WO2015063364A1 - A natural fiber plastic composite - Google Patents

A natural fiber plastic composite Download PDF

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Publication number
WO2015063364A1
WO2015063364A1 PCT/FI2013/051031 FI2013051031W WO2015063364A1 WO 2015063364 A1 WO2015063364 A1 WO 2015063364A1 FI 2013051031 W FI2013051031 W FI 2013051031W WO 2015063364 A1 WO2015063364 A1 WO 2015063364A1
Authority
WO
WIPO (PCT)
Prior art keywords
elongated
element according
groove
solid
solid element
Prior art date
Application number
PCT/FI2013/051031
Other languages
French (fr)
Inventor
Katri Parovuori
Gerhard Ernst
Piia Peltola
Original Assignee
Upm-Kymmene Corporation
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 Upm-Kymmene Corporation filed Critical Upm-Kymmene Corporation
Priority to PCT/FI2013/051031 priority Critical patent/WO2015063364A1/en
Publication of WO2015063364A1 publication Critical patent/WO2015063364A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered 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
    • B32B27/08—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion 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
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion 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
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
    • B29K2311/10—Natural fibres, e.g. wool or cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2272/00—Resin or rubber layer comprising scrap, waste or recycling material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings

Definitions

  • the invention relates to an elongated, solid, natural fiber plastic composite element, to a method for manufacturing an elongated, solid, natural fiber plastic composite element and to the use of an elon ⁇ gated, solid, natural fiber plastic composite element.
  • the invention further relates to an apparatus for man- ufacturing an elongated, solid, natural fiber plastic composite element.
  • Fig. 2 presents another elongated, solid, natural fiber plastic composite element according to the present invention.
  • the dimensions may vary within certain prac ⁇ tical limits without significantly affecting the func ⁇ tioning of the element.
  • the expression "tolerance” should be understood as the permissible limit (s) of variation in the element.
  • the tolerance of the expansion area in the groove is greater than ⁇ 3 %.
  • the tolerance of the thickness of the element is smaller than ⁇ 3 %, preferably smaller than ⁇ 2 %. In one embodiment the tolerance of the width of the ele ⁇ ment is smaller than ⁇ 2 %, preferably smaller than ⁇ 1 %. In one embodiment of the invention the tolerance of the thickness of the element is smaller than ⁇ 3 % and the tolerance of the width of the element is smaller than ⁇ 2 %; preferably the tolerance of the thickness of the element is smaller than ⁇ 2 % and the tolerance of the width of the element is smaller than ⁇ 1 %. In one embodiment of the present invention both edge surfaces of the elongated, solid element are provided with a groove.
  • the groove can be provided anywhere in the edge surface of the element. If the element has two grooves in both edge surfaces, then the grooves are located at the same point of the edge surfaces. The grooves can also be located at different points of the edge surfac ⁇ es .
  • the parallel surfaces 2 may be flat, grooved or otherwise patterned.
  • one of the par ⁇ allel surfaces may be flat and the other grooved or patterned .
  • the groove is for fastening the elements together or to a substrate directly or by a fastener.
  • the fastener may be used to fasten the elements according to the inven ⁇ tion together and/or to the base element.
  • the fastener may be, for example, a screw or a nail.
  • the fastener is used to- gether with a fastening member in order to fasten the element .
  • the bottom 6 of the groove 4 forms the expansion area.
  • the shape of the bottom of the groove can be freely formed.
  • the shape of the cross profile of the bottom of the groove can be, for example, circular, polygonal and/or square.
  • a part of the side surfaces 5 of the groove 4 forms the expansion area.
  • the tolerance of this part of the side surfaces of the groove forming an ex ⁇ pansion area is greater than the tolerance of the width and/or the thickness of the element and the tol ⁇ erance of the other part of the side surfaces of the groove is the same as the tolerance of the width and/or the thickness of the element.
  • the bottom 6 of the groove or a part of it can also have the tolerance of the width and/or the thickness of the element and a part of the side surfaces 5 of the groove 4 can form the expansion area.
  • the bottom 6 and a part of the side surfaces 5 of the groove 4 form the expansion area
  • At least 5 %, preferably at least 8 %, more preferably at least 10 % of the side surfaces 5 of the groove 4 forms the expansion area.
  • the width of the element 1 is at least 50 mm, preferably at least 100 mm.
  • the width of the element 1 is up to 400 mm, preferably up to 300 mm.
  • the width of the element 1 is 50 to 400 mm, preferably 100 to 300 mm.
  • the thickness of the element 1 is at least 15 mm, pref ⁇ erably at least 20 mm.
  • the thickness of the element is up to 40 mm, preferably up to 35 mm.
  • the thickness of the element is 15 to 40 mm, preferably 20 to 35 mm.
  • the length of the element is up to 10 m, preferably up to 6 m, more preferably up to 5 m.
  • the length of the element is 1 to 10 m, preferably 2 to 6 m, more preferably 2.3 to 5 m.
  • the length of the element is smaller than 1 m.
  • an element having a length of approx. 0.5 m and a width of approx. 120 mm can be used in combination with 4 elements as an approx. 0.5 x 0.5 m plate.
  • the distance between side surfaces 5 of the groove 4 is 2 to 25 mm, preferably 3 to 20 mm, more preferably 4 to 15 mm.
  • the length of the side surfaces 5 of the groove 4 form ⁇ ing the depth of the groove is at least 4 mm, preferably at least 6 mm.
  • the length of the side surfaces 5 of the groove 4 is up to 30 mm, preferably up to 25 mm.
  • the length of the side surfaces 5 of the groove 4 is 4 to 30, preferably 6 to 25 mm.
  • organic natu ⁇ ral fiber based material refers to particles such as fibers or fiber-like particles that contain cellulose.
  • the organic natural fiber based material is, at least partly, in the form of fibers.
  • the or ⁇ ganic natural fiber based material can originate from any plant material that contains cellulose, i.e. both wood and non-wood material can be used.
  • the wood mate ⁇ rial can be softwood trees, such as spruce, pine, fir, larch, douglas-fir or hemlock, or hardwood trees, such as birch, aspen, poplar, alder, eucalyptus, or acacia, or a mixture of softwood and hardwood.
