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US20160186382A1 - Method and apparatus for the manufacturing of composite material - Google Patents

Method and apparatus for the manufacturing of composite material Download PDF

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Publication number
US20160186382A1
US20160186382A1 US14/890,028 US201414890028A US2016186382A1 US 20160186382 A1 US20160186382 A1 US 20160186382A1 US 201414890028 A US201414890028 A US 201414890028A US 2016186382 A1 US2016186382 A1 US 2016186382A1
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Prior art keywords
substance
mixture
plastic
natural fiber
water
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Inventor
Markku Nikkilä
Timo Ture
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ELASTOPOLI Oy
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ELASTOPOLI Oy
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Publication of US20160186382A1 publication Critical patent/US20160186382A1/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C08L1/02—Cellulose; Modified cellulose
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/06—Paper forming aids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
    • B29B7/38—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/84—Venting or degassing ; Removing liquids, e.g. by evaporating components
    • B29B7/842—Removing liquids in liquid form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/84—Venting or degassing ; Removing liquids, e.g. by evaporating components
    • B29B7/845—Venting, degassing or removing evaporated components in devices with rotary stirrers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/88—Adding charges, i.e. additives
    • B29B7/90—Fillers or reinforcements, e.g. fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/286—Raw material dosing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/76—Venting, drying means; Degassing means
    • B29C48/761—Venting, drying means; Degassing means the vented material being in liquid form
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F5/00—Dryer section of machines for making continuous webs of paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/70—Inorganic compounds forming new compounds in situ, e.g. within the pulp or paper, by chemical reaction with other substances added separately
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/12—Polymer mixtures characterised by other features containing additives being liquid crystalline or anisotropic in the melt

