WO2016135525A1

WO2016135525A1 - Composition for producing imitation wood by means of a calendering, injection molding, or 3d printing process

Info

Publication number: WO2016135525A1
Application number: PCT/IB2015/000658
Authority: WO
Inventors: Antonio SIU; Bernd DUNA
Original assignee: Patenta Asia Ltd.
Priority date: 2015-02-23
Filing date: 2015-02-23
Publication date: 2016-09-01

Abstract

The invention relates to a composition for producing imitation wood by means of a calendering, injection molding, or 3D printing process, said composition containing a mixture of 45 - 80 wt.% PVC resin and 10 - 50 wt.% rice or peanut shell powder or a mixture of rice and peanut shell powder with a particle size of 10 - 250 μm. The imitation wood according to the invention has a very wood-like optical appearance and haptics and can be machined using conventional wood tools. The imitation wood can be painted and adhered in a problem-free manner and is particularly suitable for outdoor applications by virtue of the very high weather resistance of the imitation wood, in particular in humid or wet environments.

Description

Composition for the production of wood imitations by calendering, injection molding or 3-D printing

The invention relates to a composition for the production of wood imitations from a prestige and the haptic ago wood-like material by calendering, injection molding or 3-D printing.

The known plastic woods are or are made of a mixture of wood and PE / PP (polyethylene / polypropylene) (so-called "WPCs" - "Wood Plastic Composites"). These materials are mainly used without a final surface treatment, for example, for the production of outdoor floorboards. The known plastic woods can not be painted or only with great effort. Furthermore, they have the disadvantage that they feel very plastic like because of the PE content. For these reasons, the known plastic woods are hardly suitable for furniture production. A further disadvantage is that WPCs can only be processed by extrusion into profiles or molded parts. In extrusion or extrusion, solid to viscous masses such as WPCs are continuously squeezed under pressure from a forming orifice (also called a die or mouthpiece). This creates profiles with the cross section of the opening in theoretically any length. However, flexible wood imitations or arbitrarily shaped bodies can not be produced from the known WPCs, and certainly not by extrusion.

The invention has for its object to provide a composition for producing Holzimitaten that can be processed by calendering, injection molding or 3-D printing and which avoids the disadvantages and by the fundamental avoidance of the use of wood to protect the environment, in particular of the forest, contributes.

The object of the invention is achieved by a composition for the production of wood imitations by calendering, injection molding or 3-D printing as defined in claim 1.

The invention further relates to flexible wood imitations or wood imitation moldings produced by calendering, injection molding or 3-D printing of a composition according to the invention as defined in claims 11 and 12. In addition, the invention provides the uses defined in claim 14 of Holzimitate invention.

Advantageous and / or preferred embodiments of the invention are the subject of the dependent claims.

The composition of the invention for the production of wood imitations by calendering, injection molding or 3-D printing contains a mixture of 45 - 80 wt .-% PVC resin (PVC = polyvinyl chloride) and 10 - 50 wt .-% powder of rice husk or pods and / or peanut shells or pods with a particle size of 10 - 250 pm. The term "and / or" in this context means that rice husks or peanut shells can be used or a mixture of rice husks and husks.

The PVC material used is not particularly limited. In particular, PVC recycling material can also be used. For example, a PVC resin suspension having a K value of 60-70 is suitable. The K value is a number calculated from measurements of the viscosity of dilute solutions of a polymer and a measure of the degree of polymerization or the molecular size is. The K value is used for resin specification.

The rice husks or peanut shells used are likewise not subject to any particular restrictions, in particular not with respect to certain rice or nut varieties. Rice pans give better results and are therefore preferred. They can be pulverized very well and optimally mixed with the PVC resin. In addition, they contain less lignin (only about 5%) and therefore bleach less or not at all under the effects of the weather (sun, rain).

In one embodiment of the composition according to the invention for producing wood imitations by calendering, injection molding or 3-D printing, the PVC resin and the rice and / or peanut shell powder are mixed in a ratio of approximately 50:50. The ischungsreihenfoige is generally arbitrary.

