WO2020060506A1

WO2020060506A1 - Ropes reinforced wood plastic composites

Info

Publication number: WO2020060506A1
Application number: PCT/TR2018/050518
Authority: WO
Inventors: Nurettin YALCIN; Mehmet YALCIN; Melis YALCIN
Original assignee: Galiboff Plastik Kompozit Ekstruzyon Teknolojileri Ltd. Şti.
Priority date: 2018-09-21
Filing date: 2018-09-21
Publication date: 2020-03-26
Also published as: EP3853009A4; EP3853009A1

Abstract

This invention relates to a wood plastic composite extrusion system wherein the system comprises of three extruders and complex head with profile forming die. This invention includes apparatus for continuously extruding wood plastic composites mixture, co-extruding long fibers and thermoplastic materials composition mixture together with reinforcing ropes and straps as outer layer onto profile surface and co-extruding forcedly reinforcing ropes and straps together with long fibers and thermoplastic materials composition mixture inside the profile by forming intermediate filaments and at the same time surrounding the ropes and straps. Wherein co-extruded mixture plastic melt promotes bounding of reinforcing ropes and straps with wood plastic composites mixture.

Description

ROPES REINFORCED WOOD PLASTIC COMPOSITES

Technical Field of the Invention

This invention relates to system for manufacturing natural fiber filled thermoplastic and thermoset composite materials and processes for their manufacture. In particular, it relates to cellulose fiber filled compositions reinforced by injected ropes which have high strength, elastic modulus and density values inside the profile, and processes for their manufacture. Composite materials are often optimized by selecting components for their strength, stiffness, flexibility, and durability. Current development is focused on improving material qualities ranging from strength to durability, as well as improving the compatibility of matrix components for longer lasting products and examining new manufacturing methods for ropes reinforced wood plastics composites.

Background of the Invention

Wood-plastic composites (WPC) are a product class that has been developing over the last 40 years resulting in increased applications and expanded market share. Thermoplastics are a class of polymers that can be heated and softened, cooled and hardened, high density polyethylene (HDPE), polypropylene (PP) and polyvinyl chloride (PVC) are the most common thermoplastic polymers used in WPC (Klyosov 2007) ⁽¹⁾.

Wood Component

Wood has many advantages to traditional fillers like lower cost, relatively high strength to weight ratio, low density, is relatively soft and easily integrated into existing plastic production lines. Mesh sizes of particles used in WPCs will vary depending upon the desired product properties and finish and are most commonly from 10 to 80 meshes (Patterson 2001 ; Clemons 2002) ⁽²⁾.

Manufacturing Methods

WPCs started being produced by the plastics industry which had prior expertise in processing and manufacturing of plastic products (Clemons 2002) ^{i3 )}. This industry had used filler materials in the past and when wood became a viable option; it was integrated into their existing production lines. WPCs starting in a molten state can be formed into highly detailed, linear profiles using extrusion processes. In any thermoplastic composite, the components must first be blended together and then later formed into the desired product.

Compounding

Mixing or compounding is the act of combining the wood and polymer components together. It is also important in this step to wet or encapsulate the wood particles with the polymer. Proper dispersion and wetting allow uniform and more effective load transfer to occur throughout the composite. If not compounded properly, the composite will have reduced mechanical properties compared with an optimally compounded blend and increases the risk of durability issues. After compounding, the material can go directly to shape formation of the final product or can be chipped into pellets for later use.

Extrusion

The majority of WPCs are extruded into long linear profiles to use as decking planks, siding, fences, etc. Extruders serve the two main purposes of compounding the wood and filler, and then forming the shape of the extruded profile. The wood and polymer components are metered and fed into the extruder and mixed using single or twin-screw configurations. The screws act to mix and move the material forward. Throughout the barrel of the extruder, the mix is heated through friction between the barrel, screw, and wood-polymer mix as well as by heated zones along the length. At the end of the extruder is a die through which the material is fed, forming the desired profile. Twin screw extruders are sometimes used as compounding units for producing pre -blended pellets.

Manufacturers using a single screw extruder or injection moulding process often purchase these pre-blended pellets which are more easily fed into the machine and do not require an extra compounding step.

Physical Characteristics

Composite materials are often optimized by selecting components for their strength, stiffness, flexibility, and durability. When compared with individual materials, composites may also offer more consistent performance, lower production costs, and create an avenue for the utilization of renewable resources. WPCs are no different and are formulated to meet the needs of the consumer by finding the right balance of these properties. Mechanical properties and durability are among the most important to WPCs.

