WO2006005431A1 - Wood-plastic composite articles - Google Patents
Wood-plastic composite articles Download PDFInfo
- Publication number
- WO2006005431A1 WO2006005431A1 PCT/EP2005/006879 EP2005006879W WO2006005431A1 WO 2006005431 A1 WO2006005431 A1 WO 2006005431A1 EP 2005006879 W EP2005006879 W EP 2005006879W WO 2006005431 A1 WO2006005431 A1 WO 2006005431A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wood
- plastic
- article according
- wood fibre
- composite
- Prior art date
Links
Classifications
-
- 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
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
-
- 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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
-
- 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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/04—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/12—Cans, casks, barrels, or drums
-
- 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
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, 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
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
-
- 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
- B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
- B29K2311/10—Natural fibres, e.g. wool or cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7154—Barrels, drums, tuns, vats
-
- 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
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
-
- 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
- Y02W90/00—Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
- Y02W90/10—Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics
Definitions
- the invention relates to the general field of composite materials made from wood or other cellulosic materials and plastics, and particularly to articles made from such composites for use as drink containers.
- Wood-plastic composites are typically used a replacement for wood (or plastic) in commercial and residential architecture, such as windows and doors. They also have widespread application as decking, fencing and siding materials.
- the composite is typically made using an extrusion process with an input of polyolefin, polystyrene or polyvinyl chloride together with wood fibre (e.g. sawdust) to form a composite material.
- wood fibre e.g. sawdust
- Such materials often have improved processability, thermal and structural properties when compared with metal, vinyl, or wooden components.
- Wood-plastic composites are typically injection- or extrusion-moulded, although it is known to blow-mould such compositions. Such techniques are unsuitable for certain articles, such as large containers which cannot be blow-moulded due to the viscosity of the plastics involved. In such cases rotomoulding is used for pure plastic articles, although there is no disclosure in the prior art of rotomoulding having been used for making articles from wood-plastic composites.
- the present invention provides a r ⁇ tomoulded article comprising a wood-plastic composite containing at least 2wt% wood.
- Such articles can be made to have a woody smell and texture, and the use of rotomoulding enables a much greater range of shapes and sizes to be made than is possible with injection moulding.
- Applications include toys and plant pots.
- barrels for drinks such as the barrels in which wine or whisky is aged before bottling.
- Such barrels are typically made of oak, not only for historical reasons but also because the oak imparts flavour (tannin) to the liquid inside.
- plastic barrels have not replaced oak barrels, despite the obvious cost benefits.
- one particularly advantageous application of the present invention is the manufacture of rotomoulded containers for liquids comprising a wood-plastic composite. These have the cost advantages of plastic over wood, but are nevertheless able to provide flavour enhancement to the liquid by virtue of contact of the wood contained within the composite material with the liquid contained within the barrel.
- the rotomoulding process provides a container that has a smooth plastic surface on the outside, but a relatively rough inner surface containing exposed wood fibres. Thus handling of the container is convenient whilst at the same time sufficient wood is exposed internally to contact the contained liquid.
- Such containers are at least IL in volume, normally at least 5L and preferably have a volume of at least 1OL.
- the thermoplastic resin of the plastic- wood fibre composite is typically a polyolefin, or polyvinyl chloride, or polystyrene. Usually it is a polyolefin or polyvinyl chloride, with polyethylene being particularly preferred.
- a typical polyolefin material used in such composites is a polyethylene or polypropylene polymer having a melting point of about 13O 0 C and a melt index MI 2 of from 0.1 to greater than 20 g/10min.
- a preferred polyethylene is a polyethylene homopolymer, or a copolymer containing 0.01 to 10 wt% of a C2-C6 alpha-olefm comonomer, with a preferred molecular weight of about 10,000 to 60,000.
- a preferred polypropylene material is a polypropylene homopolymer or copolymer containing 0.01 to 10 wt% of ethylene or a C4-C6 alpha- olefin comonomer, having a molecular weight of about 10,000 to 60,000.
- the composite may include a resin capable of chemically bonding to wood fibres, so as to overcome the natural incompatibility between hydrophilic wood fibres and the hydrophobic polymer matrix of the thermoplastic resin, hereinafter referred to as a compatibiliser.
- compatibilisers include titanium alcoholates, esters of phosphoric, phosphorous, phosphoric and silicic acids, metallic salts and esters of aliphatic, aromatic and cycloaliphatic acids, ethylene/acrylic or methacrylic acids, ethylene/esters of acrylic or methacrylic acid, ethylene/vinyl acetate resins, styrene/maleic anhydride resins or esters thereof, acrylonitrilebutadiene styrene resins,methacrylate/butadiene styrene resins (MBS), styrene acrylonitrile resins (SAN), and butadieneacrylonitrile copolymers.
- compatibilisers include titanium alcoholates, esters of phosphoric, phosphorous, phosphoric and silicic acids, metallic salts and esters of aliphatic, aromatic and cycloaliphatic acids, ethylene/acrylic or methacrylic acids, ethylene/esters of acrylic or methacrylic acid,
- Preferred compatibilisers are resins which have been modified by a reactive group such as maleic anhydride or its esters, acrylic or methacrylic acid or their esters, vinylacetate, acrylonitrile, and styrene. Virtually any olefinically reactive residue that can provide a reactive functional group on a modified resin can be used.