In a further embodiment of the inventive composition for the production of wood imitations by calendering, injection molding or 3-D printing is / are the mixture of PVC resin and / or rice and / or peanut shell powder also one or more of the following additives or Additives added: Thermopile plastic binder (eg poly (meth) acrylate), polyethylene, chlorinated polyethylene (CPE), color pigment (s) (eg chalk, titanium dioxide, carbon black, red iron oxide, ocher), lubricants Lubricants (eg fatty acid salts such as calcium stearate, fatty acid esters, fatty acid amides, paraffin waxes, polyethylene waxes, microcrystalline paraffin), calcium carbonate / chalk and PVC processing aids ("processtng aids") (eg heat and weathering stabilizers, antioxidants, anti-aging agents, light stabilizers, ultraviolet absorbers, antistatic agents). The aforementioned additives are available from specialist retailers. The additional components can be mixed simultaneously with the PVC resin and the rice or peanut shell powder or even in several stages with it.

A further embodiment of the composition according to the invention for producing wood imitations by calendering, injection molding or 3-D printing contains a mixture of 45-80% by weight, for example 50-80, 55-80, 60-80, 70-80, 45 - 70, 50 - 70, 55 - 70, 60 - 70, 45 - 60, 50 - 60, 55 - 60, 45 - 50, 50 - 55 wt .-% PVC resin; 10 to 50% by weight, for example 20 to 50, 30 to 50, 40 to 50, 10 to 40, 20 to 40, 30 to 40, 10 to 30, 20 to 30, 25 to 35% by weight, rice and / or peanut shell powder having a particle size of 10 to 250 μm, for example 10 to 200, 50 to 200, 100 to 200, 150 to 200, 10 to 150, 50 to 150, 100 to 150, 10 to 100, 50 - 100, 80 - 100, 10 - 50, 20 - 50; 40 - 50, 10 - 40, 20 - 40, 30 - 40, 10 - 20, 25 - 35 pm; 8-12% by weight, for example 7-9% by weight, thermoplastic-based chemical binders; 5 - 10 wt .-%, for example 8 - 10 wt .-% polyethylene or chlorinated polyethylene (PCE); 0.5-1% by weight of colored pigment (s); 2 - 4 wt .-% lubricant or lubricant; 12-18 wt%, for example 11-15 wt%, calcium carbonate / chalk and 8-12 wt% PVC processing aids. Particularly advantageous for calendering, injection molding or 3-D printing is a composition with 50-55 wt.% PVC, 25-35 wt .-% rice hulls with a particle size of 10 - 250 pm, for example 125-250 pm; 5-15% by weight, for example 10% by weight, of chlorinated polyethylene. It is clear to the person skilled in the art that the percentage of the individual components must add up to 100%. This is achieved by appropriately increasing or decreasing the percentages of individual components within the ranges indicated.

The chemical binder based on thermoplastic resin, for example, has the function of removing moisture or solvents from natural fibers and combines or crosslinks strongly with the "nonwoven web" or network of natural fibers. Polyethylene and chlorinated polyethylene act as plasticizers and increase the impact resistance. PVC processing aids can accelerate the fusion, the melt strength bw. Improve melt toughness, eliminate surface defects, and reduce plate out. In addition, they can enhance the metal release properties in the production process. Suitable binders and processing aids are well known to those skilled in the art of PVC processing and are widely available commercially. In a further embodiment of the inventive composition for producing wood imitations by calendering, injection molding or 3-D printing, the PVC resin particles and the peanut shell puff have about the same grain size.

Wood imitations according to the invention are produced by calendering, injection molding or 3-D printing of a composition according to the invention. The methods used for calendering (rolls), injection molding or 3-D printing are not particularly limited. Any commercially available machines can be used for this purpose. Operation is according to the manufacturer's instructions. It will be understood by those skilled in the art that under the processing conditions (e.g., temperature and pressure), the composition of the present invention must be sufficiently homogenized and liquified to be processable with a calender, an injection molding machine or a 3-D printer. Suitable processing conditions are either those specified by the manufacturer or determined by the skilled person by simple routine experimentation.

By calendering the composition according to the invention it is possible to produce flexible wood imitations in a broad range of thicknesses, for example with a thickness in the range of 200-1000 μm. Depending on the intended use, the flexible wood imitations may have a thickness of 200 - 800, 200 - 600, 200 - 400, 400 - 800, 400 - 600, 600 - 800 or 600 pm. There are no basic restrictions here. It can also be made plates, for example, to 10 mm thick. The width of the flexible wood imitations can also be chosen arbitrarily depending on the purpose, for example, the flexible wood imitations can be 50 to 300 cm wide. The flexible Holzimitate can be suitably wound on rolls. If desired, the flexible wood imitations may be ground and glazed prior to winding. This gives them the desired woody look and feel,