Definitions

  • the invention relates to a method and an apparatus for the manufacturing of composite material according to the preambles of the independent claims.
  • Wood composite is nowadays used e.g. in building and furniture industry by utilizing e.g. extrusion or injection molding.
  • wood- and natural fiber based plastic mixtures by melt-mixing them together e.g. by utilizing an extrusion method.
  • plastic dry wood or natural fiber material and compatibility improving agents are mixed together at a high temperature in which the plastic materials are in a molten state.
  • Dry wood and natural fiber materials are, when dry, strongly hydrogen bonded and horrified, which is why these bonds may not be opened and fibrillized in the “dry process”. Therefore, the reactive surface area on the surface of the fiber remains low and the effect of the compatibilizing agents remains low, and in further processing the products easily reagglomerate.
  • the composite intermediate is formed by wet web formation from a substantially homogeneous liquid mixture that contains natural fibers, plastic particles having a diameter of less than ⁇ 1000 ⁇ m, and an agent that improves compatibility between natural fibers and plastic particles. Liquid is removed from the wet web formed in connection with the wet web formation according to this publication in order to manufacture the composite material into e.g. an intermediate to be stored on a roll or'by using the intermediate in manufacturing an end product after the inter mediate has been crushed.
  • the homogeneous compatibilization of the web which means improved compatibility between natural fibers and plastic, prevents excessive formation of hydrogen bonds in between natural fibers and provides a strong and homogeneous structure for the composite intermediate.
  • the compatibilization improving agent and small plastic particles are obtained evenly in the gaps of the natural fiber network by wet web formation, whereupon the coupling agents are active and the adhesion between natural fibers and plastic particles works well in further processing of the intermediate e.g. when higher temperatures are used in the manufacturing of an end product.
  • quality problems need for expensive cleaning procedures and a decrease in the manufacturing capacity of the process.
  • compositions and conditions wherein the above mentioned wet web formation is not suitable such as e.g. when the cellulose web containing plastic or other needed chemicals is too weak to carry its own weight, due to which it cannot be dried by traditional methods known from paper machines, such as mechanical and/or heating-based drying arrangements used in connection with traditional manufacturing processes based on wet web formation.
  • the reason for a weak cellulose web formation may be e.g.
  • This method is based on the manufactured web carrying itself, which is why in such a method different kinds of solvents, softeners or other like chemicals need to be used, which have to be removed from the manufactured web later on. Therefore, the method is not on the level of environmental friendliness that is required from technique today.
  • the purpose of the method and the apparatus for the manufacturing of composite material according to the present invention is to provide a decisive improvement in terms of the above described problems and thus to substantially upgrade prior art of the field.
  • the method and the apparatus according to the invention are principally characterized by what is presented in the characterizing parts of the independent claims related thereto.
  • the most important benefits gained by the method and the apparatus according to the invention notably include the simplicity and efficiency of functioning and device configurations used when applying the same, whereby the invention enables manufacturing of a composite material to be used e.g. as a so called intermediate product or straight in the manufacturing from compositions of which the manufacturing is not enabled by wet process or the dry mixing of which is too slow for economically efficient production due to the fluffiness of the ingredients.
  • the ability to bond with polymers of dry grinded fibers is also weaker than the same of wet grinded. Thanks to the invention, it is furthermore possible to avoid a problem that comes about with traditional technology, such as with the use of e.g. a drying section, which is due to the softening point of the polymer used in the manufacturing of composite material. If the drying temperature in the manufacturing reaches this softening point, the plastic in the web starts to stick to the drying drums and stops the process.
  • an intermediate product manufactured with wet web formation is slim and wide, e.g. 2 mm thick and 4 m wide as the thickness of the web is usually 0.05-4% of the width of the web.
  • the difference in the thickness and width of the manufactured composite material that is typical to a web does not exist.
  • the wet mixture manufactured in the first phase is a mixture produced with e.g. a pulper, by mixing or with the like technique.
  • different homogenizing apparatuses may also be used partly or fully, with which the size class of a micro- or nano level may be achieved for the particles.
  • different kinds of foaming processes may be utilized in the mixture.
  • the suspension produced by pre-mixing and having a dry-matter concentration of e.g. 0.02-50%, profitably 3-4% is fed into the devolatilization process, in which, especially aided by a sufficiently high temperature and mechanical mixing, e.g. water and other gasifying and volatile matter are removed from the mixture.
  • the softening temperature of the plastics does not restrict the process, but the temperatures may be significantly higher than in drying arrangements like the ones used in paper machines.
  • mechanical mixing causes the plastics, fibers and other possible chemical additives and/or colorants added alongside the mass to form a highly homogenous precompound, in which the dry-matter concentration is e.g. 70-100%, advantageously 70-90%, which precompound is, after water is removed, fed into the last phase that is into the compounding process.
