WO2019057292A1 - A household appliance having a component made of a composite material and a process for producing such component - Google Patents

A household appliance having a component made of a composite material and a process for producing such component Download PDF

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Publication number
WO2019057292A1
WO2019057292A1 PCT/EP2017/074003 EP2017074003W WO2019057292A1 WO 2019057292 A1 WO2019057292 A1 WO 2019057292A1 EP 2017074003 W EP2017074003 W EP 2017074003W WO 2019057292 A1 WO2019057292 A1 WO 2019057292A1
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WO
WIPO (PCT)
Prior art keywords
composite material
household appliance
polyethylene terephthalate
component
fibers
Prior art date
Application number
PCT/EP2017/074003
Other languages
French (fr)
Inventor
Orkun KAYMAKCI
Tugce ONER
Hulya KIRAZ
Cem SELCUK
Aybuke KABA
Original Assignee
Arcelik Anonim Sirketi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arcelik Anonim Sirketi filed Critical Arcelik Anonim Sirketi
Priority to PCT/EP2017/074003 priority Critical patent/WO2019057292A1/en
Priority to TR2018/06078A priority patent/TR201806078A2/en
Publication of WO2019057292A1 publication Critical patent/WO2019057292A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
    • D06F37/26—Casings; Tubs
    • D06F37/261—Tubs made by a specially selected manufacturing process or characterised by their assembly from elements
    • D06F37/262—Tubs made by a specially selected manufacturing process or characterised by their assembly from elements made of plastic material, e.g. by injection moulding
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00 
    • D06F39/02—Devices for adding soap or other washing agents
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F58/00—Domestic laundry dryers
    • D06F58/02—Domestic laundry dryers having dryer drums rotating about a horizontal axis
    • D06F58/04—Details 

Definitions

  • the present invention relates to a household appliance, such as a washer or a dryer, having a component, such as for instance a tub, a detergent drawer or a chassis, made of a composite material and to a process for producing such component. More in detail the present invention refers in particular to a washing machine or to a washer/dryer comprising a component made of a composite material having a polymer matrix and to a process for its production.
  • the tub of such household appliances is generally made of a composite material comprising a polymer matrix, such as a polypropylene matrix, reinforced with particles, such as calcium carbonate particles, or with fibers, such as glass fibers.
  • composite materials having a polymer matrix reinforced with glass fibers are generally used for realizing tubs intended to undergo high stresses, as the tubs of high-spin speed models of washing machines and washer/dryers, generally reaching 800 to 1600 rpm, while composite materials having a polymer matrix reinforced with calcium carbonate particles are generally used for realizing tubs undergoing lower stresses, such as dishwasher tubs or lower-end models of washing machines and washer/dryers, with spin speed under 1200 rpm.
  • Composite materials having a polymer matrix reinforced with calcium carbonate particles are moreover used for realizing other components of household appliances such as for instance the chassis base of laundry dryers, which holds electric and/or mechanical components such as the compressor and the motor and which, therefore, is designed to support heavy loads.
  • the chassis base of dryers moreover, must be able to counteract the effects of vibrations and high temperature that can be generated by the electric and/or mechanical components of the dryers.
  • the objective of the present invention is to design a household appliance, such as in particular a washing machine or a washer/dryer, comprising a component, such as a tub, a detergent drawer or a tub, made of a composite material having a polymer matrix which ensures the desired performances and in particular mechanical performances, while requiring a lower production cost with respect to the materials currently available on the market to be used for the same purposes.
  • a further object of the present invention is to provide a process for the production of the component of such household appliances which is easy and economical to be performed.
  • the household appliance designed to fulfill the object of the present invention, explicated in the first claim and the respective claims thereof, comprises a component made of a composite material having a polymeric matrix, in particular preferably made of a polypropylene based polymeric material, and wherein part of the polymeric material used to define the matrix is substituted with calcium carbonate particles and PET fibers, thus ensuring comparable mechanical physical and chemical performances of the component, while significantly reducing its production costs.
  • the calcium carbonate particles and the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 35% and 65%, which are sufficient to ensure adequate mechanical properties to the composite material.
  • the PET fibers are present in the composite material in a percentage by weight between 5% and 20%.
  • the composite material further comprises a maleic anhydride based compatibilizer to promote interfacial adhesion between the fibers and the polymeric material of the matrix for ensuring an adequate mechanical and chemical resistance of the composite material of the component over the time.
