DE4235530A1 - Compact sheets e.g. thermo-formed - Google Patents

Abstract

Moulded article is made of particles of thermoplastics, and of plastic films in partic., by bonding them together under heat and pressure with pieces or strips of cellulosic material. The surface of an example is made by hot pressing pieces (1) of plastic and/or plastic films (2) plus pieces (3) of cellulosic material. The pieces (2,3) concerned are bonded together, whilst they are still visible in the structure formed e.g. in relief. The pressed sheet contains air occlusions. The surface particles of plastic material (2) become fused together so that blurred areas are formed (4) with different colours. If the product is thermoformed the blurred effect is heightened by the additional heating at the surface and the enveloped pieces of paper used. The latter then become no longer recognisable. The prod. can be moulded into corrugations, e.g. to carry cables along the depressions.

Description

The invention relates to a structure made from thermoplastic plastic films the waste films in pieces or strips by printing and / or Influence of temperature were combined.

Particularly falls through the use of packaging material made of plastic films a lot of waste. Plastic waste can be chemically or mechanically recycled become. In material recycling, the old plastic is crushed, cleaned,  melted again, regranulated and then warmed up again and into one processed new product. This procedure is suitable for reusing uniform film waste. Fall foreign, difficult to qualify or colored Film waste, so they can usually only to products of poor quality and Quality can be processed at relatively high sorting and processing costs. In addition to the raw material value, the plastic films also have their own flat shape and the particularly high effort with which the film production ver is bound, a high "energy content", which in shrinking and regranulating is completely lost.

DE AS 16 79 822 describes a process for the production of raw blocks from thermo plastic plastics known. For this purpose, the plastics are first granulated, the granules calendered to a rawhide, the rawhide in chips with about cut rectangular shape and after stacking and heating the Chips welded into a block. This process involves both thermal and also mechanical processing of the output material to another material.

A similar process is known from DE AS 14 79 090. For making mold share like B. plates or sheets, the waste plastics are first granulated, that Granulate plasticized, crushed again and in a mold using Heat and pressure welded into a block. This procedure also includes one fundamental reworking of the source material.

The object of the present invention is to eco-friendly waste thermoplastic film nomically reuse, the associated process inexpensive and a should be fold.

This object is achieved by the structure specified in claim 1. A procedure to produce such a structure claims 17. The subclaims represent advantageous developments.

The structure according to the invention consists of under pressure and / or temperature influence interconnected plastic films or pieces.

To manufacture the structure according to the invention there is no material or chemical reprocessing of the plastic waste or plastic waste films  agile. The plastics are not chemically destroyed, the processing and the one set of plastic waste films according to the invention is limited to small me mechanical and / or thermal influence on the starting material. The Plastic films can be connected to each other so that either a flat or a spatial structure is created. The connection of the foils can be dependent be firm or loose from the applied pressure and / or temperature. It is both the Manufacture of structures possible, where pressure and temperature are chosen so high were that a homogeneous structure is possible, as well as of plate or web-like structures that are manufactured under a low pressure and low temperature have such a loose structure that between the individual interconnected pieces of film voids are present, and the whole Formation has air inclusion. These structures are particularly elastic. It is possible, the spatial structures also forms such. B. a spherical or cuboid shape, as well the shape of a concrete object, e.g. B. to give a cup. If desired, these structures with different spatial shapes also have air inlet and a loose structure. The structures according to the invention are also suitable for further processing methods, in particular can through the flat structures Forming processes, e.g. B. deep drawing or compression molding, given another shape the.

According to an advantageous embodiment, the structure can be made from different foils materials exist. The foils can have different colors, Thickness, order of magnitude or material properties and material composition exhibit. It is also possible to get the best in thermoplastic plastic films to work with existing structures that are very difficult to dispose of, such as e.g. B. thermosets, elastomers or polystyrene foam. You will be with or between the thermoplastic plastic film pieces or strips by melting them in the structure involved.

The starting film material used can be uneven and three-dimensional ver forms are present. Are the film waste to be processed, e.g. B. by heat or me Chanic influences have already been deformed, so they are used in this form to produce the Form according to the invention can be used. It is advantageous if the art  are pieces or strips of stretched film. They tend due to the influence of temperature to shrink and deform into three-dimensional pieces, which then arched or similarly increased in volume. It is advantageous that the Corners of such pieces of film bulge particularly strongly and thereby form "claws". By "clawing" the individual pieces together, the bond of the structure becomes improved, its structure solidified. The rectangular pieces of film or strips shrink more on their long sides than on their short sides, so that their cross section has moved in the middle. A structure made from foils of this shape is wide permeable to air and water.

The three-dimensionally deformed pieces of film have the advantages mentioned above Another advantage is that they can be easily processed using pressure.

