WO2011144752A2 - Extruded polymer product and method for making the same - Google Patents

Extruded polymer product and method for making the same Download PDF

Info

Publication number
WO2011144752A2
WO2011144752A2 PCT/EP2011/058299 EP2011058299W WO2011144752A2 WO 2011144752 A2 WO2011144752 A2 WO 2011144752A2 EP 2011058299 W EP2011058299 W EP 2011058299W WO 2011144752 A2 WO2011144752 A2 WO 2011144752A2
Authority
WO
WIPO (PCT)
Prior art keywords
polymer product
material
extruded polymer
rice hulls
cellulose
Prior art date
Application number
PCT/EP2011/058299
Other languages
French (fr)
Other versions
WO2011144752A3 (en
Inventor
Thomas Burkhart
Carsten Günter HELDMANN
Volker JÖRRES
Original Assignee
Fiberweb Corovin Gmbh
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 to EP10005313.1 priority Critical
Priority to EP10005313 priority
Application filed by Fiberweb Corovin Gmbh filed Critical Fiberweb Corovin Gmbh
Publication of WO2011144752A2 publication Critical patent/WO2011144752A2/en
Publication of WO2011144752A3 publication Critical patent/WO2011144752A3/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/02Layered products comprising a layer of synthetic resin in the form of fibres or filaments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05Filamentary, e.g. strands
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/285Feeding the extrusion material to the extruder
    • B29C48/286Raw material dosing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/285Feeding the extrusion material to the extruder
    • B29C48/288Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B29C48/2886Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling, sewing, stitching, hydroentangling, hook and loop-type fasteners to another layer, e.g. of fibres, of paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G
    • C08J7/00Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04Coating
    • C08J7/047Coating with only one layer of a composition containing a polymer binder
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10Homopolymers or copolymers of propene
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D1/00Treatment of filament-forming or like material
    • D01D1/06Feeding liquid to the spinning head
    • D01D1/065Addition and mixing of substances to the spinning solution or to the melt; Homogenising
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00General methods for the manufacture of artificial filaments or the like
    • D01F1/02Addition of substances to the spinning solution or to the melt
    • D01F1/10Other agents for modifying properties
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00Indexing scheme relating to extrusion moulding
    • B29C2948/92Measuring, controlling or regulating
    • B29C2948/92504Controlled parameter
    • B29C2948/92723Content, e.g. percentage of humidity, volatiles, contaminants or degassing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00Indexing scheme relating to extrusion moulding
    • B29C2948/92Measuring, controlling or regulating
    • B29C2948/92819Location or phase of control
    • B29C2948/92828Raw material handling or dosing, e.g. active hopper or feeding device
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0011Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16Fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Impregnation or embedding of a layer; Bonding a fibrous, filamentary or particulate layer by using a binder
    • B32B2260/02Composition of the impregnated, bonded or embedded layer
    • B32B2260/021Fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Impregnation or embedding of a layer; Bonding a fibrous, filamentary or particulate layer by using a binder
    • B32B2260/04Impregnation material
    • B32B2260/046Synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0253Polyolefin fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06Vegetal fibres
    • B32B2262/062Cellulose fibres, e.g. cotton
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06Vegetal fibres
    • B32B2262/062Cellulose fibres, e.g. cotton
    • B32B2262/067Wood fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/724Permeability to gases, adsorption
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/732Dimensional properties
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G
    • C08J2301/00Characterised by the use of cellulose, modified cellulose or cellulose derivatives
    • C08J2301/02Cellulose; Modified cellulose
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised 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
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised 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
    • C08J2323/10Homopolymers or copolymers of propene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00Applications
    • C08L2203/12Applications used for fibers

Abstract

The invention is related to an extruded polymer product comprising a polymer material comprising at least one polyolefin and wherein cellulose material obtained from rice hulls is embedded in the polymer material. Also a method is proposed by which the extruded polymer might be manufactured.

Description

Extruded polymer product and method for making the same

The invention relates to a product using a polymer material and a percentage of cellulose material, as well as a method and a device for manufacturing this product.

The manufacturing of polymer products with the use of cellulose materials has been known for many years. Frequently used cellulose materials include wood dust or wood chips. Also known is the manufacturing of textile fabrics, which are formed from spunbond, melt- blown nonwovens or needle punched nonwovens. In addition, laminates of combinations of one or more layers of a nonwoven and a film are known.

The application of film layers of a thermoplastic polymer on textile fabrics is also known. For example, multi-layer fabrics produced using thermobonding are described in WO 95/1 1803.

On the other hand, textile fabrics of polyolefins, polyester, cotton or cellulose extrusion- coated with polyolefins are known from WO96/09165.

In addition, methods are known that increase the thermodynamic compatibility between organic filler or reinforcement materials and polymers, especially non-polar polymers in order to obtain composites with a desired level of properties. Since the processing of fiber materials containing cellulose to make filler materials is very cost-intensive because of their ductile behavior, the application areas of these filler materials in the area of polymer products with moderate or low price level are restricted to products that have a relatively compact form. The object of the present invention consists of making available a polymer product using a polymer material and a cellulose material, which can be manufactured with reasonable financial expense.

