WO2013079635A1 - Procédé de liaison de substrat - Google Patents

Procédé de liaison de substrat Download PDF

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Publication number
WO2013079635A1
WO2013079635A1 PCT/EP2012/074034 EP2012074034W WO2013079635A1 WO 2013079635 A1 WO2013079635 A1 WO 2013079635A1 EP 2012074034 W EP2012074034 W EP 2012074034W WO 2013079635 A1 WO2013079635 A1 WO 2013079635A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
thermoplastic material
water
particles
water borne
Prior art date
Application number
PCT/EP2012/074034
Other languages
English (en)
Inventor
Hendrik DE KEUKELEIRE
Rudy GALLE
Original Assignee
Global Telecom Organisation S.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Global Telecom Organisation S.A. filed Critical Global Telecom Organisation S.A.
Publication of WO2013079635A1 publication Critical patent/WO2013079635A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
    • 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
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • 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
    • Y02P20/141—Feedstock
    • Y02P20/143—Feedstock the feedstock being recycled material, e.g. plastics
    • 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 a process and composition for binding of a particulate or fibrous substrate, in particular natural particles or fibres such as for example wood particles and fibers, but also other natural fibers such as straw, flax, grass, hemp, bagasse, bamboo and agricultural waste.
  • the current invention describes the composition of a cheap binder that can bind particles and fibers in a fast way, resulting in substrates that have the required mechanical properties.
  • the binder has a good sustainability so that the end product also has an improved sustainability profile.
  • the new binder composition will make the resulting substrates (composite materials) flame retardant.
  • Formaldehyde resin binders are often used to bind natural particles or fibers.
  • the best known example is the binding of wood fibers and particles leading to reconstituted wood panels.
  • Such panels are well known under the names of e.g. medium dense fiber board, high density fiber board, oriented strand board, chipboard, particle board, hard board.
  • These products are predominantly based on products with a high sustainability profile.
  • formaldehyde resins have a dramatic effect on its sustainability. Often melamine is added to the condensation reaction to make the addition reaction less reversible. As a result less formaldehyde can be released. However, there is still some release of formaldehyde.
  • the present invention provides a binder for binding of a particulate or fibrous substrate, in particular natural particles or fibres, said binder comprising a water borne binder and a thermoplastic material
  • the binder according to the present invention is characterized in that the thermoplastic material consists of solid thermoplastic particles whereby 90% wt of the particles have a particle size below 500 micrometer, in particular between and about 0.5 to 500 micrometer, more in particular, below 200 micrometer, in particular between and about 1 .0 to 200 micrometer.
  • thermoplastic material has a melting point or a glass transition temperature of between and about 40°C and 250°C.
  • thermoplastic material as used in the present invention preferably comprises a polymer selected from the group consisting of polyesters, polyamides, polyvinylacetate, polyolefins, polyvinyls, polyacrylates, polyurethanes, and combinations/ copolymers thereof, more in particular an ester-containing polymer, such as a polyester, polyvinylacetate or a polyacrylate.
  • the binder may further contain one or more other materials such as fillers, pigments, opacifiers, UV-stabilizers, cross-linkers and catalysts.
  • the thermoplastic material is present as a water borne dispersion of the thermoplastic particles.
  • the water borne binder is a binder such as water glass, starch polyvinylalcohol, styrene-butadiene, or polyvinylacetate; that is water borne by solution, emulsion, dispersion or combinations thereof; in particular the water borne binder is the combination of a water soluble binder and a water borne emulsion; more in particular the water borne binder is a water soluble binder; even more particular the water borne binder is water glass.
  • a binder such as water glass, starch polyvinylalcohol, styrene-butadiene, or polyvinylacetate
  • the water borne binder is the combination of a water soluble binder and a water borne emulsion
  • more in particular the water borne binder is a water soluble binder
  • even more particular the water borne binder is water glass.
  • the water borne binder as used in the present invention is preferably water glass having a ratio of Si0 2 to Na 2 0 ranging from about 1 to about 3.5; in particular from about 1 .5 to about 3.5.
  • the present invention also provides a binder according to the present invention whereby the ratio between the water borne binder and the thermoplastic material amounts to between about 1 : 3 and 50 : 1.
  • the present invention provides a composition comprising a binder according to the present invention and a particulate or fibrous substrate, in particular natural particles or fiber substrates such as for example consisting of wood, flax, grass, hemp, bamboo, bagasse, agricultural waste, or combinations thereof.
