WO2011117569A1 - Formation de panneaux en plastique - Google Patents

Formation de panneaux en plastique Download PDF

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Publication number
WO2011117569A1
WO2011117569A1 PCT/GB2011/000395 GB2011000395W WO2011117569A1 WO 2011117569 A1 WO2011117569 A1 WO 2011117569A1 GB 2011000395 W GB2011000395 W GB 2011000395W WO 2011117569 A1 WO2011117569 A1 WO 2011117569A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
layer
moulds
grained
layers
Prior art date
Application number
PCT/GB2011/000395
Other languages
English (en)
Inventor
Peter Aylmore
Simon Wiper
Original Assignee
Ipco Ventures 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
Priority claimed from GB1005058.1A external-priority patent/GB2478977B/en
Application filed by Ipco Ventures Limited filed Critical Ipco Ventures Limited
Publication of WO2011117569A1 publication Critical patent/WO2011117569A1/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
    • 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
    • B29C44/0461—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 by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/048—Expandable particles, beads or granules
    • 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
    • B29L2009/00—Layered products

Definitions

  • This invention relates to a method of forming a composite plastic panel or moulding from particulate material and fillers including suitable plastics and especially to a method which is useful for producing panels from a high proportion of recycled material.
  • thermoplastic material of the outer layer may not penetrate the core layer sufficiently to bind it together.
  • sheets of metal or other suitable sheet material may be utilised, but in any case the formation of such panels by conventional methods tends to involve a relatively slow and cumbersome multi-stage process, because of the necessity to pre-form some
  • the present invention provides a method of moulding articles from heat mouldable powdered material, comprising the steps of laying down at least two layers of material of different granular fineness in an open-topped mould, at least one of the layers including heat mouldable material, applying a top closure to the mould, and then heating the mould and the closure to melt and fuse the powdered material.
  • the layers of powdered material may be laid down in the mould by means of a known type of powder distributor comprising a trough which can be traversed over the mould, and has a dispensing roller arranged in the base which can be rotated at a suitable speed to control the dispensing rate.
  • At least the coarser one of the layers includes a foaming agent which is heat or chemically-activated, so that the structure expands in the closed mould to form a rigid composite article.
  • a foaming agent which is heat or chemically-activated, so that the structure expands in the closed mould to form a rigid composite article.
  • that layer includes a thermoplastic material so that application of heat to the mould while it is closed, assists in fusing or bonding the article together.
  • there is a coarse-grained layer of material which may advantageously include ground-up, recycled waste material, mixed with a foaming agent, and a finer-grained layer which comprises or includes thermoplastic material which forms a smooth outer skin.
  • a preferred form of the present invention provides a method for moulding panels having a relatively fine external finish, and a relatively coarse "core" structure which may include ground-up recycled materials, comprising the steps of:
  • the central layer includes a heat-activated or chemically-activated foaming agent.
  • heat may be applied to the moulds in advance of the addition of the moulding materials, and/or while they are being added, as well as after the moulds are closed.
  • the layers of powder are laid down by means of a multi-compartment tray distributor having a roller type dispensing mechanism at the base of each compartment, which is arranged to traverse across the mould or moulds and adapted to distribute powder at controlled rates as it moves.
  • the tray may be arranged to distribute one or more layers in each pass.
  • the top- plate is gradually retracted by a predetermined distance, whilst maintaining contact with the product, to allow the panel to expand to a suitable thickness.
  • a predetermined distance for example by means of hydraulic or pneumatic actuators with feedback control.
  • the finer grained powder is in the range of 100 to 3000 pm, most preferably 500 to 1000 pm, and may include thermoplastic material such as polyethylene, whilst the coarser grained powder may include various kinds of suitable granular filler made by grinding a variety of recycled materials, and may have a granule size of up to 10 mm.
  • the external skin layers may be 1 to 1 1 ⁇ 2 mm thick, so that the internal core is approximately 15 mm thick, and panels may, for example, be made in a similar way, up to 30 mm thick, with the same outer skin thickness.
