ITPO20100008A1 - INNOVATIVE INDUSTRIAL PROCESSES FOR THE CONSTRUCTION OF SHEETS AND SHAPED THERMOPLASTICS WITH A DIFFERENTIATED CHARGE WITH HIGH MECHANICAL, ELECTRICAL AND AESTHETIC PERFORMANCE DEFINED WAFER SHEET MOLDING COMPOUND - Google Patents

Description

Description of the industrial invention entitled: "Innovative industrial processes for the production of thermoplastic sheets and shapes with differentiated charge with high mechanical, electrical and aesthetic performance defined as wafer sheet molding compound"

Description

The systems composed of filled thermoplastic polymers (fibers, mineral fillers ... etc.) are generally condi tions expanded, in their physical - mechanical properties by an unordered arrangement of the various decomposing components (fibers, powders, etc ...), due to traditional molding systems (injection blow molding, etc ...). This condition represents an important limit to the performances (mechanical, electrical, etc ...) of complex polymeric systems. Due to these limitations, they are unable to compete with other types of more performing materials in various and specific fields (metals, semiconductors, wood, marbles, etc ...) in particular for the mechanical and / or electrical characteristics. but also aesthetic. It is also worth underlining the high energy and cost of additives / fillers to obtain complex thermoplastic polymeric systems with high performance in general.

These reasons are at the basis of some limits to the use of thermoplastic compounds.

The system object of the present invention is based on the production process of thermoplastic sheets for molding, made by mixing polymers and / or fibers and / or powders using water-soluble polysaccharide-based binders (cellulose derivatives) and / or synthetic resins. soluble / dispersible in water or solvent that act on the mixture of polymers and binder fillers, allowing to obtain sheets with a minimum thickness of 0.1 mm and / or greater. The mixing takes place at room temperature ("cold"). The binder has the function of creating a physical bond by adhesion between different polymers or between polymer and fillers, which is maintained even at the melting temperature of the polymers involved, and which at the end of the process is an inert filler.

The binder, of cellulose origin and / or synthetic resins, is soluble in water or water / alcohol and / or solvent and represents a value between 1 - 10% on the finished mass according to the characteristics to be obtained.

The process involves polymers in the form of powder and / or fillers and / or fibers and / or nano fillers and / or colloidal and / or salts. The production system, which provides for a mixing of the various components and a subsequent lamination, allows the directional ordering of the fibers (both long and short) and an excellent homogenization of all the components.

The arrangement of the nanofillers and / or colloids and / or salts, which is obtained exclusively in the interface between the various materials making up the mass, is very effective as we have a natural ordered arrangement and optimal dispersion (for physicality) of the various components, as the polymers in this process phase remain in the form of powder. The thermoplastic sheets thus obtained have directional fibers, very thin thicknesses, an orderly and "intelligent" arrangement of the various components and can be processed for the next phase, which involves pre-heating in an oven tunnel with a conveyor belt that dries and heats the sheets. up to the temperature close to the melting limit (to be defined on the basis of the polymers or blend of polymers used) which still allows the dimensional stability of the sheet to be maintained, up to loading into a vertical compression press equipped with molds. Inside this press there is a movable collection element (called container / collection and positioning oven). The various preheated sheets are superimposed on the mold, which rapidly reach the melting point by heating. They are then pressed and the resulting element is removed.

The process aimed at the realization of sheets and finished printed products consists of 4 phases.

Mixing:

This phase of the process involves mixing the polymers and fibers and / or fillers with the binder dissolved in water and / or colloidal in water and / or salts or nitrates dissolved in water and / or solvent with the aid of mechanical mixers with arms to cochlea or sigma.

The percentage of water and / or solvent / alcohol varies between 5% and 30% depending on the type of compounds or blends.

Once the conglomerate mass is obtained, it is sent to a second phase aimed at the realization of sheets, (see attached drawing 1)

Cold foil lamination:

The second phase involves the cold extrusion of the mass in the form of a sheet which is reduced to the desired thickness through a processing system with 6 - 10 pairs of overlapping cylinders which operate to reduce the thickness of the sheet until a sheet is obtained and proceed with the third phase (see attached drawing 1).