  • the homogeneous precompound speeds up the formation of the mixture in the compounding that is in melt mixing, uses less energy therein and due to the homogeneity makes the forming of chemical bonds between the plastics, fibers and chemicals easier.
  • the composite material manufactured in this way is a mixture, in which the dry-matter concentration is typically e.g. 90-100%, almost 100% at best.
  • the silanes are specifically used as the compatibility improving agent, silanes representing, as an example, liquid substances that may be mixed evenly to the cellulose specifically with the presence of water.
  • the silane forms a covalent bond with the OH group of the cellulose fiber, because the free end of the silane, depending on the silane molecule, is compatible with different types of plastics.
  • the free end of the silane forms a chemical bond with the plastic, which improves the compatibility of the mixture, which furthermore improves the mechanical properties of the manufactured composite.
  • Adding silane to dry cellulose is also possible, but then it may not be as efficiently utilized, because silane is only on the surface of dry cellulose-agglomerates
  • silane may be mixed evenly with water, cellulose, fibers and other chemicals, but the use of the same in an efficient manner is difficult, because typically over 50% of the used water gets removed through the screen in the wet end of the paper machine into a screen trap and from there furthermore as waste water. Due to environmental reasons, reactive chemicals, such as silane, may not enter waste water.
  • adding of silane takes place advantageously in a phase where e.g. running water does not exist anymore, but instead water dissolves as steam. In this case silane remains in the mixture and does not run out with water.
  • the technical advantage therein is that the same technical power is achieved with a lesser amount. Thus, silane does not get into the cleaning apparatuses of waste water, either.
  • cellulose-based so called man-made celluloses such as viscose
  • significantly improve a natural fiber composite but do not form OH bonds that is they do not form webs. If the amount of such fibers in a mixture gets too high, it prevents web formation, whereby especially wet web formation is not an option. Instead, the present invention enables also typically 10-50% of these kinds of fibers to be added into the production mixture.
  • the invention relates first of all to a method for the manufacturing of composite material, which composite material comprises at least a natural fiber substance, such as wood-derived fibers, wood-derived mechanically fiberized fibers, cellulose fiber made from natural fibers and mixtures thereof and/or the like, a plastic based substance, such as plastic particles having a diameter of less than ⁇ 4000 ⁇ m, plastic fibers and/or the like, and a substance improving compatibility between the said natural fiber substance and the said plastic based substance.
  • the composite material is being manufactured by mixing M the said substances with each other, and thereafter by mechanically pressing and/or by drying with heat the formed mixture in order to remove liquid, such as water, therefrom.
  • a wet mixture with 41-99.8% water is being formed at least from a natural fiber substance, a plastic based substance and a compatibility improving agent, whereby in order to manufacture a composite material, having an internal network structure that keeps material together by chemical bonds between the plastic based substance and the natural fiber substance, the wet mixture is being fed into a devolatilization process D, in which substance in liquid form and other gasifying volatile substances or at least a main part thereof are being removed by powerful changes in pressure [V 2 , P 2 ]->[VAtm, PAtm], heat and mechanical mixing, as well as the structure of the natural fiber substance, such as cellulose fiber, being modified if needed.
  • Volatile substances such as water or other decomposition products of cellulose, may easily be removed in the devolatilization process (PAtm, VAtm), because e.g.
  • acetate acid that autocatalytically decomposes hemicellulose and lignin, boils at the temperature of 118° C.
  • cellulose fiber is being utilized, which is hydroscopic by nature, which means that it strongly absorbs water and moisture in itself.
  • plastics are hydrofobic, ergo water repelling, by nature, when mixing plastics and natural fibers with each other, it is important that most of the water is removed before mixing the plastics and natural fibers, because a mixing happening above the boiling point of water weakens the contact between the fibers and plastics and prevents forming of chemical bonds.
  • water remaining in the structure causes porosity in the end product thus weakening its mechanical properties.
  • water degrades, ergo brakes, the structure of certain plastics by cutting the polymer chains shorter.
  • FIG. 1 is presented an exemplary process chart of the general functioning principle of the invention, with reference to which, the wet mixture containing 41-99.8% of water and being made in the previously described manner is fed straight into the devolatilization process D.
  • the wet mixture is being processed in the devolatilization process D in an essentially higher temperature than the softening temperature of the plastic substance therein.
  • a precompound being formed from the wet mixture in the devolatilization process D is being led to a compounding process C, in which the precompound being homogenized in the devolatilization process is being melt mixed.
  • the compatibility improving agent such as silane to be mixed with water or the like
  • the compatibility improving agent is being fed into the wet mixture in a phase of the devolatilization process D, wherein the wet mixture does not contain water in liquid form anymore.
