Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
  • C08L1/02—Cellulose; Modified cellulose
• • 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
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
  • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• • 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
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• • 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
  • C08J11/00—Recovery or working-up of waste materials
  • C08J11/04—Recovery or working-up of waste materials of polymers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/02—Fibres or whiskers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L97/00—Compositions of lignin-containing materials
  • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
• • 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
  • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
  • B29K2711/12—Paper, e.g. cardboard
  • B29K2711/123—Coated
• • 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
  • B29L2007/00—Flat articles, e.g. films or sheets
  • B29L2007/007—Narrow strips, e.g. ribbons, tapes, bands
• • 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
  • B29L2031/744—Labels, badges, e.g. marker sleeves
• • 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
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/50—Improvements relating to the production of bulk chemicals
  • Y02P20/582—Recycling of unreacted starting or intermediate materials
• • 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

Definitions

• the invention relates to the method for manufacturing a composite product as defined in the preamble of claim 1, to the composite product defined in the preamble of claim 9, to the use of the composite product as defined in the preamble of claim 16, and to the end product defined in the preamble of claim 20.
• an MDF board includes approximately 92% of wood fiber and approximately 8% of binder.
• a particle board is made using wood chips and adhesive. Wood-plastic composite products containing wood fibers and a polymer have also been manufactured by hot pressing.
• plate-type wood-plastic composite products have also been - manufactured by extruding melted material between press rolls.
• a problem in this method is the quality variation of the product manufactured by the method because the wood fibers do not move ahead evenly on the die.
• a problem in materials where wood fiber based material, separated mechanically from wood, has been used is the lignin contained by the wood fibers which provides poor color fastness, sus- ceptibility to graying and poor moldproofness in the product .
• An objective of the invention is to eliminate the drawbacks referred to above and to disclose a new type of a composite product and a method for manufacturing same.
• an objective of the invention is to disclose the use of the composite product, and an end product.
• the invention is based on a method for manufacturing a composite product, wherein the composite product is formed by a manufacturing method based on heat and pressure from a ' starting material with fiber based and plastic based components.
• a starting material containing adhesive laminate waste is used.
• the starting material in particle form such as in the form of particles, crush- ing, chopping or agglomerates, is applied, e.g. by sprinkling, on a planar base, the starting material is compressed by heat and pressure into a plate, and the obtained plate is cooled to form a composite plate.
• the invention is based on a com- posite product formed from a starting material containing fiber based and plastic based components by a manufacturing method based on heat and pressure.
• the starting material contains adhesive laminate waste
• the composite product is formed by applying the starting material in particle form on a planar base, compressing the starting material by heat and pressure into a plate, and cooling the obtained plate.
• the composite product may be a single layer plate-type product or a multilayer plate-type product.
• the thickness of the composite product ranges between 1 and 10 mm. In one embodiment, the thickness of the composite product ranges between 1 and 12 mm. In one embodiment, the thickness of the composite product ranges between 3 and 15 mm. In one embodiment, the thickness of the composite product ranges between 3 and 30 mm.
• the thickness of the composite product may be any predetermined thickness and is selected according to the purpose of use .
• the starting material contains as the fiber based component paper based material substantially consisting of lignin free fibers.
• a paper based material stands for any paper based material preferably mainly formed from lignin free fibers.
• the paper based material contains lignin free fibers in an amount of more than 50 w-% of the material.
• the lignin free fiber provides a light color and resistance to weather in the paper, and thus, herein, also in the composite product.
• Lignin is a coloring element, so the lack of it allows the use of a larger color scale, e.g. the light and bright colors as well.
• the paper based material is formed from wood fibers and/or other botanical fibers, e.g. straw, reed or flax. In one embodiment, the paper based material encompasses e.g. chemical pulp based paper or paper fiber or pure chemical pulp fiber .
• a plastic based component stands for any component substantially containing plastic, e.g. polyethylene, polypropylene or an equivalent plastic.
