WO2009040541A2 - Procédé de production d'un article moulé - Google Patents

Procédé de production d'un article moulé Download PDF

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Publication number
WO2009040541A2
WO2009040541A2 PCT/GB2008/003270 GB2008003270W WO2009040541A2 WO 2009040541 A2 WO2009040541 A2 WO 2009040541A2 GB 2008003270 W GB2008003270 W GB 2008003270W WO 2009040541 A2 WO2009040541 A2 WO 2009040541A2
Authority
WO
WIPO (PCT)
Prior art keywords
rubber crumb
complementary
moulds
moulded article
core material
Prior art date
Application number
PCT/GB2008/003270
Other languages
English (en)
Other versions
WO2009040541A3 (fr
Inventor
Simon Wiper
Peter Roger Aylmore
Original Assignee
Environmental Polymer Technologies Limited
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 Environmental Polymer Technologies Limited filed Critical Environmental Polymer Technologies Limited
Publication of WO2009040541A2 publication Critical patent/WO2009040541A2/fr
Publication of WO2009040541A3 publication Critical patent/WO2009040541A3/fr

Links

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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C2043/181—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles encapsulated
    • B29C2043/182—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles encapsulated completely
    • 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
    • B29K2021/00—Use of unspecified rubbers 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/08—Copolymers of ethylene
    • B29K2023/083—EVA, i.e. ethylene vinyl acetate copolymer
    • 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