Process of drying / pre-heating of sheets

In the third phase the sheets obtained, still wet, enter a tunnel / oven, with a conveyor belt, with a length between 6 and 15 meters where they are dried and preheated to the temperature close to the melting limit (to be defined on the basis of the to the polymers or blends of polymers used) which still allows to maintain the dimensional stability of the sheet until it is "loaded" into the press c to proceed to phase 4

(see attached drawing 1 and 2)

Molding process

In the fourth and last phase the sheets are loaded superimposed in a vertical press, or inside a movable box / oven, placed above the lower mold, which carries the sheets (very quickly due to the minimum thickness and pre-heating) at the melting temperature and retracts allowing the closing of the mold and its quick reopening for the removal of the finished / molded product. (see attached drawing 2)

ADVANTAGES OF THIS INVENTION

The present invention and the related technology allow to obtain the following advantages with respect to the conventional systems used up to now:

• Energy saving as the cold process is carried out in the sheet production phase and the energy required for molding with a vertical compression press (electricity consumption) is considerably lower than in a traditional system, as the planes of the press do not need to be heated and the minimum thickness of the sheets facilitates the heating / melting speed of the polymer matrix.

• Simplification of the plant and significant reduction in cost management if compared to traditional systems for the production of panels or thermoformed items. • Obtaining differentiated charge composite systems, where while maintaining the same polymeric matrix we have an arrangement, in the same, of layers of different filler materials with different functions / performances and therefore the possibility of designing multifunctional materials in a single matrix (without the need coupling / bonding / welding);

• Achievement of electrical, mechanical and aesthetic characteristics much better performing than traditional filled polymeric systems.

• EXAMPLES

Example 1 - Preparation of a polymeric system with differentiated charge in EPS matrix recovered polystyrene foam (cocoa peel - coffee grounds - fiberglass ground from processing scraps-EPS expanded polystyrene from recycling) with high mechanical and aesthetic performance

According to the present example, a first mixture of EPS polystyrol foam (from recycle), cocoa husk (ground into flour) and coffee grounds is made in varying percentages of the three components in ranges from 0 to 100%. This blend, on a 100 basis, is made up of 50 parts of pulverized EPS (from recycling), 35 parts of cocoa peel (from cocoa processing waste) and 15 parts of coffee grounds (from coffee administration waste). These powders undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water.

A second mixture is made with EPS, fiberglass ground from scraps from processing and / or disposal of boat hulls, fiberglass. This mixture, based on 100, is made up of 50 parts of pulverized EPS (from recycle), 35 parts of ground / pulverized fiberglass from scraps from processing and / or disposal of hulls and 15 parts of glass fiber (F.V. 6 mm). These powders and fibers undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water.

We therefore obtain two homogeneous masses that are processed separately with the described machinery to obtain 0.3 mm thick sheets. Once the sheets have been made, they are directed with an automated system in the necessary number by type to the preheating tunnel which then loads the press for the molding phase on a square mold size 50 cm x 50 cm thickness 3 mm with n. 7 EPS composite sheets - ground glass resin - glass fiber and n. 3 final EPS sheets - cocoa peel - calìe bottoms and then proceed to compression molding.

We therefore obtain a panel of 50 cm x 50 cm 3 mm thick with the upper side with high aesthetics (wood) and the lower side with high mechanical performance (modulus of flexion 18000 Mpa) in the same EPS matrix.

Example 2 - Preparation of a polymeric system with differentiated charge (Paó - Carbon fiber 6 mm - ceramic charge - glass fiber) with high mechanical and electrical / insulating performances

According to the present example, a first mixture of Paó and carbon fiber is made in variable percentages of the two components in ranges from 0 to 100%. This mixture, based on 100, is made up of 50 parts of pulverized Paó (Produced by Rhodia), 35 parts of 6 mm carbon fiber (not recovered) and 15 parts of 200 micron carbon fiber (not recovered) .

These components undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of a suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water.

A second blend is made with Paó, ceramic filler. This mixture, based on 100, is made up of 50 parts of Paó (Produced by Rhodia), 35 parts of ceramic filler (generic, clay) and 15 parts of 6 mm glass fiber. These powders and fibers undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water. We therefore obtain two homogeneous masses which are processed separately with the described machinery to obtain 0.5 mm thick sheets. Once made, the sheets are directed using an automated system and in the necessary number by type, to the preheating tunnel which then loads the press for the molding phase on a square mold of size 50 cm x 50 cm thickness 3 mm with n . 3 composite sheets Paó - Carbon Fiber and n. 3 Paó sheets - ceramic charge - 6 mm glass fiber. Compression molding is then carried out.