• the composite product is formed from a starting material mainly containing paper based and plastic based components.
• the starting material is formed from one or more starting, material components.
• the starting material may contain any paper based, e.g. wood fiber based or other fiber based, and/or plastic based components.
• the starting material may contain other components, preferably in smaller amounts than the paper based and plastic based components .
• the amount of the fiber based components in the starting material is 0 to 90 %, more preferably 30 to 80 %. In one embodiment, the parts of the fiber based and plastic based components may vary between 10 and 90 % of the composite product .
• the starting material contains glue matter which preferably comes from used adhesive laminate waste.
• the glue matter increases the binding between particles.
• the starting material at least partially encompasses recycling material. More pref- erably, the starting material encompasses mainly recycling material containing fiber based and plastic based material.
• the starting material consists mainly, in more than 50 w-%, of adhesive laminate waste.
• the adhesive laminate waste in formed from adhesive material onto which a layer of glue matter has been provided, and fitted onto the layer of glue matter as a protective sheet for the layer of glue is release material that can be easily released at the application site.
• the adhesive material and/or the release material contains a wood fiber based component and/or plastic or polymer based or other organic component. Also, the use of different inorganic materials is possible.
• the adhesive and/or the release material encompasses wood fiber based paper, pa- perboard or the like, preferably a lignin free material.
• the wood fiber based paper, paperboard or the like contains or is treated with a plastic or polymer based material.
• the adhesive and/or the release material may substantially be formed from a plastic or polymer based material.
• the release material contains a silicone-based component. The release material is preferably siliconized.
• finished adhesive laminate products, waste material produced from them and/or in their manufacture may be used as adhesive laminate was- te in the manufacture of the composite product.
• reject material from production and recycling material from the upgrading step or end use applications may be used.
• the adhesive laminate waste comes from adhesive laminate production which mainly produces production reject waste, edge trimming waste cut off from rolls, and roll ends, from the adhesive laminate printing plant which mainly produces roll ends and adhesive material left over from die-cutting of stickers and labels, and reject waste, and/or from the adhesive laminate end user customer who pastes the printed stickers and labels or the like on products.
• the waste from the end user encompasses mainly release material, roll ends and waste from the finished product.
• the composite product may contain, in addition to fiber based and plastic based components, different kinds of additives and/or additional plastic, e.g. to improve the mechanical properties, outdoor durability or processabilxty of the composite product.
• At least one additive is added to the starting material in connection with the manufacture of the composite product.
• a coloring agent, fire retardant, adhesion promoter, anti-mildew compound, antioxidant and uv stabi- lizer may be used as additives.
• Fibrous materials, organic fillers, inorganic fillers, powdery reinforcements, powdery additives, talc, wood fibers, chemical pulp fibers, paper and their combinations may preferably be added to the composite product as additives.
• the composite product contains a coloring agent which may be chosen from a large color scale, from light to dark colors, due to % the use of lignin free fibers.
• additional plastic is added to the starting material in connection with the manufacture of the composite product.
• Virgin or recycling plastic may be used as additional plastic.
• the composite product may be manufactured with or without additional plastic.
• E.g. polyolefin, polypropylene, poly- ethylene (HDPE, LDPE) or other suitable plastic or their mixture may be added to adhesive laminate waste material as additional plastic to manufacture the composite product.
• thermosetting plastic is added to the starting material as additional plastic.
• thermosetting plastics stand for phenolic and melamine resins, epoxies or other equivalent compounds.
• the composite product is formed so as to contain starting material in an amount of 50 to 100 w-%. In one embodiment, the composite product contains additional plastic in an amount of less than 50 w-%. In one embodiment, the composite product contains additives in an amount of less than 50 w-%.
• the starting material is crushed or ground into a particle form, e.g. into a chopping, crushing or granule form, starting material.
• the start- ing material in particle form is sorted, e.g. by screening, and the starting material particles having a suitable particle size are used in the manufacture of the composite product. By sorting, it is assured that the size of the starting material is suitable for a specific product to be manufactured. In one embodiment, the preferred particle size of the starting material is less than 35mm, more preferably less than 20mm.
