WO2015063365A1 - A method for manufacturing a natural fiber plastic composite - Google Patents
A method for manufacturing a natural fiber plastic composite Download PDFInfo
- Publication number
- WO2015063365A1 WO2015063365A1 PCT/FI2013/051032 FI2013051032W WO2015063365A1 WO 2015063365 A1 WO2015063365 A1 WO 2015063365A1 FI 2013051032 W FI2013051032 W FI 2013051032W WO 2015063365 A1 WO2015063365 A1 WO 2015063365A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- groove
- elongated
- edge surface
- solid
- side surfaces
- Prior art date
Links
- 239000011205 natural fiber plastic composite Substances 0.000 title claims abstract description 27
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 title claims description 43
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Classifications
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- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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
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- 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
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- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/06—PVC, i.e. polyvinylchloride
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- 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
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- B32B2419/00—Buildings or parts thereof
Definitions
- the invention relates to a method for manu ⁇ facturing an elongated, solid, natural fiber plastic composite element, to an elongated, solid, natural fi ⁇ ber plastic composite element and to the use of an elongated, solid, natural fiber plastic composite ele- ment .
- the invention further relates to an apparatus for manufacturing an elongated, solid, natural fiber plastic composite element.
- 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.
- incon ⁇ sistent material feeding and/or density causes the ma ⁇ terial to pump out of the extruder and causes differ- ences 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 .
- 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 1.
- the elongated, solid, natural fiber plastic composite element according to the present invention is characterized by what is presented in claim 27.
- the elongated, solid, natural fiber plastic composite element according to the present invention is characterized by what is presented in claim 28.
- the apparatus according to the present inven- tion is characterized by what is presented in claim 62.
- 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 having an L- shape cross profile according to the present inven ⁇ tion.
- Fig. 3 presents another elongated, solid, natural fiber plastic composite element according to the present invention.
- the method for manufacturing an elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces 2, a first edge sur- face 3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface, the groove 5 comprising side surfaces 6 and a bottom 7, comprises:
- the elongated solid element 1 comprising two parallel surfaces 2, a first edge surface 3 and a sec ⁇ ond edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge sur ⁇ face 3 from a raw material comprising a polymer and an organic natural fiber based material by using extru ⁇ sion, and
- 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 element.
- the measurements, i.e. dimensions, of the element vary within certain practi- cal limits without affecting the functioning of the element.
- the uncalibrated part of the groove compen ⁇ sates for the material differences of the extruded ele ⁇ ment .
- the uncalibrated part of the groove can com- pensate for the differences of the dimensions, for ex ⁇ ample in the width and/or the thickness of the extrud ⁇ ed element, which can, for example, result from the material pumping out of the extruder due to incon ⁇ sistent material feeding and/or density.
- the second edge surface 4 is parallel to the first edge surface 3 of the element, thus forming an element hav ⁇ ing a rectangular cross profile.
- the surfaces 2 are provided with 90° angles, thus form ⁇ ing an element having an L-shape cross profile.
- the second edge surface 4 is perpendicular to the first edge surface 3.
- the second edge surface 4 is also provided with a groove 5.
- the grooves are for fastening the elements together or to a substrate directly or by a fastener.
- the groove can be located anywhere in the edge surface. If the element has a groove in both edge surfaces, the grooves 5 are located at the same point of the first and second edge surface 3, 4. The grooves can also be located at different points of the first and second edge surface 3, 4.
- the groove 5 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 2 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 surface 2 located farther away from the groove being the top surface, e.g. the surface that is visible in use. The surface 2 that is located farther away from the groove stands a great deal of wear.
- the bottom 7 of the groove 5 is uncalibrated, wherein the shape of the bottom 7 of the groove 5 can be formed freely, compensating for the material differences of the extruded element.
- 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.
- the bottom 7 and a part of the side surfaces 6 of the groove 5 are uncalibrated.
- the bottom 7 of the groove or a part of it can also be calibrated and a part of the side surfaces 6 of the groove 5 can be uncalibrated.
- At least 15 % of the side surfaces 6 of the groove 5 is calibrated.
- the percentage means the part of the cali ⁇ brated edge surface area of the whole edge surface ar ⁇ ea .
- At least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces 6 of the groove 5 is calibrated .
- up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces 6 of the groove 5 is calibrat ⁇ ed .
- 15 % to 100 % of the side surfaces 6 of the groove 5 is calibrated. In one embodiment of the present invention 20 to 95 %, preferably 30 to 92 %, more preferably 50 to 90 % of the side surfaces 6 of the groove 5 is cali ⁇ brated .
- 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 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.
- 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.
- thermoplastic polymer comprises or consists of polyolefin, i.e. polypropylene (PP) and/or polyeth ⁇ ylene (PE) .
- thermoplastic polymer comprises polyethylene.
- thermo ⁇ plastic polymer comprises polypropylene.
- thermoplastic poly ⁇ mer comprises polyvinyl chloride (PVC) .