Definitions

  • This invention relates to a method of producing a moulded article, with particular reference to the production of moulded articles which are manufactured at least partially from rubber crumb. Particular, but not exclusive, reference is made to the production of moulded articles which are manufactured at least partially from recycled rubber crumb.
  • a method of producing a moulded article at least partially from rubber crumb including the steps of:
  • first and second complementary moulds each having face portions for forming respective generally opposed surfaces of said moulded article;
  • contacting at least one of the face portions with at least one material selected from the group of: a plasties particulate material and rubber crumb;
  • the present invention is a relatively low temperature moulding technique which does not employ pre-melting of the rubber. This can produce articles having a high quality finish with a little or no shearing being observed.
  • the term "rubber crumb” as used herein is understood to refer to shredded, comminuted or otherwise particularised rubber material.
  • the first aspect of the invention has some features in common with a technique for producing moulded plastics articles which is known as "powder impression moulding" (PIM).
  • steps ii) and iii) may be interchanged.
  • the core material includes rubber crumb.
  • the core material may consist essentially of rubber crumb, or, alternatively, the core material may include rubber crumb and a thermoplastic.
  • the thermoplastic is a polyolefin, preferably polyethylene.
  • the use of a polyolefin improves the toughness of the finished moulded article and can act as a carrier for fire retardant additives.
  • Other thermoplastic polymers such as nylon, ABS and EVA might be used.
  • the step (v) of bringing together the first and second complementary moulds causes the rubber crumb in the core material to compress.
  • the core material further includes a foamable material which is caused to foam so that the moulded article has a rubber foam core.
  • the core material also includes a plastics particulate material.
  • the complementary moulds may be heated so that during step v) the rubber crumb in the core material is at least partially melted.
  • the temperature of the complementary moulds during step v) may be in the range 190 to 22O 0 C.
  • a plastics particulate material but not rubber crumb may be used in step (ii). In other embodiments in which the core material includes rubber crumb, rubber crumb may be used in step (ii).
  • rubber crumb is used in step (ii) and the core material does not include rubber crumb.
  • the core material may include a foamable material which is caused to foam so that the moulded article has a foam core.
  • a mixture of a plastics particulate material and rubber crumb may be used in step (ii).
  • the mixing ratio of plastics particulate material to rubber crumb is in the range 80:20 to 20:80 by weight, preferably in the range 40:60 to 20:80 by weight, most preferably about 30:70 by weight. It has been found that such rubber "loadings" can still provide good finishes on the moulded particle.
  • the plastics particulate material is a polyolefin.
  • polyethylene is used, although other polyolefins, such as polypropylene, might be employed instead. It has been found that the use of polyolefins can provide an improved surface finish, increase the toughness of the moulded article, and can improve flow into the corners of the mould.
  • a plastics particulate material may be another thermoplastic, such as nylon or EVA.
  • the core material introduced in step (iv) may be a polyolefin.
  • the polyolefin may be polyethylene, although other polyolefins, such as polypropylene, might be used.
  • both face portions are contacted with the material in step (ii). In other embodiments, a single face portion is contacted with the material in step (ii).
  • the first complementary mould may be a female mould defining a cavity and the second complementary mould may be a male mould having a male portion which, in use, extends slightly into the cavity defined by the female mould.
  • a "slight male” mould is utilised, are particularly useful for providing a slight compression to the core material. This is particularly advantageous in embodiments in which the core material comprises rubber crumb.
  • the rubber crumb consists of particles in size range 500 to 5,000 ⁇ m.
  • any heating step takes place at temperatures below 23O 0 C, but above 12O 0 C.
  • the first and second complementary moulds are heated to a temperature in the range 190 to 22O 0 C at least during step (iii).
  • This is a relatively low temperature which causes the rubber crumb (and, if present, plastics particulate material) to more or less sinter together. It is advantageous that moulding can take place at a relatively low temperature with no pre-melting of the rubber crumb being required.
  • the invention is well suited to the production of relatively low density articles such as panels, although the production of higher density articles is within the scope of the invention.
  • the rubber crumb is a recycled rubber, such as rubber crumb formed from vehicle tyres.
  • a method of producing a moulded article at least partially from rubber crumb including the steps of:
  • the rubber crumb is not melted prior to its introduction into the moulds.
  • the first and second complementary moulds are heated to a temperature in the range of 190 to 22O 0 C.
  • the second aspect of the invention may be used in conjunction with the first aspect of the invention.
  • other forms of moulding processes might be employed.
  • transfer moulds might be used in conjunction with the second aspect to the invention.
  • a moulded article at least partially from rubber crumb including the steps of:
  • the polyolefin is polyethylene, although other polyolefins, such as polypropylene, might be employed. It has been found that mixtures of rubber crumb and the polyolefin additive are particularly useful when employed in a moulding process to produce a moulded article having a substantial rubber content. The use of the polyolefin can improve the surface finish and the toughness of the product.
  • Figure 2 is a cross sectional side view of a complementary pair of male and female mould halves;
  • Figure 3 is a schematic view of a second embodiment of a process of the invention.
  • Figure 4 is a cross sectional side view of (a) a first embodiment and (b) a second embodiment of a complementary pair of female mould halves.
  • Figure 1 shows a process for moulding an article from rubber crumb which utilises complementary male mould halves 10 and female mould halves
  • a series of female mould halves 12 are moved using a lower conveyor device 14, whereas a series of male mould halves 10 are moved using an upper conveyor device 16.
  • the conveyor device is made for a conveyor belt or a conveyor chain, and the lower and upper conveyor devices 14, 16 are designed and operated to synchronise the movement of the mould halves 10, 12 in a manner which is more fully described below.
  • each of the complementary male and female mould halves 10, 12 are positioned with their mould cavities facing upwards and the moulds are heated to raise the temperature of their inner, moulding surfaces to a temperature suitable for the moulding process by suitable heaters. Temperatures in the range 190-220°C have been found to be particularly effective.