• the manufacturing method of the composite product may include a preliminary treatment step to manufacture an intermediate product material or to treat the starting material.
• a preliminary treatment step to manufacture an intermediate product material or to treat the starting material.
• a mixing step, agglomerate forming step, granulation step, their combination or equivalent may be used as a preliminary treatment step.
• the additives and/or the additional plastic can be added to the starting material during the preliminary treatment step.
• the starting material contains agglomerates.
• agglomerates formed from a suitable material e.g. ad- hesive laminate waste, and containing fiber based and plastic based components are added to the starting ma- terial.
• the starting material is provided in the form of agglomerates e.g. in a preliminary treatment step.
• the agglomerates may also be crushed and the crushing screened to a desired size class.
• the agglomerates contain additives and/or additional plastic.
• the properties of the composite product can also be adjusted by sorting, by layering the desired particle sizes.
• the starting material can be screened and distinct layers formed from fractions with different particle sizes so as to have the optimal particle size in different layers.
• Such layering e.g. reduces the raw material costs because a cheaper and not so homogenous fraction can be used in the inside layers, and only the surface layer is formed from the fraction which is optimal for the purpose of use so as to obtain a good surface for the product.
• the surface properties of the composite product e.g. hardness, water fastness and absorption, can be adjusted by layering.
• the different layers of the composite product can be separated from each other in the manufacturing stage, e.g. by inserting a thin planar separating material, e.g. a textile material, be- tween the layers.
• a thin planar separating material e.g. a textile material
• the different layers can be formed in different colors.
• the starting material is provided on a planar base, and a composite plate is formed from the starting material by the combined effect of pres- sure, i.e. compression, and heat.
• the compression can be provided by a roll or rolls or by two horizontally arranged plate-type press tools.
• the obtained plate is cooled to room temperature.
• the cooling is performed under pressure, i.e. compression.
• the rolls or plate-type press tools of the device for forming the composite plate can be heated and/or cooled.
• a thermal compression apparatus including a base on which the starting material is applied is used in the manufacture of the composite product plate.
• the thermal compression apparatus includes a steel strip or a steel sheet which may act directly as the base.
• a thin material such as a fabric, a film, a foil or a paper, may be provided on the steel strip or steel sheet as a base. If the steel surface is used directly as a base, a release agent, such as wax or oil, is preferably applied thereon to remove the obtained plate.
• the thermal compres- sion apparatus is a roll press apparatus or a platen press .
• the thermal compression apparatus includes a heated roll forming a pressure nip with the endless steel strip.
• the steel strip is not heated, in which case the heating takes place on one side.
• the steel strip is heated, in which case the heating takes place on both sides of the starting material.
• the heating preferably takes place on both sides of the starting material.
• the heating temperature may vary between 0 and 250 °C.
• the manufacture of the com- posite product includes a plate cutting step to form a final composite product.
• a surface layer preferably a surface material, formed from a desired material, is coupled, e.g. by gluing or by partial surface melting, on one or both of the surfaces of the obtained compos- ite plate to form the desired surface on the composite plate.
• the surface layer may be coupled substantially in connection with the manufacture of the composite plate or, alternatively, after the manufacture of the composite plate.
• the plate- type composite product according to the invention can be used in both interior and exterior applications as a walling, flooring and/or ceiling/roofing material.
• the composite product may be used e.g. as a terrace, patio and balcony material or equivalent.
• the composite product may be used as a lining or surface material in different applications. Exterior claddings and interior linings can be formed from the composite product also for difficult conditions.
• different kinds of noise protection walls or noise barriers can be built from the composite product, or the composite product can be used e.g. as a flooring and walling material in diverse temporary structures, e.g. exhibition stands.
• the plate-type composite products can be assembled into a surface of a desired size.