- thermoplastic poly ⁇ mer comprises polylactide (PLA) .
- organic natural fiber based material comprises lig- nin.
- the organic natural fiber based material compris ⁇ ing lignin comprises or consist 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.
- thermoplastic polymer 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 other- wise.
- 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.
- 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 added to the fiber plastic composite element raw mate ⁇ rial in connection with its manufacture in order to ame ⁇ liorate the properties or processability of the compo- site material.
- the element 1 comprises a first layer 8 and a second layer 9, the first layer 8 covering at least a part of the second layer 9.
- the first layer 8 and the second layer 9 are formed by co-extrusion.
- a co-extrusion method two or more flows of heated raw material are combined into one ex- trudate such that the materials are associated but not blended.
- 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 9 is at least 3, pref- erably at least 5, and more preferably 8 times greater than the thickness of the first layer 8.
- the first layer 8 may form the entire surface area of the element 1. In this case the first layer 8 totally covers the second layer 9 forming a core layer. Alternatively a part of the second layer 9 may be cov ⁇ ered by the first layer 8.
- the raw material of the first layer comprises a polymer.
- the raw material of the second layer comprises a polymer and an organic natural fiber based material including lignin.
- the appearance of the element is affected by the first layer 8. The appearance of the element may be good due to the first layer 8 in spite of the lignin in the second layer 9.
- 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.
- An elongated, solid, natural fiber plastic composite element 1 according to the present invention comprises
- the groove 5 comprising side surfaces 6 and a bottom 7, formed from a raw material compris- ing a polymer and an organic natural fiber based mate ⁇ rial by using extrusion and an expansion area comprising an uncali- brated part of the groove 5.
- the elongated, solid, natural fiber plastic composite element 1 comprises two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface 3, the groove 5 comprising side surfaces 6 and a bottom 7, and is manufactured by
- the element 1 comprises a second edge surface 4 parallel to the first edge surface 3, thus forming an element 1 having a rectangular cross profile.
- the surfaces 2 are provided with 90° angles, thus form ⁇ ing an element 1 having an L-shape cross profile.
- the element comprises a second edge surface perpendicu- lar to the first edge surface.
- the second edge surface 4 is provided with a groove 5.
- the element 1 is formed by using co-extrusion.
- the groove 5 is for fastener (s) for fastening the ele ⁇ ments .
- the bottom 7 of the groove 5 is uncalibrated.
- the bottom 7 and a part of the side surfaces 6 of the groove 5 are uncalibrated.
- the bottom 7 of the groove or a part of it can also be calibrated and a part of the side surfaces 6 of the groove 5 can be uncalibrated.
- At least 15 % of the side surfaces 6 of the groove 5 is calibrated. In one embodiment of the present invention at least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces 6 of the groove 5 is calibrated .
- up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces 6 of the groove 5 is calibrat- ed.
- 15 % to 100 % of the side surfaces 6 of the groove 5 is calibrated .
- 20 to 95 %, preferably 30 to 92 %, more preferably 50 to 90 % of the side surfaces 6 of the groove 5 is calibrat ⁇ ed .
- 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 .
- the width of the element 1 is at least 2, preferably 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.
- 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 length of the element 1 is at least 10 times greater than the thickness of the element 1.
- 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 at least 1 m, preferably at least 2 m, more preferably at least 2.3 m.
- 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 6 of the groove 5 forming the width of the groove is at least 2 mm, pref ⁇ erably at least 3 mm, more preferably at least 4 mm.
- the distance between side surfaces 6 of the groove 5 is up to 25 mm, preferably up to 20 mm, more preferably up to 15 mm.
- the distance between side surfaces 6 of the groove 5 is 2 to 25 mm, preferably 3 to 20 mm, more preferably 4 to 15 mm.
- the length of the side surfaces 6 of the groove 5 form- ing the depth of the groove is at least 4 mm, preferably at least 6 mm.
- the length of the side surfaces 6 of the groove 5 is up to 30 mm, preferably up to 25 mm.
- the length of the side surfaces 6 of the groove 5 is 4 to 30, preferably 6 to 25 mm.
- 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.
- the elongated, solid, natural fiber plastic composite element is a building or ter- race element, such as a decking board or a facade panel.
- the element is a decking board.
- the element is a facade panel.
- the ele ⁇ ment can be used in a terrace or a building.
- An apparatus for manufacturing an elongated, solid, natural fiber plastic composite element 1 com ⁇ prising two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface 3, the groove 5 comprising side surfaces 6 and a bottom 7, comprises:
- a calibrating device for calibrating the measures of the element 1.
- the apparatus according to the present inven- tion 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 .
- 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 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. opening, 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 invention is well-resistant to moisture such as water and oil and repels dirt and mold and it can be easily cleaned.
- the element according to the present invention is durable and not scratched in normal use. Furthermore, the di- mensional accuracy of the element is good, which makes installation easy.
- the material of the element is en ⁇ vironmentally friendly. The material may be a recycled material, and it can be recycled further. The material does not contain toxic chemicals.