  • the particulate or fibrous substrate is a man-made (synthetic) substrate such as glass- or rock wool.
  • the present invention further provides a composition according to the present invention wherein the weight ratio between the binder and the substrate amounts between 1 : 200 to 1 : 4.
  • composition according to the present invention may further contain additives such as fillers, dyes, crosslinkers, pigments, UV-stabilizers, waxes.
  • the present invention provides substrates (composite materials) made by heating the composition according to the present invention at a temperature above the melting point or glass transition temperature of the thermoplastic material.
  • a pressure of at least 2 bar is used during the curing process.
  • the present invention is based on the finding that the presence of a thermoplastic material as solidifying agent in a binder composition for binding of a particulate or fibrous substrate, results in a composite material with previously unknown characteristics.
  • a binder according to the present invention the resulting material has a very homogenous structure, a high mechanical strength, an improved sustainability profile, an improved water resistance, and a excellent dimensional stability. It is accordingly a first aspect of the present invention to provide a binder for binding a particulate or fibrous substrate, in particular natural particles or fibers, said binder comprising a water borne binder and a thermoplastic material.
  • the thermoplastic material is characterized in that it consists of a thermoplastic material that is solid at room temperature and hence its melting point (m.p.) or its glass transition temperature (Tg) should preferably be above 40°C.
  • m.p. melting point
  • Tg glass transition temperature
  • the present invention provides the aforementioned binder, further characterized in that the thermoplastic material consists of thermoplastic particles that are solid at room temperature; more in particular wherein the thermoplastic material has a melting point or a glass transition temperature of between and about 40°C and 250°C.
  • the thermoplastic particles have a small particle size.
  • 90% wt of the thermoplastic particles have a particle size below 500 micrometer, in particular between and about 0.5 to 500 micrometer; in a further embodiment the thermoplastic material is characterized in that it consists of solid thermoplastic particles whereby 90% of the particles have a particle size below 200 micrometer, in particular between and about 1.0 to 200 micrometer.
  • thermoplastic materials are polyesters, polyamides, polyolefins such as polyethylene and polypropylene, polyvinylacetates, polyvinylchloride, polyacrylates.
  • a preferred thermoplastic binder is one that contains ester groups such as a polyester, a polyvinylacetate or a polyacrylate.
  • the thermoplastic material comprises a polymer selected from the group consisting of polyesters, polyamides, polyolefins, polyvinyls, polyvinylacetate, polyacrylates, polyurethanes, and combinations/ copolymers thereof. More in particular the thermoplastic material comprises an ester-containing polymer, such as a polyester, a polyvinylacetate or a polyacrylate.
  • thermoplastic material stems from a waste stream.
  • a waste stream is for instance the powder coming from the production and the use of powder paints.
  • powder paints usually, such a powder is contaminated with other products and can not longer be used as a powder paint.
  • This waste stream is usually burnt and the generated energy can be used for other purposes. By using the waste stream as a binder to make new substrates it gets a higher added value.
  • thermoplastic material may contain other materials such as fillers, pigments, opacifiers, UV-stabilizers, crosslinkers and catalysts.
  • the thermoplastic material further contains one or more other materials such as fillers, pigments, opacifiers, UV-stabilizers, cross-linkers and catalysts.
  • the water borne binder and the thermoplastic material can be mixed together before it is added to the fibers or the particles.
  • the thermoplastic material can be added to one of the water borne binders or to both. It is also possible to add the water borne binder and the thermoplastic material separately.
  • the water borne binder is added first to the fibers or the particles, subsequently followed by the addition of the thermoplastic binder.
  • the water borne binder will as a liquid be well distributed over the fiber or particles. Due to the presence of the water borne binder the thermoplastic binder will as well be better distributed over the fibers or particles.
  • the consistency of binder according to the present invention will change, from a more liquid (higher amount of water borne binder) to a more solid state (higher amount of thermoplastic particles).
  • the ratio between the water borne binder and the thermoplastic material typically amounts to between about 1 : 3 and 50 : 1 ; in particular to between about 1 : 2 and 40 : 1 . Irrespective of the aforementioned ratio, a proper distribution of the thermoplastic material in the binder is clearly enhanced when present as a water borne dispersion.
  • thermoplastic material Due to fine particle size of the thermoplastic material it can just be mixed with water to form a dispersion. Upon stirring the thermoplastic material will be kept homogeneously distributed in the water phase. Consequently, in a further aspect the thermoplastic material is present as a water borne dispersion of the thermoplastic particles.