We therefore obtain a panel of 50 cm x 50 cm 3 mm thick with the conductive upper side (3 ohm surface resistivity) and the insulating lower side. The bending modulus 16500 Mpa all in the same paó matrix.

Example 3 - Preparation of a polymeric system with differentiated charge in PP polypropylene matrix (PP - coffee grounds - 6 min glass fiber - aluminum powder - glass fiber) with high mechanical and aesthetic performance. According to the present example, a first blend of fiberglass, coffee grounds and PP is made in variable percentages of the three components in ranges from 0 to 100%. the ale blend, based on 100, is made up of 50 parts of pulverized PP (produced by Basell), 42 parts of coffee grounds (from coffee waste) 8 parts of 6 mm glass fiber. These powders and fibers undergo a first dry mixing with suitable machinery. Λ this mixture is then added a solution of methylcellulose diluted in water equal to 4% of the weight of the polymers with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water.

A second mixture is made with PP, aluminum powder from processing scraps and glass fiber. This mixture, based on 100, is made up of 50 parts of pulverized PP (produced by Basell), 35 parts of powdered aluminum from processing scraps and 15 parts of glass fiber (F.V. 6 mm). These powders and fibers undergo a first dry mixing with suitable machinery. Λ this mixture is then added a solution of methylcellulose diluted in water equal to 4% of the weight of the polymers with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water.

We therefore obtain two homogeneous masses which are processed separately with the described machinery to obtain 0.3 mm thick sheets. Once the sheets have been made, they are directed with an automated system in the necessary number by type to the preheating tunnel which then loads the press for the molding phase on a square mold size 50 cm x 50 cm thickness 3 mm with n. 5 composite sheets PP - aluminum powder - glass fiber and n. 5 PP sheets - Coffee grounds - Glass fiber and then proceed to compression molding.

We therefore obtain a panel of 50 cm x 50 cm 3 mm thick with both sides with a high aesthetic effect (wood - metal) and high mechanical performance (9200 Mpa flexural modulus) all in the same PP matrix.

Example 4 - Preparation of a polymeric system with differentiated charge in PE / PP matrix (PE / PP - bottom ash - fly ash - asbestos) for the inertization of toxic / dangerous materials.

According to the present example, a first mixture of bottom ash and PE / PP polypropylene polyethylene mixture is made in variable percentages of the three components in ranges from 0 to 100%. This mixture, based on 100, is made up of 70 parts of pulverized / ground PP / PE (from separate waste collection) and 30 parts of low-risk bottom ash (from waste water purification sludge incineration). These powders undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water. A second mixture is made with PP / PE (from separate waste collection), toxic fly ash (from electro-filtering municipal solid waste incinerators) asbestos in the form of powder or fiber (from dismantling of structural elements). This mixture, based on 100, is made up of 30 parts of pulverized / ground PP / PE (from separate waste collection), 35 parts of toxic fly ash and 35 parts of asbestos. These powders and / or fibers undergo a first dry mixing with suitable machinery. A solution of methylcellulose diluted in water equal to 4% of the weight of the polymers is then added to this mixture with the aid of suitable machinery with a sigma or mixing screw system. Typically 40 gr are added to one kg of polymer powder. of methylcellulose dissolved in 150 ml. of water. We therefore obtain two homogeneous masses which are processed separately with the described machinery to obtain 1 mm thick sheets. Once the sheets have been made, they are directed with an automated system in the necessary number by type to the preheating tunnel which then loads the press for the molding phase on a square mold size 50 cm x 50 cm thickness 2 cm with n.

6 composite sheets PP / PE - low hazard bottom ash and n. 14 PP / PE sheets - dangerous fly ash - Asbestos and then we proceed with compression molding.

We then obtain a panel of 50 cm x 50 cm 2 cm thick where the highly dangerous / toxic materials remain incorporated in the polymeric system (filler) and in the sheet structure (arrangement of the sheets), obtaining an inert final material according to the directives in force. which does not release dangerous / toxic substances.

Example 5 - Preparation of a polymeric system with differentiated charge in SMMA matrix methyl copolymer of styrene methacrylate (glass fiber Natural fibers - Marble powders - SMMA) with high mechanical and aesthetic performance

According to the present example, a first mixture of SMMA and component marble powders is made in ranges from 0 to 100%.