- the elongated, solid, natural fiber plastic composite element 1 comprising two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other, and grooves 5 provided on the first edge surface 3 and the second edge surface 4, the groove 5 comprising side surfaces 6 and a bottom 7, according to the invention, presented in Fig. 1, was manufactured by the extrusion tech ⁇ nique from wood dust and a thermoplastic polymer such as polyolefin.
- 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 wider temperature range may be used in the process.
- Polypropylene may also be used in the process either alone or together with polyethylene.
- the thermoplastic polymer 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 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 functionalize 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 a recycled adhesive laminate 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- tides 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 7 of the groove 5 and a part of the side surfaces 6 next to the bottom and thus leaves the bottom 7 and approximately 50 % of the area of the side surfaces 6 uncalibrated .
- the thicker line drawn to the bottom 7 of the groove 5 and to the side surface 6 represents the uncalibrated area .
- the amount of the organic natural fiber based material in the element is 40 to 50 wt . % .
- at least 90 wt . % of the fiber based material is wood based material.
- the extruded and calibrated element is conveyed to a cooling reser- voir for cooling.
- the calibration continued in the cooling reservoirs.
- the thickness of the element i.e. a distance of the parallel surfaces 2 from each other, varies within the limit of ⁇ 5% and the width of the element, i.e. a distance of the first and second edge surfaces 3,4 from each other, varies within the limit of ⁇ 3%.
- the uncalibrated part of the groove compensates for the material differences of the extruded element.
- 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.
- Figure 2 shows an element 1 having surfaces 2 that are provided with 90° angles, thus forming an ele- ment having an L-shape cross profile.
- the element was manufactured as described in example 1 by using the same raw materials.
- the calibrating device left the bottom 7 of the groove 5 and approximately 30 % of the area of the side surfaces 6 next to the bottom uncalibrated.
- the thickness of the manufactured element 1 was 25 mm, the width, i.e. the length of the longer part of the surface 2 1 which is visible in use was 100 mm and the length of the element was 4 m. The length of the shorter part of the surface 2 2 was 50 mm.
- the element 1 can be used in a terrace for example as a step board.
- EXAMPLE 3 The elongated, solid, natural fiber plastic composite element 1 according to the invention com ⁇ prising a first layer 8 and a second layer 9, presented in Fig. 3, 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 but not blended.
- the flow properties of the raw materials were easily and separately controlled during the co- extrusion process.
- the first layer 8 and the second layer 9 were formed by a co-extrusion process so that the first layer 8 forms the entire surface area of the element, covering the parallel surfaces 2 and edge surfaces 3, 4. In other words the first layer 8 covers the second layer 9.
- 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.
- the first layer 8 preferably forms the surface of a side that is visible in use.
- the first layer 8 advantageously co ⁇ vers at least the top side of said decking board.
- the raw material for the first layer 8 com ⁇ prised a thermoplastic polymer.
- the raw material for the second, core layer 9 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.
- the thermoplastic polymer comprises polypropylene (PP) .
- the total amount of the PP is at least 50 wt . % of the thermoplastic polymers in said first layer .
- the first layer 8 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 9.
- the organic nat ⁇ ural fiber based material of the first layer 8 is chemical pulp fiber.
- the lignin content in the second layer is preferably at least 3 wt . % .
- the first layer 8 of the element 1 does not comprise lignin. Alterna ⁇ tively, the amount of lignin is smaller in the first layer 8 of the element 1 than in the second layer 9 of the element.
- the second layer may comprise lots of recycled material.
- the second layer may comprise a dark colored recycled ma ⁇ terial even if the manufactured product had a light color .
- the thickness of the element i.e. a distance of the par ⁇ allel surfaces 2 from each other
- the width of the element i.e. a distance of the first and second edge surfaces 3,4 from each other
- the thickness of the manufactured element 1 was 28 mm
- the width was 150 mm
- the length was 4 m.
- the element 1 is used in a terrace as a decking board.
Abstract
The invention relates to amethod for manufacturing an elongated, solid, natural fiber plastic composite element comprising two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other,and a groove 5 provided on the first edge surface, the groove comprising side surfaces 6 and a bottom 7,by forming the elongated solid element 1 from a raw material comprising a polymer and an organic natural fiber based material by using extrusion and calibrating the element 1 and forming an expansion area in the groove by leaving a part of the groove 5 uncalibrated. The invention relates further to an elongat- ed, solid, natural fiber plastic composite element, to the use thereof and to an apparatus for manufacturing an elon- gated, solid, natural fiber plastic composite element.
Description
A METHOD FOR MANUFACTURING A NATURAL FIBER PLASTIC COMPOSITE
FIELD OF THE INVENTION
The invention relates to a method for manu¬ facturing an elongated, solid, natural fiber plastic composite element, to an elongated, solid, natural fi¬ ber plastic composite element and to the use of an elongated, solid, natural fiber plastic composite ele- ment . The invention further relates to an apparatus for manufacturing 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 an extrusion process, incon¬ sistent material feeding and/or density causes the ma¬ terial to pump out of the extruder and causes differ- ences 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 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 1.