  • the PET fibers are obtained from PET flakes by means of extrusion of a mixture comprising the polymeric material of the matrix, the glass fibers and the PET flakes.
  • the PET flakes are obtained from recovered material and preferably from used and disposed plastic bottles.
  • the household appliance is a washer and/or dryer and the component is a tub wherein the items to be washed are placeable and/or it is a detergent drawer.
  • the formulation of the composite material further comprises an elastomer, in particular in a percentage by weight up to 2%.
  • the husehold appliance is a laundry dryer and the component is a chassis base, which holds electric and/or mechanical components of the laundry dryer.
  • the process object of the present invention comprises obtaining the component by injection molding, during which the temperature of the composite material is maintained below the melting temperature of the PET fibers, in order not to alter the shape of the latter.
  • the process further comprises, before the injection molding, the extrusion of a mixture comprising the polymeric material of the matrix, the glass fibers and the PET flakes for obtaining the composite material comprising the PET fibers.
  • the temperature of the mixture is maintained between the glass transition temperature and the melting temperature of the PET, and preferably close to the melting temperature of it, for allowing the stretching of the PET flakes and the reshaping of the latter in the form of fibers.
  • the household appliance of the present invention has a component, such as for instance a tub, a detergent drawer or a chassis base as later specified, made of a composite material comprising a matrix of a polymeric material, as preferably a polypropylene based polymeric material, and calcium carbonate particles embedded in the polymeric material.
  • the calcium carbonate particles increase the stiffness of the composite material conferring to it good mechanical properties.
  • the composite material further comprises polyethylene terephthalate (PET) fibers embedded in the matrix mixed with the calcium carbonate particles.
  • PET polyethylene terephthalate
  • part of the calcium carbonate particles and polypropylene polymer in the composite material constituting the component of the household appliance according to the invention are substituted with PET fibers.
  • This allows to reduce the overall amount of virgincomposite material, for instance the overall amount of polypropylene based polymeric material, that is used in the composite material thus allowing to reduce the production costs of the component, and hence of the household appliance, while still ensuring appropriate mechanical properties.
  • the material of the component of the household appliance according to the present invention demonstrated a suitable yield strength, being suitable to be used for the realization of tubs of laundry washers/dryers also for high spin speed models.
  • the component obtained with a composite material comprising a mixture of calcium carbonate and PET fibers has a good detergent resistance and oxidation resistance, comparable to the ones of the components obtained with a composite material comprising only calcium carbonate.
  • the calcium carbonate particles and the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 35% and 65%.
  • the total amount of calcium carbonate particles and PET fibers above specified ensures in fact adequate mechanical properties to the component.
  • the PET fibers are present in the composite material in a percentage by weight between 5% and 20%.
  • the content of PET fibers in the composite material in the above specified range allows to significantly reduce the production costs of the component, in particular by diminishing the amount of the base polymer material such as polypropylene, without jeopardizing the performances of the component.
  • the composite material further comprises a maleic anhydride based compatibilizer to promote interfacial adhesion between the polyethylene terephthalate fibers and the polymeric material of the matrix.
  • compatibilizer is suitable to promote adhesion between the PET fibers and the matrix.
  • the introduction of the compatibilizer in the formulation of the composite material is particularly important for conferring an optimal resistance, both mechanical and chemical, over the time to the composite material and hence to the component realized with it.
  • the PET fibers are obtained from PET flakes, by means of extrusion of a mixture comprising the polymeric material of the matrix, the calcium carbonate particles and the PET flakes. This allows to obtain the PET fibers with the desired average aspect ratio by adjusting the operational parameters of the extrusion process.
  • the PET flakes are obtained from recovered material, i.e. from post-consumer PET. This allows both to further reduce the cost of the composite material and hence of the component obtained with it and to reduce the environmental impact of the whole production process of the household appliance according to the present invention.
  • the PET flakes might for instance be obtained from used and discarded PET packaging.
  • the PET flakes are obtained from discarded plastic bottles.
  • the flakes obtained from PET bottles in fact has an optimal thickness which allows to easily obtain upon extrusion PET fibers with the desired aspect ratio.
  • the household appliance of the invention is a washer and/or dryer and the component is a tub wherein the items to be washed are placeable.
  • the composite material above described is particularly suitable for the realization of tubs undergoing lower stresses, such as dishwasher tubs or lower-end models of laundry washing and/or drying machine, with spin speed preferably under 1200 rpm.