  • the organic natural fiber based material com ⁇ prises wood fibres, wood chips, straw, hay, rice husks, wood dust and/or the like and/or mechanical pulp and/or chemical pulp (powder and/or fibers) and/or recycled paper and/or recycled adhesive lami ⁇ nate material. Wood dust, mechanical pulp and/or chem ⁇ ical pulp are preferably used.
  • the polymer of the natural fiber based composite is a thermoplastic polymer, the most common ones being pol- yolefins such as polyethylene (PE) and polypropylene (PP) , polyvinyl chloride (PVC) and polymers based on styrene.
  • the thermoplastic polymer may be virgin or recycled .
  • the organic natural fiber based material compris ⁇ ing lignin comprises or consists of, for example, wood fibers, wood dust, wood chips, straw, hay, rice husks, mechanical pulp, recycled paper or other mechanically treated cellulose fibers or fiber-like particles.
  • the lignin is from wood dust.
  • the organic natural fiber based material includes a cellulose fiber based mate ⁇ rial that has a low lignin content.
  • the cellulose fi ⁇ ber based material may comprise chemically treated cellulose or the cellulose fiber based material origi ⁇ nates from plant material (s) in which the lignin con- tent is naturally low.
  • 20 to 80 wt.%, more preferably 30 to 70 wt . % and most preferably 40 to 60 wt.% of the composite element is organic natural fiber based material.
  • 5 to 90 wt.%, more preferably 10 to 70 wt.% and most preferably 20 to 50 wt.% of the composite element is thermoplastic polymer.
  • the natural fiber plastic composite element of the present invention may comprise at least one ad ⁇ ditive which is fed to the composite raw material in connection with its manufacture.
  • the natural fiber plastic compo ⁇ site element comprises mineral fillers.
  • the mineral filler preferably comprises ground calcium carbonate, precipitated calcium carbonate, titanium dioxide, tal ⁇ cum, silica, kaolin clay, wollastonite, or a mixture of said mineral fillers.
  • the natural fiber plastic composite el ⁇ ement comprises organic fillers.
  • the composite raw material comprises at least 2 wt . % and more preferably at least 5 wt . % of mineral fillers.
  • the mineral filler is calcium car ⁇ bonate and/or talcum.
  • the two edge surfaces are parallel, thus forming an element having a substantially rectangular cross pro ⁇ file.
  • the first layer 7 and the second layer 8 are formed by co-extrusion.
  • Co-extrusion is a method in which two or more flows of heated raw material are combined into one extrudate such that the materials are associated but not blended.
  • the extrusion is co-extrusion. This co-extrusion process is an effective way of manufacturing an element comprising two layers with at least partly different raw material compositions.
  • the thickness of the second layer 8 is at least 3 times, preferably at least 5, and more preferably 8 times greater than the thickness of the first layer 7.
  • the raw material of the first layer 7 comprises a poly- mer.
  • the raw material of the second layer 8 comprises a polymer and an organic natural fiber based material in ⁇ cluding lignin.
  • the appearance of the element is affect ⁇ ed by the first layer.
  • the appearance of the element may be good due to the first layer in spite of the lignin in the second layer.
  • the raw material of the first layer comprises a polymer and an organic natural fiber based material.
  • the raw material of the second layer is a polymer and an organic natural fiber based material including lignin.
  • the amount of lignin in the second layer is at least 1.3 times the amount of the lignin in the first layer.
  • the second layer 9 of the element 1 comprises at least 1 wt.%, more preferably at least 2 wt . % and most pref ⁇ erably at least 3 wt.% lignin.
  • the second layer may also contain other impu ⁇ rities than lignin.
  • the other impurities may comprise print inks, silicones and/or adhesives.
  • the natural fiber plastic composite element of the present invention may also comprise more than two layers.
  • the elongated solid natural fiber plastic com ⁇ posite element 1 comprising two parallel surfaces 2, which are at a distance forming a thickness of the el ⁇ ement from each other, two edge surfaces 3 which are at a distance forming a width of the element from each other, and a groove 4 provided on at least one edge surface 3, the groove 4 having side surfaces 5 and a bottom 6, from a raw material comprising a polymer and an organic natural fiber based material by using extru ⁇ sion,
  • the raw material In extrusion, the raw material is heated so as to make it soft, homogenized and compressed into a compact mass in a cylinder having (a) screw (s) there ⁇ in, and conveyed through a die, which gives it the shape of the end product.
  • the end product coming out from the die on the extrusion line is conveyed to a calibrating device which adjusts the measurements of the product .
  • the measurements, i.e. di ⁇ mensions, of the element vary within the tolerance of the thickness of the element of ⁇ 5 % and the tolerance of the width of the element of ⁇ 3 %.
  • the uncalibrated part of the groove forming the expansion area compensates for the material differences of the extruded ele ⁇ ment .
  • the extrusion is co-extrusion.
  • a calibrating device for calibrating the measures of the element.
  • the apparatus according to the present in ⁇ vention also comprises at least one supplying device to feed raw materials to the extruder.
  • the apparatus comprises a cooling reservoir for cool- ing the extruded element after the calibrating device.
  • the cooling reservoir is a water reservoir .
  • the element according to the invention need not be finished for removing the extra material from the surface, e.g. steel-brushed, in connection with the manufacture. In this way, modification, e.g. open ⁇ ing, of the surface of the element, which weakens the protective effect, is avoided.
  • the surface remains solid.
  • the surface of the element according to the in ⁇ vention is well-resistant to moisture and repels dirt and mold and it can be easily cleaned.
  • the element according to the present invention is du ⁇ rable and not scratched in normal use. Furthermore, the dimensional accuracy of the element is good, which makes installation easy.
  • the material of the element is environmentally friendly. The material may be a re ⁇ cycled material, and it can be recycled further. Fur ⁇ thermore, the material does not contain toxic chemi- cals.
  • the coupling agents used together with polyolefin are, for example maleic anhydride functionalized HDPE, maleic anhydride functionalized LDPE, maleic anhydride functionalized EP copolymers, acrylic acid functionalized PP, HDPE, LDPE, LLDPE, and EP copolymers, styrene/maleic anhydride copolymers, vinyl trialkoxy silanes, or combinations thereof.
  • the raw material may also comprise recycled adhesive lami ⁇ nate material.
  • the mass was conveyed through a die, which gives it the shape of the element. Low temperature may be used and therefore the darkening of the fiber par ⁇ ticles may be avoided.
  • the element coming out from the die on the extrusion line is conveyed to a calibrating device which adjusts the measurements of the element.
