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WO2014033725A1 - Polypropylene composite shuttering board - Google Patents

Polypropylene composite shuttering board Download PDF

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Publication number
WO2014033725A1
WO2014033725A1 PCT/IN2013/000223 IN2013000223W WO2014033725A1 WO 2014033725 A1 WO2014033725 A1 WO 2014033725A1 IN 2013000223 W IN2013000223 W IN 2013000223W WO 2014033725 A1 WO2014033725 A1 WO 2014033725A1
Authority
WO
WIPO (PCT)
Prior art keywords
board
sheets
polypropylene
layers
light weight
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/IN2013/000223
Other languages
French (fr)
Inventor
Anupam Premchand LUNAVAT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ZEP INTERNATIONAL Ltd
Original Assignee
ZEP INTERNATIONAL Ltd
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 ZEP INTERNATIONAL Ltd filed Critical ZEP INTERNATIONAL Ltd
Publication of WO2014033725A1 publication Critical patent/WO2014033725A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • B29D24/005—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having joined ribs, e.g. honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/02—Forming boards or similar elements
    • E04G9/05—Forming boards or similar elements the form surface being of plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/242—All polymers belonging to those covered by group B32B27/32
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles

Definitions

  • the present invention relates to composite boards used in civil engineering applications. More particularly, the present invention relates to a novel light weight composite shuttering board with unique synergistic combination of polypropylene boards and polypropylene based processed products i.e. self-reinforced polypropylene sheets.
  • Shuttering boards are one of the most important needs of civil construction industry. In construction work, shuttering boards are used to prepare concreting formwork. The formwork is a process of maintaining the poured concrete in predefined shape. Products used for shuttering boards are made from plywood, metal sheets as well as plastics and composites.
  • Kitply Shuttering boards made of plywood have to be thick for the strength requirements in wet conditions, the thickness being typically 18 mm, and can undergo decaying due to wood content. They are heavy to transport and have limited repeated usage.
  • Shuttering boards produced by Wall-Ties & Forms which are made from metal, are energy intensive for manufacturing. They have to be protected against corrosion and are heavy, hence energy intensive for transportation.
  • shuttering boards prepared from plastics have also been made available. They are prepared from different plastics materials and manufactured by different processes. Some of the examples of such shuttering boards are as follows: 1) Pladeck manufacture and supply PVC based boards with typical hollow rib structure, developed for Concrete moulding in columns, floors, joists and all kind of concrete mouldings.
  • Triplex is a 3-layer polypropylene composite made up of dimpled sheet sandwiched between two smooth sheets in a proprietary manufacturing process.
  • Kayserberg Plastics also provides polypropylene " based sheets for many applications including shuttering and permanent formwork.
  • Akylux® sheets made by Kayserberg are projected to be used for such applications and are claimed to have many advantages both in terms of ease of use on site, and of rigidity.
  • Nidaplast is a polypropylene honeycomb structures also claimed to be useful in many civil engineering applications, though shuttering boards are not specifically mentioned.
  • PlasPly consists of a plywood core with non-stick thermoplastic overlay edge fused all round with a solid thermoplastic edging.
  • Another product of Uber, TuffPly is metal reinforced, engineered plastic composite board which claims to have weight of 2/3 rd of conventional plywood with up to 10 times stiffness.
  • Alkus panels are also used for shuttering applications.
  • the Alkus-sheet is a patented plastic-composite-construction.
  • the so called Sandwich-panel solely consists of polypropylene and aluminium or fibres.
  • WO2008130329 discloses a composite board comprising five layers of material which are bonded in sequential fashion and the resulting board is laminated.
  • the first, third and fifth layer is a hard plastic material set which includes polyethylene, polyvinyl chlorate or polypropylene.
  • the third layer is formed in either solid or foam state which can be recycled.
  • the second and fourth layer is a metal sheet having substantially high strength to weight ratio.
  • composite board of the present invention is distinct by the fact that it consists of single type of plastic material i.e. polypropylene as opposed to the prior arts which use multiple polymeric materials as well as metal components.
  • the resulting boards have adequate stiffness, light weight and much better recyclability since it is an all Polypropylene structure.
  • the present invention discloses a novel composite board having combination of a polypropylene board and self-reinforced polypropylene sheets.
  • the polypropylene board and self-reinforced polypropylene sheets are bonded simultaneously and the resulting product is laminated.
  • polypropylene board is thermally bonded with self-reinforced polypropylene sheets on both sides to form the composite board.
  • the composite board of the present invention is prepared by a single step manufacturing process of co-extrusion followed by in-line thermal lamination.
  • Fig. 1 illustrates base hollow multilayer polypropylene board.
  • Fig.2 illustrates light weight composite board.
  • the present invention discloses a light weight composite board comprising a three layer polypropylene (PP) based hollow honey-comb type sandwich board and plurality of self- reinforced polypropylene (SRPP) sheets; wherein said hollow PP board and said SRPP sheets are bonded in-line by thermal adhesion.
  • the PP board is hollow and multi-layered.
  • the SRPP sheets are prepared by compacting multiple layers of woven mats prepared from stretched tapes made up of PP. During compaction thin PP sheets may be integrated between and top of the woven mats.
  • the multilayered hollow PP board is prepared by hot joining of two plane sheets with a middle layer of a cylindrical thermoformed structures which is produced by casting the sheet on a roller having cylindrical depressions. The vacuum in every depression helps to form the cylindrical structures.
  • Every layer of the three layers described above consists of three layers and are produced through co-extrusion dies attached to two extruders.
  • the outer layers are of PP random copolymer having the heat seal initiation temperature in a particular range i.e. around 105° C.
  • the middle layer is a proprietary mixture of PP homopolymer, PP impact copolymer, filled PP compound and additives to facilitate the process.
  • the SRPP based sheets are prepared by compacting multiple layers of woven mats prepared from stretched tapes made from either single layer of PP homopolymer or three layers of PP, outer layers being of random PP to facilitate the fusion and middle one being of PP homopolymer.
  • the multilayer compacted or surface fused woven mats, with or without a film acting as hot melt adhesive, may be coated / laminated with a thin PP sheet for providing colour, smooth surface or design pattern.
  • the SRPP based sheets available in roll form are integrated in the process by hot lamination. Both the upper and lower layers come in contact with hot surfaces of the PP sheets above the temperatures at which completion of crystallization takes place for the PP random copolymers used in the outer layers.
  • Fig. 1 illustrates the hollow multilayered PP board.
  • the PP board consists of three layers made up of polypropylene types. Every layer further consists of three layers, the out layers in each being heat sealable PP random copolymer and the inner layer being a proprietary mix of PP homopolymer, PP block-copolymer (impact copolymer) and filled PP and additives. While joining the outer layers of PP-RCP in each of the three layers ensure in-process adhesion.
  • Fig. 2 which is a preferred embodiment, illustrates the composite board of the present invention as a final product.
  • the composite board may be a shuttering board in the preferred embodiment.
  • the shuttering board consists of PP board sandwitched between two SPvPP sheets.
  • the SRPP sheets are thermally bonded with the PP board on both sides.
  • Shuttering boards are in-process integrated with SRPP based sheets to enhance the strength and stiffness of the shuttering boards.
  • the shuttering board of the present invention has following physical properties:
  • the shuttering board of the present invention is a hollow composite board made up of different types and forms of polypropylene. Due to sole use of polypropylene in the composition of shuttering board, the resulting product is ideal for recycling.
  • the hollow structures increase the stiffness yet maintains lower weight; hence light weight shuttering board of the present invention has high stiffness at low weight.
  • Shuttering board of density about 0.4 g/cm 3 renders stiffness similar to polypropylene of density 0.9 g/cm 3 .
  • the composite board is laminated in-line, making it easy to manufacture.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)

