board having a foam core By means of said production technique it is possible to manufacture a board having a foam core.
  • the foam core is created by adding blowing agent, water or inert gas such as for instance nitrogen.
  • blowing agent water or inert gas such as for instance nitrogen.
  • water or inert gas such as for instance nitrogen are brought at processing temperature and processing pressure and stored in an accumulator. From the accumulator the mixture can be injected under pressure directly into a mould, by way of various possible injection systems, such as membrane injection point or combinations of injection points.
  • volume of the mould is initially enlarged by moving the halves of the mould apart according to a special pressure profile. In a next stage of the process the halves of the mould are moved towards each other again. Said techniques and the necessary adjustments are well known to the expert however.
  • the skin obtained will in general preferably be approximately 0.2-5 mm thick at a board thickness of approximately 1 cm. Said skin thickness can be adjusted during the process.
  • the skin is substantially free from visually visible bubbles. As a result a smooth finished surface can be obtained.
  • foil which increase the scratch resistance (for instance polycarbonate foil) or decorative foils.
  • the board has a foam core, it is possible to manufacture board material having a low specific gravity. It is possible to manufacture a wood substituting board having a specific gravity of maximally 700 kg/m 3 . If so desired a board can be manufactured having a specific gravity of 600 kg/m 3 at a maximum. For an optimal wood substitute a specific gravity of 700-800 kg/m 3 turned out to be optimal. Because of its excellent properties the board according to the invention is extremely suitable for building or construction material, preferably for exterior applications.
  • figure 1 an example can be seen of a board according to the invention.
  • the foam core has a very fine foam structure.

Landscapes

  • Compositions Of Macromolecular Compounds (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention se rapporte à un carton comportant un composé synthétique à base d'un polymère thermoplastique et d'une charge cellulosique. Ce carton possède une âme alvéolaire (2) et un revêtement sensiblement solide (1) sur chacune de ses faces. La charge représente de préférence au moins 45 % en poids du carton et elle est principalement composée de cellulose, de préférence du type sciure, farine de bois, fibres agricoles ou papier. Du fait de la proportion élevée de ladite charge, ce carton présente à la fois les caractéristiques avantageuses du polymère thermoplastique et de la charge. On obtient un excellent produit de remplacement du bois lorsque la charge utilisée est principalement composée de sciure de bois ou de farine de bois.
PCT/NL2000/000287 1999-05-03 2000-05-03 Carton comportant une ame alveolaire et une proportion elevee d'une charge cellulosique WO2000073037A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP00927949A EP1094924A1 (fr) 1999-05-03 2000-05-03 Carton comportant une ame alveolaire et une proportion elevee d'une charge cellulosique
AU46252/00A AU4625200A (en) 1999-05-03 2000-05-03 Board having a foamed core and a high content of cellulose-based filler

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1011950A NL1011950C2 (nl) 1999-05-03 1999-05-03 Plaat met een geschuimde kern en een hoog gehalte aan vulmiddel op cellulose basis.
NL1011950 1999-05-03

Publications (1)

Publication Number Publication Date
WO2000073037A1 true WO2000073037A1 (fr) 2000-12-07

Family

ID=19769119

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/NL2000/000287 WO2000073037A1 (fr) 1999-05-03 2000-05-03 Carton comportant une ame alveolaire et une proportion elevee d'une charge cellulosique

Country Status (4)