  • the water borne binder can be a binder that is water borne by solution, emulsion or dispersion.
  • a solution of a water borne binder can be starch, polyvinylalcohol, water glass.
  • a water borne emulsion can be a styrene butadiene latex, polyvinylacetate or alkyd emulsion.
  • the water borne binder is a binder such as water glass, starch, polyvinylalcohol, styrene-butadiene, or polyvinylacetate; that is water borne by solution, emulsion, dispersion or combinations thereof; in particular the water borne binder is the combination of a water soluble binder and a water borne emulsion (in particular water glass and polyvinylacetate); more in particular the water borne binder is a water soluble binder; even more particular the water borne binder is water glass.
  • a binder such as water glass, starch, polyvinylalcohol, styrene-butadiene, or polyvinylacetate
  • the water borne binder is the combination of a water soluble binder and a water borne emulsion (in particular water glass and polyvinylacetate); more in particular the water borne binder is a water soluble binder; even more particular the water borne binder is water glass.
  • the binder is water glass.
  • Water glass is derived from sand and sodium hydroxide and as such does not contain products derived from fossil fuel.
  • the type of water glass is described by its ratio Si0 2 to Na 2 0. A higher ratio results in a product with lower water sensitivity. Principally, all types of water glass can be used in this application, ranging from a ratio of 1 to 3.5, but preference is given to a ratio of 1.5 to 3.5.
  • the binder of the present invention is of particular interest to bind particulate or fibrous substrate.
  • the fibers or particles that can be bound are wood, flax, grass, hemp, bamboo, bagasse and agricultural waste.
  • these products have a natural origin. It is also quite possible to use this binder concept for man-made fibers such as glass- or rock wool or their combinations with natural fibers and particles..
  • the present invention provides a composition comprising a binder as defined herein and particulate or fibrous substrate, in particular natural particles or fiber substrates such as for example ground wood, flax or bamboo, waste streams from sawing mills, rest material from sugar cane, or grass that has been cut in the desired fiber length.
  • the natural particles or fiber substrates are selected from the group consisting of wood, flax, grass, hemp, bamboo, bagasse and agricultural waste.
  • the binder and the substrate are good admixed with one another and that there is an evenly distribution of either component in the compositions thus obtained.
  • the amount of binder is below 10% of the total mass a very well mixing is crucial.
  • the weight ratio between the binder and the substrate typically amounts between 1 : 200 to 1 : 4.
  • any one of the aforementioned compositions may further contains additives such as fillers, dyes, crosslinkers, pigments, UV-stabilizers, waxes.
  • the present invention provides substrates (composite materials) made using the binder as described herein, i.e. using any one of the aforementioned compositions.
  • the aforementioned compositions comprising the natural fibers and particles, and the binder are brought in a recipient and cured under high temperature and pressure.
  • the curing temperature will be above the melting point or glass transition temperature of the thermoplastic material, alternatively even above 100°C to remove the present water.
  • a pressure of at least 2 bar is used during the curing process.
  • the binders are a combination of a water glass and an ester containing thermoplastic material. While the curing reaction takes place some hydrolysis of the ester containing thermoplastic material will take place, leading to the formation of the sodium salt of the carboxylic acid. As a result the ratio Si0 2 to Na 2 0 of the water glass will increase. Therefore the water resistance of the cured material will become higher.
  • the water resistance of the substrate can be further increased by adding hydrophobizing agents such as e.g. oil or waxes.
  • hydrophobizing agents such as e.g. oil or waxes.
  • the content of the mixture is brought into a mould with a surface of 30 cm by 30 cm and a height of 50 cm.
  • the mixture is pressed at room temperature until the height of the content is 30 cm.
  • the pressed material is now removed from the mould and brought between heated plates of 200°C that are pressed together with a pressure of 100 tons.
  • the thickness of the wood mixture is brought to a thickness of 15 mm and the pressure and the temperature of the plates at 200°C is maintained during 3 minutes. Thereafter the pressure is released and the pressed wood is removed from the heated plates. After cooling down the mechanical properties of the wood panel are measured.
  • Example 1 was repeated but now the 30 g of recycled powder paint was substituted by 15 g of a finely ground polyester.
  • the polyester has a Tg of 58°C and is mainly built up by terephthalic acid, isophthalic acid and neopentyl glycol.
  • the polyester has a particle size distribution of which 90 % lies between 1 and 150 micrometer.
  • the obtained panel has the following properties:

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  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

La présente invention concerne un procédé et une composition permettant la liaison d'un substrat particulaire ou fibreux, notamment des particules ou des fibres naturelles telles que par exemple, des particules et des fibres de bois, mais également d'autres fibres naturelles telles que la paille, le lin, l'herbe, le chanvre, la bagasse, le bambou, et des déchets agricoles. La présente invention concerne une composition d'un liant à faible coût qui peut lier des particules et des fibres de manière rapide, permettant d'obtenir des substrats qui possèdent les propriétés mécaniques requises. Le liant présente une bonne durabilité de sorte que le produit final possède également un profil de durabilité améliorée. En outre, la nouvelle composition de liant conférera un caractère ignifuge aux substrats obtenus (matériaux composites).
PCT/EP2012/074034 2011-12-01 2012-11-30 Procédé de liaison de substrat WO2013079635A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1039207 2011-12-01
NL1039207 2011-12-01

Publications (1)

Publication Number Publication Date
WO2013079635A1 true WO2013079635A1 (fr) 2013-06-06

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PCT/EP2012/074034 WO2013079635A1 (fr) 2011-12-01 2012-11-30 Procédé de liaison de substrat

Country Status (1)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3028846A1 (fr) 2014-12-03 2016-06-08 Galle, Rudy Panneau composite fabriqué à partir de matériaux recyclables et recyclés
EP3034423A1 (fr) 2014-12-19 2016-06-22 Fibreuse nv Palette en matériaux recyclés et recyclables et méthode de fabrication associée
EP3254841A1 (fr) 2016-06-07 2017-12-13 Galle, Rudy Panneau composite fabriqué à partir de matériaux recyclables et recyclés
EP3260588A1 (fr) 2016-06-21 2017-12-27 Fibreuse nv Porte-charge fait et matériaux recyclés et recyclables

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002100616A1 (fr) * 2001-06-08 2002-12-19 Ivf Industriforskning Och Utveckling Ab Materiau composite a base de bois et fabrication de ce materiau
WO2007079719A2 (fr) * 2006-01-09 2007-07-19 Kurt Koryszczuk Corps façonnes a base de residus de peintures en poudre contenant du plastique, d'agregats legers mineraux et de matieres premieres renouvelables et leur utilisation, en particulier dans le domaine du batiment et de l'artisanat
WO2007143302A1 (fr) * 2006-05-31 2007-12-13 Hni Technologies Inc. Article fibreux et méthode de fabrication
WO2008020768A1 (fr) * 2006-08-15 2008-02-21 Orica New Zealand Limited Matériau composite fabriqué à partir d'un système liant comprenant de la poudre de revêtement de poudre de déchet
WO2008128021A2 (fr) * 2007-04-13 2008-10-23 Innotec Contrepoids composite et son procédé de fabrication

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002100616A1 (fr) * 2001-06-08 2002-12-19 Ivf Industriforskning Och Utveckling Ab Materiau composite a base de bois et fabrication de ce materiau
WO2007079719A2 (fr) * 2006-01-09 2007-07-19 Kurt Koryszczuk Corps façonnes a base de residus de peintures en poudre contenant du plastique, d'agregats legers mineraux et de matieres premieres renouvelables et leur utilisation, en particulier dans le domaine du batiment et de l'artisanat
WO2007143302A1 (fr) * 2006-05-31 2007-12-13 Hni Technologies Inc. Article fibreux et méthode de fabrication
WO2008020768A1 (fr) * 2006-08-15 2008-02-21 Orica New Zealand Limited Matériau composite fabriqué à partir d'un système liant comprenant de la poudre de revêtement de poudre de déchet
WO2008128021A2 (fr) * 2007-04-13 2008-10-23 Innotec Contrepoids composite et son procédé de fabrication

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Water glass binder for mould - mixed with solid waste paint powder contg. resin and inorganic matter, for break-out of mould after pouring", DERWENT, 6 December 1977 (1977-12-06), XP002366406 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3028846A1 (fr) 2014-12-03 2016-06-08 Galle, Rudy Panneau composite fabriqué à partir de matériaux recyclables et recyclés
EP3034423A1 (fr) 2014-12-19 2016-06-22 Fibreuse nv Palette en matériaux recyclés et recyclables et méthode de fabrication associée
EP3254841A1 (fr) 2016-06-07 2017-12-13 Galle, Rudy Panneau composite fabriqué à partir de matériaux recyclables et recyclés
EP3260588A1 (fr) 2016-06-21 2017-12-27 Fibreuse nv Porte-charge fait et matériaux recyclés et recyclables
WO2017220687A1 (fr) 2016-06-21 2017-12-28 Fibreuse Nv Support de charge fabriqué à partir de matériaux recyclés et recyclables

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