Description

"POLYPROPYLENE COMPOSITE SHUTTERING BOARD"
FIELD OF INVENTION:
The present invention relates to composite boards used in civil engineering applications. More particularly, the present invention relates to a novel light weight composite shuttering board with unique synergistic combination of polypropylene boards and polypropylene based processed products i.e. self-reinforced polypropylene sheets.
BACKGROUND & PRIOR ART:
Shuttering boards are one of the most important needs of civil construction industry. In construction work, shuttering boards are used to prepare concreting formwork. The formwork is a process of maintaining the poured concrete in predefined shape. Products used for shuttering boards are made from plywood, metal sheets as well as plastics and composites.
There are several shuttering boards in market. Kitply Shuttering boards made of plywood have to be thick for the strength requirements in wet conditions, the thickness being typically 18 mm, and can undergo decaying due to wood content. They are heavy to transport and have limited repeated usage.
Shuttering boards produced by Wall-Ties & Forms, which are made from metal, are energy intensive for manufacturing. They have to be protected against corrosion and are heavy, hence energy intensive for transportation.
Nowadays, shuttering boards prepared from plastics have also been made available. They are prepared from different plastics materials and manufactured by different processes. Some of the examples of such shuttering boards are as follows: 1) Pladeck manufacture and supply PVC based boards with typical hollow rib structure, developed for Concrete moulding in columns, floors, joists and all kind of concrete mouldings.
2) TRIPLEX panels are also projected to be used for many civil engineering applications. Triplex is a 3-layer polypropylene composite made up of dimpled sheet sandwiched between two smooth sheets in a proprietary manufacturing process.
3) Kayserberg Plastics also provides polypropylene" based sheets for many applications including shuttering and permanent formwork. Akylux® sheets made by Kayserberg are projected to be used for such applications and are claimed to have many advantages both in terms of ease of use on site, and of rigidity.
4) Nidaplast is a polypropylene honeycomb structures also claimed to be useful in many civil engineering applications, though shuttering boards are not specifically mentioned.
5) Uber Engineering, Singapore have a product PlasPly boards. PlasPly consists of a plywood core with non-stick thermoplastic overlay edge fused all round with a solid thermoplastic edging. Another product of Uber, TuffPly is metal reinforced, engineered plastic composite board which claims to have weight of 2/3rd of conventional plywood with up to 10 times stiffness.
6) Alkus panels are also used for shuttering applications. The Alkus-sheet is a patented plastic-composite-construction. The so called Sandwich-panel solely consists of polypropylene and aluminium or fibres.
WO2008130329 discloses a composite board comprising five layers of material which are bonded in sequential fashion and the resulting board is laminated. The first, third and fifth layer is a hard plastic material set which includes polyethylene, polyvinyl chlorate or polypropylene. The third layer is formed in either solid or foam state which can be recycled. The second and fourth layer is a metal sheet having substantially high strength to weight ratio.
However, composite board of the present invention is distinct by the fact that it consists of single type of plastic material i.e. polypropylene as opposed to the prior arts which use multiple polymeric materials as well as metal components. The resulting boards have adequate stiffness, light weight and much better recyclability since it is an all Polypropylene structure.
SUMMARY OF INVENTION:
The present invention discloses a novel composite board having combination of a polypropylene board and self-reinforced polypropylene sheets. The polypropylene board and self-reinforced polypropylene sheets are bonded simultaneously and the resulting product is laminated.
In an aspect, polypropylene board is thermally bonded with self-reinforced polypropylene sheets on both sides to form the composite board. The composite board of the present invention is prepared by a single step manufacturing process of co-extrusion followed by in-line thermal lamination.
Brief Description:
Fig. 1 illustrates base hollow multilayer polypropylene board.
Fig.2 illustrates light weight composite board.
Detailed Description:
The present invention discloses a light weight composite board comprising a three layer polypropylene (PP) based hollow honey-comb type sandwich board and plurality of self- reinforced polypropylene (SRPP) sheets; wherein said hollow PP board and said SRPP sheets are bonded in-line by thermal adhesion. In accordance with the present invention, the PP board is hollow and multi-layered. The SRPP sheets are prepared by compacting multiple layers of woven mats prepared from stretched tapes made up of PP. During compaction thin PP sheets may be integrated between and top of the woven mats.
The multilayered hollow PP board is prepared by hot joining of two plane sheets with a middle layer of a cylindrical thermoformed structures which is produced by casting the sheet on a roller having cylindrical depressions. The vacuum in every depression helps to form the cylindrical structures. Every layer of the three layers described above consists of three layers and are produced through co-extrusion dies attached to two extruders. In each of the three layers the outer layers are of PP random copolymer having the heat seal initiation temperature in a particular range i.e. around 105° C. The middle layer is a proprietary mixture of PP homopolymer, PP impact copolymer, filled PP compound and additives to facilitate the process.
The SRPP based sheets are prepared by compacting multiple layers of woven mats prepared from stretched tapes made from either single layer of PP homopolymer or three layers of PP, outer layers being of random PP to facilitate the fusion and middle one being of PP homopolymer. The multilayer compacted or surface fused woven mats, with or without a film acting as hot melt adhesive, may be coated / laminated with a thin PP sheet for providing colour, smooth surface or design pattern.
The SRPP based sheets available in roll form are integrated in the process by hot lamination. Both the upper and lower layers come in contact with hot surfaces of the PP sheets above the temperatures at which completion of crystallization takes place for the PP random copolymers used in the outer layers.
The present invention can be understood with the help of accompanying figures.
Fig. 1 illustrates the hollow multilayered PP board. In a preferred embodiment, the PP board consists of three layers made up of polypropylene types. Every layer further consists of three layers, the out layers in each being heat sealable PP random copolymer and the inner layer being a proprietary mix of PP homopolymer, PP block-copolymer (impact copolymer) and filled PP and additives. While joining the outer layers of PP-RCP in each of the three layers ensure in-process adhesion.
Fig. 2, which is a preferred embodiment, illustrates the composite board of the present invention as a final product. The composite board may be a shuttering board in the preferred embodiment. The shuttering board consists of PP board sandwitched between two SPvPP sheets. The SRPP sheets are thermally bonded with the PP board on both sides. Shuttering boards are in-process integrated with SRPP based sheets to enhance the strength and stiffness of the shuttering boards.
The shuttering board of the present invention has following physical properties:
Length 2440 mm - Can vary
Width 1220 mm maximum
Thickness 9.5 mm to 15 mm
Surface density 4000 to 5000
grams/meter2 (GSM)
Density ~ 0.4 grams / cm3
Hardness Shore 65 - 75
Tensile Strength at Yield (ASTM 12 - 18 MPa
D638)
Elongation at Yield (ASTM 4 - 8 %
D638)
Tensile Modulus (ASTM D638) 700 - 900 MPa
Flexural Strength (ASTM D790) 12.5 - 16.5 MPa
Flexural Modulus (ASTM D790) 1 100 - 1600 MPa
Compressivity (ASTM D695) 4 - 8 MPa Although the standard dimensions of shuttering board are same as the plywood i.e. 8' X 4' (2440 mm X 1220 mm), higher lengths can be provided by keeping width same.
The shuttering board of the present invention, as described above, is a hollow composite board made up of different types and forms of polypropylene. Due to sole use of polypropylene in the composition of shuttering board, the resulting product is ideal for recycling. The hollow structures increase the stiffness yet maintains lower weight; hence light weight shuttering board of the present invention has high stiffness at low weight. Shuttering board of density about 0.4 g/cm3 renders stiffness similar to polypropylene of density 0.9 g/cm3.
Advantages:
1) Since only the polypropylene is used to prepare the composite board, the lightweight product is obtained. The hollow nature of the product provides the required stiffness along at lower weight.
2) The composite board is laminated in-line, making it easy to manufacture.
3) The resulting product is easy to recycle since single polymer is used.
4) The properties of composite boards do not deteriorate on keeping in contact with water, where as properties of plywood do deteriorate on keeping in contact with water.
5) The resulting composite board is sound resistant as well as heat resistant.

