WO2001021367A1

WO2001021367A1 - Construction material comprising recycled pvb (polyvinyl butyral)

Info

Publication number: WO2001021367A1
Application number: PCT/NO2000/000314
Authority: WO
Inventors: Frank Mundt; Stein Fr. Dietrichson
Original assignee: Sd-Konsult Stein Fr. Dietrichson
Priority date: 1999-09-22
Filing date: 2000-09-22
Publication date: 2001-03-29
Also published as: AU7817700A

Abstract

According to the invention, a construction material is disclosed comprising recycled PVB (polyvinyl butyral), one or more thermoplastic component(s) other than PVB, and cellulose-based material. Said cellulose material may in another embodiment of the invention also comprise a lignin component. In another embodiment of the invention, said construction material also comprises a glass particle component, and that said glass particle component is present in the form of particles or dust associated with the PVB. A further object of the invention is to provide a construction material comprising recycled PVB containing particles. With the construction material according to the invention, a field of use for PVB waste is provided, which at the same time can help solving the problem of the storage capacity of the increasing stocks of PVB waste.

Description

CONSTRUCTION MATERIAL COMPRISING RECYCLED PVB (POLYVINYL BUTYRAL)

Field of the invention

This invention relates to a construction material comprising recycled PVB, one or more thermoplastic component (s) other than PVB, and cellulose-based material.

Background of the invention

PVB (polyvinylbutyral) is a polymer material having a chemical composition without any harmful substances, so that burning of the material may take place without giving rise to any particular problems. PVB film does not contain additives classified as dangerous or harmf l.

PVB is primarily used as a laminated film in wind- screens in all modern vehicles such as cars and trucks . The PVB film prevents glass from splintering when damaged in a crash, etc. In some cases, PVB is included in glazing in buildings, especially in areas with hurricanes, or in safety windows . The Michigan Molecular Institute has for several years tried to find applications for the PVB waste on assignment from the automotive industry in the USA and Du Pont^®, one of 3 large PVB-producers in the world. A publication covering this topic has been issued. New applications of recycled PVB has been developed, e.g., as insulation material for cables, in flooring application (Hoechst^®) , but none of these applications seems to have been a commercial success. Recycled PVB has also been tested for use as an additive in thermoplastic road marking materials. PVB also adheres well to glass, and a market for

PVB may for this reason be present in this field in the future .

In Japan, the only Japanese PVB manufacturer, Sekisui^®, has for some years attempted to find fields of use for PVB being recycled from the automotive industry. Apparently,

Sekisui^® has ended their project as no economically feasible field of use for recycled PVB has been discovered.

Unofficial figures state that in the USA, approximately 10 000 tons of PVB waste is generated per year from condemned vehicles . The total volume of recycled PVB is estimated to be between 40 000 and 75 000 tons, increasing by minimum 4-6% annually the next 10 years. Similarly, in Europe and Japan, volumes of 6 000 - 10 000 metric tons are generated per year.

Prior to the disclosure of the present invention, the only economically and practically feasible way of reducing the stocks of PVB waste has been through incineration of waste and recycling of energy. PVB carries a high amount of chemically bound energy. Less harmful fumes are released when burning PVB, than when burning heating oil. However, the price of energy recovered from such a waste product is sometimes lower than the price of energy recovered from oil, as bales of PVB waste are difficult to handle and large incinerators are needed in order to recover the energy.

Large amounts of PVB waste are stored world wide, which are very reasonable priced due to the large surplus and few applications for PVB. Most of the PVB waste contains some glass particles, which make the use more difficult. A lot of scrap plastic dealers are today selling recycled PVB-film in bales at very low prices.

Outdoor storage of PVB material is not recommended, as moisture and ultraviolet radiation will degrade the PVB waste. In addition, the PVB material will easily dirty when stored outdoors.

Because of the sticky and soft surface of the PVB film waste, glass particles, dust and other impurities easily stick to the surface and reduce the quality and the fields of use of the recycled product.

The storing capacity in many countries is limited. Accordingly, some of the problems with PVB waste are increasing storage costs and decreasing quality of the PVB waste due to degradation and impurities. The automotive industry and manufacturers of PVB are trying to find economical and relevant fields of uses for the waste generated from the manufacturing processes of these industries. In some countries, such as Germany, all industry by law have to take care of the waste their products generate in the whole life cycle. This means that the manufacturer is responsible for handling all waste created by the product from packaging to the recycled components of the product after being disposed of. In fact, few economically or practically feasible fields of uses have been discovered for material of PVB, which may contain glass particles, pure or mixed with other materials. PVB film for use in windscreens is designed to prevent glass from splintering. Modern equipment for automatic separation of glass and PVB film has been developed, so that most of the glass can be recycled into new products. However, fragments of glass remaining in the PVB material may be inevitable, and complete separation of glass and PVB film seems not possible to achieve. In prior art, no solutions have been provided for using recycled PVB film containing particles.