• the plate- type composite products of same and/or different sizes can be composed in different manners, e.g. side by side, staggeredly and/or sequentially or in another desired or predetermined manner.
• the plate-type composite product may be e.g. square, rectangular, elongated parallelogram or equivalent in shape.
• the composite product or its surface can be provided with a desired pattern, color, surface roughness or appearance, depending on the application of use.
• the surface pattern can be formed in connection with the manufacture of the composite product e.g. by pressing with a patterned cloth or by other manners.
• the pattern may be for example a diamond-shaped pattern improving the frictional properties of the composite product.
• the pattern may also be a purely decorative design.
• the pattern may also be formed by post-processing the product. In one embodiment, the pattern may be produced by machining the sur- face.
• the composite product is used as a coating or a surfacing plate or one forming a desired layer in connection with at least one other material, e.g. in connection with a plate-type material or plate-type materials.
• the invention relates to an end product, preferably a combination product, formed from a plate-type composite product and at least one other material, the plate-type composite product being formed from a starting material containing adhesive laminate waste by a manufacturing method based on heat and pressure so that the starting material in particle form is applied on a planar base, the starting material is compressed by heat and pressure into a plate, and the ob- tained plate is cooled, and the plate-type composite product is provided in connection with at least one other material.
• the other material is plate-type or planar.
• the plate-type composite product is provided as a coating on at least one surface of at least one other material to form the end product.
• the thickness of the composite product to be used as a coating ranges between 1 and 12 mm.
• the plate-type composite product is inserted between two other material layers to form the end product.
• the plate- type composite product is arranged to form at least one layer in connection with a layered product to form the end product .
• the other material is a substrate material.
• a substrate material stands for a material with which the composite . product is combined to form the end product.
• the composite product can be fitted on top of or under the substrate material or inserted between two substrate materials which may be same or different.
• the composite product is formed onto a planar substrate material formed from the other material during the manufacture of the composite product in the manner according to the invention. This way, the end product on the surface of which a second coating or pattern or equivalent can be provided, if desired, is obtained directly.
• the other material may be selected from the group of a wood panel, a wood based panel, plywood, veneer, a veneer product, a particle board, fiberboard, a polymeric material, a polymer based material, a wood-plastic based material, an MDF board, an OSB board, steel, aluminum, an EPS board, a tissue, a fabric and their different combinations.
• the other material may be treated or coated in the manner required by the purpose of use.
• the composite product is provided with a backing material.
• both of the planar sur- faces of the composite product are provided with a backing material.
• the backing material is selected from the group of a polymer based film, a nonwoven fabric and their combinations.
• the polymer based film is formed from poly- propylene, polyamide and their combinations.
• the backing material may contain one or more layers.
• the backing material has gluing properties which may be activated e.g. by heating.
• One such backing material having gluing properties is a PP (polypropylene) /PA (polyamide) film.
• the backing mate- rial can be provided on the composite product during manufacturing or on a finished composite product.
• the composite product can be manufactured directly onto the backing material by sprinkling the starting material directly onto the backing mate- rial, in which case the backing material acts as the base.
• the backing material is used to form a surface layer on the surface of the composite product .
• the composite product con- tains a backing material provided on the surface from which the composite product is coupled to the other material, such as the substrate material.
• the composite product includes a backing material selected from the group of a PP/PA film and a nonwoven fabric.
• the composite product is provided with the PP/PA film as the backing material by providing the PP side of the film against the surface of the composite product.
• the starting material is applied onto a backing material placed on a planar base in the manufacture of the composite product, the backing material being selected from the group of a PP/PA film and a nonwoven fabric.
• the composite product can be formed as a layered composite product onto a base or onto a substrate material and/or backing material provided onto a base by providing the starting material onto the base, substrate material or backing material in layers.
• the different layers can be separated on the basis of color or mixing ratios of the materials.
• the different layers are made from the same material.
• the different layers can be separated from each other by a separating material, e.g. a textile material, a sheet- ing, a film or equivalent, in connection with the manufacture of the composite product.