This object is achieved with an extruded polymer product with the characteristics of Claim 1 , with a method for use of rice hulls according to Claim 15, with a system for manufacturing an extruded polymer product according to Claim 20, as well as with a master batch to be extruded for manufacturing preferably spun fibers according to Claim 23. Preferred embodiments are defined in the subclaims. However, the characteristics included can also be linked with other characteristics from the following description for further designs and are not restricted solely to the respective claimed further development.

The extruded polymer product has the advantage that relatively thin-walled polymer prod- ucts or polymer products with very small diameters can be manufactured, which have a wood-like character and can be manufactured on the usual plastic processing systems.

An extruded polymer product comprising at least one polyolefin and wherein cellulose material obtained from rice hulls is embedded in the polymer material is suggested. The cellulose material is embedded as a filler material in the polymer material, which acts as a matrix component in the composite that occurs. Preferably the polymer material has at least one polyolefin, preferably a polyethylene or a polypropylene.

In one embodiment of the invention, the extruded polymer product is formed as a film. This film can be designed with one or more layers and be created by means of an extrusion process.

Another embodiment of the invention provides that the extruded polymer product is a spun fiber. Nonwovens that contain these types of fibers can be produced in various ways. Ad- vantageously, the nonwoven is produced according to a spun bond method. A method of this type is described, for example in DE 10322460 and DE 10240191. However, in addition, embodiments are possible for this nonwoven, in which, e.g., a melt-blown process has been used for manufacturing the nonwoven, as is described in DE 19923344. However, the polymer product can have as matrix-forming components, in addition to a polyolefin or its copolymers, other film-forming or spinnable plastics, for example polyam- ides, polyesters, polyurethanes, acrylate-based polymers and similar polymers. If necessary, other additives in the form of processing aids, other fillers, especially of an inorganic nature, like, e.g., calcium carbonate, dyes, pigments or functional additives, for example antioxidants, UV stabilizers, flame inhibitors or antistatics are provided. The polymer products in the following can have a surface treatment, which is carried out during the manufacturing process for the polymer product or can be carried out in a subsequent process step. For example, they can be provided with a hydrophilic coating, which is preferably sprayed on or applied to the polymer product in an immersion process.

For example, as a polymer material, a polyethylene with an MFI between 15 and 35 g/10 min, and preferably between 15 and 20 g/10 min. according to ISO 1 133 and a density of 0.935 to 0.965 g/cm3 according to ASTM D-792 can be used. Also, the use of an LLDPE with a density between 0.85 and 0.90 g/cm3 according to ASTM D-762 is possible. In addition, a polymer mixture consisting of polyethylene homopolymers and/or polyethylene copolymers can be used. For example, a polymer mixture of a polyethylene manufactured by the Dow company under the manufacturer designation "ASPUN 6834" can be used as polymer matrix. This has an MFI of 17 g/10 min according to ISO 1 133 at a density of 0.95 g/cm3 according to ASTM D-792 and a melting point of 130°C according to DSC measurement. This material is suitable for purchase by the manufacturer for the manufacturing of nonwoven fibers and/or polymer fibers. Another polymer that can be used as matrix is the polyethylene sold by the Dow company under the manufacturer designation "ASPUN 6834A." This has a density of 0.955 g/cm3 according to ASTM D.792, a MFI of 30 according to ASTM D-1238 and a DSC melting point of 131 °C.

The term "cellulose material" is understood to mean organic filler or reinforcement materials, which in addition to other constituents, e.g., lignin, also have a portion of cellulose or hemi-cellulose.

One embodiment of the invention provides that the cellulose material is obtained from a renewable plant material. Polymer products in the sense of this invention are not restricted to cellulose materials of rice hulls. In the dry substance, rice hulls exhibit about 50 weight-% cellulose and hemi- cellulose and 26 weight-% lignin, and thus belong to the so-called lignocellulose- containing materials and with respect to the composition are related to other natural fibers, e.g., wood fibers.

In addition, the cellulose material can also be obtained from wood in the form of sawing or planing chips, peat, kenaf, flax, linen, hulls from seed shells, especially grain hulls, grass seed, bran, compost of rinds, coconut fibers or substances with low or no fiber content, especially rinds or nut shells or mixtures of natural materials containing fiber, with low fiber or free of fiber. Depending on the cell structure, the average raw density of the cellulose fibers, especially the percentage of cell wall substance and the degree of fiber inclusion is between 0.3 to 1.3 g/cm3, preferably between 0.4 to 0.8 g/cm3 and more preferably between 0.4 to 0.6 g/ g/cm3. The apparent density of the cellulose fibers lies between 90 and 500 kg/m3, preferably between 130 to 330 kg/m3, measured according to DIN EN 12580.

In order to be able to embed filler or reinforcement materials, for example rice hulls or other materials containing cellulose in a suitable way in a polymer and process it to a polymer product, it is necessary to pretreat the filler or reinforcement material. This require- ment results, for one thing, from the lack of compatibility of a lignocellulosic fiber to a non- polar surface, as is present in the case of the polyolefins. For another, during filling or reinforcing, an elastic component is created in a visco-elastic component. In load cases, with a characteristic yield point for each material, microcracks and cracks develop at the boundary surface of the multi-phase system, which can lead to failure of the system.