Claims

We claim,
1. A light weight composite board comprising a three layer polypropylene (PP) based hollow honey-comb type sandwich board and plurality of self-reinforced polypropylene (SRPP) sheets; wherein said hollow PP board and said SRPP sheets are bonded in-line by thermal adhesion.
2. The light weight composite board as claimed in claim 1 ; wherein said PP board comprises of three layers of polypropylene polymers.
3. The light weight composite board as claimed in claim 2; wherein each layer of polypropylene polymers comprises three layers, outer layers being PP random copolymers and middle layer being a mixture of PP homopolymer, PP impact copolymer, filled PP compound and additives.
4. The light weight composite board as claimed in claim 1 ; wherein said SRPP sheets are prepared by compacting one or multiple layers of woven fabric mats made from highly oriented PP tapes and one or more layers of thin PP sheets.
5. The light weight composite board as claimed in claim 4; wherein multilayer compacted woven mats are coated / laminated with a thin PP sheet.
6. The light weight composite board as claimed in claim 1 ; wherein said PP board is thermally bonded with SRPP sheets on both sides.
PCT/IN2013/000223 2012-08-31 2013-04-03 Polypropylene composite shuttering board Ceased WO2014033725A1 (en)

Applications Claiming Priority (2)

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IN2538/MUM/2012 2012-08-31
IN2538MU2012 2012-08-31

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015192948A1 (en) * 2014-06-19 2015-12-23 Imballaggi Protettivi S.R.L. Honeycomb sandwich sheet or panel, based on thermoplastic polypropylene
CN105172277A (en) * 2015-10-30 2015-12-23 成都同明新材料技术有限公司 Self-reinforcing polypropylene composite panel
EP3098629A1 (en) 2015-05-27 2016-11-30 ZKW Group GmbH Composite assembly for covering a flat luminaire

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1787790A1 (en) * 2005-11-21 2007-05-23 Lankhorst Indutech B.V. Method for forming a thermoplastic composite
WO2011001174A1 (en) * 2009-06-30 2011-01-06 Omnia (Cs) Limited Table having a central cellular honeycomb structure thermally fused in a sandwich configuration between two fibre-reinforced polypropylene face sheets

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1787790A1 (en) * 2005-11-21 2007-05-23 Lankhorst Indutech B.V. Method for forming a thermoplastic composite
WO2011001174A1 (en) * 2009-06-30 2011-01-06 Omnia (Cs) Limited Table having a central cellular honeycomb structure thermally fused in a sandwich configuration between two fibre-reinforced polypropylene face sheets

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015192948A1 (en) * 2014-06-19 2015-12-23 Imballaggi Protettivi S.R.L. Honeycomb sandwich sheet or panel, based on thermoplastic polypropylene
US10596777B2 (en) 2014-06-19 2020-03-24 Imballaggi Protettivi S.R.L. Honeycomb sandwich panel
EP3098629A1 (en) 2015-05-27 2016-11-30 ZKW Group GmbH Composite assembly for covering a flat luminaire
CN105172277A (en) * 2015-10-30 2015-12-23 成都同明新材料技术有限公司 Self-reinforcing polypropylene composite panel

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