Mechanical Characteristics

With WPC decking making up the largest share of the WPC market (Clemons 2002) ⁱ⁴⁾, we can look at mechanical properties important to this market. WPC deck boards are subjected to bending when they span a gap between supports and are being dynamically loaded when walked on and supporting the static loads (e.g. furniture and grills). For decking, this is important for limiting deflection of the product. It should be mentioned that a true elastic response in plastic composites is debatable, and the response of the material is highly dependent on the testing rate, temperature, previous history of the specimen, etc. WPC formulations and specimens from different testing facilities are difficult, but for research and development purposes determining these values as a comparison is helpful. WPCs have found success in a variety of markets including outdoor decking, railings, fences and landscaping timbers, but the number of applications for WPCs is limited to service requiring high -mechanical performance (Clemons 2002) ⁽⁵⁾.

Durability

When compared with solid wood materials, Table 1, WPCs have lower mechanical properties in strength, stiffness, and creep resistance.

Elastic and strength properties are the primary criteria to select materials or to establish design or product specifications. Common applications include decking, railings, window profiles, roof tiles, and siding. These lumber products are generally manufactured using profile extrusion. Flexural and tensile properties of wood plastic composite (WPC) lumber generally fall between those of solid wood lumber. According to Table 1, most commercial wood plastic composites are considerably less stiff than solid wood (Clemons 2002) ⁱ⁶⁾.

Table 1: General Technical Report for static bending properties of different wood and wood- based composites ^[7] Therefore, there is a need for increasing physical properties of a thermoplastics-based wood filled composites (WPC) which can be processed during manufacturing and with the need for complex extrusion process, head and die arrangements to feed ropes into extruded materials to increase flexural properties, impact resistance and tensile properties of extruded profile.

Objects and Summary of the Invention

According to Table 1, there is a clear need for improving material qualities ranging from strength to durability, as well as improving the compatibility of matrix components for longer lasting products. Current work is focused on examining the environmental and performance impacts of using new wood plastic composites as substitution products in various new applications, using materials with increased flexural properties, impact resistance and tensile strength reinforcement, and examining new manufacturing methods for new natural fiber filled plastic composites extrusion. This invention relates to a wood plastics composite (WPC) profiles and to a method of production of such a profile. Resulting composite profile will have hard cracking as a wood beam and desirable reinforced features with increased flexural properties, impact resistance and tensile properties to use them under load. To reach desirable reinforcement of any WPC profile by injecting ropes (C) and Straps (D) with high modulus of elasticity materials we have to make choice from‘Table 2: Modulus of elasticity’ and inject them inside the profile during extrusion manufacturing process (Fig. l, Fig.2).

Table 2: Modulus of Elasticity

Referring to‘Table 3 : Fiber physical properties’ (C) we can choose reinforcing material, predict how many ropes shall we use according to cross section of the profile and calculate the diameter of ropes for certain profile application. Using different materials with different rope’s diameter we can create materials with whatever mechanical properties we need. According to application of the profile we can choose reinforcing ropes (C) from Table 2 and Table 3 knowing that mechanical properties of polymer rope < hemp < steel wire < carbon nanotubes graphene rope.

Reinforcing ropes (C) are injected inside the profile through injectors (5) by extruder (11) together with long fibers and resins materials (B2) composition. Other reinforcing materials are Composite and Textile Straps D materials:

Composite Strapping (D) is produced by a co-extrusion where polyester fibers are covered with plastic. Tensile strength of the strapping depends on the number and diameter of the fibers used.

Textile Strapping (D) is manufactured by hot-melt gluing polyester fibers together. Physical properties of the strapping are function of the number and the diameter of the fiber used.

Textile and Composite Straps (D) are injected inside by extruder (11) together with (B2) composition and outside application by extruder (12) together with long fibers and resins materials (Bl) composition.

Reinforcing long fibers and resins materials (B) are extruded with extruder (11) as an intermediate filament formation (B2) and extruder (12) as an outside layer film (Bl) onto the profile (8).

Composite materials (B) contains plastic resins from 30% to 70% and long fibers up to 20 mm fiber elongation which content is from 70% to 30% respectively to plastic resins. Reinforced fibers are chosen from materials in Table 2.