The elongated, solid, natural fiber plastic composite element according to the present invention is characterized by what is presented in claim 27.
The elongated, solid, natural fiber plastic composite element according to the present invention is characterized by what is presented in claim 28.
The use according to the present invention is characterized by what is presented in claim 61.
The apparatus according to the present inven- tion is characterized by what is presented in claim 62.
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 having an L- shape cross profile according to the present inven¬ tion.
Fig. 3 presents another elongated, solid, natural fiber plastic composite element according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The method for manufacturing an elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces 2, a first edge sur-
face 3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface, the groove 5 comprising side surfaces 6 and a bottom 7, comprises:
forming the elongated solid element 1 comprising two parallel surfaces 2, a first edge surface 3 and a sec¬ ond edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge sur¬ face 3 from a raw material comprising a polymer and an organic natural fiber based material by using extru¬ sion, and
calibrating the element 1 and forming an expansion area in the groove 5 by leaving a part of the groove 5 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 element.
After calibration, the measurements, i.e. dimensions, of the element vary within certain practi- cal limits without affecting the functioning of the element. The uncalibrated part of the groove compen¬ sates for the material differences of the extruded ele¬ ment .
The uncalibrated part of the groove can com- pensate for the differences of the dimensions, for ex¬ ample in the width and/or the thickness of the extrud¬ ed element, which can, for example, result from the material pumping out of the extruder due to incon¬ sistent material feeding and/or density.
In one embodiment of the present invention the second edge surface 4 is parallel to the first edge
surface 3 of the element, thus forming an element hav¬ ing a rectangular cross profile.
In one embodiment of the present invention the surfaces 2 are provided with 90° angles, thus form¬ ing an element having an L-shape cross profile. In this case the second edge surface 4 is perpendicular to the first edge surface 3.
In one embodiment of the present invention the second edge surface 4 is also provided with a groove 5. The grooves are for fastening the elements together or to a substrate directly or by a fastener.
The groove can be located anywhere in the edge surface. If the element has a groove in both edge surfaces, the grooves 5 are located at the same point of the first and second edge surface 3, 4. The grooves can also be located at different points of the first and second edge surface 3, 4.
In one embodiment of the present invention the groove 5 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 2 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 surface 2 located farther away from the groove being the top surface, e.g. the surface that is visible in use. The surface 2 that is located farther away from the groove stands a great deal of wear.
In one embodiment of the present invention the bottom 7 of the groove 5 is uncalibrated, wherein the shape of the bottom 7 of the groove 5 can be formed freely, compensating for the material differences of the extruded element.
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 the bottom 7 and a part of the side surfaces 6 of the groove 5 are uncalibrated. The bottom 7 of the groove or a part of it can also be calibrated and a part of the side surfaces 6 of the groove 5 can be uncalibrated.
In one embodiment of the present invention at least 15 % of the side surfaces 6 of the groove 5 is calibrated. The percentage means the part of the cali¬ brated edge surface area of the whole edge surface ar¬ ea .
In one embodiment of the present invention at least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces 6 of the groove 5 is calibrated .
In one embodiment of the present invention up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces 6 of the groove 5 is calibrat¬ ed .
In one embodiment of the present invention 15 % to 100 % of the side surfaces 6 of the groove 5 is calibrated. In one embodiment of the present invention 20 to 95 %, preferably 30 to 92 %, more preferably 50 to 90 % of the side surfaces 6 of the groove 5 is cali¬ brated .
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 consist 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 other- wise.
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 added to the fiber plastic composite element raw mate¬ rial in connection with its manufacture in order to ame¬ liorate the properties or processability of the compo- site material.
In one embodiment of the present invention the element 1 comprises a first layer 8 and a second layer 9, the first layer 8 covering at least a part of the second layer 9.
In one embodiment of the present invention the first layer 8 and the second layer 9 are formed by co-extrusion. In a co-extrusion method two or more flows of heated raw material are combined into one ex- trudate such that the materials are associated but not blended. 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 9 is at least 3, pref- erably at least 5, and more preferably 8 times greater than the thickness of the first layer 8.
The first layer 8 may form the entire surface area of the element 1. In this case the first layer 8 totally covers the second layer 9 forming a core layer. Alternatively a part of the second layer 9 may be cov¬ ered by the first layer 8.
In one embodiment of the present invention the raw material of the first layer comprises a polymer. The raw material of the second layer comprises a polymer and an organic natural fiber based material including lignin. The appearance of the element is affected by the first layer 8. The appearance of the element may be good due to the first layer 8 in spite of the lignin in the second layer 9.
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.
An elongated, solid, natural fiber plastic composite element 1 according to the present invention comprises
two parallel surfaces 2, a first edge surface
3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface 3, the groove 5 comprising side surfaces 6 and a bottom 7, formed from a raw material compris- ing a polymer and an organic natural fiber based mate¬ rial by using extrusion
and an expansion area comprising an uncali- brated part of the groove 5.