  • a plastics particulate material is then introduced into the mould cavity of each mould half 10, 12 so as to contact the heated surfaces of the mould thereby to. melt and form a continuous skin.
  • the mould halves are heated to around 22O 0 C before the plastics particulate material is introduced therein.
  • the supply of heat to the mould halves may be removed before the plastics particulate material is introduced to the mould halves, but the residual applied heat is sufficient to form the skin.
  • the temperature of the mould halves may drop to about 15O 0 C. Good results have been obtained using polyethylene as the plastics particulate material.
  • excess particulate material is removed from the mould halves by any suitable method such as vacuuming, blowing or inversion, to leave each mould coated with molten plastic materials, optionally including melted or partially melted rubber crumb, to the required thickness.
  • the upper conveyor belt device 16 has heating, filling and removal stations which enable the layer or skin to be formed on the male mould halves 10.
  • the lower conveyor device 14 has heating, filling and removal stations enabling the skin or layer to be formed on the female mould halves, and has an additional filling station which enables the female mould halves 12 to be subsequently loaded with rubber crumb.
  • the movement of the male and female mould halves 10, 12 on the lower and upper conveyor devices 14, 16 is synchronised so that complementary pairs of male and female mould halves 10, 12 are brought together in register.
  • Heat is continued to be applied to the complementary pair of male and female mould halves 10, 12 causing the rubber crumb in the core to at least partially melt thereby enabling the rubber crumb in the core to bind with itself and also with the skins or layers.
  • a preferred range of temperatures for this step is 190-220 0 C, most preferably 200-210 0 C.
  • the heating is removed, and after a further suitable delay, the mould defined by the complementary pair of male and female mould halves 10, 12 is open to release the moulded rubber product.
  • Figure 2 shows a preferred form of a pair of complementary moulds consisting of a male mould half 10/female mould half 12, in which the male mould half 10 has a relatively shallow male portion 10a which extends only a short distance into the mould cavity defined by the female mould half 12.
  • a complementary mould pair of this type is particular advantageous when rubber core is utilised, such as described in relation'to Figure 1. This is because the male member slightly compresses the rubber core, which aids in the binding of the particles in the core to themselves and also to the skin or layer as present on the mould halves.
  • the rubber crumb applied to the female mould halves 12 in order to form the core may be blended with other material.
  • the rubber crumb is blended with a polyolefin, such as polyethylene. Additionally or alternatively, it may be possible to form a single skin or layer on one of the male or female mould halves, rather than forming a skin or layer on both the male or female mould halves in a complementary pair.
  • a polyolefin such as polyethylene
  • Figure 3 shows a second process for moulding a rubber article according to the invention which utilises complementary pairs of female mould halves 30, each of which define a mould cavity.
  • Each of the complementary female mould halves 30 are moved along a path with the mould cavity facing upwards, and the mould halves are heated to raise the face portions thereof to a. suitable temperature, for example in the range 190-210°C.
  • a plastics particulate material is introduced into the mould cavities of the mould halves 30 so as to contact the heated surfaces of the mould thereby to melt and form a continuous skin.
  • Excess particulate material is then removed from the mould halves 30 by a suitable technique.
  • a suitable foamable core material is then loaded into one or both of the mould halves 30 in a complementary pair, with the moulds then being fully closed to enclose the core material.
  • the material is heated to cause the foamable core material to expand to bond the skins in the mould halves 30 in a complementary pair both to each other and to the core material.
  • the air or gas originally in the space between the skins is caused to vent out between the mating surfaces of the mould halves in the complementary pair as the core material expands to fill the space.
  • a pin or other suitable duct or vent hole may be provided which allows for the escape of gas as the core material expands.
  • rubber crumb can be introduced in a number of ways.
  • rubber crumb may be blended with the plastics particulate material which is used to form the skin on one or other of the mould halves 30. In this instance, it may be more accurate to describe the coating thus formed as a layer rather than a skin per se, particularly if the rubber crumb is only partially melted.
  • the core material may comprise rubber crumb blended with another material, such as a plastics particulate material. It is. preferred that wherever a plastics particulate material is utilised, a polyolefin, especially polyethylene, is employed.
  • Figure 4(a) shows a complementary pair of female mould halves 40 which are well suited to the process depicted in Figure 3 in embodiments in which a skin or layer is formed on both of the mould halves in a complementary pair.
  • the mould halves are designed so as to form a central split line 42 when the mould is assembled which enables gas or air to be vented from the mould cavity.
  • Figure 4b shows a complementary pair of mould halves 44a, 44b which are well suited for use in the process depicted in Figure 3 in the instance in which a single skin or layer is formed on one of the mould halves in the complementary pair.
  • the skin or layer is formed on the upper mould half 44a, which is a "slight" female mould half defining a shallow mould cavity.
  • the other mould half 44b in the complementary pair has a much deeper mould cavity into which the core material is placed.
  • the application of heat and the use of a blowing agent causes the core material to foam up to fill the remaining void in the cavity.
  • the mould halves 44a, 44b may be configured so as to form a split line 46 which allows for the escape of air or gas during the foaming process.
  • the rubber crumb utilised in the invention does not need to be pre-melted before being introduced into the moulding process. Furthermore, it is not necessary to fully melt the rubber crumb during the moulding process. Rather, it has been found that even partially melted rubber crumb has enough "gel factor" associated with cross linked material to allow satisfactory binding to take place during the moulding process. It may be possible to use other forms of moulding processes, such as transfer moulds, to produce moulded rubber articles without pre-melting the rubber crumb.
  • a variety of articles can be manufactured using the present invention.
  • the invention is well suited to essentially flat items, such as tiles.
  • the invention is not limited in this regard, but rather may be used to produce a wide range of differently shaped articles.