One embodiment of the invention provides that the filler or reinforcement materials for example the cellulose material such as rice hulls are crushed and coated. Since the materials containing cellulose provided in the scope of this invention have a ductile behavior, impact and centrifugal mills are required for their crushing process. Versions of these crushing devices, which have milling elements resting on a rotor that rotate at high speed like impact bars, hammers, arms, pins or tabs, which crush the material in flight by impact and bouncing, but not by cutting or by pressure against a base, are known, for example, from a book by Vauck and Mijller "Basic operations of chemical process technology" 10th Edition (1994) Deutscher Verlag fur die Grundstoffindustrie Leipzig Stuttgart pp. 324-328.

Depending on the required fineness of the milled material for the polymer product to be manufactured, a cooling compound can be used during the crushing process.

One embodiment of the invention provides for a method in which the rice hulls are cryo- genically crushed to a specified average size before they are mixed with the polymer material. In a further development of the invention, the rice hulls are crushed in a cryogenic crushing system in which the crushing mill itself is chilled. A coolant will then especially be preferred if a material containing cellulose used in the sense of this invention requires increased crushing force in order to be brought to the necessary milled fineness or in order to be able to adequately fibrillate the cellulose material.

In connection with the cellulose material used, the named crushing options supply very different particle shapes, particle sizes, particle size distributions and a different morpho- logical fine structure. These factors have an effect on the pore percentage, the pore size and their distribution, as well as the absorption and swelling behavior of the cellulose material. The milled material obtained can have fibers with a length of up to 200 μηη and a diameter up to 20 μηι. In addition to the particle size and particle shape of the cellulose material used, for uniform metering of these particles in a downstream processing procedure for manufacturing a polymer product, e.g., by extrusion, a uniformity of the material containing cellulose is necessary in order to obtain uniform product qualities. Very large or very small fibers lying at 150 - 250 kg/h, for example with flat products, can lead to metering problems at high production speeds. Since the fiber materials have a high tendency to bridge formation, they are hard to meter. Since the milling process can result in a wide distribution of the fiber grains, during the milling process or immediately thereafter, a sieving of the milled material can be provided in order to ensure uniform flowing of the fiber materials during their further processing.

In a further development of the method, the use of rice hulls is planned, whereby the rice hulls are crushed and added to the polymer material having a polyolefin to form a mixture and extruding a polymer product from the mixture. The rice hulls are crushed to a size that can be specified.

A preferred further development of the invention provides an extruded polymer product, wherein the cellulose material,for instance the rice hulls have a fiftieth percentile (D50) from 1 to 2 μηη. The 90th percentile (D90) of the cellulose material is preferably less than 10 μηη.

In order to ensure processing capability that is as free from interference as possible for the cellulose materials during the forming process during the manufacturing of the polymer product, the diameter of the forming tool, for example a spinning nozzle, should be about three times the diameter of the cellulose fiber. In analogy to this, it also proves to be advantageous if during creation of a polymer product in the form of a film, for example, the thickness of the slot of a wide slit dye is three times the diameter of the cellulose fiber.

At an air temperature of about 25°C and a relative humidity between 50% - 65%, cellulose materials contain a compensating moisture of about 8% to 12%. In order to make the incorporation of the cellulose fibers into the polymer mixture possible such that the resulting composite in the form of the polymer product has adequate bonding properties, it is nec- essary to further reduce the water content of the cellulose material before further processing.

A further development of the invention provides a method in which the rice hulls are dried after they have been crushed.

The effort required for the drying process for the cellulose materials after a crushing process can be very different, depending on the quality of the cell structure and the surface geometry. In the scope of the invention, moisture contents of the cellulose materials after the drying process that lie between 3 weight% to 6 weight-% have proved to be advantageous.

In order to be able to mix polymers with cellulose materials, for example rice hulls, and obtain therefrom an extruded polymer product with a characteristic level suitable for the respective application, a surface treatment of the cellulose materials is provided, which makes it possible to achieve an adequate bonding strength between a non-polar matrix that is present in the case of the polyolefins and a natural fiber, which tends to high water absorption. In this process it is necessary to disperse the cellulose particles, preferably in the polymer matrix in order to prevent agglomeration of the particles.

A further development of the invention provides an extruded polymer product wherein the cellulose material is treated with an additional material and wherein the additional material is embedded in the polymer material.

By using such a surface treatment, an adaptation of the boundary surfaces occurs in the bond between the polymer matrix and the cellulose material, which leads to an improvement of the phase bonding due to the increase in the adhesion forces between the polymer matrix and the plant fibers. In addition to the surface treatment of the fiber material, a modification of the polymer matrix or a combination of the two possibilities can occur. Variations of the adhesion increase of the composite partners polymer matrix and cellulose material consist, for example, in equipping the cellulose material with silanes or substances with hydrophobizing effects or coating with a functionalized polymer material, for example a functionalized polyolefin material or a functionalizing of the polymer matrix cou- pled with a silanized cellulose material. For example, silanes can involve radical reactions with the polymer matrix. Silanes can contribute to an improvement to an improvement of the adhesion between the cellulose fibers and the polymer matrix, but also to better dispersion of the fibers in the matrix. In addition, for example, the option exists of using male- ic acid anhydride for functionalizing the polymer matrix, for example a polyolefin, whereby the binding of the polymer matrix to the cellulose material can occur using the formation of a covalent ester bond by way of available OH groups of the cellulose material or by way of hydrogen bridge bonds between the hydrolyzed maleic acid anhydride, i.e., the acid function and the OH groups of the cellulose material can be affected. In addition, to promote compatibility between cellulose fibers and a polyolefin matrix, stearic acids and salts thereof can be used.