  • the calibrating device does not extend to all parts of the groove. In this example the calibrating device does not extend to the bottom 6 of the groove 4 and a part of the side surfaces 5 next to the bottom and thus leaves the bottom 6 and approximately 50 % of the area of the side surfaces 5 uncalibrated.
  • the thicker line drawn to the bottom 6 of the groove 4 and to the side surface 5 represents uncalibrated ar ⁇ ea .
  • the extruded and calibrated element is conveyed to a cooling reservoir for cooling.
  • the calibration continued in the cooling reservoirs .
  • the thickness of the element i.e. a distance of the par ⁇ allel surfaces 2 from each other, varies within the limit of ⁇ 5% and the width of the element, i.e. a distance of the edge surfaces 3 from each other, var- ies within the limit of ⁇ 3%.
  • the tol ⁇ erance of the thickness of the element is smaller than ⁇ 5 % and the tolerance of the width of the element is smaller than ⁇ 3 %.
  • the uncalibrated part of the groove forming the expansion area compensates for the material differences of the extruded element.
  • the parallel surfaces 2 are flat. However, the parallel surfaces or one of the parallel surfaces may also be grooved or otherwise patterned. The groov ⁇ ing or embossing of the parallel surface does not af- feet the tolerances of the thickness or the width.
  • the thickness of the manufactured element 1 was 25 mm, the width was 140 mm and the length was 6 m.
  • the element 1 is used in a terrace as a decking board.
  • the elongated, solid, natural fiber plastic composite element 1 according to the invention com ⁇ prising a first layer 7 and a second layer 8, presented in Fig. 2, was manufactured by a co-extrusion process.
  • a co-extrusion process two or more flows of heat ⁇ ed raw material were combined into one extrudate such that the materials are associated.
  • the flow properties of the raw materials were easily and separately controlled during the co-extrusion process.
  • the first layer 7 and the second layer 8 were formed by a co-extrusion process so that the first layer 7 forms the entire surface area of the element, covering the parallel surfaces 2 and edge surfaces 3. In other words the first layer 7 covers the second layer 8.
  • the thickness of the element i.e. a distance of the par ⁇ allel surfaces 2 from each other, varies within a ⁇ 5% limit and the width of the element, i.e. a distance of the edge surfaces 3 from each other, varies within a ⁇ 3% limit.
  • the thickness of the manufactured element 1 was 28 mm, the width was 150 mm and the length was 4 m.
  • the element 1 is used in a terrace as a decking board .

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  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

The invention relates to an elongated, solid, natural fiber plastic composite element (1 ) comprising two parallel surfaces (2), which are at a distance forming a thickness of the element (1) from each other, two edge surfaces (3) which are at a distance forming a width of the element (1) from each other, and a groove (4) provided on at least one edge surface (3), the groove (4) comprising side surfaces (5) and a bottom (6), formed by extrusion and wherein the tolerance of the thickness of the element is smaller than ±5 % and the tolerance of the width of the element is smaller than ±3 % and wherein the groove has an expansion area. The invention further relates to a method for manufacturing an elongated, solid, natural fiber plastic composite element, to the use thereof and to an apparatus for manufacturing the elongated, solid, natural fiber plastic composite element.

Description

A NATURAL FIBER PLASTIC COMPOSITE
FIELD OF THE INVENTION
The invention relates to an elongated, solid, natural fiber plastic composite element, to a method for manufacturing an elongated, solid, natural fiber plastic composite element and to the use of an elon¬ gated, solid, natural fiber plastic composite element. The invention further relates to an apparatus for man- ufacturing an elongated, solid, natural fiber plastic composite element.
BACKGROUND OF THE INVENTION
Solid natural fiber plastic elements comprise wood material and at least one kind of plastic poly¬ mer. The solid natural fiber plastic elements may be used, depending on their material, in exterior or interior locations for several purposes, for example for terraces and floors.
When manufacturing solid natural fiber plastic composite elements by the extrusion process, in¬ consistent material feeding and/or density causes the material to pump out of the extruder and causes dif¬ ferences in the width or the thickness of the element. The removing of the extra material from the surface of the element, for example by steel brushing, opens the surface and exposes the surface to dirt, water, oil etc .
SUMMARY
The elongated, solid, natural fiber plastic composite element according to the present invention is characterized by what is presented in claim 1. The method for manufacturing an elongated, solid, natural fiber plastic composite element accord¬ ing to the present invention is characterized by what is presented in claim 52.
The use according to the present invention is characterized by what is presented in claim 55.
The apparatus according to the present inven¬ tion is characterized by what is presented in claim 56.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and constitute a part of this specification, illus¬ trate embodiments of the invention and together with the description help to explain the principles of the invention. In the drawings:
Fig. 1 presents an elongated, solid, natural fiber plastic composite element according to the pre¬ sent invention.
Fig. 2 presents another elongated, solid, natural fiber plastic composite element according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The elongated, solid, natural fiber plastic composite element 1 according to the present invention comprises two parallel surfaces 2, which are at a dis- tance forming a thickness of the element from each other, two edge surfaces 3 which are at a distance forming a width of the element from each other and a groove 4 provided on at least one edge surface. The groove 4 comprises side surfaces 5 and a bottom 6 forming an expansion area, and the element is formed by extrusion. According to the invention the tolerance of the thickness of the element 1 is smaller than ±5 % and the tolerance of the width of the element (1) is smaller than ±3 % and the groove 4 has an expansion area .
The dimensions may vary within certain prac¬ tical limits without significantly affecting the func¬ tioning of the element. In this specification, unless otherwise stated, the expression "tolerance" should be understood as the permissible limit (s) of variation in the element.
The expansion area of the groove can compensate for the differences of the dimensions, for exam¬ ple in the width and/or the thickness of the extruded element, which can, for example, result from the mate- rial pumping out of the extruder due to inconsistent material feeding and/or density.
In one embodiment of the present invention the tolerance of the expansion area in the groove is greater than ±3 %.
In one embodiment of the present invention the tolerance of the expansion area in the groove is greater than ±5.
In one embodiment of the present invention the tolerance of the thickness of the element is smaller than ±3 %, preferably smaller than ±2 %. In one embodiment the tolerance of the width of the ele¬ ment is smaller than ±2 %, preferably smaller than ±1 %. In one embodiment of the invention the tolerance of the thickness of the element is smaller than ±3 % and the tolerance of the width of the element is smaller than ±2 %; preferably the tolerance of the thickness of the element is smaller than ±2 % and the tolerance of the width of the element is smaller than ±1 %. In one embodiment of the present invention both edge surfaces of the elongated, solid element are provided with a groove.