Country Link
EP (1) EP1094924A1 (fr)
AU (1) AU4625200A (fr)
NL (1) NL1011950C2 (fr)
WO (1) WO2000073037A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004103687A1 (fr) * 2003-05-20 2004-12-02 Stanelco Rf Technologies Ltd Fabrication de corps alveoles
EP2441558A1 (fr) * 2009-06-29 2012-04-18 Michio Komatsu Objet moulé en résine contenant de la poudre de bois et son procédé de production
EP2559541A1 (fr) * 2010-12-28 2013-02-20 Komatsu, Michio Corps moulé en résine contenant une fine poudre de papier, et son procédé de production
CN103213294A (zh) * 2013-05-11 2013-07-24 安徽省温禾木业有限公司 一种防火环保木塑地板的生产工艺
US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US9637920B2 (en) 2006-01-20 2017-05-02 Material Innovations Llc Carpet waste composite
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1052289A (fr) * 1900-01-01
US3773873A (en) * 1970-06-22 1973-11-20 Allied Chem Method of injection molding foamable plastic with minimized wastage
US4818604A (en) * 1987-03-27 1989-04-04 Sub-Tank Renewal Systems, Inc. Composite board and method
FR2684966A1 (fr) * 1991-12-12 1993-06-18 Gomez Daniel Materiau vegetal expanse, recyclable, son procede de fabrication et son utilisation dans les domaines du calage, de la protection, de l'emballage, des revetements et des materiaux en feuille.
JPH1134148A (ja) * 1997-07-14 1999-02-09 Mitsui Chem Inc 寸法精度に優れる木質様塩化ビニル系発泡成形品の製造方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1052289A (fr) * 1900-01-01
US3773873A (en) * 1970-06-22 1973-11-20 Allied Chem Method of injection molding foamable plastic with minimized wastage
US4818604A (en) * 1987-03-27 1989-04-04 Sub-Tank Renewal Systems, Inc. Composite board and method
FR2684966A1 (fr) * 1991-12-12 1993-06-18 Gomez Daniel Materiau vegetal expanse, recyclable, son procede de fabrication et son utilisation dans les domaines du calage, de la protection, de l'emballage, des revetements et des materiaux en feuille.
JPH1134148A (ja) * 1997-07-14 1999-02-09 Mitsui Chem Inc 寸法精度に優れる木質様塩化ビニル系発泡成形品の製造方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 199916, Derwent World Patents Index; Class A14, AN 1999-185055, XP002152040 *

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004103687A1 (fr) * 2003-05-20 2004-12-02 Stanelco Rf Technologies Ltd Fabrication de corps alveoles
US11773592B2 (en) 2006-01-20 2023-10-03 Material Innovations Llc Carpet waste composite
US10822798B2 (en) 2006-01-20 2020-11-03 Material Innovations Llc Carpet waste composite
US10294666B2 (en) 2006-01-20 2019-05-21 Material Innovations Llc Carpet waste composite
US9637920B2 (en) 2006-01-20 2017-05-02 Material Innovations Llc Carpet waste composite
US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US10875281B2 (en) 2008-12-19 2020-12-29 Fiber Composites Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
EP2441558A4 (fr) * 2009-06-29 2013-04-17 Michio Komatsu Objet moulé en résine contenant de la poudre de bois et son procédé de production
EP2441558A1 (fr) * 2009-06-29 2012-04-18 Michio Komatsu Objet moulé en résine contenant de la poudre de bois et son procédé de production
EP2559541A4 (fr) * 2010-12-28 2013-10-09 Komatsu Michio Corps moulé en résine contenant une fine poudre de papier, et son procédé de production
KR101447548B1 (ko) 2010-12-28 2014-10-08 코마츠, 미치오 종이 미분체 함유 수지 성형체 및 그 제조방법
US9174370B2 (en) 2010-12-28 2015-11-03 Eco Research Institute Ltd. Fine paper powder-containing resin molded object and manufacturing method thereof
CN102971128A (zh) * 2010-12-28 2013-03-13 小松道男 含纸微粉体树脂成型体及其制造方法
EP2559541A1 (fr) * 2010-12-28 2013-02-20 Komatsu, Michio Corps moulé en résine contenant une fine poudre de papier, et son procédé de production
CN103213294A (zh) * 2013-05-11 2013-07-24 安徽省温禾木业有限公司 一种防火环保木塑地板的生产工艺
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

Also Published As

Publication number Publication date
NL1011950C2 (nl) 2000-11-09
AU4625200A (en) 2000-12-18
EP1094924A1 (fr) 2001-05-02

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