• the composite product is provided in connection with the other material by gluing.
• the glue is selected from the group of phenolic resin adhesives, phenol-formaldehyde based adhesives, urea-formaldehyde based adhesives, phenol based films, polyurethane based hotmelt adhesives, 2 component dispersions, 2 component polyure- thanes, epoxy adhesives, polyester adhesives and their different combinations. Also other adhesives or gluing agents or materials can be used.
• the adhesive is chosen according to the purpose of use, i.e. the choice of the adhesive depends on the obtained composite product or its backing material and the other material used, such as the substrate material on which the composite product is glued.
• the composite product is provided in connection with the other material by heat and pressure. In one embodiment, the composite product is provided in connection with the other material during the manufacturing process of the material in question or the composite product.
• the composite product and its manufacture and use and the end product containing the composite prod- uct according to the invention have many important advantages compared with the ' prior art.
• an advantage of the invention is an inexpensive product in harmony with the sustain- able development, thanks to the use of a recycling material .
• the composite product is easily provided with a warm and natural, e.g. woodlike or stonelike, sur- face.
• the composite product according to the invention is substantially lighter in square weight.
• the composite product according to the inven- tion need not be post-processed, e.g. brushed, polished or painted, in connection with the manufacture. This enables avoiding surface modifications to the element, e.g. opening, where the protective effect of additives is weakened. In addition, the composite products according to the invention are easily cleans- able .
• a composite product which can be easily manufactured on an industrial scale and used' for many purposes in both interior and exterior use is achieved by the invention.
• the composite products according to the invention are easily machineable. No special tools are needed for machining, but the normal tools used for treating wood are sufficient.
• an advantage of the invention is that, compared with products formed by e.g. extrusion, a fraction with different types of plastics, such as waste plastic and recycling plastic, with different melt flow properties can be used as the start- ing material.
• the use of such fractions is difficult in extrusion-type manufacturing applications, but in the method according to the invention there are no problems .
• Plate-type composite products according to the invention were formed from a starting material mainly formed from adhesive laminate waste.
• the starting material used was mainly, in approximately 60 w-%, adhesive laminate waste containing chemical pulp based, i.e. lignin free, paper, plastic based material, glue matter and a silicone based component.
• polypropylene was mixed as additional plastic in an amount of approximately 25 w- % and additives in an amount of approximately 15 w-% in a preliminary treatment device, and agglomerates of less than approximately 20mm were formed from the starting material.
• the agglomerates were sprinkled on an even planar base of a platen press, moved to a pressing step and compressed by heat and pressure into a composite plate.
• the heating was effected on both sides of the starting material by adjusting the temperature of the press plates to approximately 250°C.
• the obtained plate was cooled to room temperature.
• plates were formed having a thickness of 3 to 30 mm, most suitably 3 to 15 mm, and having a surface pattern resembling a stone-like surface due to the starting material used.
• Plate-type composite products according to the invention were formed from a starting material mainly formed from adhesive laminate waste.
• the starting material used was mainly, in approximately 90 w-%, adhesive laminate waste containing chemical pulp based, i.e. lignin free, paper, plastic based mate- rial, glue matter and a silicone based component.
• polypropylene was mixed in an amount of approximately 10 w-% as additional plastic in a preliminary treatment device, and agglomerates of less than approximately 20mm were formed from the starting material.
• the agglomerates were sprinkled on an even planar base of a platen press, moved to a pressing step and compressed by heat and pressure into a composite plate.
• the heating was effected on both sides of the starting material by adjusting the temperature of the press plates to approximately 250°C.
• the obtained plate was cooled to room temperature.
• plates were formed having a surface pattern resembling a stone-like surface due to the starting material used.
• Plate-type composite products according to the invention were formed from a starting material mainly formed from adhesive laminate waste.
• the starting material used was mainly, in approximately 60 w-%, adhesive laminate waste containing chemical pulp based, i.e. lignin free, paper, plastic based material, glue matter and a silicone based component.