- Useful base resins are polyethylene, polypropylene, polystyrene and polyvinyl chloride. Ionomers of these resins may also be used.
- the wood fibre of the resin- wood fibre composite usually comprises the by ⁇ product of sawing or milling, commonly known as sawdust or milling tailings. Such wood fibre has a regular, reproducible shape and aspect ratio. Fibres are typically 0.01- 5mm in length, up to lmm in thickness and usually have an aspect ratio of at least 1.8.
- the wood can also be in the form of a ground powder, and the term "wood fibre" in this specification includes this.
- the wood used for the wood fibre is preferably oak, so as to replicate the flavour imparted by traditional oak barrels.
- the wood fibre may be any type of wood, for example pine or beech. Mixtures of woods may of course be employed.
- the wood fibre may also be derived from other sources such as ground newsprint, magazines, books, cardboard and wood pulps, and also various agricultural wastes (rice hulls, wheat, oat, barley and oat chaff, coconut shells, peanut shells, walnut shells, straw, corn husks, corn stalks, jute, hemp, bamboo, flax etc). All of the above are considered to be covered by the term "wood fibre” as used herein.
- the ratio of resin to wood fibre in the composite may be any which provides a composite suitable for the purpose for which it is intended. For large liquid storage containers, the amount must be sufficient to modify the taste of the liquid within the container, but not.so much as to render the mechanical properties unsuitable.
- the amount of wood fibre is from 2 to 60wt%, and the amount of resin from 40 to 98wt%.
- the preferred amount of wood fibre is from 3-10wt%.
- the resin- wood fibre composite may also contain conventional additives such as fillers, lubricants, oxidation stabilizers, UV stabilizers, antistatic agents, antioxidants, fire retardants, dyes, pigments, plasticizers, mould release agents, extrusion mould release agents and the like. These additives are typically present at levels up to about 20 wt%, more usually from 0.1 to about 10 wt%, and most typically from 0.2 to 5 wt%.
- the process of rotomoulding is well-known.
- the resin and wood fibre, together with the other required additives, are loaded into a closed mould, which is then heated whilst being continuously rotated, typically in an oven. This results in the resin melting into a layer on the inner surface of the mould.
- the mould is then cooled, and the solidified article removed.
- the resin and wood fibre may be introduced into the mould either in the form of a dry mixture of granulated resin plus wood fibre, or the resin may first be compounded with the wood fibre and the resulting wood-plastic composite granulated prior to introduction into the mould.
- the other additives in the composition are usually incorporated into the resin prior to introduction into the mould, for example during compounding, although the compatibiliser may be added separately into the mould.
- the large liquid storage containers of the invention preferably comprise either a single layer of wood-plastic composite or alternatively an outer plastic layer surrounding an inner layer of wood-plastic composite, the outer plastic layer being present to provide improved mechanical properties, especially impact properties, to the container.
- the plastic is preferably polyethylene, and the wood fibre is preferably oak.
- a sample of wood-plastic composite for fabrication into an article was made by rotomoulding at 250 0 C for 12 minutes and having the composition:
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP20050754492 EP1765916A1 (en) | 2004-07-15 | 2005-06-24 | Wood-plastic composite articles |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0415880.4 | 2004-07-15 | ||
GB0415880A GB0415880D0 (en) | 2004-07-15 | 2004-07-15 | Wood-plastic compsite articles |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2006005431A1 true WO2006005431A1 (en) | 2006-01-19 |
Family
ID=32893636
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2005/006879 WO2006005431A1 (en) | 2004-07-15 | 2005-06-24 | Wood-plastic composite articles |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1765916A1 (en) |
GB (1) | GB0415880D0 (en) |
WO (1) | WO2006005431A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1381863A (en) * | 1971-03-17 | 1975-01-29 | Bp Chem Int Ltd | Rotationally moulded articles |
US3923190A (en) * | 1974-05-13 | 1975-12-02 | Continental Can Co | Plastic containers having improved physical properties fabricated from a composite billet |
US20030228454A1 (en) * | 2002-06-07 | 2003-12-11 | Rayonier, Inc. | Cellulose fiber reinforced composites having reduced discoloration and improved dispersion and associated methods of manufacture |
-
2004
- 2004-07-15 GB GB0415880A patent/GB0415880D0/en not_active Ceased
-
2005
- 2005-06-24 EP EP20050754492 patent/EP1765916A1/en not_active Withdrawn
- 2005-06-24 WO PCT/EP2005/006879 patent/WO2006005431A1/en not_active Application Discontinuation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1381863A (en) * | 1971-03-17 | 1975-01-29 | Bp Chem Int Ltd | Rotationally moulded articles |
US3923190A (en) * | 1974-05-13 | 1975-12-02 | Continental Can Co | Plastic containers having improved physical properties fabricated from a composite billet |
US20030228454A1 (en) * | 2002-06-07 | 2003-12-11 | Rayonier, Inc. | Cellulose fiber reinforced composites having reduced discoloration and improved dispersion and associated methods of manufacture |
Also Published As
Publication number | Publication date |
---|---|
EP1765916A1 (en) | 2007-03-28 |
GB0415880D0 (en) | 2004-08-18 |
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