Preferably, in the sense of this invention, substances with hydrophobizing action are provided to treat the cellulose fibers. Especially preferably, in the extruded polymer product fatty acid derivatives are used as coating materials for the crushed rice hulls. The addition of the materials with hydrophobizing action for treating the cellulose fibers can be between 0.05 and 10 weight-% related to the portion of the cellulose fibers. Usual additives, which are added to the polymer as compatibility promoter can lie between 0.05 - 5 weight-% related to the polymer. With the use of polymers, for example polyester or polyamide, which have a lower hydrophobia than polyolefins, the addition of the compatibility promoter preferably lies between 0.05 - 5 weight-% related to the portion of cellulose fibers.

One version of the invention provides that the extruded polymer product can have a cellu- lose material wherein the percentage of the cellulose material of the total weight of the extruded polymer product is larger than or equal to 2 weight-% or 20 weight-% and smaller than or equal to 90 weight-% or 45 weight-%. Preferably, the percentage of the cellulose material is between 20 to 90 weight-%, related to the total weight of the polymer product. In a preferred embodiment the polymer product has a percentage of the second portion of the total weight of the polymer product between 2 weight-% and 45 weight-%.

In another embodiment of the invention, it is provided that the cellulose material is added to the extruded polymer product as a master batch from polymer material and the cellulose material. In this case, the percentage of the cellulose material of the master batch can be between 4 weight-% to 90 weight-%, related to the total weight of the master batch.

Depending on the filler material selected as the second component in the polymer products and the desired material properties of the polymer product, filler contents can be ad- justed as desired.

In addition, the cellulose material can have different arrangements in this product by the selection of the process parameters during manufacturing of the polymer product. In one embodiment of the invention the extruded polymer product is characterized in that a distribution of the cellulose materials over a cross section of the extruded polymer products is not uniform, whereby a first area that is adjustable by the manufacturing of the extruded polymer product has a higher percentage of cellulose material than a second area. The invention provides that a polymer product designed as a spun fiber can be present as a fiber-filled one- or multiple-component fiber. In this case, the components of a multi- component fiber can be present in a mixture or as separate components. In the latter case, bi-component or multi-component fibers with different structures and distributions of the components over the fiber cross section can be formed. The fibers formed in this way can be present as conjugated fibers.

For manufacturing multi-component fibers, there are various known possibilities, which have been described, for example, in US5336552, US5382490, US5759926 and

US5783503. With the requirement that the polymer matrix and/or the cellulose fibers have been prepared and/or pretreated according to the previously named embodiments, the methods described above for manufacturing multi-component fibers can also be used for the manufacturing of the polymer products.

In a further development of the invention, the extruded polymer product is a spun fiber with a core-sheath structure, whereby in the core a higher percentage of cellulose material is arranged than in the sheath. In a preferred version of the invention, the extruded polymer product is designed as a spinnable material. The extruded polymer product comprises a spun fiber manufactured from a single polymer material, wherein the concentration of the cellulose material, preferably of the crushed rice hull material, is larger at its surface than inside the fiber. Preferably spun fibers are formed with a content of cellulose fibers between 10 weight-% and 30 weight-% related to the total weight of the spun fibers.

The fibers were manufactured under the following spinning conditions:

- Spinning package with 105 spinning holes with a diameter of 0.6 mm and a length of 1 .6 mm;

- Melt filter, with sieves having a mesh width of 33 μηη and 80 μηη in two layers;

- Temperatures at the extruder head of 235°C, in the melting line of 240°C, in the spinning pump of 240°C and on the spinning package 240°C;

- Specific throughput, 0.61 g/spinning hole min;

- Temperature of the quenching air: 15°C.

In one embodiment of the invention, the formed spun fibers or polymer fibers with the use of a polypropylene of the type Moplen HP462R and cellulose fiber content between 10 - 20 weight-% exhibit the following properties:

- Filament titers in the range between 1 to 5 dtex, and preferably between 2 to 3.5 dtex,

- a strength in the range between 3,8 - 6 dN/tex and

- a stretching in the range between 100 to 370 % according to DIN 29073-3 The values determined for the stretching and strength of the spun fibers lie in the range of values that are known for spun fibers of polypropylene with average molecular orientation. Also the extruded polymer product can be formed as a coextruded film, comprising coex- trusion layers having different weight percentages of cellulose material. Preferably weight parts between 20 weight-% and 45 weight-% are provided in these film.

In this process, the drying of the cellulose materials can occur in one or several steps.