Reinforcing ropes (C) (9) are forcibly extruded through injectors (5) by extruder (11) with (B2) materials which is surrounding the ropes inside the profile (8).

After testing the extruded profile, we can evaluate mechanical and physical properties of rope reinforced wood-plastic composites (RRWPC) products. This will lead us to create new standards for naturel fiber filled plastic composite products which will be used in various new applications and especially in construction sector to replace wooden beams and boards.

Table: 3 Fiber physical properties

For the future it will be important, that rope reinforced WPC profiles can be used as construction materials. They will replace wood beams and boards so trees will grow in factories. This application is done with adding (injecting) materials with strong Mechanical Properties to the recipe. And with calculating injected material for certain cross section beam, we can reach times better Mechanical Properties by making choice of added material from Table 2 and Table 3 and reach more and more the existing hardest wood beam properties.

Physical Characteristics ofRRWPC Mechanical properties and durability are among the most important to WPC. New ropes reinforced composite materials will be optimized by selecting components for their strength, stiffness, flexibility, and durability. When compared with existing WPC materials, they will offer more consistent performance, and create an avenue to save natural resources by replacing wood beams and boards in construction. Mechanical Properties ofRRWPC

New ropes reinforced composite profiles, beams, lumbers and deck boards will be resistant to bending according to injected rope material, radius of cross section and quantity. Ultimate tensile stress (UTS) is the maximum stress that a material can be subjected to before breaking. Modulus of elasticity (MOE) refers to a material’s ability to resist deformation and in a general sense is the stiffness of the material. Both the ultimate tensile stress (UTS) and modulus of elasticity (MOE) are increased properties in this case by adding reinforced materials like Polymer < Hemp < Steel wire < Graphene ropes. The number of applications for new rope RWPC is unlimited to service requiring high-mechanical performance of the extruded profile.

Durability ofRRWPC

When compared with solid wood materials, Table 1, new rope RWPC will have higher mechanical properties in strength, stiffness, and creep resistance by injecting reinforced materials like polymer < hemp < steel wire < graphene ropes. Elastic and strength properties of these materials are the primary criteria to select or to establish design or product specifications for common applications include decking, railings, window profiles, roof tiles, construction timbers and siding profiles. Flexural and tensile properties of new Rope Reinforced Wood Plastic Composites (RRWPC) lumber profile will be increased as much as used ropes number and cross-sectional area of used ropes are.

Utility/Industrial Application ofRRWPC

These new ropes reinforced lumbers, boards and profile products are generally manufactured by using Wood Plastic Composites (WPC) profile extrusion methods where production process is more complicated.

Detailed Description of the Invention

The system for manufacturing ropes reinforced wood plastic composites (RRWPC) that is provided in order to reach the aims of the invention has been illustrated in the attached figures. According to the figures;

Figure 1: Extrusion Process front view is a cross sectional illustration of an exemplary profile extrusion in accordance with an embodiment of the present invention.

Figure 2: Extrusion Process top view is a cross sectional illustration of an exemplary profile extrusion in accordance with Figure 1.

Figure 3: Extrusion Process top view is a cross sectional illustration of an exemplary Complex head with a die (7) connection with Extruder XI (4) for wood plastic composites (WPC) mixture (A) extrusion, Extruder X3 (12) for outside application of long fibers and plastics mixture materials (B l) extrusion, Extruder X2 (11) for inside extrusion of long fibers and plastics mixture materials (B2) extrusion together with injection of reinforcing ropes (C) and composite straps (D). Figure 4: Cross sectional view of extruded profile with materials A, Bl thick outside film and B2 as intermediate filaments with changeable radius applications.

Figure 5: Cross sectional view of extruded profile with materials A, Bl and B2 together with reinforcing ropes C.

Figure 6: Cross sectional view of extruded profile with materials A, B2 as tube filament and Bl together with composite straps D-outside application.

Figure 7: Cross sectional view of extruded profile with materials A, Bl and B2 together with composite straps D-inside application.

Figure 8: Cross sectional view of extruded profile with materials A, Bl and B2 together with C and composite straps D-outside application.

Figure 9: Cross sectional view of extruded profile with materials A, Bl and B2 together with reinforcing ropes C and composite straps D-inside application.

Figure 10: Cross sectional view of Complex head with a die for extrusion of materials A, B 1 thick film and B2 as tube filaments.