  • the household appliance in case the household appliance is a dishwasher it further comprises one or more baskets which are removably placed in the tub and in which the dishes to be washed, i.e. dishes, kitchenware, tableware, crockery etc. to be washed, are placed by the user.
  • the household appliance is a washing machine, a dryer or a washer/dryer it further comprises a drum rotatably placed in the tub and in which the laundry to be washed and/or dried is placed by the user.
  • the household appliance of the invention is a washer and/or dryer and the component is a detergent drawer.
  • the composite material above described and used for realizing the component according to the invention in fact, demonstrated good chemical resistance over the time, so that it is suitable for prolongated contact with detergent agents.
  • the household appliance according to the invention may comprise more than one components made of the composite material above specified.
  • the household appliance is a laundry washer and/or dryer, for instance, it may comprise both a tub and a detergent drawer made of the composite material comprising calcium carbonate particles and PET fibers.
  • the composite material further comprises an elastomer. Therefore, the formulation of the composite material comprises, beside a matrix of a polymeric material, calcium carbonate particles embedded in the polymeric material and PET fibers, also one or more elastic polymers, such as for instance poly(styrene-butadiene-styrene) (SBS) rubber or, more preferably, styrene ethylene butylene styrene (SEBS) rubber.
  • SBS poly(styrene-butadiene-styrene)
  • SEBS styrene ethylene butylene styrene
  • the addition of an elastomer in the formulation allows to increase the impact resistance of the composite material. More in detail, composite materials according to the invention comprising an elastomer in the formulation demonstrated a 20% higher impact resistance when tested by means of the Izod impact testing with respect to the same formulation not including elastomer.
  • This mechanical feature renders the composite material particularly suitable for the realization of components which have to bear heavy loads or that might be subject to impacts. Moreover the composite material comprising elastomer is suitable for limiting the transmission of vibrations.
  • the household appliance according to the invention is a laundry dryer and the component is a chassis base, which holds electric and/or mechanical components of the laundry dryer, such as for instance the compressor, the heat pump and/or the motor.
  • the chassis base made of such material is capable of safely carry the electric and/or mechanical components and of dampening the vibrations of the dryer when in use. Moreover it limits the transmission of heat that might be developed by the electric and/or mechanical components.
  • the elastomer or the elastomers is present in the composite material in a percentage by weight up to 2%.
  • This amount of elastomer in the formulation is in fact sufficient for conferring to the final composite material the above mentioned properties, while ensuring a sufficient mechanical strength of the material.
  • the process of the invention comprises obtaining the component from the composite material by means of injection molding. More in detail the process comprises injecting the composite material in a mold for forming the component.
  • the temperature of the composite material is maintained below the melting temperature of the PET fibers, which is about 250°C. This allows to preserve the shape of the PET fibers, so that the desired mechanical features of the composite material as designed are not altered by the injection molding process for obtaining the component.
  • the process comprises, before the injection molding, the extrusion of a mixture comprising the polymeric material of the matrix, the calcium carbonate particles and the PET flakes for obtaining the composite material comprising the PET fibers.
  • the PET flakes are stretched thus forming the PET fibers.
  • the PET fibers such obtained, which have a significantly high aspect ratio, reinforce the polymer matrix so that they improve the overall mechanical properties of the composite material.
  • the PET fibers having a cost which is lower than the cost of the polymeric materials generally used for defining the matrix of the composite material, such as in particular polypropylene, allow to reduce the cost of the final composite material. As a result, the overall cost of the composite material is reduced without significantly compromising the mechanical properties of the latter and still using an easy and economical production process.
  • the temperature of the mixture is maintained between the glass transition temperature and the melting temperature of PET.
  • the temperature of the mixture is maintained close to, and below as above specified, the melting temperature. More in detail the temperature is maintained in proximity of the melting temperature of the PET, i.e. at maximum 10°C-15°C below the melting temperature.
  • the PET flakes that are added into the polymeric material are softened in the extruder by setting temperature profiles of the extrusion process which are close to melting temperature of PET. In this manner, the PET flakes are more easily reshaped in the form of fibers.
  • the process for producing the components of a household appliance according to the present invention allow therefore to obtain components with good mechanical properties, while significantly reducing the production costs of them.
