TWI574810B - 製造不含甲醛之模製品及相關部件之方法 - Google Patents
製造不含甲醛之模製品及相關部件之方法 Download PDFInfo
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- TWI574810B TWI574810B TW098124388A TW98124388A TWI574810B TW I574810 B TWI574810 B TW I574810B TW 098124388 A TW098124388 A TW 098124388A TW 98124388 A TW98124388 A TW 98124388A TW I574810 B TWI574810 B TW I574810B
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- Prior art keywords
- moldable mixture
- molding
- mold
- mixture
- binder
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- 238000000034 method Methods 0.000 title claims description 39
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 239000000203 mixture Substances 0.000 claims description 118
- 238000000465 moulding Methods 0.000 claims description 44
- 239000000463 material Substances 0.000 claims description 40
- 239000011230 binding agent Substances 0.000 claims description 37
- 239000000835 fiber Substances 0.000 claims description 30
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims description 24
- 238000000748 compression moulding Methods 0.000 claims description 23
- 238000002156 mixing Methods 0.000 claims description 19
- 235000013312 flour Nutrition 0.000 claims description 14
- 239000000945 filler Substances 0.000 claims description 12
- 230000006835 compression Effects 0.000 claims description 11
- 238000007906 compression Methods 0.000 claims description 11
- 238000011049 filling Methods 0.000 claims description 11
- 239000004848 polyfunctional curative Substances 0.000 claims description 11
- 241000209140 Triticum Species 0.000 claims description 9
- 235000021307 Triticum Nutrition 0.000 claims description 9
- 239000006184 cosolvent Substances 0.000 claims description 8
- 238000005303 weighing Methods 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- 239000004609 Impact Modifier Substances 0.000 claims description 6
- 238000007599 discharging Methods 0.000 claims description 5
- 108010068370 Glutens Proteins 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 235000021312 gluten Nutrition 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims 1
- 239000000047 product Substances 0.000 description 17
- 239000002023 wood Substances 0.000 description 15
- 235000010469 Glycine max Nutrition 0.000 description 13
- 239000007788 liquid Substances 0.000 description 8
- 238000003825 pressing Methods 0.000 description 8
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 6
- 238000011068 loading method Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000004033 plastic Substances 0.000 description 6
- 229920003023 plastic Polymers 0.000 description 6
- 241000209094 Oryza Species 0.000 description 5
- 235000007164 Oryza sativa Nutrition 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 5
- 229920002522 Wood fibre Polymers 0.000 description 5
- 238000003958 fumigation Methods 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 235000009566 rice Nutrition 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000002025 wood fiber Substances 0.000 description 5
- 241000607479 Yersinia pestis Species 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- 239000000284 extract Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000005022 packaging material Substances 0.000 description 4