For example, to produce a wood imitation according to the invention, the PVC resin is dried in a high speed mixer with dried rice husk powder (ponds size 10-250 μm, moisture content eg 0.5-1.0%) and optional filler (eg calcium carbonate / chalk) 10-150 min - 140 ° C mixed. The optional additives such as color pigment, stabilizer, processing aids, lubricants (eg epoxy soybean oil, wax) are mixed in a small mixer / blender for 10 minutes and then added to the high speed mixer to the PVC resin / rice husk powder / filler mixture. Then the entire mixture is thoroughly mixed for a further 10 minutes. Finally, the mixture is allowed to cool in a cooling tank for about 30 minutes and then calendered or further processed by injection molding or 3-D printing to a wood imitation. The hue of the wood imitations according to the invention can be controlled by the color pigments contained in the composition used for their preparation. Practically, no intense hue is set, but a comparatively paler. The final desired shade is then adjusted by painting or glazing the Holzimitate invention. This saves the production and storage of a variety of wood imitations with different shades.

The grinding of the wood imitations according to the invention can e.g. with an abrasive material such as sand or abrasive adapters having a grain size in the range of 24 to 60, for example, using an electrically operated hand grinder. When grit is a smaller number for a coarser grit and a higher numerical value for a finer grit. A grain size of 24 is rather coarse and is suitable e.g. for removing glue or varnish layers, while a grain size of 60 is rather medium and is used, for example, for rough pre-grinding of raw wood surfaces. The suitable grain size is selected by the person skilled in the art in accordance with the practical conditions or the effect to be achieved. Also sandblasting is possible.

In a further embodiment of the wood imitations according to the invention, their surface, if appropriate after a corresponding pretreatment (for example priming), is varnished or varnished or oiled. For example, water-based one-component paints are suitable for painting. Two-component paints are particularly suitable for extreme use.

Depending on pigmentation and surface tinting, various wood looks and haptics can be realized, e.g. from tropical wood such as Burma teak, Siam teak, Java teak or Aged teak.

The wood imitations according to the invention have many uses and are suitable for example as veneers or sheathing for table tops, glass plates, aluminum profiles, window sills, window profiles, doors, gates, wallpapers (eg in the roof area of buildings). Furthermore, they can be used, for example, as parquet films or laminations for renovations and in the facade and floor area of buildings. The Holzimitate invention are simply glued to a commercial contact adhesive or a commercially available adhesive film. If an adhesive film is used, it is provided with a peel-off film until it is used on the sticky side. The wood imitations according to the invention serve, for example, as Baumateriai, floor material, wall material, ceiling material, sleepers, casements, fences, furniture, umbrella stand (eg parasol stand) or housing for electrical equipment. The wood imitations according to the invention have a very wood-like appearance as well as feel. This is a surprising result, as due to the high PVC percentage, a plastic-like appearance and feel would have been expected. The wood imitations according to the invention offer in many respects substantially improved properties compared to the vast majority of wood species.

Due to the polar properties of the PVC used, the surface of the wood imitations according to the invention can be easily oiled, varnished or painted. PVC increases the impact resistance of the material, i. it becomes more elastic and therefore less brittle and does not break easily. The polar properties also allow easy gluing and give anti-static properties. Conventional wood / PE composites (WPCs) are not or only very difficult to paint, not glued and not antistatic because of the non-polar properties of PE.

Due to their stability, dimensional stability and absolute resistance to moisture influences such as rain, the wood imitations according to the invention are far superior to the conventional wood / PE composites (WPCs) and also many types of wood. The wood imitations according to the invention are almost waterproof. The PVC used is non-hygroscopic and does not absorb water, thus preventing the ingress of water due to surface damage, so that there is no infiltration of applied layers of lacquer and no lacquer chips appear. The wood imitations according to the invention are therefore also dimensionally stable, so that deformation by natural means (for example by swelling or shrinkage) is not possible. By contrast, conventional wood / PE composites swell under the influence of moisture. Lacquers no longer adhere because the penetrating water infiltrates and thereby dissolves.

The wood imitations according to the invention are therefore particularly suitable for use in the maritime area, e.g. near the sea or in the sea or in wet areas (for example in swimming pools), or as an outdoor parquet or ship deck. Fungus or insect infestation does not occur.