Other recycled bulk- and special polymers like, e.g., polyethylene, polypropylene, polyvinyl chloride, polycarbonate and polystyrene, has successfully been included in construction elements such as window profiles, decks, fences and vehicle components. Frequently, the recycled thermoplastics are compounded with virgin material and with reinforcing additives or fillers like glass or wood fibres. Recycled materials are also used in insulation foams and other construction materials.

Composites of wood fibre and plastics (plastic lumber/- composite wood) have also been increasingly utilised by the automotive industry for vehicle components, e.g., as interior details such as hat shelves and door panels . Thermoplastic composites comprising cellulose-based materials like wood fibres, etc. based on PE, PP and PVC have been widely used in the USA for 2-3 years. Substitution of materials used in outdoor products such as decks, yacht harbours, fences, window frames and playgrounds will become more widespread. Today, common materials used for such products are different types of plastic, hard types of wood, and impregnated wooden material (such material often includes poisonous substances such as arsenic or arsenic compounds) . The latter materials are environmentally ø"

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None of these publications show a construction material comprising recycled PVB. Furthermore, no solutions disclosed in the prior art has been provided for using recycled PVB film containing particles. The present invention makes use of a PVB waste material which now finds very few uses, if any at all.

Summary of the invention

According to the invention, a construction material is disclosed comprising recycled PVB (polyvinyl butyral) , one or more thermoplastic component (s) other than PVB, and cellulose-based material. Said cellulose material may in another embodiment of the invenion also comprise a lignin component . In another embodiment of the invention, said construction material also comprises a glass particle component, and that said glass particle component is present in the form of particles or dust associated with the PVB.

A further object of the invention is to provide a con- struction material comprising recycled PVB containing particles. With the construction material according to the invention, a field of use for PVB waste is provided, which at the same time can help solving the problem of the storage capacity of the increasing stocks of PVB waste.

Detailed description of the invention

PVB (polyvinyl butyral) is a generic term of a group of plasticized polymers, which, in general, are manufactured through a reaction between a polyvinyl alcohol and a butyl aldehyde. The structural formula will vary dependent among other things on the conditions under which the reaction takes place. This group of polymers is supplied under several trade names, such as Butacite® from Du Pont®, Mowital® from Hoechst® and F-LEC B® from Sekisui®.

Below follows the structural formula of Mowital® (I) and F-LEC B® (II) :

According to the invention, a construction material is disclosed comprising the following components: recycled PVB (polyvinyl butyral) one or more thermoplastic component (s) other than PVB, and cellulose-based material.

By adding recycled PVB to construction materials comprising thermoplastic and cellulose-based components, the following advantages can be obtained: - lower price, as use of PVB is more cost effective than use of virgin and recycled polyolefins and PVC, better flow properties of the material and that the material becomes more easily workable because of the low melt viscosity of PVB, - the possibility to load more cheap wood flour into the composite material to obtain a stiffer construction material, which lower weight of the product with more wood fibres, better flexibility and low temperature properties of the composite.

Said thermoplastic component (s) are preferably chosen from the group including recycled polyetylen (PE) of any kind such as LDPE, HDPE, LLDPE, MDPE and UHM PE, poly- propylen (PP) as a copolymer or homopolymer, and rigid or plasticized polyvinyl chloride (PVC) .

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tion material comprise foam-forming agent (s). The result is a construction material having a relatively low density, which may, e.g., be used for manufacturing light-weight construction elements, such as interior details like hat shelves and door panels in cars .

Dependent on other desired properties, the construction material may also comprise one or more of the components selected from the group including lubricant (s) , pigment (s), stabilizer (s) , and flame retardant (s) .

In the following, test procedures and test results will be presented and discussed.

EXAMPLE 1

Testing done by the inventors at Forschungsinstitutt fur Kunststoffe und Recycling (FKuR) in Willich, Germany, which belongs to the Fraunhofer Institute in Dusseldorf, lead to the results which are described below.

7 test samples having compositons as described in the table 1 below were tested, named Ml, M2 , ... , M6, M7. In the table 1, the amount of each component in each of the test samples is indicated in weight% of the total weight of each test sample. The melt index of the high density polyetylen used in the test sample was 2,9.

Table 1 All mixtures were extruded on a Leitriz ZSE 40 GL single screw extruder with a 40 mm 36 D screw at 80 rpm at temperatures from 140 to 200 °C at the nozzle for all mixtures .