- 239000010902 straw Substances 0.000 description 4
- 240000003183 Manihot esculenta Species 0.000 description 3
- 235000016735 Manihot esculenta subsp esculenta Nutrition 0.000 description 3
- 235000019270 ammonium chloride Nutrition 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- HANVTCGOAROXMV-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine;urea Chemical compound O=C.NC(N)=O.NC1=NC(N)=NC(N)=N1 HANVTCGOAROXMV-UHFFFAOYSA-N 0.000 description 3
- 239000006082 mold release agent Substances 0.000 description 3
- 235000020712 soy bean extract Nutrition 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 240000002791 Brassica napus Species 0.000 description 2
- 235000004977 Brassica sinapistrum Nutrition 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 229920001807 Urea-formaldehyde Polymers 0.000 description 2
- GZUXJHMPEANEGY-UHFFFAOYSA-N bromomethane Chemical compound BrC GZUXJHMPEANEGY-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- 238000010409 ironing Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000010355 oscillation Effects 0.000 description 2
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 238000009834 vaporization Methods 0.000 description 2
- 230000008016 vaporization Effects 0.000 description 2
- 244000068988 Glycine max Species 0.000 description 1
- 206010028980 Neoplasm Diseases 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 1
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 1
- 235000011130 ammonium sulphate Nutrition 0.000 description 1
- 201000011510 cancer Diseases 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 230000009514 concussion Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229940102396 methyl bromide Drugs 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 235000018102 proteins Nutrition 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000012258 stirred mixture Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
-
- 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
- B27N1/00—Pretreatment of moulding material
- B27N1/003—Pretreatment of moulding material for reducing formaldehyde gas emission
-
- 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
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/08—Moulding or pressing
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- 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
- B27N5/00—Manufacture of non-flat articles
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L99/00—Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
- B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
- B29C2043/3405—Feeding the material to the mould or the compression means using carrying means
- B29C2043/3427—Feeding the material to the mould or the compression means using carrying means hopper, vessel, chute, tube, conveying screw, for material in discrete form, e.g. particles or powder or fibres
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
- B29C2043/3488—Feeding the material to the mould or the compression means uniformly distributed into the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
- B29K2311/14—Wood, e.g. woodboard or fibreboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
- B29K2711/14—Wood, e.g. woodboard or fibreboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/001—Profiled members, e.g. beams, sections