  • Table 1 the density and the results of mechanical tests conducted on a composite material comprising a polypropylene matrix and 43%wt of calcium carbonate particles embedded in it, on a composite material comprising a polypropylene matrix and 50%wt of calcium carbonate particles embedded in it and on a composite material comprising a polypropylene matrix, 43%wt of calcium carbonate particles and 7%wt of PET fibers embedded in it.
  • the introduction of PET fibers in the formulation allows to diminish the overall amount of virgin polymer material used for the matrix slightly affecting the physical and mechanical properties of the composite material.
  • the physical properties of the composite material wherein substantially 50%wt of the polymeric material of the matrix has been replaced by 43%wt of calcium carbonate particles and 7%wt of PET fibers are more advantageous than the physical properties of the composite material wherein substantially 50%wt of the polymeric material of the matrix has been replaced by 50%wt of calcium carbonate particles.
  • the composite material such obtained is perfectly suitable to be used for the realization of components of household appliance such as for instance detergent drawers or tub of dishwashers or of washing machines, dryers and washers/dryers characterized by low spin speed, preferably below 1200 rpm, while allowing a significant decrease in the production costs of such components.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

A household appliance having a component made of a composite material comprising a matrix made of a polymeric material and calcium carbonate particles embedded in the polymeric material. It is an object of the present invention also a process for producing the household appliance having the above mentioned component.

Description

A HOUSEHOLD APPLIANCE HAVING A COMPONENT MADE OF A COMPOSITE MATERIAL AND A PROCESS FOR PRODUCING SUCH COMPONENT
The present invention relates to a household appliance, such as a washer or a dryer, having a component, such as for instance a tub, a detergent drawer or a chassis, made of a composite material and to a process for producing such component. More in detail the present invention refers in particular to a washing machine or to a washer/dryer comprising a component made of a composite material having a polymer matrix and to a process for its production.
In the state of the art household appliances, such as dishwashers, washing and/or drying machines, having components, such as in particular a tub, a detergent drawer or a chassis base, made of a composite material are well known. The tub of such household appliances is generally made of a composite material comprising a polymer matrix, such as a polypropylene matrix, reinforced with particles, such as calcium carbonate particles, or with fibers, such as glass fibers.
An example of a household appliance comprising a tub as above specified is for instance disclosed in the patent application n. US 2004/123633.
More in detail, composite materials having a polymer matrix reinforced with glass fibers are generally used for realizing tubs intended to undergo high stresses, as the tubs of high-spin speed models of washing machines and washer/dryers, generally reaching 800 to 1600 rpm, while composite materials having a polymer matrix reinforced with calcium carbonate particles are generally used for realizing tubs undergoing lower stresses, such as dishwasher tubs or lower-end models of washing machines and washer/dryers, with spin speed under 1200 rpm. Composite materials having a polymer matrix reinforced with calcium carbonate particles are moreover used for realizing other components of household appliances such as for instance the chassis base of laundry dryers, which holds electric and/or mechanical components such as the compressor and the motor and which, therefore, is designed to support heavy loads. The chassis base of dryers, moreover, must be able to counteract the effects of vibrations and high temperature that can be generated by the electric and/or mechanical components of the dryers.
The high cost of the raw materials, and in particular of the polypropylene, affects the overall production costs of the household appliances comprising one or more components made of such a composite material.
The objective of the present invention is to design a household appliance, such as in particular a washing machine or a washer/dryer, comprising a component, such as a tub, a detergent drawer or a tub, made of a composite material having a polymer matrix which ensures the desired performances and in particular mechanical performances, while requiring a lower production cost with respect to the materials currently available on the market to be used for the same purposes.
A further object of the present invention is to provide a process for the production of the component of such household appliances which is easy and economical to be performed.
The household appliance designed to fulfill the object of the present invention, explicated in the first claim and the respective claims thereof, comprises a component made of a composite material having a polymeric matrix, in particular preferably made of a polypropylene based polymeric material, and wherein part of the polymeric material used to define the matrix is substituted with calcium carbonate particles and PET fibers, thus ensuring comparable mechanical physical and chemical performances of the component, while significantly reducing its production costs.
In an embodiment, the calcium carbonate particles and the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 35% and 65%, which are sufficient to ensure adequate mechanical properties to the composite material.
In a further embodiment, the PET fibers are present in the composite material in a percentage by weight between 5% and 20%.
In another embodiment, the composite material further comprises a maleic anhydride based compatibilizer to promote interfacial adhesion between the fibers and the polymeric material of the matrix for ensuring an adequate mechanical and chemical resistance of the composite material of the component over the time.