The structure of the Ge made from three-dimensionally deformed pieces or strips bilde has air trapping and is particularly loose. This is for many uses advantageous. Such a loose connection gives the structure high elasticity. The specific volume of the structure according to the invention is a maximum of 10x and min at least 1.5 times larger than the bulk volume of the untreated raw material.

Other materials, such as e.g. B. Reinforcing fiber. But it can also be powder, such as. B. thermoplastic powder or Fire extinguishing powder can be used. The addition of these materials is of the order requirements or the area of application of the finished product.

According to an advantageous embodiment, the structure has a homogeneous structure on. It is available when particularly thin foils have been used and the Process temperature was high enough for the foils to fuse together. A Product that has such a homogeneous structure provides a new film-like Plastic material and can be processed and used like a plastic film become. With such "melting together" of the starting foils to a homogeneous Structures are created by the use of different colored foils flowing new Template. These products do not require foil coloring such as B. in the production of new Plastic material foils.

The structure according to the invention can advantageously be flat or spatial. A  Homogeneous material structure can be present with flat structures. With spatial order The film pieces or strips lying in the area of the surface can be included be connected. The connection is created by pressure and / or Influence of temperature. At a correspondingly high temperature, they sinter in the region of Pieces of film on the surface. The firm outer skin keeps the inside of the Ge loosely bound pieces of film or strips. The The inventive structure remains despite the solid cohesion and a stable Spatial form elastic; between the individual pieces or strips of film Air gives the structure high elasticity.

It is advantageous if fillers are entered into the structure, such as. B. chalk, Rubber or glass powder, but also small materials such as. B. different Ma materials with different properties. These materials become the structure expediently added before the connection process. When connecting corridor, the spaces between the pieces of film become smaller or more closed hend, whereby even the powdered fillers do not trickle out of the structure. When using the structure according to the invention as geo-material or geo-fleece he there follows a "penetration" of the structure with earth. With long-term use the mixing of the two substances is completed.

In a development of the invention it is provided that the film strips parallel to each other derlie and the structure is delimited by four side surfaces, the film strips are welded together at least on one side surface. Such one Form represents a coherent block of film, its dimensions and Composition the area of application or the requirements of another process processing procedure can be adjusted. Is the foil block along its one Welded side surface, so the film strips fan depending on their mate riale properties and the amount of pressure under which they were connected, more or less apart. If more rigid blocks of film are to be produced, then the film strips are welded together along two side surfaces. This creates a structure with a particularly good cohesion, but still one has some elasticity. The structure can be made in different sizes become. Normally, elongated, narrow blocks are made. These structures  can e.g. B. 200 mm long, 10 mm wide and 10 mm deep. This size results when stacked waste films cut into strips and at the same time with be connected. The elongated film blocks can be cut into smaller ones as needed Pieces / blocks are cut (e.g. 10 mm × 10 mm × 10 mm), especially if when used as feed for an extruder or after heating for an Injection molding machine should serve. After heating above their melting point can the chopped blocks z. B. sprayed with a spray gun, e.g. B. to fill in voids.

Another advantageous training provides that the stack of films fen are connected by a stamped seam to form uniform structures. On both sides of the The foil strips fan out the embossed seam. The embossed seam can, depending on the application formation of the structure, run in the longitudinal direction of the strips, or the foils can through several, e.g. B. running in the transverse direction of the strips embossed seams. Several transverse seams contribute to the stability of the structure.

Waste films can also be used to produce the structure according to the invention different sizes can be used. Since the structure by cutting the foils in Stripes and simultaneous joining of the strips to one another are the Dimensions of the starting material also for the production of blocks one size is not important.

According to a particularly preferred embodiment of the invention, the structure in the temperature range around the melting point of the film material used Longitudinal axis twisted. This creates a cord-like structure in which the foils firmly, but at the same time so loosely connected that the structure ela is stish. Such a structure is particularly suitable as an insert for various also elongated shapes, e.g. B. as a sealing cord for window joints.

The process for producing the structure according to the invention is simple feasible and inexpensive. The thermoplastic plastic film pieces or strips are connected to a structure under pressure and / or temperature influence.

The connection can advantageously be made in a rolling or pressing process.

For some applications it may be advantageous if the forming temperature is the  Melting temperature of the plastic films used exceeds. This ensures that the films at least partially fuse. To make the Form according to the invention, different materials can be used where can be achieved through different properties of the structure. In this In this case, it is advisable to coat the higher melting materials with a layer of low surrounding melting materials. At a processing temperature which corresponds to the melting point of the lower melting material, a structure with a loose core surrounded by a homogeneous skin.