• the starting material was chopped and screened so that the particles of less than approximately 20mm were used for manufacturing the composite plate.
• polypropylene was mixed as additional plastic in an amount of approximately 25 w-% and additives in an amount of approximately 15 w-% in a mixer.
• the starting material particles together with additives and additional plastic were sprinkled on an even planar base of a platen press, moved to a pressing step and compressed by heat and pressure into a composite plate.
• the heating was effected on both sides of the starting material by adjusting the temperature of the press plates to approximately 250°C.
• the obtained plate was cooled to room temperature.
• plates were formed having a surface pattern resembling a stone-like surface due to the starting material used.
• Examples 1 to 3 textured plates resembling a natural material were easily provided by a technique known per se, using the sprinkling and pressing technique.
• a layered composite product is formed using as the starting material 40 to 90 w-% of adhesive laminate waste containing chemical pulp based, i.e. lignin free, paper, plastic based material, glue matter and a silicone based component.
• the starting material is chopped and mixed with approximately 10 to 60 w-% of recycling plastic.
• the recycling plastic may contain polyethylene, polypropylene and polyethylene terephthalate .
• the starting material is sprinkled in layers on an even planar base.
• the layers of different colors and different qualities are separated from each other by textile materials.
• a layered composite product plate is formed by compressing using heat and pressure.
• the composite product is provided with a total thickness of 1 to 12 mm.
• a composite plate formed in this manner can be used as such or in association with another mate- rial e.g. in traffic signs, info boards, billboards or equivalent .
• a backing material can be associated, if desired, in connection with the manufacture on one or both sides of the composite product manufactured in the manner described above. If the. obtained composite product is used in association with e.g. a wood based material, a PP (polypropylene) /PA (polyamide) film is provided on the surface of the composite plate as a backing material, so that the PP side of the film is coupled against the surface of the composite plate. Alternatively, a nonwoven fabric can be used as a backing material.
• the layers of different colors allow the ma- chining out of the color in the lower layers by a suitable machining method, e.g. cnc technique.
• Different kinds of end products are formed by combining the obtained composite product with different substrate materials.
• a composite product plate is formed using as a basic material 40 to 90 w-% of adhesive laminate waste.
• the starting material is chopped and mixed with approximately 10 to 60 w-% of recycling plastic.
• the recycling plastic may contain polyethylene, polypropylene and polyethylene terephthalate .
• the starting material and plastic mixture is sprinkled on a planar base, moved to a pressing step and compressed by heat and pressure into a composite plate.
• the thickness of the obtained composite plate is 1 to 12 mm.
• End product A A 2 layered
• PP (polypropylene) /PA (polyamide) film is provided as a backing material for the obtained composite product by providing the PP side of the film against the surface of the composite product.
• the PP/PA film is provided on the product in connection with the manufacture of the composite product by placing the film on a planar base with the PA side against the base.
• the starting material/recycling plastic mixture is sprinkled onto the film and led together to a pressing step.
• the PP side of the PP/PA film is fused by the effect of heat on the composite product, forming this way a backing material for the composite product.
• Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• End product B A nonwoven fabric is provided in connection with the manufacture of the composite product as a backing material for the obtained compos- ite product by placing the fabric on a planar base. The starting material/recycling plastic mixture is sprinkled onto the fabric and led together to a pressing step. In the pressing step, the nonwoven fabric adheres by the effect of heat and pressure on the com- posite product, forming this way a backing material for the composite product. Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• End product C Composite product A is com- bined with plywood by providing the PA side of the backing material film against the plywood.
• Composite product A is glued on the surface of the plywood by a phenolic film, i.e. phenolic resin integrated with paper.
• a desired pattern can be provided on the out- wardly visible composite product surface of the end product. In this connection, a checkered pattern is pressed in the pressing step of the manufacture of the composite product on the outwardly visible surface of the composite product.