The groove can be provided anywhere in the edge surface of the element. If the element has two grooves in both edge surfaces, then the grooves are located at the same point of the edge surfaces. The grooves can also be located at different points of the edge surfac¬ es .
In one embodiment of the present invention the groove is located so that the middle point of the edge surface is in the groove. In other words, the groove is located so that at least a part of it is in the middle of the edge surface. The element can be used as a one- or two-sided element. In one embodiment the groove is located closer to one of the parallel surfaces and at least a part of it is in the middle of the edge surface. In this case, the element can be used as a one¬ sided element, the parallel surface located farther away from the groove being the top surface, e.g. the surface that is visible in use. The parallel surface that is lo¬ cated farther away from the groove stands a great deal of wear.
The parallel surfaces 2 may be flat, grooved or otherwise patterned. Alternatively one of the par¬ allel surfaces may be flat and the other grooved or patterned .
In one embodiment of the present invention the groove is for fastening the elements together or to a substrate directly or by a fastener. The fastener may be used to fasten the elements according to the inven¬ tion together and/or to the base element. The fastener may be, for example, a screw or a nail. In one embodi¬ ment of the present invention the fastener is used to- gether with a fastening member in order to fasten the element . In one embodiment of the present invention the bottom 6 of the groove 4 forms the expansion area. The shape of the bottom of the groove can be freely formed. The shape of the cross profile of the bottom of the groove can be, for example, circular, polygonal and/or square.
In one embodiment of the present invention a part of the side surfaces 5 of the groove 4 forms the expansion area. In other words, the tolerance of this part of the side surfaces of the groove forming an ex¬ pansion area is greater than the tolerance of the width and/or the thickness of the element and the tol¬ erance of the other part of the side surfaces of the groove is the same as the tolerance of the width and/or the thickness of the element. The bottom 6 of the groove or a part of it can also have the tolerance of the width and/or the thickness of the element and a part of the side surfaces 5 of the groove 4 can form the expansion area.
In one embodiment of the present invention the bottom 6 and a part of the side surfaces 5 of the groove 4 form the expansion area
In one embodiment of the present invention at least 5 %, preferably at least 8 %, more preferably at least 10 % of the side surfaces 5 of the groove 4 forms the expansion area.
In one embodiment of the present invention up to 80 %, preferably up to 70 %, more preferably up to 50 % of the side surfaces 5 of the groove 4 forms the ex- pansion area.
In one embodiment of the present invention 5 to 80 %, preferably 8 to 70 %, more preferably 10 to 50 % of the side surfaces 5 of the groove 4 forms the ex¬ pansion area. In one embodiment of the present invention the width of the element is at least 2, preferably at least 4 times greater than the thickness.
In one embodiment of the present invention the width of the element 1 is at least 50 mm, preferably at least 100 mm.
In one embodiment of the present invention the width of the element 1 is up to 400 mm, preferably up to 300 mm.
In one embodiment of the present invention the width of the element 1 is 50 to 400 mm, preferably 100 to 300 mm.
In one embodiment of the present invention the length of the element 1 is at least 10 times greater than the thickness of the element 1.
In one embodiment of the present invention the thickness of the element 1 is at least 15 mm, pref¬ erably at least 20 mm.
In one embodiment of the present invention the thickness of the element is up to 40 mm, preferably up to 35 mm.
In one embodiment of the present invention the thickness of the element is 15 to 40 mm, preferably 20 to 35 mm.
In one embodiment of the present invention the length of the element is at least 1 m, preferably at least 2 m, more preferably at least 2.3 m.
In one embodiment of the present invention the length of the element is up to 10 m, preferably up to 6 m, more preferably up to 5 m.
In one embodiment of the present invention the length of the element is 1 to 10 m, preferably 2 to 6 m, more preferably 2.3 to 5 m.
In one embodiment of the present invention the length of the element is smaller than 1 m. For example, an element having a length of approx. 0.5 m and a width of approx. 120 mm can be used in combination with 4 elements as an approx. 0.5 x 0.5 m plate.
In one embodiment of the present invention the distance between side surfaces 5 of the groove 4 forming the width of the groove is at least 2 mm, pref¬ erably at least 3 mm, more preferably at least 4 mm.
In one embodiment of the present invention the distance between side surfaces 5 of the groove 4 is up to 25 mm, preferably up to 20 mm, more preferably up to 15 mm.
In one embodiment of the present invention the distance between side surfaces 5 of the groove 4 is 2 to 25 mm, preferably 3 to 20 mm, more preferably 4 to 15 mm.
In one embodiment of the present invention the length of the side surfaces 5 of the groove 4 form¬ ing the depth of the groove is at least 4 mm, preferably at least 6 mm.
In one embodiment of the present invention the length of the side surfaces 5 of the groove 4 is up to 30 mm, preferably up to 25 mm.
In one embodiment of the present invention the length of the side surfaces 5 of the groove 4 is 4 to 30, preferably 6 to 25 mm.
The raw material of the elongated, solid, nat¬ ural fiber plastic composite element comprises an or¬ ganic natural fiber based material and a polymer.
In this application, the term "organic natu¬ ral fiber based material" refers to particles such as fibers or fiber-like particles that contain cellulose. The organic natural fiber based material is, at least partly, in the form of fibers. In other words, the or¬ ganic natural fiber based material can originate from any plant material that contains cellulose, i.e. both wood and non-wood material can be used. The wood mate¬ rial can be softwood trees, such as spruce, pine, fir, larch, douglas-fir or hemlock, or hardwood trees, such as birch, aspen, poplar, alder, eucalyptus, or acacia, or a mixture of softwood and hardwood. The non-wood material can be agricultural residues, grasses or oth- er plant substances such as straw, leaves, bark, seeds, hulls, flowers, vegetables or fruits from cot¬ ton, corn, wheat, oat, rye, barley, rice, flax, hemp, manila hemp, sisal hemp, jute, ramie, kenaf, bagasse, bamboo, or reed. The organic natural fiber based mate- rial may be virgin or recycled.