In one embodiment of the present invention the elongated, solid, natural fiber plastic composite element 1 according to the present invention comprises two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface 3, the groove 5 comprising side surfaces 6 and a bottom 7, and is manufactured by
forming the elongated solid element 1 com¬ prising two parallel surfaces 2, a first edge surface 3 and a second edge surface 4 connecting said surfaces to each other, and a groove 5 provided on the first edge surface 3 from a raw material comprising a poly¬ mer and an organic natural fiber based material by us¬ ing extrusion, and
calibrating the element 1 and forming an expansion area in the groove by leaving a part of the groove 5 uncalibrated .
In one embodiment of the present invention the element 1 comprises a second edge surface 4 parallel to the first edge surface 3, thus forming an element 1 having a rectangular cross profile.
In one embodiment of the present invention the surfaces 2 are provided with 90° angles, thus form¬ ing an element 1 having an L-shape cross profile.
In one embodiment of the present invention the element comprises a second edge surface perpendicu- lar to the first edge surface.
In one embodiment of the present invention the second edge surface 4 is provided with a groove 5.
In one embodiment of the present invention the element 1 is formed by using co-extrusion.
In one embodiment of the present invention the groove 5 is for fastener (s) for fastening the ele¬ ments .
In one embodiment of the present invention the bottom 7 of the groove 5 is uncalibrated.
In one embodiment of the present invention the bottom 7 and a part of the side surfaces 6 of the groove 5 are uncalibrated. The bottom 7 of the groove or a part of it can also be calibrated and a part of the side surfaces 6 of the groove 5 can be uncalibrated.
In one embodiment of the present invention at least 15 % of the side surfaces 6 of the groove 5 is calibrated. In one embodiment of the present invention at least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces 6 of the groove 5 is calibrated .
In one embodiment of the present invention up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces 6 of the groove 5 is calibrat- ed.
In one embodiment of the present invention 15 % to 100 % of the side surfaces 6 of the groove 5 is calibrated .
In one embodiment of the present invention 20 to 95 %, preferably 30 to 92 %, more preferably 50 to 90 % of the side surfaces 6 of the groove 5 is calibrat¬ ed .
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 width of the element 1 is at least 2, preferably 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 6 of the groove 5 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 6 of the groove 5 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 6 of the groove 5 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 6 of the groove 5 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 6 of the groove 5 is up to 30 mm, preferably up to 25 mm.
In one embodiment of the present invention the length of the side surfaces 6 of the groove 5 is 4 to 30, preferably 6 to 25 mm.
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.
An apparatus for manufacturing an elongated, solid, natural fiber plastic composite element 1 com¬ prising two parallel surfaces 2, a first edge surface
3 and a second edge surface 4 connecting said surfaces 2 to each other, and a groove 5 provided on the first edge surface 3, the groove 5 comprising side surfaces 6 and a bottom 7, comprises:
an extruder and a die for forming the element
1,
a calibrating device for calibrating the measures of the element 1.
The apparatus according to the present inven- tion 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.
By using the method according to the invention, the element 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. opening, 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 invention is well-resistant to moisture such as water and oil and repels dirt and mold and it can be easily cleaned. In addition, the element according to the present invention is durable and not scratched in normal use. Furthermore, the di-
mensional accuracy of the element is good, which makes installation easy. The material of the element is en¬ vironmentally friendly. The material may be a recycled material, and it can be recycled further. The material does not contain toxic chemicals.
EXAMPLES
The description discloses some embodiments 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 embodiments are discussed in detail, as many of the steps will be ob¬ vious 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, a first edge surface 3 and a second edge surface 4 connecting said surfaces 2 to each other, and grooves 5 provided on the first edge surface 3 and the second edge surface 4, the groove 5 comprising side surfaces 6 and a bottom 7, according to the invention, presented in Fig. 1, was manufactured by the extrusion tech¬ nique 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 wider temperature range may be used in the process. Polypropylene may also be used in the process either alone or together with polyethylene. The thermoplastic polymer 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 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 functionalize 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 a recycled adhesive laminate 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- tides 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 7 of the groove 5 and a part of the side surfaces 6 next to the bottom and thus leaves the bottom 7 and approximately 50 % of the area of the side surfaces 6 uncalibrated . In figure 1, the thicker line drawn to the bottom 7 of the groove 5 and to the side surface 6 represents the uncalibrated area .
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 reser-
voir for cooling. The calibration continued in the cooling reservoirs. After calibration of the measure¬ ments, the thickness of the element, i.e. a distance of the parallel surfaces 2 from each other, varies within the limit of ± 5% and the width of the element, i.e. a distance of the first and second edge surfaces 3,4 from each other, varies within the limit of ± 3%. The uncalibrated part of the groove compensates for the material differences of the extruded element.