  • silanes and the like chemicals such as siloxanes, titanates, zirconates, isocyanates and different acids, such as maleic and acrylic acid, form a bond in two phases: a hydrogen bond, when the mixture contains water, and on the other hand, after the water has left, aided by heat a covalent bond.
  • the use of these chemicals is not possible in wet web formation, because they disengage to the waste water through the screen.
  • the devolatilization and compounding of the wet mixture is executed using a mixing device, such as an extruder E or like, which enables high pressures (>10 mP) and temperatures (>350° C.) to be used and changed even in a very speedy manner simply by changing the shape of the screw.
  • a mixing device such as an extruder E or like
  • high pressures >10 mP
  • temperatures >350° C.
  • water may be very efficiently removed from the inner structure of the fiber, but also the fiber may be worked into a more advantageous form regarding the melt mixing.
  • these kinds of implementations are about preprocessing of fibers by so called “steam explosion”.
  • the wet mixture is advantageously handled in at least two phases in the devolatilization process D, when in the first phase D 1 the wet mixture and the needed additives are fed into the basic volume V 1 in the mixing device, such as in an extruder E as shown in FIG. 3 .
  • Powerful mixing of the wet mixture is executed in a sufficiently high temperature and steam pressure P 1 (typically >180° C., >1 MPa), wherein during premixing water/steam, fiber substance and plastic substance forma mixture, in which the plastic substance at least partly starts to melt.
  • the needed furthermore raised pressure P 2 is achieved in the manner described above advantageously by decreasing the basic volume V 1 in the extruder E, being used as the mixing device, between a screw E 1 and a wall thereof into a decreased volume V 2 by changing the shape of the screw that is its pitch.
  • the natural fiber used in the method according to the invention may, as described above, be e.g. pure cellulose fiber.
  • a part of the natural fiber may be microfibrillated cellulose fibers and/or nanocellulose fibers.
  • lignin free natural fibers it is also possible to use colorants in the manufacturing of the composite in such a way that the desired color remains optimally also in the end product.
  • delignified natural fibers it is also possible to use delignified natural fibers.
  • Fibers may be used, which are soaked before the process, and especially so called never dried-forms, which come straight from the pulping process or the like process. Fibers may also be functionalized, in which case there is a group formed on the surface thereof that has a better compatibility with the chosen plastic.
  • the amount of plastic of the dry composite intermediate product may be e.g. 10-90 weight percent, advantageously 30-60 weight percent.
  • the plastic is advantageously arranged in particle form, e.g. as micro granulates or powder, wherein the size of the particles may vary differing from the typical under ⁇ 4000 ⁇ m size of e.g. granulates, flakes or other polymers to under ⁇ 1000 ⁇ m.
  • the diameter of the plastic particles may furthermore advantageously be e.g. under ⁇ 500 ⁇ m, because small plastic particles drift between the fibers thus strengthening the structure of the intermediate composite product being formed as well as therefore also the structure of the end product.
  • a plastic substance formed of small size particles has a larger specific surface area.
  • the shape of the plastic particles may furthermore of any type, e.g. cubelike, elliptical, fiberlike or slatelike.
  • plastic fibers that may melt,, not melt or melt partly in the compounding process while forming chemical bonds with plastic or cellulose fiber.
  • plastic fibers may melt, not melt or melt partly in the compounding process while forming chemical bonds with plastic or cellulose fiber.
  • PP-, PLA- or PET-fibers as well as fibers that are bicomponent by structure, in which the outer surface is reactive that can be e.g. maleicanhydride grafted olefin plastic or the like.
  • thermoplastic polymer advantageously thermoplastic.
  • the plastic material used may be e.g. one of the following: polyethylene (PE), polypropylene (PP), ethylene/propylene-copolymer, polycarbonate (PC), polystyrene (PS), polyethylene terephthalate (PET), polyactic acid (PLA), polyhydroxybutyrate, acrylic nitrile/butadiene/styrene copolymer (ABS), styrene/acrylic nitrile copolymer (SAN), polyoxometalate (POM), biodegradable thermoplastic, starch-based thermoplastic, their derivatives and their mixtures.
  • PE polyethylene
  • PP polypropylene
  • PP ethylene/propylene-copolymer
  • PC polycarbonate
  • PS polystyrene
  • PET polyethylene terephthalate
  • PLA polyactic acid
  • ABS acrylic nitrile/butadiene/styrene copolymer
  • ABS
  • plastic matter may be added into the process in the middle of its own polymerization process, if that is seen as advantageous for the manufacture of the composite.
  • plastic matter may be mentioned among others unfinished forms of PLA or biobased plastics made from carbon dioxide.
  • the wet mixture used in the method according to the invention may be a water based mixture that contains water, natural fibers, plastic particles and a compatibility improving agent.
  • the wet mixture may be in the form of a solution, dispersion, suspension or the like.
  • a compatibility improving agent is an agent that improves the adhesion between plastic and natural fibers that is compatible and/or reactive with the reactive groups in plastic and natural fibers. Therefore, in the compatibility improving agent, there may be at least one reactive group that is compatible and/or reactive with the reactive groups of cellulose that is a hydrophilic substance and polymer that is a hydrophobic substance.
  • the compatibility improving agent may also be e.g. an anhydride of maleic acid, a maleic acid grafted polymer, polybutadiene, polymethyl methacrylate (PMMA), EVA, a derivative of previously mentioned substances or a mixture of the same.