In an embodiment, the PET fibers are obtained from PET flakes by means of extrusion of a mixture comprising the polymeric material of the matrix, the glass fibers and the PET flakes.
In a version of this embodiment, the PET flakes are obtained from recovered material and preferably from used and disposed plastic bottles.
According to an embodiment, the household appliance is a washer and/or dryer and the component is a tub wherein the items to be washed are placeable and/or it is a detergent drawer.
In an embodiment the formulation of the composite material further comprises an elastomer, in particular in a percentage by weight up to 2%.
In a version of this embodiment, the husehold appliance is a laundry dryer and the component is a chassis base, which holds electric and/or mechanical components of the laundry dryer.
The process object of the present invention comprises obtaining the component by injection molding, during which the temperature of the composite material is maintained below the melting temperature of the PET fibers, in order not to alter the shape of the latter.
In a version, the process further comprises, before the injection molding, the extrusion of a mixture comprising the polymeric material of the matrix, the glass fibers and the PET flakes for obtaining the composite material comprising the PET fibers.
In a further version, during the extrusion the temperature of the mixture is maintained between the glass transition temperature and the melting temperature of the PET, and preferably close to the melting temperature of it, for allowing the stretching of the PET flakes and the reshaping of the latter in the form of fibers.
DETAILED DESCRIPTION:
The household appliance of the present invention has a component, such as for instance a tub, a detergent drawer or a chassis base as later specified, made of a composite material comprising a matrix of a polymeric material, as preferably a polypropylene based polymeric material, and calcium carbonate particles embedded in the polymeric material. The calcium carbonate particles increase the stiffness of the composite material conferring to it good mechanical properties.
According to the present invention, the composite material further comprises polyethylene terephthalate (PET) fibers embedded in the matrix mixed with the calcium carbonate particles.
More in detail, part of the calcium carbonate particles and polypropylene polymer in the composite material constituting the component of the household appliance according to the invention are substituted with PET fibers. This allows to reduce the overall amount of virgincomposite material, for instance the overall amount of polypropylene based polymeric material, that is used in the composite material thus allowing to reduce the production costs of the component, and hence of the household appliance, while still ensuring appropriate mechanical properties. For instance, the material of the component of the household appliance according to the present invention demonstrated a suitable yield strength, being suitable to be used for the realization of tubs of laundry washers/dryers also for high spin speed models.
Moreover, it has been verified that the component obtained with a composite material comprising a mixture of calcium carbonate and PET fibers has a good detergent resistance and oxidation resistance, comparable to the ones of the components obtained with a composite material comprising only calcium carbonate.
According to an embodiment, the calcium carbonate particles and the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 35% and 65%. The total amount of calcium carbonate particles and PET fibers above specified ensures in fact adequate mechanical properties to the component.
In a further embodiment, the PET fibers are present in the composite material in a percentage by weight between 5% and 20%. The content of PET fibers in the composite material in the above specified range, in fact, allows to significantly reduce the production costs of the component, in particular by diminishing the amount of the base polymer material such as polypropylene, without jeopardizing the performances of the component.
According to another embodiment, the composite material further comprises a maleic anhydride based compatibilizer to promote interfacial adhesion between the polyethylene terephthalate fibers and the polymeric material of the matrix.
It has in fact been verified that such compatibilizer is suitable to promote adhesion between the PET fibers and the matrix. The introduction of the compatibilizer in the formulation of the composite material is particularly important for conferring an optimal resistance, both mechanical and chemical, over the time to the composite material and hence to the component realized with it.
In an embodiment, the PET fibers are obtained from PET flakes, by means of extrusion of a mixture comprising the polymeric material of the matrix, the calcium carbonate particles and the PET flakes. This allows to obtain the PET fibers with the desired average aspect ratio by adjusting the operational parameters of the extrusion process.
In a version of this embodiment, the PET flakes are obtained from recovered material, i.e. from post-consumer PET. This allows both to further reduce the cost of the composite material and hence of the component obtained with it and to reduce the environmental impact of the whole production process of the household appliance according to the present invention.
The PET flakes might for instance be obtained from used and discarded PET packaging. In particular, according to a preferred version of this embodiment, the PET flakes are obtained from discarded plastic bottles. The flakes obtained from PET bottles in fact has an optimal thickness which allows to easily obtain upon extrusion PET fibers with the desired aspect ratio.