The cavities between the Pieces or strips of film can be attached before or after the structure has solidified filled with a filler. The fillers are expediently placed in front of the Solidification used, because they shrink during the solidification process enclose the fillers in the cavities. In particular, it can be act powdery or granular materials such. B. gypsum, cement or rubber powder.

When producing a flat structure, the film pieces or strips are pre-drawn the connection to a railway heaped up. In an advantageous embodiment, is before seen that the film pieces or strips on a support made of film, Ge weave, monofilament, thread or net can exist, filed and with this to one Formations are connected. It can also be a very thin layer of thin Pieces of film on a carrier consisting of a thin film material e.g. B. abandoned by a vacuum perforated roller and with this under pressure and / or Temperature. This creates a new, thin film.

The flat structure can already during its manufacturing process Stamping or rolling with a corrugated structure with different surface patterns and structures are provided.

The flat structure according to the invention can preferably be used as a carrier for needled Pro products are used. Furthermore, use as insulation under tensioning pichen, insulation in the building area or as insulation under external facades possible.

Another embodiment of the method is that the film strips or -filling pieces into a mold before joining. This allows the structure  certain spatial form can be given. This can be a ball, a cuboid or the like be. It is also possible to apply For such as plates, cups, egg containers or pipes. The structure of such Products are uniform, they have a smooth surface and sufficient Stability on. The production of plate-like or web-like structures can either in in a form or in a continuous process of connection under pressure and temperature temperature of the pieces or film of film piled up to form a laterally limited web fen. These structures also have a spatial shape. The thickness of the sheets or Plate is advantageously about 10 mm. These structures are also further order molding processes accessible, such as B. lamination, pressing, calendering, etc.

The film material already in a form or stacked on top of one another can be sintered during or after connection. At train or plate-shaped structures is this process by applying heat in the form of Hot air, radiation or flame treatment possible. The outer, sintered layer ten give the structure high dimensional stability. However, the sintering process must not only restrict to the surface layers, also those inside the structure Foils can be sintered. Consist of the pieces or strips a stretched film material that tends to shrink, this deforms through the three-dimensional heat treatment to form "corner claws" and confiscation of the cross section. This in places strong deformation of the film terials and the "clawing" of the individual pieces of film together contribute significantly better connection of the structure.

A particular advantage of the structure according to the invention is that the film material can either be combined into a homogeneous, new flat structure, or that in spatial structures the connection of the film strips or pieces to each other which is stable and the structure nevertheless has cavities. The loose structure of the Forms gives it a stable shape, high elasticity and due to the air inlet excellent insulation properties.

Another method of producing the film structure is the art Fabric films are stacked on top of each other and by knife or cutting disc in one Block cut into strips. By using hot and cold knives who  which the cut film strips on one side of the structure in section with each other welded direction. Round knives can also be used, each of which second knife is hot. The film blocks can also be along their two side surfaces be connected; for this purpose they are only used with hot knives cut.

According to an advantageous embodiment of the method, the individual can struggle fen cut foils together by hot stamping along a seam be bound. The embossed seam is expediently under pressure and Influence of temperature applied.

The invention is explained in more detail with reference to the following figures. Show it:

Fig. 1 perspective view of a small-cut film block, in which the plastic film strips are connected to one another on one side surface.

Fig. 2 Schematic representation of a section through a spatial structure in the form of a sphere.

Fig. 3 perspective view of a spatial structure in the form of a web.

Fig. 4 A sheet-like structure,

Fig. 5 is a schematic representation of a shrunk film strip.

Fig. 6 is a plan view of a shrunk piece of film.

The structure according to the invention in the form of a film block 1 consists of individual fo strip strips 2 , which are connected to one another on a side surface 3 by welding. In the example shown in Fig. 1 slide block 1 is of a size as z. B. is particularly well suited for feeding an extruder.

As shown in FIG. 2, the spatial, spherical structure 7 produced in a mold consists of loosely connected film strips and pieces 8 , which are surrounded by a skin 9 . The skin 9 is formed by film pieces or strips located in the region of the surface of the ball 7 and connected to one another by partial melting. It holds the loose pieces of film 8 located inside the ball 7 and is so elastic that the inside 8 of the ball 7 can be easily compressed through the skin 9 and relaxed again.

In Fig. 3, a spatial, web or plate-shaped structure 10 is shown, in which the connection of the film material 11 is so loose throughout that 11 voids are present between the individual pieces or strips of film. The cohesion of the structure 10 is outstanding due to partially sintered or interlocked pieces of film. The shape of such pieces of film or strips 5 is shown in more detail in FIGS. 5 and 6. If the pieces of film to be joined are stretched films, they tend to shrink particularly strongly at elevated temperatures. The corners of the film pieces 5 bulge particularly strongly upwards and form "claws" 6 . The individual pieces of film 5 "claw" with their "claws" 6 into other pieces of film, so that the structure produced from such pieces 5 has very good cohesion and high elasticity.