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
Figure 2 shows an element 1 having surfaces 2 that are provided with 90° angles, thus forming an ele- ment having an L-shape cross profile.
The element was manufactured as described in example 1 by using the same raw materials. In this example the calibrating device left the bottom 7 of the groove 5 and approximately 30 % of the area of the side surfaces 6 next to the bottom uncalibrated.
The thickness of the manufactured element 1 was 25 mm, the width, i.e. the length of the longer part of the surface 21 which is visible in use was 100 mm and the length of the element was 4 m. The length of the shorter part of the surface 22 was 50 mm. The element 1 can be used in a terrace for example as a step board.
EXAMPLE 3
The elongated, solid, natural fiber plastic composite element 1 according to the invention com¬ prising a first layer 8 and a second layer 9, presented in Fig. 3, 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 but not blended. In the process the flow properties of the raw materials were easily and separately controlled during the co- extrusion process. The first layer 8 and the second layer 9 were formed by a co-extrusion process so that the first layer 8 forms the entire surface area of the element, covering the parallel surfaces 2 and edge surfaces 3, 4. In other words the first layer 8 covers the second layer 9.
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 8 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 8 advantageously co¬ vers at least the top side of said decking board.
The raw material for the first layer 8 com¬ prised a thermoplastic polymer. The raw material for the second, core layer 9 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 8 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 9. Advantageously the organic nat¬ ural fiber based material of the first layer 8 is chemical pulp fiber. The lignin content in the second layer is preferably at least 3 wt . % . The first layer 8 of the element 1 does not comprise lignin. Alterna¬ tively, the amount of lignin is smaller in the first layer 8 of the element 1 than in the second layer 9 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 a dark colored recycled ma¬ terial even if the manufactured product had a light color .
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 it 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 7 of the groove 5 and ap¬ proximately 20 % of the area of the side surfaces 6 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 first and second edge surfaces 3,4 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
CLAIMS 1. A method for manufacturing an elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces (2), a first edge surface (3) and a second edge surface (4) connecting said surfaces (2) to each other, and a groove (5) pro- vided on the first edge surface, the groove (5) com¬ prising side surfaces (6) and a bottom (7), wherein the method comprises:
forming the elongated solid element (1) comprising two parallel surfaces (2), a first edge surface (3) and a second edge surface (4) connecting said surfaces (2) to each other, and a groove (5) provided on the first edge surface (3) from a raw material comprising a pol¬ ymer and an organic natural fiber based material by using extrusion, and
calibrating the element (1) and forming an expansion area in the groove (5) by leaving a part of the groove (5) uncalibrated .
2. The method according to claim 1, wherein the second edge surface (4) is parallel to the first edge surface (3) .
3. The method according to claim 1, wherein the surfaces (2) are provided with 90° angles, thus forming an element having an L-shape cross profile.
4. The method according to claim 3, wherein the second edge surface (4) is perpendicular to the first edge surface (3) .
5. The method according to any of claims 1 to 4, wherein the second edge surface (4) is provided with a groove (5) .
6. The method according to any one of claims 1 to 5, wherein the groove (5) is located so that the middle point of the edge surface is in the groove.
7. The method according to any of claims 1 to 6, wherein the bottom (7) of the groove (5) is uncali- brated, wherein the shape of the bottom (7) of the groove (5) can be formed freely, compensating for the material differences of the extruded element.
8. The method according to any one of claims 1 to 7, wherein at least 15 % of the side surfaces (6) of the groove (5) is calibrated.
9. The method according to any one of claims 1 to 8, wherein at least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces (6) of the groove (5) is calibrated.
10. The method according to any one of claims 1 to 9, wherein up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces (6) of the groove (5) is calibrated.
11. The method according to any one of claims 1 to 10, wherein 15 % to 100 % of the side surfaces (6) of the groove (5) is calibrated.
12. The method according to any one of claims
1 to 11, wherein 20 to 95 %, preferably 30 to 92 %, more preferably 50 to 90 % of the side surfaces (6) of the groove (5) is calibrated.
13. The method according to any one of claims 1 to 12, wherein the polymer is a thermoplastic poly¬ mer .
14. The method according to any one of claims 1 to 13, wherein the thermoplastic polymer is polyole- fin .
15. The method according to any one of claims
1 to 14, wherein the thermoplastic polymer is polyethylene and/or polypropylene.
16. The method according to any one of claims 1 to 15, wherein the thermoplastic polymer is polyeth- ylene.
17. The method according to any one of claims 1 to 16, wherein the organic natural fiber based mate¬ rial comprises lignin.
18. The method according to any one of claims 1 to 17, wherein the lignin is from wood dust.
19. The method according to any one of claims 1 to 17, wherein the raw material comprises at least 2 wt . % and more preferably at least 5 wt . % of mineral fillers .
20. The method according to claim 19, wherein the mineral filler is calcium carbonate and/or talcum.
21. The method according to any one of claims 1 to 20, wherein the element (1) comprises a first lay¬ er (8) and a second layer (9), the first layer (8) cov- ering at least a part of the second layer (9) .