All components were mixed in a dry state before being fed into a hopper and the melted materials were extruded into flat profiles of 110x12 mm and cut into lengths of 250 mm which were annealed for 2 days and tested in a bending machine after DIN 53 452 with the following results:

Table 2

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4-) rH 4-1 0 u Φ 4-1 5 φ -H rH H 0 -H 0 φ φ ft 0 Φ 1 μ 1 rd X! μ 4J td A 40 rH -H 0 -H Cfl -H 40 A -H n A μ rH 40

0 rH ^■H φ I Φ H Φ TJ rH -H 03 H 01 0 40 rd μ rH 40 40 o H 01 cn Φ μ ro _ø Φ Λ Φ φ Φ 40 rd rH 01 td μ rH φ rH υ 4-1 rd 0 φ 3 Φ 03 4-1 3 _ . 40 3 U Φ Φ Φ φ 0 rd rH A -H ø 0 40 o μ φ 4-3 rd Ό φ Φ -H rd 0 U υ 0 tn ft -H 40 3 TJ 40 Φ 0 u • μ td 0 01 μ μ 3 40 φ f Φ O O φ Φ 3! μ o 40 Φ CQ

Φ 4 3 A rd 0 P. O 03 A μ TJ μ TJ μ cn 0 - μ Oi 0 3 0 Φ μ X U -H 3 φ 40 φ 0 -H ft & 40 4H 01 ft 0 40 0 -H 3 o Φ 0 ø CN Ό Φ μ 1 ,0 3 td φ 3 td U 40 -H •H 0 rd m O cn rH Λ μ μ 4-1 40 CQ ) A -H Φ φ Φ T TJ 4 μ τ μ φ ω -H - 0 0 Ό 0 01 0 0 4-1 A Φ Φ μ 01 -H φ 44 μ rd 4-1 S cn O >. 01 4-1 φ 4-1 -H >, S -H 4-1 A A O A > 01

Φ _ø ϋ μ μ . 3 rH Φ μ rd 0 O 3 O N rd CQ Φ 0 03 01 o 0 0 -H S

_0 0 φ Φ 4-3 A 0 Φ O 0 -H 3 e td ^■H u 01 Φ H o

4J CQ μ 0 X 0 0 rd O TJ 0 -H 4-3 υ r- O . 0 o 4-1 0 rd -H TJ

> 40 -H -H Φ O μ 0 • -H 40 0 φ Φ ^■H tn Φ M O o -H td CQ 40 0

TJ ft 01 .0 3 3 -H Φ Φ -H rH U Φ A > 40 0 μ -H rH 4H rH -H 0 ^•H ro 0 0 ϋ ft 4-1 -l μ A rd 01 0 3 Φ CQ ^■H 0 A 01 rd tn 1 • rd n & H r 03 0 rd _^ -H ϋ Φ 0 -H 40 τj φ φ H rd CQ 40 40 Φ -H 0 -H CQ -H rd A tn td ϋ 3 01 0 Φ μ 4-1 TJ μ 0 Φ > μ rH CQ _< -H A μ -H 3 Φ μ U 0 TJ μ φ f ^■ι— l ft Φ φ Φ Φ μ O 0 Φ ft Φ -H S TJ φ 3 Φ H Φ TJ -H -H 0 φ - φ υ 0 Φ 0 A CQ 4J 0 μ 40 ! Ό 3 td 40 μ 01 -H 40 Φ A Φ td

TJ 4-) .0 -H -H ^■H J rd rd o rd ft X 40 ^•5 o rH td o 4-1 td CQ _5 Λ

0 O 01 4-J 4-> A σ> iH r-H A 3 ft 3 -H Φ μ TJ rd φ 3 4H 4H O 3 0 CQ

-H 0 φ cn ϋ 0 μ 0 rd 1 3 o -H 3 0 μ ft 0 -H A O μ CQ _^ φ

A T) 4-3 4-1 rd rd -H O O -H rH φ 0 40 -H u ø μ 40 0 3 ft 0 Φ H TJ u o rd o rH 3 TJ £i μ ι 01 o 0 φ 01 _^ O Φ o 0 01 o A rd o 0

Ό μ μ ft iH Oi 01 Φ 0 o Ό rd A Φ . 1 Oi ft 40 _^ -H 0 0 μ -H -H o φ φ P. 4-1 Oi tn 0 0 40 -H H r-H td 40 03 Φ 0 0 3 rd 01 40 u -H O 40 μ 3: 4H

CO 01 0 0 0 O -H e rd > 0 H Φ 0 rd r-\ o ^■H O 3 0 CJ rd rH \ J rH φ rd 03 A -H £ -H 3 Ό 3 rH rd rH 40 40 φ A 0 μ O ^■H 0 > r-{ TJ 0 01 40 TJ -