A preferred version of the invention provides that a system with an extruder is used, whereby the extruder has a degassing system. This has the advantage that a complicated upstream drying step for the cellulose material that is present with an enlarged surface due to the milling process is not necessary. On the other hand, the liquid particles that still adhere in spite of a drying process can be eliminated during the processing method in order to obtain a polymer product free of bubbles.

In another embodiment of the invention, a system for manufacturing a polymer product has a drying unit for the cellulose material that is connected to the extrusion device of the system, whereby the drying unit makes possible the use of waste heat from the drying of the cellulose material. In this case, for example, hot air resulting from the processing step can be used.

A preferred version of the invention provides a system, wherein an extrusion device and a drying unit for drying the crushed rice hulls are connected by heat transport means arranged to transport waste heat of the extrusion device to the drying unit and wherein the drying unit is arranged to dry the crushed rice hulls using the waste heat.

The incorporation of the cellulose material into the polymer matrix can occur in different ways. For example, the crushed and possibly fractionated cellulose materials can be processed together with one or more polymers, which can also be present in a finely divided form, in a mixer, for example, in a heating-cooling mixer combination to an agglomerate. In this process, other additives, e.g., processing aids, can be measured in. These agglomerates are formed, for example, in a subsequent extrusion process to a polymer product in the form of a fiber or film.

The incorporation of the cellulose material into the polymer material can, for example, also take place in a stream of gas, in which mixing and possibly milling of cellulose particles occurs, as well as a batch coating of the cellulose particles with polymer material in the gas stream.

In another embodiment of the invention, a polymer material can result by a direct pro- cessing of the polymer and cellulose fiber components on a double screw extruder with screw shafts running in the same direction or opposite directions.

A preferred version of the invention provides that a system with a double screw extruder is used, whereby the double screw extruder has a degassing system.

Preferable here is a system for manufacturing an extruded polymer product comprising a polymer material comprising at least a polyolefin and a cellulose material obtained from rice hulls, whereby a double screw extruder is used to mix polymer material and dried crush rice hulls. The double screw extruder comprises mixing zones for mixing the poly- mer material and the dried crushed rice hulls. In this direct processing, a polymer mixture can be measured into the extruder and the cellulose material can be supplied by way of a separate hopper, which opens into the supply line to the extruder.

A preferred embodiment of the method provides that a master batch to be extruded is prepared.

A master batch is understood to mean a material produced in granulate form, which has a polymer component and a portion of cellulose material. If necessary, other additive can also be used in the form of processing aids, dyes, pigments or functional additives, for example, flame retardants or antistatics. This master batch can preferably be equipped with a very high content of cellulose materials and manufactured on a double screw extruder with screw shafts running in the same direction, a so-called compounder. This master batch can then be used directly for manufacturing a polymer product or portions can be added to a polymer in order to be able to process it to a polymer product.

In one embodiment, the invention provides a master batch, which is preferably used for manufacturing spun fibers, but also films, whereby in the master batch a polyolefin is provided that contains rice hulls that have been crushed to a maximum size that can be specified.

The manufactured polymer product can be designed alone or as a composite with other nonwovens or materials, for example, with another polymer product in the form of a film or several films. In particular it can be connected with the other material to form a layered material. After it is manufactured, the resulting flat monolayer or multilayer fabric can also be embossed, bonded, laminated and/or mechanically treated, especially connected with another material. For example, this can occur physically, chemically and/or with form fitting. For example, thermal and/or ultrasonic connection possibilities can be used in order to connect the individual layers to each other. In embossing-bound polymer products in the form of monolayer or multilayer nonwovens or nonwoven-film laminates, embossing surfaces can be provided with a percentage of 10%-50%, related to the entire surface of the flat fabric. Manufacturing of a laminate of several layers of a nonwoven from spunbond or melt-blown fibers or combinations thereof can be manufactured according to the tech- nical teaching disclosed, for example, in US5178931 , US3704198, US3849241 and

US5188885, whereby the polymer product has a first portion of a polymer material and a second portion of cellulose material.

In addition, an adhesive, for example a spray adhesive or a so-called hot-melt adhesive, latex-based adhesive or other adhesive can be used.

In a further development of the invention, several spun bonds of the same or different types can be combined and formed to make a laminate of these spun bonds. Advantageously, a laminate can also be formed in which at least one film is combined with at least one nonwoven.

For laminate formation, different types of processing are possible. For example, individual layers can be manufactured as nonwoven or film in separate processing steps, which are joined in another processing step, for example a calendering step, to form a laminate, whereby different calender roller arrangements can be provided that cause a thermal compacting of the laminate. A calendering method such as this is described, for example, in US 3,855,046. Usually, smooth or profiled calender rollers are used, which can be combined with each other according to the planned usage purpose and required characteristics profile for the laminate. With the use of embossing rollers, discrete embossed bonds can be formed in the laminate. Methods for manufacturing separate layers and lam- inate produced from them are described, for example, in DE 431 1867.