In an embodiment, the household appliance of the invention is a washer and/or dryer and the component is a tub wherein the items to be washed are placeable. The composite material above described is particularly suitable for the realization of tubs undergoing lower stresses, such as dishwasher tubs or lower-end models of laundry washing and/or drying machine, with spin speed preferably under 1200 rpm. More in detail, as it is known, in case the household appliance is a dishwasher it further comprises one or more baskets which are removably placed in the tub and in which the dishes to be washed, i.e. dishes, kitchenware, tableware, crockery etc. to be washed, are placed by the user. In case the household appliance is a washing machine, a dryer or a washer/dryer it further comprises a drum rotatably placed in the tub and in which the laundry to be washed and/or dried is placed by the user.
In a further embodiment, the household appliance of the invention is a washer and/or dryer and the component is a detergent drawer. The composite material above described and used for realizing the component according to the invention, in fact, demonstrated good chemical resistance over the time, so that it is suitable for prolongated contact with detergent agents. Obviously the household appliance according to the invention may comprise more than one components made of the composite material above specified. In case the household appliance is a laundry washer and/or dryer, for instance, it may comprise both a tub and a detergent drawer made of the composite material comprising calcium carbonate particles and PET fibers.
In an embodiment, the composite material further comprises an elastomer. Therefore, the formulation of the composite material comprises, beside a matrix of a polymeric material, calcium carbonate particles embedded in the polymeric material and PET fibers, also one or more elastic polymers, such as for instance poly(styrene-butadiene-styrene) (SBS) rubber or, more preferably, styrene ethylene butylene styrene (SEBS) rubber. The addition of an elastomer in the formulation allows to increase the impact resistance of the composite material. More in detail, composite materials according to the invention comprising an elastomer in the formulation demonstrated a 20% higher impact resistance when tested by means of the Izod impact testing with respect to the same formulation not including elastomer.
This mechanical feature renders the composite material particularly suitable for the realization of components which have to bear heavy loads or that might be subject to impacts. Moreover the composite material comprising elastomer is suitable for limiting the transmission of vibrations.
In an embodiment, the household appliance according to the invention is a laundry dryer and the component is a chassis base, which holds electric and/or mechanical components of the laundry dryer, such as for instance the compressor, the heat pump and/or the motor. Thanks to the above specified properties of the composite material comprising elastomer, the chassis base made of such material is capable of safely carry the electric and/or mechanical components and of dampening the vibrations of the dryer when in use. Moreover it limits the transmission of heat that might be developed by the electric and/or mechanical components.
Preferably, the elastomer or the elastomers is present in the composite material in a percentage by weight up to 2%. This amount of elastomer in the formulation is in fact sufficient for conferring to the final composite material the above mentioned properties, while ensuring a sufficient mechanical strength of the material.
It is an object of the present invention also a process for producing a component for a household appliance as above described. The process of the invention comprises obtaining the component from the composite material by means of injection molding. More in detail the process comprises injecting the composite material in a mold for forming the component.
According to the invention, during the injection molding of the component, the temperature of the composite material is maintained below the melting temperature of the PET fibers, which is about 250°C. This allows to preserve the shape of the PET fibers, so that the desired mechanical features of the composite material as designed are not altered by the injection molding process for obtaining the component.
In a version, the process comprises, before the injection molding, the extrusion of a mixture comprising the polymeric material of the matrix, the calcium carbonate particles and the PET flakes for obtaining the composite material comprising the PET fibers. During the extrusion, the PET flakes are stretched thus forming the PET fibers. The PET fibers such obtained, which have a significantly high aspect ratio, reinforce the polymer matrix so that they improve the overall mechanical properties of the composite material. Moreover the PET fibers, having a cost which is lower than the cost of the polymeric materials generally used for defining the matrix of the composite material, such as in particular polypropylene, allow to reduce the cost of the final composite material. As a result, the overall cost of the composite material is reduced without significantly compromising the mechanical properties of the latter and still using an easy and economical production process.
According to a further version of the process, during the extrusion the temperature of the mixture is maintained between the glass transition temperature and the melting temperature of PET. This allows the thermoplastic PET material of the flakes to be softened and reshaped in the form of fibers. More in detail the temperature of the mixture during the extrusion is maintained between around 100°C and 260°C, which are respectively the glass transition temperature and the melting temperature of PET.