Figure 11: Cross sectional view of Complex head with a die for extrusion of materials A, B l and B2 together with reinforcing ropes C.

Figure 12: Cross sectional view of Complex head with a die for extrusion of materials A, B 1 and B2 together with composite straps D-inside application.

Figure 13: Cross sectional view of Complex head with a die for extrusion of materials A, Bl and B2 together with composite straps D outside application.

Figure 14: Cross sectional view of Complex head with a die for extrusion of materials A, B 1 and B2 together with reinforcing ropes C and composite straps D inside application.

The parts in the figures have been numbered as follows;

1. Rope Coils Bobbins Carrier

2. Electric Induction Motor

3. Wood Plastic Composites Mixture Granule Feeding Tank

4. Extruder XI for Wood Plastic Composites Mixture (A)

5. Injectors:

5.1 Extrusion injectors for melt mixture (Bl)

5.2 Extrusion injectors for melt mixture (Bl) with Reinforcing Ropes (C)

5.3 Extrusion injectors for Reinforcing Ropes (C)

5.4 Extrusion injectors for melt mixture (Bl) with reinforcing composite straps (D) 5.5 Extrusion Injectors for Vertical Application (DV) of Composite and Textile Strap (D) inside in the profile

5.6 Extrusion Injectors for Horizontal Application (DH) of Composite and Textile Straps (D) inside in the profile

5.7 Extrusion Injectors for Vertical Application (DV) of Composite and Textile Strap (D) outside onto the profile

5.8 Extrusion Injectors for Horizontal Application (DH) of Composite and Textile Strap (D) outside onto the profile

6. Adaptor

7. Complex profile extrusion head with a die:

7.1 Complex Profile extrusion head with die for (A), (Bl) and (B2) melt mixtures

7.2 Complex Profile extrusion head with die for (A), (Bl) and (B2) melt mixtures and reinforcing ropes (C)

7.3 Complex Profile extrusion head with die for (A), (Bl) and (B2) melt mixtures and reinforcing composite straps (D) inside in (A) mixture inside the profile

7.4 Complex Profile extrusion head with die for (A), (Bl) and (B2) melt mixtures and reinforcing composite straps (D) outside in (Bl) mixture onto the profile

7.5 Complex Profile extrusion head with die for (A), (Bl) and (B2) melt mixtures and reinforcing ropes (C) and reinforcing composite straps (D) inside in (A) mixture in the profile

8. Ropes reinforced wood plastic composite (RRWPC) extruded profile

9. Ropes- Reinforcing materials such as: steel wire rope, hemp fiber rope, polymer fiber rope or carbon nanotubes graphene fiber rope (C) and composite and textile straps (D)

10. Extruder XI Screw

11. Extruder X2 for Long Fibers and Plastics Mixture (Bl) for outside applications

12. Extruder X3for Long Fibers and Plastics Mixture (B2) for inside applications

13. Melt Flow Channel of Wood Plastic Composite (A)

14. Melt Chamber for (A) materials

15. Melt Chamber for (Bl) materials

16. Channels for (Bl) materials extrusion

17. Melt Chamber for (B2) materials

Materials flow in the figures have been explained as follows; A - Flow of Wood Plastic Composite Mixture melt from Extruder XI (4)

B1 - Flow of Long Fibers and Plastic Mixture melt from Extruder X3 (12) for outside film formation and melt surrounding of reinforcing ropes and straps in the profile

B2 - Flow of Long Fibers and Plastic Mixture melt from Extruder X2 (11) for intermediate filament formation and melt surrounding of reinforcing ropes and straps in the profile

C - Flow of reinforcing ropes such as: steel wire rope, hemp fiber rope, polymer fiber rope or carbon nanotubes graphene fiber rope

D - Flow of reinforcing ropes such as: Composite and Textile Straps

A system for manufacturing ropes reinforced wood plastic composites profiles wherein the system comprises, feeding injectors (5) fixed in complex die head (7) to supply reinforcing ropes and apply them inside and outside surface of the profile (8) and surround them by long fibers and plastics mixture melt (B1 and B2),

extruder XI to supply wood plastic composite mixture (A) melt to complex die head