Another possibility for laminate formation can consist in that a nonwoven is formed and this nonwoven is coated in-line with a film. On the other hand, a film can be extruded first, which, for example, is placed on a holding line, whereby a created nonwoven is deposited in-line on this film. The composite formation can also occur here using a calendering arrangement. In addition, other types of composite formation are also possible, for example by needling or water stream compacting. Special variations for the formation of this flat fabric can be seen, for example, in DE10360845A1 , US 4,021 ,284 and US 4,024,612. In one embodiment of the invention, the manufactured polymer product in the form of a nonwoven fabric is characterized, for example, by the following characteristic values:

- Thickness of the nonwoven fabric between 50 μηη and 2000 μηη

- weight per surface area between 7 and 500 g/m2, and preferably between 10 and 200 g/m2,

- Product of the weight per surface area (g/m2) and the air permeability (1/m2s, acc. to DIN EN ISO 9237) in the range of 1 10,000 +- 20%,

- Values for the quotients from the water column (according to DIN EN 2081 1 ) and the weight per surface area of 2.5 +- 20%,

- Filament surface is hydrophilized and has values for penetration times, measured according to EDANA ERT 150, of less than 5 s.

- Values for the quotient of maximum tensile force (according to DIN 29073-3) and weight per surface area in machine direction of 1.7 +- 20%, and in transverse direction of 1.0 +- 20%.

- Values for the quotient of maximum tensile force extension (according to DIN 29073-3) and weight per surface area in machine direction of 3.3 +- 20%, and in transverse direction of 4.0 +- 20%. In another embodiment of the invention, a polymer product created in the form of a film can have densities between 0.60 to 0.9 g/cm3.

In addition, with the use of cellulose materials, in the majority of which the cell structure has become broken up due to the preparation, for example by milling of the fibers, and a majority of the cell wall substance is available for further processing, the polymer product manufactured from it, for example, in the form of a film, has densities from 0.9 to 1 .2 g/cm3.

Depending on the finishing of the polymer products created, these can be used in all dif- ferent types of application areas, for example, for:

- Packages,

- Covers, e.g., CD cases,

- Decorations, for example trim materials for covering objects to create a wood-like char- acter of the object,

- Covering material in the area of agriculture or for environmental purposes,

- Coating, roofing, heat or noise insulation or filter material,

- Wall covers in the building area, - Cleaning cloths,

which are given here only by way of example without any claim to completeness.

Claims

Claims
1. Extruded polymer product comprising a polymer material comprising at least one pol- yolefin and wherein cellulose material obtained from rice hulls is embedded in the polymer material.
2. Extruded polymer product according to claim 1 , wherein the extruded polymer product is a film.
3. Extruded polymer product according to claim 1 , wherein the extruded polymer product is a spun fiber.
4. Extruded polymer product according to one of the preceding claims, wherein the cellulose material is obtained from crushed and coated rice hulls.
5. Extruded polymer product, according to claim 4, wherein the rice hulls are coated with a coating material comprising a fatty acid derivative.
6. Extruded polymer product according to one of the preceding claims, wherein the cel- lulose material has a fiftieth percentile (D50) of from 1 to 2 μηη.
7. Extruded polymer product according to one of the preceding claims, wherein the cellulose material is treated with an additional material and wherein the additional material is embedded in the polymer material.
8. Extruded polymer product according to one of the preceding claims, wherein the percentage of the cellulose material of the total weight of the extruded polymer product is larger than or equal to 2 weight-%, especially larger than or equal to 20 weight-% and smaller than or equal to 90 weight-%, especially larger than or equal to 45 weight-%
9. Extruded polymer product according to one of the preceding claims, wherein the cellulose material is added to the extruded polymer product as a master batch of the polymer material and the cellulose material.
10. Extruded polymer product according to Claim 9, wherein the percentage of the cellulose material of the master batch lies between 4 weight-% and 90 weight-%, related to the total weight of the master batch.
11. Extruded polymer product according to one of the preceding claims, wherein a distribution of the cellulose material over a cross section of the extruded polymer product is not uniform, whereby a first area adjustable by the manufacturing of the extruded polymer product has a higher percentage of cellulose material than a second area.
12. Extruded polymer product according to one of the preceding claims, wherein the extruded polymer product is a spun fiber with a core-sheath structure, whereby in the core a higher percentage of cellulose material is arranged than in the sheath.
13. Extruded polymer product according to one of the preceding claims, wherein the extruded polymer product is a coextruded film comprising coextrusion layers having different weight percentages of cellulose material.
14. Extruded polymer product according to one of the preceding claims, comprising a spun fiber manufactured from a single polymer material, wherein the concentration of the cellulose material is larger at its surface than inside the fiber.
15. Method for use of rice hulls comprising:
• crushing the rice hulls;
· adding the crushed rice hulls to a polymer material having a polyolefin to form a mixture; and
• extruding a polymer product from the mixture.
16. Method according to Claim 15, comprising drying the rice hulls after crushing the rice hulls.
17. Method according to claim 15 or 16, comprising crushing the rice hulls cryogenically.
18. Method according to claim 17, comprising using a chilled crushing mill for cryogeni- cally crushing the rice hulls.
19. Method according to any of the claims 15 to 18, comprising crushing the rice hulls to an average particle size of 2 to 10 μηη
20. System for manufacturing an extruded polymer product comprising a polymer material comprising at least one polyolefin and a cellulose material obtained from rice hulls, the system comprising a double screw extruder arranged to mix polymer material and dried crushed rice hulls.
21. System according to Claim 20, wherein the extruder comprises a degassing system.
22. System according to Claim 20 or 21 , wherein an extrusion device and a drying unit for drying the crushed rice hulls are connected by heat transport means arranged to transport waste heat of the extrusion device to the drying unit and wherein the drying unit is arranged to dry the crushed rice hulls using the waste heat.
23. Master batch for manufacturing spun fibers, having a polyolefin and crushed rice hulls crushed to a maximum size that can be specified.
PCT/EP2011/058299 2010-05-21 2011-05-20 Extruded polymer product and method for making the same WO2011144752A2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP10005313.1 2010-05-21
EP10005313 2010-05-21