The organic natural fiber based material com¬ prises wood fibres, wood chips, straw, hay, rice husks, wood dust and/or the like and/or mechanical pulp and/or chemical pulp (powder and/or fibers) and/or recycled paper and/or recycled adhesive lami¬ nate material. Wood dust, mechanical pulp and/or chem¬ ical pulp are preferably used.
In one embodiment of the present invention the polymer of the natural fiber based composite is a thermoplastic polymer, the most common ones being pol- yolefins such as polyethylene (PE) and polypropylene (PP) , polyvinyl chloride (PVC) and polymers based on styrene. The thermoplastic polymer may be virgin or recycled .
In one embodiment of the present invention the thermoplastic polymer comprises or consists of polyolefin, i.e. polypropylene (PP) and/or polyeth¬ ylene (PE) . In one embodiment of the present invention the thermoplastic polymer comprises polyethylene. In one embodiment of the present invention the thermo¬ plastic polymer comprises polypropylene. In one embod¬ iment of the present invention the thermoplastic poly¬ mer comprises polyvinyl chloride (PVC) . In one embodi¬ ment of the present invention the thermoplastic poly- mer comprises polylactide (PLA) . In one embodiment of the present invention the organic natural fiber based material comprises lig- nin. The organic natural fiber based material compris¬ ing lignin comprises or consists of, for example, wood fibers, wood dust, wood chips, straw, hay, rice husks, mechanical pulp, recycled paper or other mechanically treated cellulose fibers or fiber-like particles. In one embodiment the lignin is from wood dust.
In one embodiment, the organic natural fiber based material includes a cellulose fiber based mate¬ rial that has a low lignin content. The cellulose fi¬ ber based material may comprise chemically treated cellulose or the cellulose fiber based material origi¬ nates from plant material (s) in which the lignin con- tent is naturally low.
In one embodiment of the present invention 20 to 80 wt.%, more preferably 30 to 70 wt . % and most preferably 40 to 60 wt.% of the composite element is organic natural fiber based material.
In one embodiment of the present invention 5 to 90 wt.%, more preferably 10 to 70 wt.% and most preferably 20 to 50 wt.% of the composite element is thermoplastic polymer.
In this disclosure, all percentages are by dry weight, if not indicated otherwise.
The natural fiber plastic composite element of the present invention may comprise at least one ad¬ ditive which is fed to the composite raw material in connection with its manufacture. In one embodiment of the present invention the natural fiber plastic compo¬ site element comprises mineral fillers. The mineral filler preferably comprises ground calcium carbonate, precipitated calcium carbonate, titanium dioxide, tal¬ cum, silica, kaolin clay, wollastonite, or a mixture of said mineral fillers. In one embodiment of the pre- sent invention the natural fiber plastic composite el¬ ement comprises organic fillers.
In one embodiment of the present invention the composite raw material comprises at least 2 wt . % and more preferably at least 5 wt . % of mineral fillers. In one embodiment, the mineral filler is calcium car¬ bonate and/or talcum.
Other additives, for example additional plas¬ tics, colouring agents, coupling agents, lubricants, fire retardants, foaming agents, adhesion promoters, bi- ocides, antioxidants and uv-stabilizers may also be add¬ ed to the fiber plastic composite element raw material in connection with its manufacture in order to amelio¬ rate the properties or processability of the composite material.
In one embodiment of the present invention the two edge surfaces are parallel, thus forming an element having a substantially rectangular cross pro¬ file.
In one embodiment of the present invention the element 1 comprises a first layer 7 and a second layer 8, the first layer 7 covering at least part of the second layer 8.
In one embodiment of the present invention the first layer 7 and the second layer 8 are formed by co-extrusion. Co-extrusion is a method in which two or more flows of heated raw material are combined into one extrudate such that the materials are associated but not blended. In one embodiment of the present in- vention the extrusion is co-extrusion. This co-extrusion process is an effective way of manufacturing an element comprising two layers with at least partly different raw material compositions.
In one embodiment of the present invention the thickness of the second layer 8 is at least 3 times, preferably at least 5, and more preferably 8 times greater than the thickness of the first layer 7.
The first layer 7 may form the entire surface area of the element 1. In this case the first layer 7 totally covers the second layer 8 forming a core layer. Alternatively a part of the second layer 8 may be cov¬ ered by the first layer 7.
In one embodiment of the present invention the raw material of the first layer 7 comprises a poly- mer. The raw material of the second layer 8 comprises a polymer and an organic natural fiber based material in¬ cluding lignin. The appearance of the element is affect¬ ed by the first layer. The appearance of the element may be good due to the first layer in spite of the lignin in the second layer.
In one embodiment of the present invention the raw material of the first layer comprises a polymer and an organic natural fiber based material. The raw material of the second layer is a polymer and an organic natural fiber based material including lignin.
In one embodiment of the present invention the amount of lignin in the second layer is at least 1.3 times the amount of the lignin in the first layer.
In one embodiment of the present invention the second layer 9 of the element 1 comprises at least 1 wt.%, more preferably at least 2 wt . % and most pref¬ erably at least 3 wt.% lignin.
The second layer may also contain other impu¬ rities than lignin. The other impurities may comprise print inks, silicones and/or adhesives.
The natural fiber plastic composite element of the present invention may also comprise more than two layers.
The element according to the invention can be used as a wall, floor and/or ceiling element in inte¬ rior applications such as residential spaces, public spaces or industrial spaces, and exterior applications such as terrace, patio and balcony. In one embodiment of the present invention the elongated, solid, natural fiber plastic composite element is a building or ter- race element, such as a decking board or a facade panel. In one embodiment the element is a decking board. In one embodiment the element is a facade panel. The ele¬ ment can be used in a terrace or a building.
The method for manufacturing an elongated, solid, natural fiber plastic composite element 1 com¬ prising two parallel surfaces 2, which are at a dis¬ tance forming a thickness of the element from each other, two edge surfaces 3 which are at a distance forming a width of the element from each other, and a groove 4 provided on at least one edge surface 3, the groove having side surfaces 5 and a bottom 6, compris¬ es :
forming the elongated solid natural fiber plastic com¬ posite element 1 comprising two parallel surfaces 2, which are at a distance forming a thickness of the el¬ ement from each other, two edge surfaces 3 which are at a distance forming a width of the element from each other, and a groove 4 provided on at least one edge surface 3, the groove 4 having side surfaces 5 and a bottom 6, from a raw material comprising a polymer and an organic natural fiber based material by using extru¬ sion,
calibrating the element 1 and forming an expansion area in the groove 4 by leaving a part of the groove 4 uncalibrated .