  • the external skin layers may be anywhere between 1 ⁇ 2 mm and 7 mm thick while the panel may have a total thickness of up to 10 cm.
  • the powder is added to the mould, while still at least at ambient temperature, and the temperature is raised to a temperature of up to 350°C, but typically between 190° and 220°after the mould has been closed, and held there for a length of time which depends on the thickness and density of the resulting product but is usually in the range of 5 to 40 minutes. In a typical case it will be 10 to 20 minutes.
  • heat is applied by means of fluid passages in the material of the moulds which may be made from a relatively easily workable material such as aluminium, since the temperature and pressure involved in the process are not particularly high.
  • the moulds may be made from more resistant materials such as pyrex glass or ceramic.
  • fluid heating electric resistance, inductive, or microwave heating may be employed.
  • the moulds must be rigidly supported, and the upper mould also requires a suitable mechanism behind it, such as an arrangement of pneumatic or hydraulic rams, to hold it in position during the process.
  • the process is able to utilise a wide range of recycled material, including paper, cardboard, rubber, plastics and metal, fibres and minerals, so long as it is of a suitable size, although preferably, a proportion of suitable thermoplastic material is included, especially in the outer skin layers, so as to fuse the material into a unitary structure. Additional material can also be included such as glass or carbon fibre,
  • reinforcement steel mesh or organic fibre such as bamboo or banana fibre as well as material intended to add specific properties such as fire-retardant or anti-ballistic material.
  • a plurality of tray-shaped lower moulds are arranged in an array and a corresponding array of upper moulds are arranged to be movable into a position above the filled lower moulds to be lowered into engagement with them, to form panels using the steps of the method set out above, and the formed panels can then be removed from the lower moulds which are then refilled so as to enable a continuous production process to be achieved.
  • Figure 1 shows a first arrangement comprising two sets of moulds "A" and "B", each consisting of an array of four female formers or trays 2, 4, (making eight lower moulds) and corresponding array of four male moulds 6, 8 (making eight upper moulds);
  • Figures 2-18 illustrate successive steps in the forming process for the arrangement of Figure 1 ;
  • Figures 19-34 illustrate corresponding steps utilising an alternative arrangement including a total of sixteen female formers to optimise the use of the other equipment as explained in more detail below;
  • Figure 35 is a diagrammatic cross-section through a powder distribution device.
  • Figure 36 is a diagrammatic cross-section through a single-mould arrangement.
  • Figure 36 illustrates the basic principle of the invention utilising a single female mould 100 into which successive layers 102, 104 of different powdered materials have been laid down. A male mould half is then lowered into contact with the top layer 104 which comprises relatively fine-grained thermoplastic material, and heat is applied to melt the layer.
  • the coarser grained material of the lower layer 102 may include a foaming agent which is also heat-activated, and thus the lower layer expands so that the two layers become compressed between the mould halves forming a rigid composite panel.
  • the upper mould half 106 may then be allowed to retract slightly in response to the pressure, to allow the panel to reach a predetermined thickness.
  • Figures 1-35 illustrate in more detail, a system for producing panels in batches, rather than singly.
  • Figure 1 shows an arrangement including of a first mould set "A" which comprises a rectangular female mould 2 including four female formers or trays 10, 12, 14, 16, and a male mould including four corresponding rectangular lands or projections 18, 20, 22, 24 which are sized to fit into the openings of female trays 10-16.
  • a second mould set “B” comprises four female formers or trays 26-34 and four corresponding male projections 36-42.
  • Female mould sets 2 and 4 are arranged beneath corresponding sets of vertically movable actuators, not shown, which are used as explained in more detail below, for bringing the corresponding male mould sets 6, and 8, into engagement with them in the course of the moulding process.
  • a powder dosing unit 44 comprising a compartmented tray for moulding powders is arranged on a suitable support track so that it can traverse across the female mould sets 2 and 4. At the start of the process ( Figure 1 ), all the moulds start at least at ambient temperature, and the powder dosing unit is traversed across the female moulds 2 of mould set "A".