Such a mixture. on base 100, it is made up of 50 parts of SMMA (produced by Rohm and Haas) pulverize it, 50 parts of marble powders selected by color (from marble processing waste). These powders undergo a first dry mixing with suitable machinery. Acetone equal to 30% of the weight of the powder compound (polymers and marble powders) is then added to this mixture and mixed with the aid of suitable machinery with a sigma system or mixing screw until a homogeneous mass is reached.

A second blend is made with SMMA, hemp fiber, rice husk. This mixture, on a 100 basis, is made up of 50 parts of EPS (from recycled) pulverize it, 35 parts of rice husk flour, 15 parts of hemp fiber (processing waste). These powders and fibers undergo a first dry mixing with suitable machinery. Acetone equal to 30% of the weight of the powder compound (polymers and marble powders) is then added to this mixture and mixed with the aid of suitable machinery with a sigma system or mixing screw until a homogeneous mass is reached.

We therefore obtain two homogeneous masses which are processed separately with the described machinery to obtain 0.3 mm thick sheets. Once the sheets have been made, they are directed with an automated system in the necessary number by type to the preheating tunnel which then loads the press for the molding phase on a square mold size 50 cm x 50 cm thickness 3 mm with n. 5 SMMA composite sheets - Vegetable fibers / farinc and n. 5 SMMA final sheets - marble powders and then we proceed with compression molding.

We therefore obtain a panel of 50 cm x 50 cm 3 mm thick with the upper side with high aesthetics (marble) and the lower side with good mechanical performance (bending module 4500 Mpa) all in the same SMMA matrix.

Claims (10)

Claims of the industrial invention entitled: "Innovative industrial processes for the production of thermoplastic sheets and shaped shapes with differentiated charge with high mechanical, electrical and aesthetic performance defined wafer sheet molding compound" Claims 1. Cold physical process performed with suitable machinery for the production of sheets of composite materials containing thermoplastic polymers, mineral powders, vegetable flours, fibers in general with the aid of binders of cellulosic and / or acrylic origin and / or solvents and / or synthetic resins, which act on the mixture of polymers and binder fillers, allowing cold sheets to be obtained with a minimum thickness of 0.1 inm and / or. higher, remaining chemically and physically unchanged even at the melting temperatures of the polymers involved, and which at the end of the process result in an inert charge. 2. Process according to claim 1 wherein the composite sheet is made by means of a binder of cellulosic and / or acrylic origin and / or thermoplastic and / or thermosetting resin without the aid of thermal induction. 3. Process according to claim 1 in which the mixture of the basic materials for the production of the sheet is made cold in a mixing machine with sigma arms equipped with a material discharge system and an Extrusion system in the form of a plate which is brought to the desired thickness through a subsequent in-line processing system with 6 - 10 pairs of superimposed cylinders adjusted to different thicknesses, and sent to a drying and pre-heating tunnel system. 4. Process according to claim 1 in which one of the polymers to be mixed is a thermoplastic polymer that can be melted in a temperature range between 100 and 250 ° C. 5. Sheet molding process carried out with suitable machinery that allows them to be overlapped automatically and heated to the melting point to proceed with the molding of elements by compression. 6. Process according to claim 5 in which the heating and positioning of the sheets, inside a vertical compression press, takes place by means of an oven system with temperatures ranging between 100 and 280 °, adjustable in size according to the mold to be used, in the form of a container with vertical loading slot and horizontal vertical hydraulic movement functional to positioning. 7. Process according to claims 1 and 5 in which an element in panel form with differentiated charge is made, composed of a single matrix in thermoplastic polymer, carbon fiber and ceramic fillers, with a conductive upper surface and the other lower insulating surface. 8. Process according to claims 1 and 5 in which an element in panel form with differentiated charge is made, composed of a single matrix in thermoplastic polymer, cocoa peel flour, coffee grounds, fiberglass powder from processing and / or dismantling waste hulls, fiberglass, with an upper surface with a high aesthetic level like wood and the other lower surface, support, with high mechanical performance. 9. Process according to claims 1 and 5 in which an element is made in the form of a monolith with differentiated charge aimed at inerting dangerous / toxic materials in the form of powders or fibers, composed of a single matrix in recycled thermoplastic polymer (PE / PP or EPS), inert bottom ash, toxic / dangerous light ash, asbestos, where following an arrangement of thermoplastic sheets loaded with inert materials and sheets loaded with toxic / dangerous materials and proceeding with the molding we obtain a monolith where toxic / dangerous substances are global and inertized. 10. Other materials obtained according to the processes described in the preceding claims 1-6.