In extrusion, the raw material is heated so as to make it soft, homogenized and compressed into a compact mass in a cylinder having (a) screw (s) there¬ in, and conveyed through a die, which gives it the shape of the end product. The end product coming out from the die on the extrusion line is conveyed to a calibrating device which adjusts the measurements of the product .
After calibration, the measurements, i.e. di¬ mensions, of the element vary within the tolerance of the thickness of the element of ±5 % and the tolerance of the width of the element of ±3 %. The uncalibrated part of the groove forming the expansion area compensates for the material differences of the extruded ele¬ ment .
In one embodiment of the present invention the extrusion is co-extrusion.
An apparatus for manufacturing an elongated, solid, natural fiber plastic composite element 1 com¬ prising two parallel surfaces 2, which are at a dis- tance forming a thickness of the element from each other, two edge surfaces 3 which are at a distance forming a width of the element from each other, and a groove 4 provided on at least one edge surface 3, the groove having side surfaces 5 and a bottom 6, compris- es :
an extruder and a die for forming the element,
a calibrating device for calibrating the measures of the element.
The apparatus according to the present in¬ vention also comprises at least one supplying device to feed raw materials to the extruder.
In one embodiment of the present invention the apparatus comprises a cooling reservoir for cool- ing the extruded element after the calibrating device. In one embodiment the cooling reservoir is a water reservoir .
The embodiments of the invention described hereinbefore may be used in any combination with each other. Several of the embodiments may be combined to¬ gether to form a further embodiment of the invention. A method, a composition or a use, to which the invention is related, may comprise at least one of the em¬ bodiments of the invention described hereinbefore.
The element according to the invention need not be finished for removing the extra material from the surface, e.g. steel-brushed, in connection with the manufacture. In this way, modification, e.g. open¬ ing, of the surface of the element, which weakens the protective effect, is avoided. The surface remains solid. The surface of the element according to the in¬ vention is well-resistant to moisture and repels dirt and mold and it can be easily cleaned. In addition, the element according to the present invention is du¬ rable and not scratched in normal use. Furthermore, the dimensional accuracy of the element is good, which makes installation easy. The material of the element is environmentally friendly. The material may be a re¬ cycled material, and it can be recycled further. Fur¬ thermore, the material does not contain toxic chemi- cals.
EXAMPLES
The description below discloses some embodi¬ ments of the invention in such a detail that a person skilled in the art is able to utilize the invention based on the disclosure. Not all steps of the embodi¬ ments are discussed in detail, as many of the steps will be obvious for the person skilled in the art based on this specification.
EXAMPLE 1
The elongated, solid, natural fiber plastic composite element 1 comprising two parallel surfaces 2, edge surfaces 3 connecting said surfaces 2 to each other, and grooves 4 provided on the edge surfaces 3, the groove 4 comprising side surfaces 5 and a bottom 6, according to the invention, presented in Fig. 1, was manufactured by the extrusion technique from wood dust and a thermoplastic polymer such as polyolefin. Preferably, the thermoplastic polymer comprised high- density polyethylene (HDPE) having the melting point in the range of 120 to 130 °C. If HDPE is used, a wid¬ er temperature range may be used in the process. Poly¬ propylene may also be used in the process either alone or together with polyethylene. The thermoplastic poly- mer may also comprise polyvinyl chloride (PVC) . The organic natural fiber based material may also comprise mechanical pulp.
This raw material was heated, homogenized and compressed into a compact mass in a cylinder having a screw therein. It was also possible to feed the de¬ sired additives and additional polymers to the extrud¬ er. The desired additives may comprise additives such as mineral fillers, e.g. calcium carbonate or talcum, colorants, UV stabilizers, coupling agents, lubricants and foaming agents. The coupling agents used together with polyolefin are, for example maleic anhydride functionalized HDPE, maleic anhydride functionalized LDPE, maleic anhydride functionalized EP copolymers, acrylic acid functionalized PP, HDPE, LDPE, LLDPE, and EP copolymers, styrene/maleic anhydride copolymers, vinyl trialkoxy silanes, or combinations thereof. The raw material may also comprise recycled adhesive lami¬ nate material.
The mass was conveyed through a die, which gives it the shape of the element. Low temperature may be used and therefore the darkening of the fiber par¬ ticles may be avoided. The element coming out from the die on the extrusion line is conveyed to a calibrating device which adjusts the measurements of the element. The calibrating device does not extend to all parts of the groove. In this example the calibrating device does not extend to the bottom 6 of the groove 4 and a part of the side surfaces 5 next to the bottom and thus leaves the bottom 6 and approximately 50 % of the area of the side surfaces 5 uncalibrated. In figure 1, the thicker line drawn to the bottom 6 of the groove 4 and to the side surface 5 represents uncalibrated ar¬ ea .
The amount of the organic natural fiber based material in the element is 40 to 50 wt . % . In the exam¬ ple, at least 90 wt . % of the fiber based material is wood based material.
After the calibrating device the extruded and calibrated element is conveyed to a cooling reservoir for cooling. The calibration continued in the cooling reservoirs .
After calibration of the measurements, the thickness of the element, i.e. a distance of the par¬ allel surfaces 2 from each other, varies within the limit of ± 5% and the width of the element, i.e. a distance of the edge surfaces 3 from each other, var- ies within the limit of ± 3%. In other words, the tol¬ erance of the thickness of the element is smaller than ±5 % and the tolerance of the width of the element is smaller than ±3 %. The uncalibrated part of the groove forming the expansion area compensates for the material differences of the extruded element.
The parallel surfaces 2 are flat. However, the parallel surfaces or one of the parallel surfaces may also be grooved or otherwise patterned. The groov¬ ing or embossing of the parallel surface does not af- feet the tolerances of the thickness or the width.
The thickness of the manufactured element 1 was 25 mm, the width was 140 mm and the length was 6 m. The length of the side surface of the groove, i.e. the depth of the groove, was 11 mm. The element 1 is used in a terrace as a decking board. EXAMPLE 2
The elongated, solid, natural fiber plastic composite element 1 according to the invention com¬ prising a first layer 7 and a second layer 8, presented in Fig. 2, was manufactured by a co-extrusion process. In the co-extrusion process two or more flows of heat¬ ed raw material were combined into one extrudate such that the materials are associated. In the process the flow properties of the raw materials were easily and separately controlled during the co-extrusion process. The first layer 7 and the second layer 8 were formed by a co-extrusion process so that the first layer 7 forms the entire surface area of the element, covering the parallel surfaces 2 and edge surfaces 3. In other words the first layer 7 covers the second layer 8.