• End product D The obtained composite product is glued on at least one surface of a substrate mate- rial, e.g. plywood. Adhesives presented in Table 1 can be used as the adhesive. Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• End product E The obtained composite product is inserted between layer materials, e.g. wood veneers, by gluing to form a layered end product.
• Adhesives presented in Table 1 can be used as the adhesive.
• Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• End product F A thin film-type material chosen from the group of plastic films, a decorative film, a fabric, artificial leather, leather, wood ve- neer, an aluminum sheet and a steel sheet is provided as a surface layer for the obtained composite product.
• the total thickness of the composite product is 3 to 30 mm.
• Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• End product G End product F is combined with at least one surface of a structural board, such as a veneer product, to form an end product.
• Adhesives presented in Table 1 can be used as the adhesive.
• End product H End product F is inserted between wood veneers to form a layered end product from veneers and the composite product.
• Adhesives presented in Table 1 can be used as the adhesive.
• End product I Serving utensils, such as trays, and noise abatement and sound insulation components are formed from a composite plate having a thickness of 1 to 10 mm.
• the desired surface materials such as a plastic film or a nonwoven fabric, and the desired patterns can be provided on the surface of the composite plate, depending on the purpose of use of the end product.
• the composite plate and parts cut off from it are heated and shaped into end products by pressing. Layered or single-layer composite products formed in the manner described above can be used as the composite product.
• a composite product plate is formed using as a basic material 40 to 90 w-% of adhesive laminate waste.
• the starting material is chopped and mixed with approximately 10 to 60 w-% of recycling plastic.
• the recycling plastic may contain polyethylene, polypropylene and polyethylene terephthalate .
• the starting material and plastic mixture is sprinkled on a planar base, moved to a pressing step and compressed by heat and pressure into a composite plate.
• the thickness of the obtained composite plate is 1 to 12 mm.
• a layered PP/PA film is provided as a backing material on both of the planar surfaces of the composite plate.
• the PP/PA films are provided on the product in connection with the manufacture of the composite product by placing the first film on a planar base with the PA side against the base.
• the starting material/recycling plastic mixture is sprinkled onto the film.
• the second PP/PA film is placed onto the start- ing material/recycling plastic mixture so that the PP side is against the starting material/recycling plastic mixture.
• the layered product structure is led to a pressing step.
• the PP side of the PP/PA films is fused on the composite product by the effect of heat.
• the polypropylene contained by the starting material crushing is fused with the polypropylene layer of the film.
• the obtained composite product is glued by phenolic resin adhesive between two plywoods from the side of the PA film layers to form an end product.
• the end products formed in the examples can be used in transport vehicle industry, e.g. lining plates, walls and floors in vans and trucks, walls and floors in horse hauling trailers, floors in trailers, lining plates in caravans, floors in pickup trucks, as lining plates and equivalent in refrigerated containers; as construction elements, e.g. non-bearing wall elements, washable wall and floor panels, roof cover- ing sheetings, wind shield boards, concrete slabs, door panels, floor panels in terraces, terrace floor boards, temporary dismountable and mountable floor and wall panels, e.g. in stadiums, indoor ice-skating rinks or exhibition facilities, exterior wall ele- ments, noise barrier panels and equivalent; in shipbuilding industry, e.g.
• deck plates in freighters, lining plates in ships or equivalent; in boat industry, e.g. as deck solutions or equivalent; in packaging industry, e.g. as transport pallets and crate panels; in furniture, e.g. as table surfaces or equivalent; and in information applications, e.g. as billboards, info boards, traffic signs or equivalent.
• the composite product according to the invention suits in different embodiments to be used as most different kinds of material solutions in different applications and to form most different end products.

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• Environmental & Geological Engineering (AREA)
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• 2009
  • 2009-10-28 FI FI20096106A patent/FI20096106A/sv not_active IP Right Cessation
• 2010
  • 2010-09-17 WO PCT/FI2010/050722 patent/WO2011051546A1/en active Application Filing

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