  • the dosing unit has three laterally-extending compartments as described below, with reference to Figure 35, the leading compartment dispensing a first, relatively fine powder to form the lower surface of the moulding, the middle compartment dispensing a relatively coarse powder, including a blowing agent to form the core, and finally the trailing compartment being arranged to dispense a further fine layer to form the upper surface.
  • Figure 6 shows the next stage where the powder dosing unit 44 has completed its traverse of female mould 4 and in the meantime the temperature of the heaters of mould set "A" is raised to a level which is sufficient to create skins on both the upper and lower surfaces of the powder bodies in the four moulds.
  • mould set "A” is closed, the actuators being carefully controlled to a precise vertical position to contact the hot male mould surface with the powder, for example by feedback control in accordance with the back pressure.
  • the male moulds 8 of mould set B are being shifted towards the engagement position above their corresponding female moulds 4, while moulds 4 and 8 are both heating up.
  • Figures 9 and 10 show the stage of the process where the material in mould set A has reached the point where the blowing agent of the core is activated, and when the resulting increase in back pressure is detected, male mould set 6 is retracted to allow expansion towards a preset position which defines the intended thickness of the moulded panel, which is achieved by foaming of the blowing agent. At the same time, male and female mould halves "B" are closed together, while continuing to heat up. The powder dosing unit which has returned to the central position, is now being topped up ready for the next powder dispensing cycle.
  • each "set” includes female mould trays, for 8 panels, and male moulds for 4 panels so that a total of 16 panels can be in different stages of foaming at the same time.
  • the adjacent female moulds of one set are shown as “A” and “C”, with the male moulding being shown as “X”.
  • the female moulds of the other set are shown as "B” and “D” and the male mould as ⁇ ", as indicated in Figure 20.
  • This figure illustrates how the first pass of the dosing unit (44) is used to fill female mould "C” so that the first (lower) layer of fine powder material, and 50% of the core material are laid down, and then on the return pass ( Figure 21 ) the other 50% of core material and the second (top) layer of fine material are added so that the dosing unit is traversed back to the central position.
  • the dosing unit then continues to traverse in the same direction in Figure 22, to lay down a first layer of fine material and 50% of the core material in mould “D” while male mould “X” moves to cover female mould “C” and reverses direction to dispense the remaining 50% of the core material, and the second layer of fine material in mould set “D", so that the male mould set "Y” can then be moved to cover it (Figure 23).
  • the dosing unit can be moved laterally to a position between the second female mould sets "A” and “B” which are exposed by movement of the male moulds "S” and ⁇ " away from their mutual positions ( Figure 24). Then, in a similar sequence to that described above for filling mould sets "C” and “D” ( Figures 19-23) the dosing unit is first traversed across mould set "A” first "outwardly” ( Figure25) and then “inwardly” ( Figure 26) directions, and then traversed across mould set "B” “outwardly” ( Figure 27) and then “inwardly” ( Figure 28).
  • Upper moulds have generally been referred to as male in the above description but both could of course be female depending on the shape to be moulded.
  • FIG 35 is a diagrammatic cross-section through an exemplary powder dosing unit having three compartments 52, 54, 56 which in use carry the different powder constituents for the three layers in the process described above.
  • the compartments are generally trough-shaped and each is provided with a respective dispensing roller 58, 60, 62 at its base, so that powder can be dispensed at a controlled rate.
  • Each roller is provided in known fashion, with projections (usually pinlike) which are distributed all over its circumference, or may be arranged in a pattern to match the mould shapes, the size and spacing being arranged to suit the granularity of the powder.
  • thermoplastic materials including but not limited to poiyolefins eg polyethylenes, styrenics eg polystyrene, polyesters (eg PET), thermosets eg phenolics and rubbers.
  • foaming or "blowing” agent which may be utilised are for chemical systems: exothermics, eg azodicarbonamide i.e. "Porofor" (Lanxess) or “Celogen” (Lion Copolymer), or sodium bicarbonate.
  • exothermics eg azodicarbonamide i.e. "Porofor” (Lanxess) or “Celogen” (Lion Copolymer
  • endothermics are hydroxypropane tricarboxylic acid eg "Hydrocerol” (Clariant).
  • Physical systems can include for instance nitrogen or other gases, for example a gas such as pentane may be preimpregnated in polystyrene or expanded polypropylene and then released as a gas. Alternatively nitrogen can be utilised in a system such as the "Zotefoam” nitrogen saturation process.