In Fig. 6 a stretched, heat-treated foil strips 4 is shown. The indentation of its cross-section Q is clearly visible. This form of film pieces is particularly favorable for the production of permeable structures.

In FIG. 4, a sheet-like structure 12 is shown in which the foil strips 13 were joined together under pressure and temperature influence. The structure 12 can be viewed as a new film, the connection of the individual film strips to one another is so good that the flat structure can even be given a spatial shape in a further process.

Claims (31)

1. Structure made of thermoplastic waste films, in which in Waste foils in piece or strip form due to pressure and / or tempera influence of the door have been connected to one another. 2. Structure according to claim 1, characterized in that it consists of different Plastic materials exist. 3. Structure according to claim 1 or 2, characterized in that the film mat rial is uneven.   4. A structure according to claim 3, characterized in that the plastic film pieces or strips (4, 5) are stretched film and tend to shrink. 5. Structure according to one of claims 1 to 4, characterized in that the speci fish volume of the finished structure is a maximum of 10x and at least 1.5x as large, like the volume of the untreated raw material. 6. Structure according to one of claims 1 to 5, characterized in that the Ab Fall films other materials, especially reinforcing fibers such as beige glass fibers are mixed. 7. A structure according to claim 1 or 2, characterized in that a homogeneous Ma material structure is present. 8. A structure according to one or more of the preceding claims, characterized in that the structure ( 12 ) is flat. 9. A structure according to one or more of claims 1 to 6, characterized in that the structure ( 10 ) is spatial. 10. A structure according to claim 9, characterized in that at least the film pieces or strips located in the region of the surface of the structure ( 7 ) are connected to one another. 11. A structure according to claim 10, characterized in that a homogeneous skin ( 9 ) is formed by the film strips or pieces lying in the region of the surface. 12. A structure according to one or more of the preceding claims, characterized ge indicates that it is filled with fillers. 13. A structure according to one of claims 1 to 6, characterized in that the foil strips ( 2 ) lie parallel on one another and the structure ( 1 ) is delimited by four side surfaces, the foil strips being welded to one another on at least one side surface ( 3 ). 14. A structure according to one or more of claims 1 to 6, formed by one another the lying strip, which are connected to each other by an embossed seam. 15. A structure according to claim 13 or 14, characterized in that the strips ( 2 ) are the same size. 16. A structure according to claim 13, characterized in that it is mechanically increased temperature around its longitudinal axis into a kind of cord. 17. A method for producing the structure according to one of claims 1 to 16, characterized in that waste films made of thermoplastic materials are shredded into strips or pieces and under pressure and / or temperature influence to form a Ge ( 1 , 7 , 10 , 12 ) will. 18. The method according to claim 17, characterized in that the merged set film strips have different melting temperatures and the Ma material with the higher melting temperature due to the material with the lower Melting temperature is surrounded on at least one side.   19. The method according to any one of claims 17 to 18, characterized in that the Temperature of the manufacturing process above the melting temperature at least is a type of plastic material used. 20. The method according to any one of claims 17 to 19, characterized in that the Formed part is compacted. 21. The method according to claim 17, characterized in that the connection under Pressure and / or temperature influence takes place by rolling or pressing. 22. The method according to any one of claims 17 to 21, characterized in that the Cavities in the structure before or after it is solidified with a filler fill out. 23. The method according to claim 22, characterized in that the filler is small-sized or powdery material such as rubber powder, plaster or cement. 24. The method according to any one of claims 17 to 23, characterized in that the Foil strips or pieces are heaped up before connecting to a web. 25. The method according to claim 24, characterized in that the forming the web Plastic film strips or pieces on a carrier made of film, fabric, monofilaments, Threads or net are filed. 26. The method according to claim 24, characterized in that the carrier from a There is thin polyethylene film and the plastic pieces forming the web  Form a thin layer and consist of a thin film. 27. The method according to any one of claims 17 to 23, characterized in that the Pieces or strips of film can be connected to form a spatial structure. 28. The method according to claim 27, characterized in that the film strips or pieces are filled into a mold before joining. 29. The method according to claim 27 or 28, characterized in that the Pieces or strips of film heat-treated before, during or after joining and be sintered. 30. The method according to any one of claims 17 to 20, characterized in that plastic films or sheets of film are stacked on top of one another and cut into strips ( 2 ) in a block by means of knives or cutting disks and at the same time are welded to one another along at least one cut surface ( 3 ). 31. The method according to any one of claims 17 to 20, characterized in that plastic films or sheets of film are stacked on top of one another and cut into strips ( 5 ) in a block by means of knives or cutting disks and then a seam ( 6 ) is joined together by hot stamping.