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP11721298A EP2572019A2 (en) 2010-05-21 2011-05-20 Extruded polymer product and method for use of rice hulls

Publications (2)

Publication Number Publication Date
WO2011144752A2 true WO2011144752A2 (en) 2011-11-24
WO2011144752A3 WO2011144752A3 (en) 2012-04-05

Family

ID=44379924

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2011/058299 WO2011144752A2 (en) 2010-05-21 2011-05-20 Extruded polymer product and method for making the same

Country Status (2)

Country Link
EP (1) EP2572019A2 (en)
WO (1) WO2011144752A2 (en)

Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3704198A (en) 1969-10-09 1972-11-28 Exxon Research Engineering Co Nonwoven polypropylene mats of increased strip tensile strength
US3849241A (en) 1968-12-23 1974-11-19 Exxon Research Engineering Co Non-woven mats by melt blowing
US3855046A (en) 1970-02-27 1974-12-17 Kimberly Clark Co Pattern bonded continuous filament web
US4021284A (en) 1972-11-13 1977-05-03 Johnson & Johnson Nonwoven fabric and method and apparatus for producing the same
US4024612A (en) 1976-04-02 1977-05-24 E. I. Du Pont De Nemours And Company Process for making an apertured nonwoven fabric
US5178931A (en) 1990-11-26 1993-01-12 Kimberly-Clark Corporation Three-layer nonwoven laminiferous structure
US5188885A (en) 1989-09-08 1993-02-23 Kimberly-Clark Corporation Nonwoven fabric laminates
US5336552A (en) 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
DE4311867A1 (en) 1993-04-10 1994-10-13 Corovin Gmbh A multilayer sheet, as well as process for producing a multilayer sheet
US5382490A (en) 1991-08-30 1995-01-17 Nippon Kayaku Kabushiki Kaisha Electrophotographic toner
WO1995011803A1 (en) 1993-10-28 1995-05-04 Textiles Et Plastiques Chomarat Method for making a flexible, fluid-tight sheet comprised of a textile support coated on both faces with a polypropylene-based coating layer
WO1996009165A1 (en) 1994-09-20 1996-03-28 Exxon Chemical Patents Inc. Microporous film/nonwoven composites
US5759926A (en) 1995-06-07 1998-06-02 Kimberly-Clark Worldwide, Inc. Fine denier fibers and fabrics made therefrom
US5783503A (en) 1996-07-22 1998-07-21 Fiberweb North America, Inc. Meltspun multicomponent thermoplastic continuous filaments, products made therefrom, and methods therefor
DE19923344A1 (en) 1999-05-21 2000-11-23 Corovin Gmbh Modification of surface properties of melt blown fiber batts or films e.g. for sanitary wear, involves spraying additive on freshly extruded material
DE10240191A1 (en) 2002-08-28 2004-03-25 Corovin Gmbh Spun bonded continuous fibers
DE10322460A1 (en) 2003-05-16 2004-12-16 Corovin Gmbh Method and apparatus for producing a spunbond nonwoven made of filaments
DE10360845A1 (en) 2003-12-20 2005-07-21 Corovin Gmbh A soft nonwoven based on polyethylene

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1088007A (en) * 1996-07-22 1998-04-07 Kankyo Create:Kk Resin composition and molded material
JP2000326382A (en) * 1999-05-24 2000-11-28 Sekisui Chem Co Ltd Method for producing thermoplastic resin molded body
US6172144B1 (en) * 1999-09-13 2001-01-09 Amonollah Yekani Process and composition for producing articles from rice hulls
JP2001270508A (en) * 2000-03-23 2001-10-02 Dainichiseika Color & Chem Mfg Co Ltd Food container
KR20060090037A (en) * 2005-02-04 2006-08-10 인성파우더 테크(주) Functional fiber containing powder of carbonated rice-hull
US20080093763A1 (en) * 2006-10-06 2008-04-24 Douglas Mancosh Multi-color fiber-plastic composites and systems and methods for their fabrication
US20090110654A1 (en) * 2007-10-29 2009-04-30 Hagemann Ronald T Bio-Plastic Composite Material, Method of Making Same, And Method of Using Same
US20100055437A1 (en) * 2008-08-28 2010-03-04 Tyco Healthcare Group Lp Anti-microbial fibers and related articles and methods
KR101020275B1 (en) * 2010-10-06 2011-03-07 (주)홍지 Degradable film and method of the same