(7),

extruder X3 to supply long fibers and plastics mixture (Bl) melt to complex die head (7) for profile’s outside film formation and surround reinforcing ropes (C) and straps (D) supplied,

extruder X2 to supply long fibers and plastics mixture (B2) melt to complex die head (7) for profile’s inner filament formation and surround reinforcing ropes (C) and straps (D) supplied,

complex die head (7) with melt chambers (14, 15 and 17) to receive molten mixture, complex die head (7) with injectors (5.1) to supply long fibers and plastics mixture (B2) melt to complex die head for profile’s inner filament formation,

complex die head (7) with injectors (5.2) to supply long fibers and plastics mixture melt to complex die head for profile’s inner surround tubing formation and injectors (5.3) for reinforcing ropes (C),

complex die head (7) with injectors (5.4) to supply long fibers and plastics mixture melt to complex die head for profile’s inner surround tubing formation, injectors (5.5) for horizontal and injectors (5.6) for vertical supply of reinforcing composite and textile straps (D),

extrusion die (7.1,7.2, 7.3, 7.4, 7.5) design for final shape forming of profiles such as circular, square, rectangular, I, H, U cross sections.

The process of manufacturing of reinforced wood plastic composites profiles comprising composite materials:

wherein wood plastic composites materials which cellulose containing is variable from 30% to 70% by weight or ready to use wood plastic composites (WPC) granules from granules suppliers (A),

wherein long fibers and thermoplastic materials composition (Bl, B2) with variable ratio from 40% to 60% respectively. Long fibers which length is up to 20 mm are chosen from materials Hemp, ABS Plastic, Nylon, Carbon steel, Graphene, Aramid HT, Aramid copolymer, Aramid SM, Gel-spun PE, LC polyester, Steel wire, polypropylene, Bexcoline, Polyester, Nylon,

wherein continuous reinforcing ropes (C) with variable diameter cross section are chosen from materials Hemp, ABS Plastic, Nylon, Carbon steel, Graphene, Aramid HT, Aramid copolymer, Aramid SM, Gel-spun PE, LC polyester, Steel wire, polypropylene, Bexcoline, Polyester, Nylon,

wherein continuous reinforcing textile or composite straps (D) which physical properties are function of the number and the diameter of the fiber used from different suppliers.

REFERENCES

[1], [2], [3], [4], [5], [6] Wood-Plastic Composites - Performance and Environmental Impacts Matthew John Schwarzkopf and Michael David Burnard

[7] Mechanical Properties of Wood-Based Composite Materials, Zhiyong Cai, Supervisory Research Materials Engineer, Robert J. Ross, Supervisory Research General Engineer

Claims

1. A system for manufacturing ropes reinforced wood plastic composites profiles wherein the system comprises of feeding injectors (5) fixed in complex die head (7) to supply reinforcing ropes and apply them inside and outside surface of the profile (8) and surround them by long fibers and plastics mixture melt (Bl and B2).

2. A system according to claim 1 comprising of extruder XI to supply wood plastic composite mixture (A) melt to complex die head (7).

3. A system according to claim 2 comprising of extruder X3 to supply long fibers and plastics mixture (Bl) melt to complex die head (7) for profile’s outside film formation and surround reinforcing ropes (C) and straps (D) supplied.

4. A system according to claim 2 comprising of extruder X2 to supply long fibers and plastics mixture (B2) melt to complex die head (7) for profile’s inner filament formation and surround reinforcing ropes (C) and straps (D) supplied.

5. A system according to claim 1 comprising of complex die head (7) with melt chambers (14, 15 and 17) to receive molten mixture.

6. A system according to claim 5 comprising of complex die head (7) with injectors (5.1) to supply long fibers and plastics mixture (B2) melt to complex die head for profile’s inner filament formation.

7. A system according to claim 6 comprising of complex die head (7) with injectors (5.2) to supply long fibers and plastics mixture melt to complex die head for profile’s inner surround tubing formation and injectors (5.3) for reinforcing ropes (C).

8. A system according to claim 6 comprising of complex die head (7) with injectors (5.4) to supply long fibers and plastics mixture melt to complex die head for profile’s inner surround tubing formation, injectors (5.5) for horizontal and injectors (5.6) for vertical supply of reinforcing composite and textile straps (D).

9. According to claim 8 extrusion die (7.1,7.2, 7.3, 7.4, 7.5) design for final shape forming of profiles such as circular, square, rectangular, I, H, U cross sections.

10. The process of manufacturing of reinforced wood plastic composites profiles comprising composite materials:

wherein continuous reinforcing textile or composite straps (D) which physical properties are function of the number and the diameter of the fiber used from different suppliers