Due to the excellent strength of the hammering of nails or screwing screws in the wood imitations according to the invention as in conventional wood materials is possible. Also, the machining is easy, so that simple cutting with a saw, drilling, milling, grinding or even sandblasting is possible. The wood imitations according to the invention do not crack and do not splinter, and cut wastes are 100% recyclable.

The rice and / or peanut shells function as a kind of "active filler" and impart to the wood imitations according to the invention for most applications. serte processing properties. The thermal expansion is lower and the consistency and feel of natural wood is achieved, as a result of which the wood imitations according to the invention are superior to conventional "Wood Plastic Composites" or even pure PVC.

Conventional wood / PE composites are prone to graying and yellowing due to the high lignin content in the wood used, as a result of the sun and rain that decompose the lignin, making them unsightly. In contrast, the wood imitations according to the invention contain very little lignin, so that they do not yellow.

Other properties of the wood imitations according to the invention, such as sound insulation or thermal insulation, are similar to the characteristic properties of natural wood.

In the manufacture of the wood imitations according to the invention, the mixture of PVC resin and peanut and / or rice husk powder may also to a certain extent be recycled wood imitations according to the invention, e.g. Trimmings, which are e.g. can happen if such is available for disposal.

Claims

claims

1. A composition for the production of wood imitations by calendering, injection molding or 3-D printing, comprising a mixture of 45-80% by weight of PVC resin and 10-50% by weight of rice or peanut shell powder or a mixture of rice and peanut shell powder having a particle size of 10 - 250 pm.

2. The composition of claim 1, wherein the PVC resin and the rice and / or peanut shell powder are mixed at about 50:50 ratio.

3. Composition according to claims 1 or 2, wherein the mixture of PVC resin and / or rice and / or peanut shell powder also one or more of the following additives is / are mixed: chemical (r) binders on thermoplastic - plastic base , Polyethylene, chlorinated polyethylene (CPE), color pigment (s), lubricants. Lubricant, calcium carbonate / chalk and PVC processing aids.

A composition according to any one of the preceding claims comprising a blend of 45-80% by weight of PVC resin, 10-50% by weight of rice or peanut peel powder or a mixture of rice and peanut peel powder having a particle size of 10-250 pm, 8-12% by weight of thermoplastic-based chemical binders, 5-10% by weight of polyethylene or chlorinated polyethylene (CPE), 0.5-1% by weight of colored pigment (s), 2-4 % By weight lubricant, 12-18% by weight calcium carbonate / chalk and 8-12% by weight PVC processing aid.

5. A composition according to claim 4, which contains 50-55% by weight of PVC resin

A composition according to claim 4 or 5, which contains 25-35% by weight of rice or peanut peel powder or a mixture of rice and peanut peel powder having a particle size of 125-250 μm.

7. A composition according to any one of claims 4 to 6, which contains 7 to 9% by weight of thermoplastic polymer-based binder (s).

8. A composition according to any one of claims 4 to 7, which contains 10% by weight of chlorinated polyethylene.

A composition according to any one of claims 4 to 8 which contains 11-15% by weight of calcium carbonate / chalk.

A composition according to any preceding claim, wherein the PVC resin particles and the peanut shell powder have about the same grain size.

11. Flexible wood imitation, producible by calendering a composition according to any one of the preceding claims.

12. Holzimitatformkörper, produced by injection molding or 3-D printing a composition according to any one of the preceding claims.

13. Flexible imitation wood or wood imitation molding according to claim 11 or 12, the surface of which is painted or varnished.

14. Use of a wood imitation according to one of claims 11 - 13 as veneers or sheathing for table tops, glass plates, aluminum profiles, window sills, window profiles, doors, gates, wallpaper, parquet films, linings in renovations and in the facade and floor area of buildings, building material, floor material , Wall material, ceiling material, sleepers, casements, fences, furniture, umbrella stands or housings for electrical appliances.

15. A method for producing a wood imitation according to claims 11 or 12, wherein:

a) mixing 45-80% by weight of PVC resin in a high-speed mixer with 10% -50% by weight rice husk powder having a particle size of 10-250 μm and optionally filler for 10 to 15 minutes at 110 ° to 140 ° C.,

b) optional additives such as color pigment, stabilizer, processing aid, lubricant Mix in a small mixer / blender for 10 minutes and then add this mixture in the high speed mixer to the mixture of step a) and mix thoroughly for a further 10 minutes.

c) the mixture from step b) is cooled in a cooling tank for about 30 minutes, and d) the mixture from step c) is calendered or further processed to a wood imitation by injection molding or 3-D printing.