Abstract

Conformément à l'invention, il est conçu un procédé de production d'un article moulé au moins partiellement à partir de granules de caoutchouc, incluant les étapes consistant à : i) fournir des premier et second moules complémentaires possédant chacun des parties faciales pour façonner des surfaces généralement opposées dudit article moulé, ii) faire entrer en contact au moins une des parties faciales avec au moins un matériau sélectionné à partir du groupe constitué : d'un matériau de particules de plastique et des granules de caoutchouc, iii) transmettre de la chaleur aux moules pour provoquer ainsi la fusion au moins partielle du matériau afin de former au moins une première couche ou peau, iv) introduire un matériau noyau entre les premier et second moules complémentaires dans lesquels, si le matériau entrant en contact avec la partie faciale ou avec des parties constituées à l'étape ii) comprend des granules de caoutchouc alors le matériau noyau comprend en option des granules de caoutchouc, et si le matériau entrant en contact avec la partie faciale ou les parties constituées à l'étape ii) ne comprend pas de granule de caoutchouc alors le matériau noyau comprend des particules de caoutchouc et, v) réunir les premier et second moules complémentaires pour former l'article moulé.
PCT/GB2008/003270 2007-09-26 2008-09-26 Procédé de production d'un article moulé WO2009040541A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0718815A GB0718815D0 (en) 2007-09-26 2007-09-26 Method for producing a moulded article
GB0718815.4 2007-09-26

Publications (2)

Publication Number Publication Date
WO2009040541A2 true WO2009040541A2 (fr) 2009-04-02
WO2009040541A3 WO2009040541A3 (fr) 2009-07-23

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2008/003270 WO2009040541A2 (fr) 2007-09-26 2008-09-26 Procédé de production d'un article moulé

Country Status (2)

Country Link
GB (1) GB0718815D0 (fr)
WO (1) WO2009040541A2 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5283028A (en) * 1990-05-02 1994-02-01 Penda Corporation Process for producing a selectively reinforced thermoformed article
JPH06278223A (ja) * 1993-03-26 1994-10-04 Toyota Motor Corp 樹脂容器の製造方法
WO2002062550A1 (fr) * 2001-02-05 2002-08-15 3Dm Technologies, Inc. Procedes pour former des plastiques, appareils pour former des plastiques et articles formes a partir de ces derniers
GB2425505A (en) * 2005-04-26 2006-11-01 3Dm Europ Ltd Moulded transit or location article

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5283028A (en) * 1990-05-02 1994-02-01 Penda Corporation Process for producing a selectively reinforced thermoformed article
JPH06278223A (ja) * 1993-03-26 1994-10-04 Toyota Motor Corp 樹脂容器の製造方法
WO2002062550A1 (fr) * 2001-02-05 2002-08-15 3Dm Technologies, Inc. Procedes pour former des plastiques, appareils pour former des plastiques et articles formes a partir de ces derniers
GB2425505A (en) * 2005-04-26 2006-11-01 3Dm Europ Ltd Moulded transit or location article

Also Published As

Publication number Publication date
GB0718815D0 (en) 2007-11-07
WO2009040541A3 (fr) 2009-07-23

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