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3849241A (en) 1968-12-23 1974-11-19 Exxon Research Engineering Co Non-woven mats by melt blowing
US3704198A (en) 1969-10-09 1972-11-28 Exxon Research Engineering Co Nonwoven polypropylene mats of increased strip tensile strength
US3855046A (en) 1970-02-27 1974-12-17 Kimberly Clark Co Pattern bonded continuous filament web
US4021284A (en) 1972-11-13 1977-05-03 Johnson & Johnson Nonwoven fabric and method and apparatus for producing the same
US4024612A (en) 1976-04-02 1977-05-24 E. I. Du Pont De Nemours And Company Process for making an apertured nonwoven fabric
US5188885A (en) 1989-09-08 1993-02-23 Kimberly-Clark Corporation Nonwoven fabric laminates
US5178931A (en) 1990-11-26 1993-01-12 Kimberly-Clark Corporation Three-layer nonwoven laminiferous structure
US5382490A (en) 1991-08-30 1995-01-17 Nippon Kayaku Kabushiki Kaisha Electrophotographic toner
US5336552A (en) 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
DE4311867A1 (en) 1993-04-10 1994-10-13 Corovin Gmbh A multilayer sheet, as well as process for producing a multilayer sheet
WO1995011803A1 (en) 1993-10-28 1995-05-04 Textiles Et Plastiques Chomarat Method for making a flexible, fluid-tight sheet comprised of a textile support coated on both faces with a polypropylene-based coating layer
WO1996009165A1 (en) 1994-09-20 1996-03-28 Exxon Chemical Patents Inc. Microporous film/nonwoven composites
US5759926A (en) 1995-06-07 1998-06-02 Kimberly-Clark Worldwide, Inc. Fine denier fibers and fabrics made therefrom
US5783503A (en) 1996-07-22 1998-07-21 Fiberweb North America, Inc. Meltspun multicomponent thermoplastic continuous filaments, products made therefrom, and methods therefor
DE19923344A1 (en) 1999-05-21 2000-11-23 Corovin Gmbh Modification of surface properties of melt blown fiber batts or films e.g. for sanitary wear, involves spraying additive on freshly extruded material
DE10240191A1 (en) 2002-08-28 2004-03-25 Corovin Gmbh Spun bonded continuous fibers
DE10322460A1 (en) 2003-05-16 2004-12-16 Corovin Gmbh Method and apparatus for producing a spunbond nonwoven made of filaments
DE10360845A1 (en) 2003-12-20 2005-07-21 Corovin Gmbh A soft nonwoven based on polyethylene

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
VAUCK, MUTTER: "Basic operations of chemical process technology", 1994, DEUTSCHER VERLAG FUR DIE GRUNDSTOFFINDUSTRIE LEIPZIG, pages: 324 - 328

Also Published As

Publication number Publication date
WO2011144752A3 (en) 2012-04-05
EP2572019A2 (en) 2013-03-27

Similar Documents

Publication Publication Date Title
Klason et al. The efficiency of cellulosic fillers in common thermoplastics. Part 1. Filling without processing aids or coupling agents
Youngquist Wood-based composites and panel products
US5064689A (en) Method of treating discontinuous fibers
EP1963573B1 (en) Improved cellulose articles containing an additive composition
US5057166A (en) Method of treating discontinuous fibers
Mo et al. Compression and tensile strength of low-density straw-protein particleboard
US6511757B1 (en) Compression molding of synthetic wood material
US5082605A (en) Method for making composite material
US7625961B2 (en) Biopolymer and methods of making it
Faruk et al. Biocomposites reinforced with natural fibers: 2000–2010
US5554330A (en) Process for the manufacturing of shaped articles
US5866264A (en) Renewable surface for extruded synthetic wood material
CA2278144C (en) Wet-laid nonwoven web from unpulped natural fibers and composite containing same
US20080029917A1 (en) Process for making modified cellulosic filler from recycled plastic waste and forming wood substitute articles
Leao et al. Applications of natural fibers in automotive industry in Brazil—thermoforming process
US20090065975A1 (en) Manufacturing process for high performance lignocellulosic fibre composite materials
EP1675892B1 (en) Development of thermoplastic composites using wet use chopped strand (wucs)
CN101990586B (en) Non-woven material and method of making such material
CN101698749B (en) Wood-plastic composite material and prepration method thereof
Haque et al. Physico-mechanical properties of chemically treated palm and coir fiber reinforced polypropylene composites
Adhikary et al. Dimensional stability and mechanical behaviour of wood–plastic composites based on recycled and virgin high-density polyethylene (HDPE)
US20100310893A1 (en) Engineered wood product
DE60311124T2 (en) With natural fiber reinforced polyolefinverbundwerkstoffe
EP1746209B1 (en) Multilayer nonwoven fibrous mats, laminates and method
CA2012532A1 (en) Coated fiber product covered with adhered super absorbent particles

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 11721298

Country of ref document: EP

Kind code of ref document: A2

NENP Non-entry into the national phase in:

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 2011721298

Country of ref document: EP