  • the compatibility improving polymers may furthermore be copolymers that contain groups that are compatible and/or reactive with hydrophilic natural fibers as well as groups that are compatible and/or reactive with hydrophobic plastics. Also other molecules that have the like qualities may be used in the compatibilization.
  • the compatibility improving agent may be in a powderlike, liquid and/or polymerlike form, the quantity of the same being typically under 5 weight percent or in some embodiments furthermore under 3 weight percent of dry matter.
  • the composite material to be manufactured with the method may contain one or more additives, such as starch, fillers, surface reactive materials, retention materials, dispergation materials, foam inhibitors and mixtures thereof.
  • additives such as starch, fillers, surface reactive materials, retention materials, dispergation materials, foam inhibitors and mixtures thereof.
  • all ingredients needed may be added into the liquid manufacturing mixture, wherein the intermediate composite product contains ingredients needed in the applications of further processing or end product embodiments immediately after compounding.
  • the wet mixture may be predried K by removing liquid therefrom by e.g. squeezing and/or drying, which may be executed in manners known from the field of manufacturing e.g. os paper pulp slurry or cellulose pulp slurry by using any apparatus components known as such in the field.
  • the mass produced with e.g. a grinder or a pulper is being led into a mixing device M, in which other chemistry to be added into the wet mixture is added.
  • Dry matter concentration in the mixing device may be 0.02-50%, advantageously 3-4%.
  • dry matter concentration may be typically e.g. 30-50%, advantageously 50-70%.
  • the dry matter concentration is 90-100%, almost 100% at best.
  • the invention relates on the other hand to an apparatus for the manufacturing of composite material, which composite material comprises at least a natural fiber substance, such as wood-derived fibers, wood-derived mechanically fiberized fibers, cellulose fiber made from natural fibers and mixtures thereof and/or the like, a plastic based substance, such as plastic particles having a diameter of less than ⁇ 4000 ⁇ m, plastic fibers and/or the like, and a substance improving compatibility between the said natural fiber substance and the said plastic based substance.
  • the apparatus used in the manufacturing of the composite material comprises, e.g. with reference to the exemplary process charts shown in FIGS.
  • the apparatus comprises a devolatilization arrangement D in order to remove substance in liquid form and other gasifying volatile substances or at least a main part thereof by powerful changes in pressure [V 2 , P 2 ]->[VAtm, PAtm], heat and mechanical mixing, as well as the structure of the natural fiber substance, such as cellulose fiber, getting modified if needed advantageously by utilizing a higher temperature than the melting point of the plastic in the wet mixture.
  • the apparatus comprises furthermore a compounding arrangement C in order to melt mix the homogenized precompound having been achieved in the devolatilization arrangement D.
  • the apparatus comprises especially with reference to FIG. 2 mechanical predrying means K, such as a web and suction box arrangement, a screw dryer and/or the like.
  • mechanical predrying means K such as a web and suction box arrangement, a screw dryer and/or the like.
  • the apparatus comprises a mixing device, such as an extruder E or like, functioning as a devolatilization arrangement D, in which the devolatilization process is carried out by changing the shape of a screw E 1 in the extruder E in order to decrease the basic volume V 1 between a screw E 1 and a wall thereof into a decreased volume V 2 .
  • a mixing device such as an extruder E or like, functioning as a devolatilization arrangement D, in which the devolatilization process is carried out by changing the shape of a screw E 1 in the extruder E in order to decrease the basic volume V 1 between a screw E 1 and a wall thereof into a decreased volume V 2 .
  • a releasing zone that lets the devolatized mixture into a free volume preferably in an atmospheric pressure PAtm, Vatm, in order to change the water in the mixture rapidly into steam and for disengaging the same from the mixture, in order to remove separated steam in a controlled manner through an outlet in the releasing zone and through the atmospheric ventilation of the apparatus.
  • the extruder E comprises furthermore advantageously a compounding zone C in order to mix the manufactured plastic-fiber mixture and to lead the same for further processing thereof.
  • the invention is not limited to the embodiments shown or described above, but instead, on the grounds of the basic principles of the invention, it may be varied in various ways depending on e.g. desired properties of the composite material being manufactured at any given time etc. Therefore in the process according to the invention, it is possible to use any substitutive liquid mediums instead of water and, respectively, instead of silane, any other suitable compatibility improving agent.
  • natural fiber used in the invention may be recycled fiber or reuse fiber. Therefore natural fiber may be e.g. wood-, sisal-, jute-, hemp-, flax-, cotton-, straw-fiber or fiber from another annual plant and their mixtures.
  • the natural fiber may be mechanically dried fiber, dissolving pulp fiber, sulphite pulp fiber, sulphate pulp fiber or viscose fiber.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Materials Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Reinforced Plastic Materials (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Nonwoven Fabrics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
US14/890,028 2013-05-08 2014-05-05 Method and apparatus for the manufacturing of composite material Abandoned US20160186382A1 (en)