Preferably, in a further version of the process, during the extrusion the temperature of the mixture is maintained close to, and below as above specified, the melting temperature. More in detail the temperature is maintained in proximity of the melting temperature of the PET, i.e. at maximum 10°C-15°C below the melting temperature.
Therefore, the PET flakes that are added into the polymeric material are softened in the extruder by setting temperature profiles of the extrusion process which are close to melting temperature of PET. In this manner, the PET flakes are more easily reshaped in the form of fibers.
The process for producing the components of a household appliance according to the present invention allow therefore to obtain components with good mechanical properties, while significantly reducing the production costs of them.
It has in fact been verified that by partially substituting the calcium carbonate particles of the composite material used to produce the components with PET fibers, the mechanical properties of the composite material are improved.
As an example, below are reported in Table 1 the density and the results of mechanical tests conducted on a composite material comprising a polypropylene matrix and 43%wt of calcium carbonate particles embedded in it, on a composite material comprising a polypropylene matrix and 50%wt of calcium carbonate particles embedded in it and on a composite material comprising a polypropylene matrix, 43%wt of calcium carbonate particles and 7%wt of PET fibers embedded in it. Table 1
Test standards 43%wt CaCO 3 -PP 50%wt CaCO 3 -PP 43%wt CaCO 3 -PP-7%PET
Density (g/cm 3 ) ISO 1183 1,27 1,37 1,29
Yield strength (MPa) ISO 527 22,23 19,69 19,62
Elongation at yield (%) ISO 527 3,4 2,45 2,40
E Modulus (MPa) ISO 527 3221 3969 2910
Izod impact strength (KJ/m 2 ) ISO 180/1A 3,6 3,1 2,7
Flexural strength (MPa) ISO 178 38,5 37,53 36
Flexural Modulus (MPa) ISO 178 2718 3771 2805
Table 1
As can be easily verified by the results reported in Table 1, the introduction of PET fibers in the formulation, allows to diminish the overall amount of virgin polymer material used for the matrix slightly affecting the physical and mechanical properties of the composite material. In particular the physical properties of the composite material wherein substantially 50%wt of the polymeric material of the matrix has been replaced by 43%wt of calcium carbonate particles and 7%wt of PET fibers are more advantageous than the physical properties of the composite material wherein substantially 50%wt of the polymeric material of the matrix has been replaced by 50%wt of calcium carbonate particles. The composite material such obtained is perfectly suitable to be used for the realization of components of household appliance such as for instance detergent drawers or tub of dishwashers or of washing machines, dryers and washers/dryers characterized by low spin speed, preferably below 1200 rpm, while allowing a significant decrease in the production costs of such components.
As a further example, below are reported in Table 2 the results of mechanical tests conducted on a composite material comprising a polypropylene matrix, 43%wt of calcium carbonate particles, 7%wt of PET fibers and 2%wt of SEBS (styrene ethylene butylene styrene rubber) embedded in it, on a composite material comprising a polypropylene matrix, 43%wt of calcium carbonate particles, 7%wt of PET fibers and 2%wt of SBS (poly(styrene-butadiene-styrene)) embedded in it and, as a reference, on a composite material comprising a polypropylene matrix and only 43%wt of calcium carbonate particles and 7%wt of PET fibers embedded in it.
Table 2
Test standards 43%wt CaCO 3 -PP-7%PET -2%wt SEBS 43%wt CaCO 3 -PP-7%PET -2%wt SBS 43%wt CaCO 3 -PP-7%PET
Yield strength (MPa) ISO 527 16,32 17,36 19,62
Elongation at yield (%) ISO 527 3,43 2,53 2,40
E Modulus (MPa) ISO 527 2545 2708 2910
Izod impact strength (KJ/m 2 ) ISO 180/1A 3,13 3,12 2,7
Flexural strength (MPa) ISO 178 32,84 32,82 36
Flexural Modulus (MPa) ISO 178 2611 2528 2805
Table 2
As can be verified by the results reported in Table 2, the introduction of elastomer in the formulation, allows to decrease the stiffness of the composite material, thus rendering the latter for instance more suitable for dampening vibration.

Claims (15)

  1. A household appliance having a component made of a composite material comprising a matrix of a polymeric material and calcium carbonate particles embedded in the polymeric material, characterized in that the composite material further comprises polyethylene terephthalate fibers embedded in the matrix mixed with the calcium carbonate particles.
  2. A household appliance as in Claim 1, characterized in that the calcium carbonate particles and the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 35% and 65%.