The element can also be manufactured so that the first layer covers a part of the second layer, for example so that the first layer covers only the sur¬ face of one of the parallel surfaces 2. For example, in the case of a building element, the first layer 7 preferably forms the surface of a side that is visible in use. In the case of a decking board that forms a part of a floor, the first layer 7 advantageously co¬ vers at least the top side of said decking board.
The raw material for the first layer 7 com¬ prised a thermoplastic polymer. The raw material for the second, core layer 8 comprised a thermoplastic polymer, an organic natural fiber based material such as wood dust and/or wood chips and/or mechanical and/or chemical pulp including lignin. Preferably, the thermoplastic polymer comprises polypropylene (PP) . In this example, the total amount of the PP is at least 50 wt . % of the thermoplastic polymers in said first layer .
The first layer 7 may also comprise an organ¬ ic natural fiber based material. This material may be the same as the organic natural fiber based material of the second layer 8. Advantageously the organic nat¬ ural fiber based material of the first layer 7 is chemical pulp fiber. The lignin content in the second layer is preferably at least 3 wt . % . The first layer 7 of the element 1 does not comprise lignin. Alterna¬ tively, the amount of lignin is smaller in the first layer 7 of the element 1 than in the second layer 8 of the element. Thanks to the first layer covering at least a part of the second layer, the second layer may comprise lots of recycled material. For example, the second layer may comprise dark colored recycled mate¬ rial even if the manufactured product has a light col¬ or .
It was also possible to feed the desired ad¬ ditives and additional plastic to the extruder. The associated materials were conveyed through a die, which gives them the shape of the element. The element coming out from the die on the extrusion line is con- veyed to a calibrating device which adjusts the meas¬ urements of the element. In this example the calibrat¬ ing device left the bottom 6 of the groove 4 and ap¬ proximately 20 % of the area of the side surfaces 5 next to the bottom uncalibrated .
After calibration of the measurements, the thickness of the element, i.e. a distance of the par¬ allel surfaces 2 from each other, varies within a ± 5% limit and the width of the element, i.e. a distance of the edge surfaces 3 from each other, varies within a ± 3% limit. The thickness of the manufactured element 1 was 28 mm, the width was 150 mm and the length was 4 m. The element 1 is used in a terrace as a decking board .

Claims

1. An elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces (2), which are at a distance forming a thickness of the element (1) from each other, two edge surfaces (3) which are at a distance forming a width of the element (1) from each other, and a groove (4) provided on at least one edge surface (3), the groove (4) comprising side surfaces (5) and a bottom (6), formed by extru¬ sion, wherein:
the tolerance of the thickness of the element (1) is smaller than ±5 % and the tolerance of the width of the element (1) is smaller than ±3 % and wherein the groove (4) has an expansion area.
2. The elongated, solid element according to claim 1, wherein the tolerance of the expansion area in the groove (4) is greater than ±3 %.
3. The elongated, solid element according to claim 1 or 2, wherein the tolerance of the expansion area in the groove (4) is greater than ±5 %.
4. The elongated, solid element according to any one of claims 1 to 3, wherein the tolerance of the thickness of the element (1) is smaller than ±3 %, preferably smaller than ±2 %.
5. The elongated, solid element according to any one of claims 1 to 4, wherein the tolerance of the width of the element (1) is smaller than ±2 %, preferably smaller than ±1 %.
6. The elongated, solid element according to any one of claims 1 to 2, wherein the tolerance of the thickness of the element (1) is smaller than ±3 % and the tolerance of the width of the element (1) is smaller than ±2 %, preferably the tolerance of the thickness of the element (1) is smaller than ±2 % and the tolerance of the width of the element (1) is smaller than ±1 % .
7. The elongated, solid element according to any one of claims 1 to 6, wherein both edge surfaces (3) are provided with a groove (4) .
8. The elongated, solid element according to any one of claims 1 to 7, wherein the groove is located so that the middle point of the edge surface (3) is in the groove (4) .
9. The elongated, solid element according to any one of claims 1 to 8, wherein the groove (4) is for fastener (s) for fastening the elements.
10. The elongated, solid element according to any one of claims 1 to 9, wherein the bottom (6) of the groove (4) forms the expansion area.
11. The elongated, solid element according to any one of claims 1 to 9, wherein a part of the side surfaces (5) of the groove (4) forms the expansion ar¬ ea .
12. The elongated, solid element according to any one of claims 1 to 11, wherein the bottom (6) and a part of the side surfaces (5) of the groove (4) form the expansion area.
13. The elongated, solid element according to any of claims 1 to 12, wherein at least 5 %, preferably at least 8 %, more preferably at least 10 % of the side surfaces (5) of the groove (4) forms the expansion ar¬ ea .
14. The elongated, solid element according to any one of claims 1 to 13, wherein up to 80 %, prefera¬ bly up to 70 %, more preferably up to 50 % of the side surfaces (5) of the groove (4) forms the expansion ar¬ ea .
15. The elongated, solid element according to claim 1 to 14, wherein 5 to 80 %, preferably 8 to 70 %, more preferably 10 to 50 % of the side surfaces (5) of the groove (4) forms the expansion area.
16. The elongated, solid element according to any one of claims 1 to 15, wherein the width of the el- ement (1) is at least 2, preferably at least 4 times greater than the thickness.
17. The elongated, solid element according to any one of claims 1 to 16, wherein the width of the el¬ ement (1) is at least 50 mm, preferably at least 100 mm.
18. The elongated, solid element according to any one of claims 1 to 17, wherein the width of the el¬ ement (1) is up to 400 mm, preferably up to 300 mm.
19. The elongated, solid element according to any one of claims 1 to 18, wherein the width of the el- ement (1) is 50 to 400 mm, preferably 100 to 300 mm.
20. The elongated, solid element according to any one of claims 1 to 19, wherein the length of the element (1) is at least 10 times greater than the thick¬ ness of the element (1) .
21. The elongated, solid element according to any one of claims 1 to 20, wherein the thickness of the element (1) is at least 15 mm, preferably at least 20 mm.
22. The elongated, solid element according to any one of claims 1 to 21, wherein the thickness of the element is up to 40 mm, preferably up to 35 mm.
