WO1999051425A1 - Foamed polymer-fiber composite - Google Patents
Foamed polymer-fiber composite Download PDFInfo
- Publication number
- WO1999051425A1 WO1999051425A1 PCT/US1999/007312 US9907312W WO9951425A1 WO 1999051425 A1 WO1999051425 A1 WO 1999051425A1 US 9907312 W US9907312 W US 9907312W WO 9951425 A1 WO9951425 A1 WO 9951425A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composite
- building material
- blowing agent
- wood
- fiber
- Prior art date
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 78
- 229920005594 polymer fiber Polymers 0.000 title claims abstract description 14
- 239000004566 building material Substances 0.000 claims abstract description 33
- 239000000835 fiber Substances 0.000 claims abstract description 18
- 239000004604 Blowing Agent Substances 0.000 claims abstract description 15
- 229920005989 resin Polymers 0.000 claims abstract description 14
- 239000011347 resin Substances 0.000 claims abstract description 14
- 230000005484 gravity Effects 0.000 claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 11
- 238000001125 extrusion Methods 0.000 claims abstract description 9
- 239000002243 precursor Substances 0.000 claims abstract description 9
- 239000000203 mixture Substances 0.000 claims description 28
- 239000002023 wood Substances 0.000 claims description 28
- 239000004800 polyvinyl chloride Substances 0.000 claims description 14
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 14
- 239000002666 chemical blowing agent Substances 0.000 claims description 13
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 11
- 235000013312 flour Nutrition 0.000 claims description 10
- 239000003607 modifier Substances 0.000 claims description 10
- 229920000642 polymer Polymers 0.000 claims description 7
- 239000007787 solid Substances 0.000 claims description 7
- 229920002522 Wood fibre Polymers 0.000 claims description 6
- 230000000996 additive effect Effects 0.000 claims description 6
- 239000000155 melt Substances 0.000 claims description 6
- 239000002025 wood fiber Substances 0.000 claims description 6
- 239000002952 polymeric resin Substances 0.000 claims description 5
- 229920003002 synthetic resin Polymers 0.000 claims description 5
- 239000000049 pigment Substances 0.000 claims description 4
- 239000000975 dye Substances 0.000 claims description 3
- 239000010881 fly ash Substances 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- 238000013329 compounding Methods 0.000 claims 2
- 238000003856 thermoforming Methods 0.000 abstract description 2
- 239000007789 gas Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- -1 Polyethylene Polymers 0.000 description 7
- 206010042602 Supraventricular extrasystoles Diseases 0.000 description 7
- 239000000178 monomer Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 6
- 229920001169 thermoplastic Polymers 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 150000001875 compounds Chemical class 0.000 description 5
- 239000004416 thermosoftening plastic Substances 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 239000011121 hardwood Substances 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 3
- 210000004027 cell Anatomy 0.000 description 3
- 238000005660 chlorination reaction Methods 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 239000004088 foaming agent Substances 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 239000004014 plasticizer Substances 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Natural products CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 2
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 239000011122 softwood Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- CZGWDPMDAIPURF-UHFFFAOYSA-N (4,6-dihydrazinyl-1,3,5-triazin-2-yl)hydrazine Chemical compound NNC1=NC(NN)=NC(NN)=N1 CZGWDPMDAIPURF-UHFFFAOYSA-N 0.000 description 1
- LGXVIGDEPROXKC-UHFFFAOYSA-N 1,1-dichloroethene Chemical compound ClC(Cl)=C LGXVIGDEPROXKC-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- MARUHZGHZWCEQU-UHFFFAOYSA-N 5-phenyl-2h-tetrazole Chemical compound C1=CC=CC=C1C1=NNN=N1 MARUHZGHZWCEQU-UHFFFAOYSA-N 0.000 description 1
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-M Bicarbonate Chemical class OC([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-M 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- MWRWFPQBGSZWNV-UHFFFAOYSA-N Dinitrosopentamethylenetetramine Chemical compound C1N2CN(N=O)CN1CN(N=O)C2 MWRWFPQBGSZWNV-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 1
- 239000004609 Impact Modifier Substances 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 229920000459 Nitrile rubber Polymers 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 244000082204 Phyllostachys viridis Species 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004614 Process Aid Substances 0.000 description 1
- 240000000111 Saccharum officinarum Species 0.000 description 1
- 235000007201 Saccharum officinarum Nutrition 0.000 description 1