  3. A household appliance as in Claim 1 or 2, characterized in that the polyethylene terephthalate fibers are present in the composite material in a percentage by weight between 5% and 20%.
  4. A household appliance as in any of the above claims, characterized in that the polymeric material of the composite material is a polypropylene based polymeric material.
  5. A household appliance as in any of the above claims, characterized in that the composite material further comprises a maleic anhydride based compatibilizer to promote interfacial adhesion between the polyethylene terephthalate fibers and the polymeric material of the matrix.
  6. A household appliance as in any of the above claims, characterized in that the polyethylene terephthalate fibers are obtained from polyethylene terephthalate flakes, by means of extrusion of a mixture comprising the polymeric material of the matrix, the calcium carbonate particles and the polyethylene terephthalate flakes.
  7. A household appliance as in Claim 6, characterized in that the polyethylene terephthalate flakes are obtained from recovered material.
  8. A household appliance as in any of the above claims, characterized in that it is a washer and/or dryer and the component is a tub wherein the items to be washed are placeable.
  9. A household appliance as in any of the claims 1 to 7, characterized in that it is a washer and/or dryer and the component is a detergent drawer.
  10. A household appliance as in any of the above claims, characterized in that the composite material further comprises an elastomer.
  11. A household appliance as in Claim 10, characterized in that the elastomer is present in the composite material in a percentage by weight up to 2%.
  12. A household appliance as in Claim 10 or 11, characterized in that it is a laundry dryer and the component is a chassis base, which holds electric and/or mechanical components of the laundry dryer.
  13. A process for producing a household appliance according to any of the above claims, comprising injecting the composite material in a mold for forming a component of the household appliance characterized in that during the injection molding the temperature of the composite material is maintained below the melting temperature of the PET fibers.
  14. A process as in claim 13, characterized in that it further comprises, before the injection molding, the extrusion of a mixture comprising the polymeric material of the matrix, the glass fibers and the polyethylene terephthalate flakes for obtaining the composite material comprising the polyethylene terephthalate fibers.
  15. A process as in claim 14, characterized in that during the extrusion the temperature of the mixture is maintained between the glass transition temperature and the melting temperature of the polyethylene terephthalate.
PCT/EP2017/074003 2017-09-22 2017-09-22 A household appliance having a component made of a composite material and a process for producing such component WO2019057292A1 (en)

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PCT/EP2017/074003 WO2019057292A1 (en) 2017-09-22 2017-09-22 A household appliance having a component made of a composite material and a process for producing such component
TR2018/06078A TR201806078A2 (en) 2017-09-22 2018-04-30 A HOUSEHOLD DEVICE CONTAINING A COMPONENT MADE FROM A COMPOSITE MATERIAL AND A METHOD USED IN THE PRODUCTION OF SUCH COMPONENT

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10216517A1 (en) * 2002-04-15 2003-09-11 Ticona Gmbh Washing machine drum or dishwasher interior, is made from closed cell polymer foam with pore size of 1 -50 microns
US20040123633A1 (en) 2002-10-16 2004-07-01 Lg Electronics Inc. Drum-type washing machine
DE102007057606A1 (en) * 2007-11-28 2009-06-04 Basell Polyolefine Gmbh Modular built rotary drum for electrical and household appliances
CN104327465A (en) * 2014-10-23 2015-02-04 金宝丽科技（苏州）有限公司 Modified PET (polyethylene terephthalate) composite material
EP3260594A1 (en) * 2016-06-20 2017-12-27 Electrolux Appliances Aktiebolag Component for household appliances made from recycled polyolefin

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10216517A1 (en) * 2002-04-15 2003-09-11 Ticona Gmbh Washing machine drum or dishwasher interior, is made from closed cell polymer foam with pore size of 1 -50 microns
US20040123633A1 (en) 2002-10-16 2004-07-01 Lg Electronics Inc. Drum-type washing machine
DE102007057606A1 (en) * 2007-11-28 2009-06-04 Basell Polyolefine Gmbh Modular built rotary drum for electrical and household appliances
CN104327465A (en) * 2014-10-23 2015-02-04 金宝丽科技（苏州）有限公司 Modified PET (polyethylene terephthalate) composite material
EP3260594A1 (en) * 2016-06-20 2017-12-27 Electrolux Appliances Aktiebolag Component for household appliances made from recycled polyolefin

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