A 0 0 μ 0 TJ 0 ft μ H rd μ -H Φ TJ μ μ -H 0 μ 0 td Φ 01

1 0 01 0 0 r-H H μ φ O Φ 4-1 rH TJ A o 03 μ TJ . Φ Φ 40 _^ μ td 40 o 3 40 _y rH φ 4-3 M 0 rd 4-3 φ 03 υ o rH 0 40 0 03 Φ 0 μ 01 Ό cn . Ό 01 Φ td CJ 1 0 4-) ϋ 0 0 X .0 0 υ ^■H πJ ^■H 0 A Φ J rd 0 0 01 01 0 01 0 0 φ

0 φ 01 rd oi 3 O φ 4-1 rH -H TJ tn S O ft 40 r-* A Φ o Ό Ό o rd o Oi TJ

-H Oi 0 4-1 0 -H 0 0 Φ 0 μ 03 0 0 rd •. 1 rH o Φ 0 0 υ TJ -H φ o 3 0 -H 0 4-3 0 «. rH -H 40 -H 0 φ td 01 ϋ H φ rd rd μ 0 40 μ ..

3 0 01 o rd φ rH H 4-1 rd X o T_J .. H μ Φ 01 υ φ .. Φ rd O ft r- μ 0 o rd 0 -H 4-3 _ø rd Φ Φ 0 ^■H -H 0 Φ Φ rd 0 01 40 0 A A 01 - A > 0 3 Oi

0 A 4-> S 4-) O 3 -H U r-i 0) S cn ^■H μ M -H Pn td Φ rH Φ H 01 0 01 H TJ μ -H φ ϋ μ μ O φ 0 A 0 rd μ H 0 μ 0 ^■H 40 rd 40 φ u Φ Φ a ! 1 μ μ 40 3 φ A & rH O o TJ Φ cn . e rd ^■n τj 4J 4-1 rH & 40 Φ X 40 υ 3 H 4H μ 0 Φ 0 0 Oi - rH O 0 0 rd -H O 3 X A -H μ rd 0 0 Φ φ _ø φ A td 0 . CQ

P. -H rd 3 _5 ft -H φ 40 3 O 3 01 u O A 40 A 01 U Ό Φ rd

Claims

C l a i m s

1. Construction material c h a r a c t e r i z e d by comprising the following components : recycled PVB (polyvinyl butyral) , one or more thermoplastic component (s) other than PVB, and cellulose-based material.

2. Construction material according to claim 1, c h a r a c t e r i z e d i n that said thermoplastic component (s) are chosen from the group including recycled polyetylen (PE) of any kind such as LDPE, HDPE, LLDPE, MDPE and UHMWPE, polypropylen (PP) as a copolymer or homo- polymer, and rigid or plasticized polyvinyl chloride (PVC) .

3. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d i n that said cellulose material also comprises a lignin component.

4. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d i n that said cellulose-based material is chosen from the group including saw dust, wood flour, wood fibres, wooden chips or shavings, plant fibres such as straw in any form, recycled paper and cardboard, and PE-coated cardboard boxes.

5. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d in that the amount of the thermoplastic component (s) included in the construction material is from 1 weight% to 70 weight% of the total weight ^"of the construction material.

6. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d in that the amount of said cellulose-based material included in said construction material is from 20 weight% to 90 weight% of the total weight of said construction material.

7. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d in that the amount of said PVB component included in said construction material is from 0,5 weight% to 25 weight% of the total weight of the construction material.

8. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d in that the amount of said PVB component included in said construction material is from 2 weight% to 5 weight% of the total weight of said construction material.

9. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d in that said PVB component include plasticizer (s) in an amount of up to 30 weight% of the total weight of the PVB component of the construction material .

10. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d b y also comprising a glass particle component, and that said glass particle component is present in the form of particles or dust associated with the PVB.

11. Construction material according to claim 10, c h a r a c t e r i z e d in that the amount of said glass particle component included in said construction material is up to 8 weight% of the total weight of said construction material.

12. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d by also comprising grafted reactive polymer (s) and/or compati- bilizer (s) .

13. Construction material according to claim 12, c h a r a c t e r i z e d that the amount of said grafted reactive polymer (s) and/or compatibilizer (s) included in said construction material is from 0,1 weight% to 5 weight% of the total weight of said construction material.

14. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d by also comprising one or both of the following components: reinforcing fibres or particles, such as glass fibres, carbon fibres, metal filaments or similar, and inorganic fillers, such as mineral sand or similar.

15. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d by also comprising foam-forming agent (s).

16. Construction material according to anyone of the preceding claims, c h a r a c t e r i z e d by also comprising one or more of the following components: lubricant (s) , pigment (s), stabilizer (s) , and flame retardant (s) .

17. Use of PVB as a wetting agent to impregnate cellulose- based material, with or without a content of lignin.