- UIIMBOGNXHQVGW-DEQYMQKBSA-M Sodium bicarbonate-14C Chemical compound [Na+].O[14C]([O-])=O UIIMBOGNXHQVGW-DEQYMQKBSA-M 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 230000006750 UV protection Effects 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- LDVAXRWOGUHMKM-UHFFFAOYSA-N benzene-1,3-disulfonohydrazide Chemical compound NNS(=O)(=O)C1=CC=CC(S(=O)(=O)NN)=C1 LDVAXRWOGUHMKM-UHFFFAOYSA-N 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- OHJMTUPIZMNBFR-UHFFFAOYSA-N biuret Chemical compound NC(=O)NC(N)=O OHJMTUPIZMNBFR-UHFFFAOYSA-N 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- QXDMQSPYEZFLGF-UHFFFAOYSA-L calcium oxalate Chemical compound [Ca+2].[O-]C(=O)C([O-])=O QXDMQSPYEZFLGF-UHFFFAOYSA-L 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 150000007942 carboxylates Chemical class 0.000 description 1
- 230000010261 cell growth Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 210000003850 cellular structure Anatomy 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000003623 enhancer Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 1
- 238000005562 fading Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229920000578 graft copolymer Polymers 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 1
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 229920005684 linear copolymer Polymers 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229940102838 methylmethacrylate Drugs 0.000 description 1
- 229910003455 mixed metal oxide Inorganic materials 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- WSDQIHATCCOMLH-UHFFFAOYSA-N phenyl n-(3,5-dichlorophenyl)carbamate Chemical compound ClC1=CC(Cl)=CC(NC(=O)OC=2C=CC=CC=2)=C1 WSDQIHATCCOMLH-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920006380 polyphenylene oxide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920003225 polyurethane elastomer Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000012260 resinous material Substances 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- DUIOPKIIICUYRZ-UHFFFAOYSA-N semicarbazide Chemical compound NNC(N)=O DUIOPKIIICUYRZ-UHFFFAOYSA-N 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 125000000472 sulfonyl group Chemical group *S(*)(=O)=O 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 239000003017 thermal stabilizer Substances 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 239000001038 titanium pigment Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002983 wood substitute Substances 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/005—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and foam
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0085—Use of fibrous compounding ingredients
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/03—Extrusion of the foamable blend
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
- C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
- C08J2327/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
- C08J2327/06—Homopolymers or copolymers of vinyl chloride
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F2011/1885—Handrails or balusters characterized by the use of specific materials
- E04F2011/1897—Handrails or balusters characterized by the use of specific materials mainly of organic plastics with or without reinforcements or filling materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S521/00—Synthetic resins or natural rubbers -- part of the class 520 series
- Y10S521/92—Cellular product containing a dye or pigment
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249986—Void-containing component contains also a solid fiber or solid particle
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249987—With nonvoid component of specified composition
- Y10T428/249988—Of about the same composition as, and adjacent to, the void-containing component
- Y10T428/249989—Integrally formed skin
Definitions
- This invention relates to polymer-fiber composites used for the fabrication of decking
- Synthetic lumber has been used as a substitute for wood in areas where wood can deteriorate quickly due to environmental conditions. Although in the past, its commercialization was limited by costs, modern recycling techniques and low cost extrusion
- decking planks typically are not recommended for structural wood substitutes, such as the lattice structure often used as a support for decks.
- Polyethylene composites are attractive because they permit screw fasteners to "countersink", such that the heads of the screws bury or at least become flush with the board surface, without predrilling.
- These synthetic wood products are weather resistant and
- TREX product initially is a light coffee brown color and converts to a weathered gray appearance when exposed to rain water and sunlight.
- Polyethylene-wood composite boards do not require painting, and never include knots which often result in damage to the surface of ordinary wood lumber, and usually more
- PNC Polyvinyl-chloride
- This invention provides foamed polymer-fiber composite building materials which may include about 35-75 wt. % of the polymeric resin, about 25-65 wt. % fiber, and a specific gravity of less than about 1.25g/cc.
- the resulting composite includes a plurality of
- the composites of this invention are nearly 10% lighter than non-foamed synthetic boards of similar composition.
- the preferred vinyl-resin boards are stiffer than polyethylene wood composites of similar thickness.
- PNC can be foamed through the addition of a blowing
- the tensile and flexural modulus of the preferred board-like members of this invention is less that
- the polymer-fiber composites of this invention can also include additives for improving the melt strength of a molten precursor of the composite during extrusion operations.