23. The elongated, solid element according to any one of claims 1 to 22, wherein the thickness of the element (1) is 15 to 40 mm, preferably 20 to 35 mm.
24. The elongated, solid element according to any one of claims 1 to 23, wherein the length of the element (1) is at least 1 m, preferably at least 2 m, more preferably at least 2,3 m.
25. The elongated, solid element according to any one of claims 1 to 24, wherein the length of the element (1) is up to 10 m, preferably up to 6 m, more preferably up to 5 m.
26. The elongated, solid element according to any one of claims 1 to 25, wherein the length of the element (1) is 1 to 10 m, preferably 2 to 6 m, more preferably 2.3 to 5 mm.
27. The elongated, solid element according to any one of claims 1 to 26, wherein the distance between side surfaces (5) of the groove (4) is at least 2 mm, preferably at least 3 mm, more preferably at least 4 mm.
28. The elongated, solid element according to any one of claims 1 to 27, wherein the distance between side surfaces (5) of the groove (4) is up to 25 mm, preferably up to 20 mm, more preferably up to 15 mm.
29. The elongated, solid element according to any one of claims 1 to 28, wherein the distance between side surfaces (5) of the groove (4) is 2 to 25 mm, preferably 3 to 20 mm, more preferably 4 to 15 mm.
30. The elongated, solid element according to any one of claims 1 to 29, wherein the length of the side surfaces (5) of the groove (4) is at least 4 mm, preferably at least 6 mm.
31. The elongated, solid element according to any one of claims 1 to 30, wherein the length of the side surfaces (6) of the groove (4) is up to 30 mm, preferably up to 25 mm.
32. The elongated, solid element according to any one of claims 1 to 31, wherein the length of the side surfaces (5) of the groove (4) is 4 to 30 mm, preferably 6 to 25 mm.
33. The elongated, solid element according to any one of claims 1 to 32, wherein the raw material of the element (1) comprises a polymer and an organic natu¬ ral fiber based material.
34. The elongated, solid element according to any one of claims 1 to 33, wherein the polymer is a thermoplastic polymer.
35. The elongated, solid element according to any one of claims 1 to 34, wherein the thermoplastic polymer is polyolefin.
36. The elongated, solid element according to any one of claims 1 to 35, wherein the thermoplastic polymer is polyethylene and/or polypropylene.
37. The elongated, solid element according to any one of claims 1 to 36, wherein the thermoplastic polymer is polyethylene.
38. The elongated, solid element according to any one of claims 1 to 37, wherein the organic natural fiber based material comprises lignin.
39. The elongated, solid element according to any one of claims 1 to 38, wherein the lignin is from wood dust.
40. The elongated, solid element according to any one of claims 1 to 39, wherein the raw material comprises at least 2 wt . % and more preferably at least 5 wt . % of mineral fillers.
41. The elongated, solid element according to claim 40, wherein the mineral filler is calcium car- bonate and/or talcum.
42. The elongated, solid element according to any one of claims 1 to 41, wherein the two edge surfac¬ es are parallel, thus forming an element having a sub¬ stantially rectangular cross profile.
43. The elongated, solid element according to any one of claims 1 to 42, wherein the element (1) com¬ prises a first layer (7) and a second layer (8) , the first layer (7) covering at least a part of the second layer (8) .
44. The elongated, solid element according to claim 43, wherein the first layer (7) and the second layer (8) are formed by co-extrusion.
45. The elongated, solid element according to any one of claims 43 to 44, wherein the thickness of the second layer (8) is at least 3 times, preferably at least 5, and more preferably 8 times greater than the thickness of the first layer (7) .
46. The elongated, solid element according to any one of claims 43 to 45, wherein the raw material of the first layer (7) comprises a polymer and the raw ma¬ terial of the second layer (8) comprises a polymer and an organic natural fiber based material including lig- nin .
47. The elongated, solid element according to any one of claims 43 to 46, wherein the raw material of the first layer comprises a polymer and an organic natu¬ ral fiber based material.
48. The elongated, solid element according to any one of claims 43 to 47, wherein the second layer
(8) of the element (1) comprises at least 1 wt . ~6 , more preferably at least 2 wt . % and most preferably at least 3 wt . % lignin.
49. The elongated, solid element according to any one of claims 1 to 48, wherein the element (1) is a building element, such as a decking board or a facade panel .
50. The elongated, solid element according to any one of claims 1 to 49, wherein the element (1) is a decking board.
51. The elongated, solid element according to any one of claims 1 to 49, wherein the element (1) is a facade panel.
52. A method for manufacturing an elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces (2), which are at a distance forming a thickness of the element from each other, two edge surfaces (3) which are at a distance forming a width of the element from each other, and a groove (4) provided on at least one edge surface (3), the groove (4) having side surfaces (5) and a bottom (6), wherein the method comprises:
forming the elongated solid natural fiber plastic composite element (1) comprising two parallel surfaces (2), which are at a distance forming a thick- ness of the element from each other, two edge surfaces (3) which are at a distance forming a width of the el¬ ement from each other, and a groove (4) provided on at least one edge surface (3), the groove (4) having side surfaces (5) and a bottom (6), from raw material com- prising a polymer and an organic natural fiber based material by using extrusion,
calibrating the element (1) and forming an expansion area in the groove (4) by leaving a part of the groove (5) uncalibrated .
53. The method according to claim 52, wherein the bottom (6) of the groove (4) is uncalibrated, where¬ in the shape of the bottom (6) of the groove (4) can be formed freely, compensating for the material differences of the extruded element.
54. The method according to claim 52 or 53, wherein the extrusion is co-extrusion.
55. A use of the elongated, solid element ac¬ cording to any one of claims 1 to 51 in a terrace or a building .
56. An apparatus for manufacturing an elongat¬ ed, solid, natural fiber plastic composite element (1) comprising two parallel surfaces (2), which are at a distance forming a thickness of the element from each other, two edge surfaces (3) which are at a distance forming a width of the element from each other, and a groove (4) provided on at least one edge surface (3), the groove (4) comprising side surfaces (5) and a bot¬ tom (6), comprising:
an extruder and a die for forming the element
(1) ,
a calibrating device for calibrating the measures of the element (1) .
PCT/FI2013/051031 2013-10-31 2013-10-31 A natural fiber plastic composite WO2015063364A1 (en)

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