Landscapes

  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

La présente invention se rapporte à un procédé de moulage d'objets à partir d'un matériau en poudre, comprenant les étapes consistant à étaler au moins deux couches de matériau en poudre de finesse granulaire différente qui comprennent un matériau moulable à chaud, dans un moule à partie supérieure ouverte, à appliquer une fermeture supérieure au moule, puis à chauffer le moule et la fermeture pour faire fondre et fusionner le matériau en poudre. De cette façon, un objet, tel qu'un panneau de construction, peut être créé pour renfermer le matériau recyclé, avec trois couches, comprenant deux revêtements extérieurs de matériau à grains relativement fins, et un noyau intérieur comprenant un matériau à gros grains tels que des chutes broyées.
PCT/GB2011/000395 2010-03-25 2011-03-21 Formation de panneaux en plastique WO2011117569A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB1005058.1 2010-03-25
GB1005058.1A GB2478977B (en) 2010-03-25 2010-03-25 Forming plastic panels
US12/960,028 2010-12-03
US12/960,028 US20110298147A1 (en) 2010-03-25 2010-12-03 Forming plastic panels

Publications (1)

Publication Number Publication Date
WO2011117569A1 true WO2011117569A1 (fr) 2011-09-29

Family

ID=44041733

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2011/000395 WO2011117569A1 (fr) 2010-03-25 2011-03-21 Formation de panneaux en plastique

Country Status (1)

Country Link
WO (1) WO2011117569A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10731346B2 (en) 2017-03-16 2020-08-04 Thomas L. Kelly Roofing cover board with coating
US10808405B2 (en) 2017-03-16 2020-10-20 Thomas L. Kelly Roofing cover board with coating

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1327028A (en) * 1970-09-09 1973-08-15 Serck Industries Ltd Stratified fluoro-carbon resin material
US4734231A (en) 1985-12-23 1988-03-29 Gunei Kagaku Kogyo Kabushiki Kaisha Process for the preparation of fiberboards
DE4406039C1 (de) * 1994-02-24 1995-03-30 Erlenbach Gmbh & Co Kg Formkörper aus Verbundmaterial und Verfahren zur Herstellung eines solchen Verbundmaterials
US5693273A (en) * 1995-09-11 1997-12-02 Redound Industries, Inc. Method of making multi-porosity porous plastic strips
US6180203B1 (en) * 1997-04-09 2001-01-30 Peter J. Unkles Rotational moulding process
JP2003112329A (ja) 2001-10-03 2003-04-15 Yaita Kako Sangyo:Kk モミガラ、ワラを表面材としたボードの製造方法
EP1375129A2 (fr) * 2002-06-27 2004-01-02 Lucobit AG Procédé pour fabriquer une plaque en matière plastique et plaque en matière plastique
US20050202253A1 (en) * 2004-02-09 2005-09-15 Thomas Grafenauer Wooden board and a method for producing a wooden board
EP1690662A1 (fr) * 2003-10-17 2006-08-16 Shiina Kasei Co. Procede pour produire une mousse plastique composite

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1327028A (en) * 1970-09-09 1973-08-15 Serck Industries Ltd Stratified fluoro-carbon resin material
US4734231A (en) 1985-12-23 1988-03-29 Gunei Kagaku Kogyo Kabushiki Kaisha Process for the preparation of fiberboards
DE4406039C1 (de) * 1994-02-24 1995-03-30 Erlenbach Gmbh & Co Kg Formkörper aus Verbundmaterial und Verfahren zur Herstellung eines solchen Verbundmaterials
US5693273A (en) * 1995-09-11 1997-12-02 Redound Industries, Inc. Method of making multi-porosity porous plastic strips
US6180203B1 (en) * 1997-04-09 2001-01-30 Peter J. Unkles Rotational moulding process
JP2003112329A (ja) 2001-10-03 2003-04-15 Yaita Kako Sangyo:Kk モミガラ、ワラを表面材としたボードの製造方法
EP1375129A2 (fr) * 2002-06-27 2004-01-02 Lucobit AG Procédé pour fabriquer une plaque en matière plastique et plaque en matière plastique
EP1690662A1 (fr) * 2003-10-17 2006-08-16 Shiina Kasei Co. Procede pour produire une mousse plastique composite
US20050202253A1 (en) * 2004-02-09 2005-09-15 Thomas Grafenauer Wooden board and a method for producing a wooden board

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10731346B2 (en) 2017-03-16 2020-08-04 Thomas L. Kelly Roofing cover board with coating
US10808405B2 (en) 2017-03-16 2020-10-20 Thomas L. Kelly Roofing cover board with coating

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