- the preferred additives for this purpose include acrylic modifiers in amounts
- FIG. 1 is a partial, cross-sectional, front perspective view of a preferred foamed polymer-fiber composite building material of this invention
- FIG. 2 is a front perspective, partial view, of a deck construction and home using the preferred composite building materials of this invention
- FIG. 3 is a side, cross-sectional view of the composite building material of FIG. 1
- FIG. 4 is a partial, cross-sectional, front perspective view of a preferred railing of this invention.
- FIG. 5 is a graph depicting specific gravity versus wood flour concentration for the
- FIG. 6 is a graph depicting specific gravity versus acrylic modifier concentration for the composites of this invention.
- FIG. 7 is a graph depicting specific gravity versus chemical blowing agent
- FIG. 8 is a graph depicting flexural modulus versus wood flour concentration for the composites of this invention.
- FIG. 9 is a graph depicting flexural modulus versus acrylic modifier concentration for the composites of this invention.
- FIG. 10 is a graph depicting flexural modulus versus chemical blowing agent concentration for the composites of this invention
- FIG. 11 is a graph depicting flexural strength versus wood flour concentration for the composites of this invention
- FIG. 12 is a graph depicting flexural strength versus acrylic modifier concentration for the composites of this invention.
- FIG. 13 is a graph depicting flexural strength versus chemical blowing agent
- foamed polymer-fiber composites of this invention can be used by themselves, or in conjunction with "capstock” or coextrusions of other materials, such as, for example, pure
- This invention also pertains to a process for making foamed polymer-fiber composites, such as building materials, including roof shingles, siding, floor tiles, paneling,
- house and garden items such as planters, flower pots, landscape tiles, decking, outdoor furniture, fencing, and playground equipment
- farm and ranch items including pasture fencing, posts and barn components
- marine items for example, decking, bulkheads and pilings.
- FIG. 1 there is shown a preferred foamed polymer-fiber composite 100 which includes about 35-75% of a polymeric resin, about 25- 65% fiber with a specific gravity of less than about 1.25 g/cc, and preferably about .5-1.2 g/cc.
- This composite 100 includes a plurality of pores or cells defining porosity 20 therein resulting from the addition of a blowing agent or gas to a molten precursor of said composite
- the porosity desirably measures at least about 1%, and preferably about 5-40% by volume of solids in the composite 100.
- the composites of this invention also may include one or more additives, such as a process aid, pigment, or plasticizer. As shown in FIGS. 2-4, the foamed polymer-fiber composite 100 of this invention is ideally suited for decking, siding, railings, window frames, including styles and rails, and
- the composite 100 is light-weight, it generally has a flexural
- the composite 100 preferably allows screw and nail fasteners, such as screw 35, to be secured in a countersink relationship with the surface of the composite 100 or below the surface, without predrilling. This is generally accomplished by the use of plasticizing agents to lower the compression strength of the composite 100, and/or by the careful use of
- blowing agents or gas in the molten precursor of the composite 100 so as to provide a cellular internal structure containing porosity 20 surrounded by a polymeric skin 10.
- This porosity even without plasticizing agents, provides enough compressive strength relief to permit screw fasteners to countersink without predrilling. This permits a very attractive deck
- the support structure and columns of the deck are made from wood.
- the preferred composite 100 can be fashioned, for example, by extrusion, in the shape of siding 55 or window frame components 58, such as styles or rails, for a house 50.
- the composite 100 can also be shaped into a railing
- the composites generally contain about 35-75 wt.% resinous materials, such as thermoplastic and thermosetting resins, for example, PNC, polyethylene, polypropylene, nylon, polyesters, polysulfones, polyphenylene oxide and sulphide, epoxies, cellulosics, etc.
- a preferred thermoplastic material for the panels of this invention is PNC.
- PVC thermoplastics comprise the largest volume of thermoplastic polymers in commercial use. Vinyl chloride monomer is
- Polyvinyl chloride is typically manufactured by the free radical polymerization of vinyl chloride. After polymerization, polyvinyl chloride
- Polyvinyl chloride can also be combined with other vinyl monomers in the manufacture of polyvinyl chloride copolymers.
- Such copolymers can be linear copolymers, graft copolymers, random copolymers, regular repeating copolymers, block copolymers, etc.