Applications Claiming Priority (3)

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FI20135482 2013-05-08
FI20135482 2013-05-08
PCT/FI2014/050326 WO2014181036A1 (en) 2013-05-08 2014-05-05 Method and apparatus for the manufacturing of composite material

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EP (1) EP2994279B1 (fi)
KR (1) KR20160006725A (fi)
CN (1) CN105263683A (fi)
FI (1) FI2994279T3 (fi)
WO (1) WO2014181036A1 (fi)

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CN110396247A (zh) * 2018-04-24 2019-11-01 佛吉亚内饰工业公司 复合材料及其制备方法和使用以及车辆部件及其制备方法
US11084907B2 (en) * 2017-07-05 2021-08-10 Tuskegee University Nanocellulosic compositions
US20230054285A1 (en) * 2020-02-11 2023-02-23 Ningbo Institute Of Materials Technology And Engineering, Chinese Academy Of Scieinces Supercritical fluid injection foaming polylactide foam material and preparation method therefor
CN117945114A (zh) * 2024-03-25 2024-04-30 江苏君华特种高分子材料股份有限公司 一种peek板用物料上料输送系统及其工艺方法
JP2024161256A (ja) * 2017-01-18 2024-11-15 パナソニックホールディングス株式会社 ペレットおよび成形体

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CN104629075A (zh) * 2015-01-21 2015-05-20 南京瑞柯徕姆环保科技有限公司 一种柔性喷磨材料制备方法
US11148974B2 (en) * 2016-09-09 2021-10-19 Forta, Llc Enhancement of reinforcing fibers, their applications, and methods of making same
CN115652688A (zh) * 2022-10-31 2023-01-31 西昌学院 一种土豆纸的生产工艺方法、装置、电子设备及存储介质

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CN106976192A (zh) * 2017-03-21 2017-07-25 江苏肯帝亚木业有限公司 木质纤维热改性木塑复合材料设备及木塑材料的制备工艺
US11084907B2 (en) * 2017-07-05 2021-08-10 Tuskegee University Nanocellulosic compositions
CN110396247A (zh) * 2018-04-24 2019-11-01 佛吉亚内饰工业公司 复合材料及其制备方法和使用以及车辆部件及其制备方法
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US20230054285A1 (en) * 2020-02-11 2023-02-23 Ningbo Institute Of Materials Technology And Engineering, Chinese Academy Of Scieinces Supercritical fluid injection foaming polylactide foam material and preparation method therefor
US12202179B2 (en) * 2020-02-11 2025-01-21 Ningbo Institute Of Materials Technology And Engineering, Chinese Academy Of Sciences Supercritical fluid injection foaming polylactide foam material and preparation method therefor
CN117945114A (zh) * 2024-03-25 2024-04-30 江苏君华特种高分子材料股份有限公司 一种peek板用物料上料输送系统及其工艺方法

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FI2994279T3 (fi) 2024-02-14
EP2994279A4 (en) 2017-01-25
EP2994279A1 (en) 2016-03-16
CN105263683A (zh) 2016-01-20
WO2014181036A1 (en) 2014-11-13
EP2994279B1 (en) 2023-11-15
KR20160006725A (ko) 2016-01-19

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