22. The method according to claim 21, wherein the first layer (8) and the second layer (9) are formed by co-extrusion.
23. The method according to any one of claims 21 to 22, wherein the thickness of the second layer (9) is at least 3, preferably at least 5, and more prefera¬ bly 8 times greater than the thickness of the first lay¬ er (8) .
24. The method according to any one of claims 21 to 23, wherein the raw material of the first layer comprises a polymer and the raw material of the second layer comprises a polymer and an organic natural fiber based material including lignin.
25. The method according to any one of claims 21 to 24, wherein the raw material of the first layer comprises a polymer and an organic natural fiber based material .
26. The method according to any of claims 21 to 25, wherein the second layer (9) of the element (1) comprises at least 1 wt.%, more preferably at least 2 wt . % and most preferably at least 3 wt.% lignin.
27. An elongated, solid, natural fiber plas¬ tic composite element (1) comprising two parallel sur¬ faces (2), a first edge surface (3) and a second edge surface (4) connecting said surfaces (2) to each oth- er, and a groove (5) provided on the first edge sur¬ face (3), the groove (5) comprising side surfaces (6) and a bottom (7), formed from a raw material compris¬ ing a polymer and an organic natural fiber based mate¬ rial by using extrusion
and an expansion area comprising an uncalibrated part of the groove (5) .
28. An elongated, solid, natural fiber plas¬ tic composite element (1) according to claim 25 com¬ prising two parallel surfaces (2), a first edge sur- face (3) and a second edge surface (4) connecting said surfaces (2) to each other, and a groove (5) provided on the first edge surface (3) , the groove (5) compris¬ ing side surfaces (6) and a bottom (7), manufactured by
forming the elongated solid element (1) com¬ prising two parallel surfaces (2), a first edge sur¬ face (3) and a second edge surface (4) connecting said surfaces to each other, and a groove (5) provided on the first edge surface (3) from a 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 by leaving a part of the groove (5) uncalibrated.
29. The elongated, solid element according to claim 27 or 28, wherein the element (1) comprises a second edge surface (4) parallel to the first edge sur¬ face (3), thus forming an element (1) having a rectan¬ gular cross profile.
30. The elongated, solid element according to claim 27 or 28, wherein the surfaces (2) are provided
with 90° angles, thus forming an element (1) having an L-shape cross profile.
31. The elongated, solid element according to claim 30, wherein the element comprises a second edge surface perpendicular to the first edge surface.
32. The elongated, solid element according to any one of claims 27 to 31, wherein the second edge surface (4) is provided with a groove (5) .
33. The elongated, solid element according to any of claims 27 to 32, wherein the element (1) is formed by using co-extrusion.
34. The elongated, solid element according to any of claims 27 to 33, wherein the groove (5) is for fastener (s) for fastening the elements.
35. The elongated, solid element according to any of claims 27 to 34, wherein the bottom (7) of the groove (5) is uncalibrated.
36. The elongated, solid element according to any one of claims 27 to 35, wherein at least 15 % of the side surfaces (6) of the groove (5) is calibrated.
37. The elongated, solid element according to any one of claims 27 to 36, wherein at least 20 %, preferably at least 30 %, more preferably at least 50 % of the side surfaces (6) of the groove (5) is cali- brated.
38. The elongated, solid element according to any one of claims 27 to 37, wherein up to 95 %, preferably up to 92 %, more preferably up to 90 % of the side surfaces (6) of the groove (5) is calibrated.
39. The elongated, solid element according to any one of claims 27 to 38, wherein 15 % to 100 % of the side surfaces (6) of the groove (5) is calibrated.
40. The elongated, solid element according to any one of claims 27 to 39, wherein 20 to 95 %, prefer- ably 30 to 92 %, more preferably 50 to 90 % of the side surfaces (6) of the groove (5) is calibrated.
41. The elongated, solid element according to any one of claims 27 to 40, wherein the width of the element (1) is at least 2, preferably 4 times greater than the thickness.
42. The elongated, solid element according to any one of claims 27 to 41, wherein the width of the element (1) is at least 50 mm, preferably at least 100 mm.
43. The elongated, solid element according to any one of claims 27 to 42, wherein the width of the element (1) is up to 400 mm, preferably up to 300 mm.
44. The elongated, solid element according to any one of claims 27 to 43, wherein the width of the element (1) is 50 to 400 mm, preferably 100 to 300 mm.
45. The elongated, solid element according to any one of claims 27 to 44, wherein the length of the element (1) is at least 10 times greater than the thick¬ ness of the element (1) .
46. The elongated, solid element according to any one of claims 27 to 45, wherein the thickness of the element (1) is at least 15 mm, preferably at least 20 mm.
47. The elongated, solid element according to any one of claims 27 to 46, wherein the thickness of the element is up to 40 mm, preferably up to 35 mm.
48. The elongated, solid element according to any one of claims 27 to 47, wherein the thickness of the element (1) is 15 to 40 mm, preferably 20 to 35 mm.