- chloride to form vinyl chloride copolymers include acrylonitrile; alpha-olefins such as ethylene, propylene, etc.; chlorinated monomers such as vinylidene, dichloride; acrylate momoners such as acrylic acid, methylacrylate, methyl-methacrylate, acrylamide, hydroxethyl acrylate, and others; styrenic monomers such as styrene, alpha methyl styrene,
- PNCs can be compounded to be flexible or rigid, tough or strong, to have high or low density, or to have any of a wide spectrum of physical properties or processing characteristics. PNC resins can also be alloyed with other polymers, such as
- ABS acrylic, polyurethane, and nitrile rubber to improve impact resistance, tear strength, resilience, or processability. They can be produced water-white in either rigid or flexible compositions, or they can be pigmented to almost any color.
- rigid PNC optionally containing a
- This material is a hard and tough and can be
- weatherability e.g., fading color to a wood grey appearance. It also has a tensile strength of about 6,000-7,500 psi, a percent elongation of about 40-80%, and a tensile modulus of about 3.5-6.0X10 6 psi. It can be acceptably used without chlorination, to about 140° F., and with
- chlorination to about 220° F. It also has a coefficient of thermal expansion of about 3-6X10 "5 inch/inch- °F.
- the composite building materials of this invention can be injection or vacuum molded, extruded and drawn, using customary manufacturing techniques for thermoplastic and thermosetting materials.
- a mixture of PVC regrind or virgin compound is compounded and then heated and extruded through a die to produce
- thermoplastic boards and other shapes having a length of about 4-20 feet and thicknesses ranging from .05 - 6.0 inches.
- the extruded thermoplastic boards can be subject to further molding, calendaring, and finishing to provide a wood grain or fanciful texture.
- the building material 100 of this invention also can contain about 25-60 wt.% fiber,
- the fibers are "cellulosic" in nature.
- Cellulosic fibers can be derived from recycled paper products, such as agrifibers, pulp, newsprint, soft woods, such as pine, or hard woods from deciduous trees. Hard woods are generally preferred for fiber manufacture because they absorb less moisture.
- additional fiber make-up can be derived from a number of secondary sources including soft wood fibers, natural fibers including bamboo, rice, sugar cane, and recycled or reclaimed fiber from newspapers, cardboard boxes, computer printouts, etc.
- This invention can utilize wood flour of about 10- 100 mesh, preferably 20-30 mesh.
- this invention combines the resin and wood flour components with a
- the mixture is mixed with 20-30 mesh wood flour of about grass-seed size which has been pre-dried to release any trapped moisture as steam.
- the mixture also includes a melt enhancer, such a high molecular weight acrylic modifier, which improves melt elasticity and strength and enhances cellular structure, cell growth and distribution.
- a chemical blowing agent or gas can also be added to the mixture to reduce the
- a chemical blowing agent is used, it is mixed into the compound during blending or at the feed throat of the extruder. In the extruder, the blowing agent is decomposed, disbursing gas, such as nitrogen or CO 2 , into the melt. As the melt exits the extrusion die, the gas sites experience a pressure drop expanding into small cells or bubbles trapped by the surrounding polymer.
- Chemical blowing agents can be any of a variety of chemicals which release a gas upon thermal decomposition. Chemical blowing agents may also be referred to as foaming agents.
- the blowing agent, or agents, if more than one is used, can be selected from chemicals containing decomposable groups such as azo, N-niroso, carboxylate, carbonate, 10
- hetero-cyclic nitrogen-containing and sulfonyl hydrazide groups are solid
- Representative compounds include azodicarbonamide, bicarbonates, dinitrosopentamethylene tetramethylene tetramine, p,p'-oxy-bis (ben-zenesulfonyl)- hydrazide, benzene- 1,3-disulfonyl hydrazide, aso-bis-(isobutyronitrile), biuret and urea.
- the blowing agent may be added to the polymer in several different ways which are known to those skilled in the art, for example, by adding the solid power, liquid or gaseous
- the blowing agent is added before the extrusion process and is in the form of a solid.
- foaming agents are selected from endothermic and exothermic varieties, such as dinitrosopentamethylene tetramine, p- toluene solfonyl semicarbazide, 5-phenyltetrazole, calcium oxalate, trihydrazino-s-triazine, 5-
- a coloring agent can be added to the compounded mixture, such as dyes, colored pigments, or flyash, or a mixture of these ingredients depending on the resulting color, and cost considerations.
- a coloring agent can be added to the compounded mixture, such as dyes, colored pigments, or flyash, or a mixture of these ingredients depending on the resulting color, and cost considerations.
- Such additives can provide "weatherability" or a
- Examples 1-16 were formulated and extruded into test boards. Mechanical properties formulation were measured and compared.
Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT99916324T ATE257078T1 (en) | 1998-04-03 | 1999-04-01 | FOAMED POLYMER/FIBER COMPOSITE |
IL13872899A IL138728A0 (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite building materials and methods for the preparation thereof |
EP99916324A EP1100675B1 (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite |
AU34671/99A AU757392B2 (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite |
DE69913972T DE69913972T2 (en) | 1998-04-03 | 1999-04-01 | FOAMED POLYMER / FIBER COMPOSITE |
CA002325692A CA2325692A1 (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite building material |
JP2000542168A JP2002510568A (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite |
KR1020007010974A KR20010034724A (en) | 1998-04-03 | 1999-04-01 | Foamed Polymer-Fiber Composite |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/055,098 US6344268B1 (en) | 1998-04-03 | 1998-04-03 | Foamed polymer-fiber composite |
US09/055,098 | 1998-04-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1999051425A1 true WO1999051425A1 (en) | 1999-10-14 |
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ID=21995582
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/007312 WO1999051425A1 (en) | 1998-04-03 | 1999-04-01 | Foamed polymer-fiber composite |
Country Status (11)
Country | Link |
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US (2) | US6344268B1 (en) |
EP (1) | EP1100675B1 (en) |
JP (1) | JP2002510568A (en) |
KR (1) | KR20010034724A (en) |
CN (1) | CN1142056C (en) |
AT (1) | ATE257078T1 (en) |
AU (1) | AU757392B2 (en) |
CA (1) | CA2325692A1 (en) |
DE (1) | DE69913972T2 (en) |
IL (1) | IL138728A0 (en) |
WO (1) | WO1999051425A1 (en) |
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US6784230B1 (en) | 1999-09-23 | 2004-08-31 | Rohm And Haas Company | Chlorinated vinyl resin/cellulosic blends: compositions, processes, composites, and articles therefrom |
US7030179B2 (en) | 1999-09-23 | 2006-04-18 | Rohm And Haas Company | Chlorinated vinyl resin/cellulosic blends: composition, processes, composites, and articles therefrom |
WO2001046303A3 (en) * | 1999-12-20 | 2002-05-10 | Advanced Plastics Technologies | Hydroxy-phenoxyether polymer/fiber composites and foams |
WO2001046303A2 (en) * | 1999-12-20 | 2001-06-28 | Advanced Plastics Technologies, Ltd. | Hydroxy-phenoxyether polymer/fiber composites and foams |
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WO2001092385A1 (en) * | 2000-05-30 | 2001-12-06 | Möller Plast GmbH | Method for producing foamed structural parts that are mixed with vegetable carrier materials |
US7435483B2 (en) | 2001-04-04 | 2008-10-14 | Advanced Plastics Technologies Luxembourg S.A. | Process for coating paper, paperboard, and molded fiber with a water-dispersible polyester polymer |
EP1477524A1 (en) * | 2002-02-21 | 2004-11-17 | Asahi Kasei Kabushiki Kaisha | Woody synthetic resin compositions |
EP1477524A4 (en) * | 2002-02-21 | 2007-01-10 | Asahi Chemical Ind | Woody synthetic resin compositions |
WO2006125034A2 (en) * | 2005-05-17 | 2006-11-23 | Exxonmobil Research And Engineering Company | Fiber reinforced polypropylene compositions |
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US7482402B2 (en) | 2005-05-17 | 2009-01-27 | Exxonmobil Research And Engineering Company | Fiber reinforced polypropylene compositions |
WO2009077124A1 (en) * | 2007-12-14 | 2009-06-25 | Baukulit Handelsgesellschaft Mbh | Plastic extrusion part for finishing the interior and exterior of buildings |
Also Published As
Publication number | Publication date |
---|---|
IL138728A0 (en) | 2001-10-31 |
US20040170818A1 (en) | 2004-09-02 |
EP1100675B1 (en) | 2004-01-02 |
DE69913972D1 (en) | 2004-02-05 |
EP1100675A1 (en) | 2001-05-23 |
AU757392B2 (en) | 2003-02-20 |
CA2325692A1 (en) | 1999-10-14 |
CN1298342A (en) | 2001-06-06 |
DE69913972T2 (en) | 2004-10-28 |
ATE257078T1 (en) | 2004-01-15 |
AU3467199A (en) | 1999-10-25 |
KR20010034724A (en) | 2001-04-25 |
EP1100675A4 (en) | 2001-11-21 |
CN1142056C (en) | 2004-03-17 |
JP2002510568A (en) | 2002-04-09 |
US6344268B1 (en) | 2002-02-05 |
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