49. The elongated, solid element according to any one of claims 27 to 48, wherein the length of the element (1) is at least 1 m, preferably at least 2 m, more preferably at least 2.3 m.
50. The elongated, solid element according to any one of claims 27 to 49, wherein the length of the element (1) is up to 10 m, preferably up to 6 m, more preferably up to 5 m.
51. The elongated, solid element according to any one of claims 27 to 50, wherein the length of the element (1) is 1 to 10 m, preferably 2 to 6 m, more preferably 2.3 to 5 m.
52. The elongated, solid element according to any one of claims 27 to 51, wherein the distance be¬ tween side surfaces (6) of the groove (5) is at least 2 mm, preferably at least 3 mm, more preferably at least 4 mm.
53. The elongated, solid element according to any one of claims 27 to 52, wherein the distance be¬ tween side surfaces (6) of the groove (5) is up to 25 mm, preferably up to 20 mm, more preferably up to 15 mm.
54. The elongated, solid element according to any one of claims 27 to 53, wherein the distance be¬ tween side surfaces (6) of the groove (5) is 2 to 25 mm, preferably 3 to 20 mm, more preferably 4 to 15 mm.
55. The elongated, solid element according to any one of claims 27 to 54, wherein the length of the side surfaces (6) of the groove (5) is at least 4 mm, preferably at least 6 mm.
56. The elongated, solid element according to any one of claims 27 to 55, wherein the length of the side surfaces (6) of the groove (5) is up to 30 mm, preferably up to 25 mm.
57. The elongated, solid element according to any one of claims 27 to 56, wherein the length of the side surfaces (6) of the groove (5) is 4 to 30, prefer¬ ably 6 to 25 mm.
58. The elongated, solid element according to any one of claims 27 to 57, wherein the element (1) is a building element, such as a decking board or a facade panel .
59. The elongated, solid element according to any one of claims 27 to 58, wherein the element (1) is a decking board.
60. The elongated, solid element according to any one of claims 27 to 58, wherein the element (1) is a facade panel.
61. A use of the elongated, solid element ac- cording to any one of claims 27 to 60 in a terrace or a building .
62. An apparatus for manufacturing an elongated, solid, natural fiber plastic composite element (1) comprising two parallel surfaces (2), a first edge surface (3) and a second edge surface (4) connecting said surfaces (2) to each other, and a groove (5) pro¬ vided on the first edge surface (3) , the groove (5) comprising side surfaces (6) and a bottom (7), comprising :
an extruder and a die for forming the element
(1) ,
a calibrating device for calibrating the measures of the element (1) .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/FI2013/051032 WO2015063365A1 (en) | 2013-10-31 | 2013-10-31 | A method for manufacturing a natural fiber plastic composite |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/FI2013/051032 WO2015063365A1 (en) | 2013-10-31 | 2013-10-31 | A method for manufacturing a natural fiber plastic composite |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2015063365A1 true WO2015063365A1 (en) | 2015-05-07 |
Family
ID=49619959
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/FI2013/051032 WO2015063365A1 (en) | 2013-10-31 | 2013-10-31 | A method for manufacturing a natural fiber plastic composite |
Country Status (1)
| Country | Link |
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| WO (1) | WO2015063365A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3608080A1 (en) * | 2018-08-09 | 2020-02-12 | Salamander Industrie-Produkte GmbH | Composite material, extrudate and extrusion method |
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|---|---|---|---|---|
| US3929951A (en) * | 1973-07-18 | 1975-12-30 | Sumitomo Chemical Co | Method of extruding hollow structure having plural parallel cells |
| EP1108529A2 (en) * | 1999-12-14 | 2001-06-20 | Mannington Mills, Inc. | Thermoplastic planks and methods for making the same |
| US20090152759A1 (en) * | 2007-12-17 | 2009-06-18 | Malone Bruce A | Shaping die and its use in a solid state drawing process |
| WO2010072357A2 (en) * | 2008-12-22 | 2010-07-01 | Parcolys N.V. | Covering panel |
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2013
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3929951A (en) * | 1973-07-18 | 1975-12-30 | Sumitomo Chemical Co | Method of extruding hollow structure having plural parallel cells |
| EP1108529A2 (en) * | 1999-12-14 | 2001-06-20 | Mannington Mills, Inc. | Thermoplastic planks and methods for making the same |
| US20090152759A1 (en) * | 2007-12-17 | 2009-06-18 | Malone Bruce A | Shaping die and its use in a solid state drawing process |
| WO2010072357A2 (en) * | 2008-12-22 | 2010-07-01 | Parcolys N.V. | Covering panel |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3608080A1 (en) * | 2018-08-09 | 2020-02-12 | Salamander Industrie-Produkte GmbH | Composite material, extrudate and extrusion method |
| WO2020030809A1 (en) * | 2018-08-09 | 2020-02-13 | Salamander Industrie-Produkte Gmbh | Composite material, extrudate, and extrusion process |
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