- B29L2031/003—Profiled members, e.g. beams, sections having a profiled transverse cross-section
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B29L2031/772—Articles characterised by their shape and not otherwise provided for
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Wood Science & Technology (AREA)
- Manufacturing & Machinery (AREA)
- Forests & Forestry (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Composite Materials (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Description
本發明係關於包裝材料及其相關建構方法。更特定言之,本發明係關於用於建構托板之可模製材料及其製造方法。甚至更特定言之,本發明係關於可模製材料及其用於建構實質上不含甲醛之托板的相關使用方法。
托板為由木材、塑膠、紙、金屬及複合材料製成之平坦運輸結構,其可以穩定方式支撐多種物品,同時可由任何可移動托板提昇裝置提昇。該托板之目的在於改良儲存及產品分配效率且保護該產品。托板同樣可充當包裝產品與粗糙產品分配環境之間的界面,該粗糙環境包括卡車、鐵路或航空運輸期間之許多不同振動及衝擊。
現今,據估計全世界每年製造超過十億個新托板。據估計超過93%之所製造的托板由木材製成。由於使用木材作為原料,故現在用於製造木托板之木材的消耗被公認為是造成全球變暖之主要影響因素之濫伐森林的一部分。根據國際癌症研究機構(International Agency for Research of Cancer),使用三聚氰胺尿素甲醛(Melamine Urea Formaldehyde,MUF)或尿素甲醛(Urea Formaldehyde,UF)作為黏合劑之壓縮木托板可能會危害健康。除上述環境問題外,木托板亦具有引入及/或傳播檢疫害蟲之危險。名為“國際貿易中木質包裝材料之國際管理標準(International Standards for Regulating Wood Packaging
Material in International Trade)”之新準則(ISPM 15)著手控制木質包裝材料之使用。根據ISPM 15準則,所有木托板均需要經熱處理或薰蒸以便確保無活害蟲自一個國家運輸至另一個國家。令人遺憾的是,並非所有類型之木材均可經熱處理且用於薰蒸之化學物質(尤其溴代甲烷)似乎會危害健康。
由於上述使用木質包裝材料之缺點,故已使用諸如塑膠、金屬、複合材料之替代性材料。然而,此等包裝材料既不環保,亦不節省成本。舉例而言,塑膠托板需要超過100年才能降解。塑膠及金屬托板亦相對成本較高及較重。因為油價達到新高,所以使用塑膠及金屬托板不再節省成本,尤其藉由航空單向運輸物品,因為費用更可能集中於包裝貨物之重量(包括托板之重量)。
習知敞開式模製方法(open-molding process)主要用來製造平薄板或板材。因為沿著週邊(parameter)無拼裝壁(built-up wall),故模製品通常需要修整且具有相對低的密度。該等方法中所用之複合材料僅需要添加低含量黏合劑而無需使用填充材料或促流劑。然而,敞開式模製品之主要缺點在於模製品之輪廓限於平薄板且通常具有標準尺寸。由修整4條邊緣所引起之損耗亦相對較高。就材料利用率而言,其並不節省成本。
與敞開式模製方法相比,藉由典型封閉式模製方法(close-molding process)製造之產品具有相對較高的密度且可產生模製品之更複雜輪廓。因為無需修整邊緣,故亦
不存在材料損耗。然而,大部分習知封閉式模製品仍然依賴於使用成本較高且不環保之金屬及塑膠。如專利公開案WO2005/120787及WO/2005/120967中所述之替代性方法已使用木纖維作為基本材料來形成可模製混合物。此等參考文獻在其用於模製其產品之可模製混合物中使用相對高百分率之木纖維且使用高百分率之三聚氰胺尿素甲醛作為液體黏合劑。其可模製混合物中所用之液體黏合劑將甲醛帶至模製品中,已知甲醛對環境有害且可能對吾等健康有害。因此,需要昂貴排氣系統在加工期間在受控環境下消除甲醛。
WO 2005/120787及WO 2005/120967中所用之可模製混合物亦需要使用大豆萃取物作為脫模劑以便自模具移出模製品,及使用棕櫚纖維作為抗衝擊改質劑以向模製品提供緩衝作用。因為使用液體黏合劑,所以根據此等方法之可模製混合物的水分含量亦相對較高。因為木纖維相對較脆且難以流動,所以用木纖維模製之產品通常具有較低衝擊及彎曲強度。為了製造具有所需性質(諸如高衝擊及彎曲強度、高密度及更重要為所需輪廓)之產品,藉由此等方法使用其他添加劑來形成可模製混合物,且亦需要大量液體來促進可模製混合物在模具中之流動以形成所需輪廓及強度。
使用大量液體黏合劑來促進可模製混合物在模製程序中流動之缺點包括:a)在模製程序期間汽化之高含量的水分增加模製混合物中之壓力,此又在打開模具時由於突然
釋放壓力而增加模製品分層之風險;b)液體黏合劑中之高水含量可使所添加之黏著劑稀釋至某一程度,導致模製時間較長,且因此需要硬化劑加速硬化過程來確保模製品在其排出之前在模具中充分固化;c)若不及時釋放經由水分/液體汽化過程產生之高壓,則該壓力可能會引起模具***。因此,將壓力排放口併入模具設計中,此舉繁重且昂貴;及d)用該方法製造之模製品通常很快導致黴菌侵襲,且具有相對高的收縮率且其容易由於模製品中之高水分含量而翹曲;e)需要藉由反覆打開及關閉模具以使過量水分/蒸汽在模製程序中逸出之另一熨燙過程以便給與模製品在其排出之前足以在模具中固化之時間。
另外,專利公開案WO 2005/120787及WO 2005/120967中所揭示之方法使用氣化銨作為硬化劑以使模製品在其排出之前在模具中硬化,因為可模製混合物具有高水分含量。硬化劑於高溫下易於硬化且因此在習知模製方法中必須避免高溫。除此以外,亦使用大豆萃取物作為脫模劑以促進排出過程。使用大豆萃取物之主要缺點在於大豆萃取物可能不會促進木纖維之木細胞之間的黏結。因此需要更多液體黏合劑來提供所需黏結性質。然而,使用愈多黏合劑,在模製程序期間放出愈多甲醛。
達成所需模製品之另一替代方法在於使用具有低水分含量之可模製混合物。然而,若可模製混合物含有在低水分含量下難以在模製腔中流動的材料,則難以模製具有複雜輪廓之產品。另外,水分含量愈低,延伸比愈低。延伸
比為可模製混合物會在密封模具中流動之程度的指數。
鑒於上述與使用木托板相關之問題(其為環境、健康或成本問題),市場上可得到之所有其他替代托板無論如何均具有其自身缺點。因此,首要的是開發一種不含甲醛且水分含量低之新穎可模製混合物。節省成本、安全且能夠製造高密度、輕質及更複雜模製品之製造模製品及相關部件的方法亦很重要。
本發明之第一態樣在於提供一種含有至少一種農業纖維、實質上不含甲醛之黏合劑及促流填充材料但不存在硬化劑、抗衝擊改質劑、共溶劑及脫模劑之可模製混合物。農業纖維可為油菜稈、水稻稈或兩者之組合,其佔混合物中之大部分。農業纖維之重量百分率介於可模製混合物總重量之85%-95%之間。可模製混合物之農業纖維具有少於可模製混合物之8重量%的水分含量。更佳地,該農業纖維之水分含量少於可模製混合物之5重量%。可模製混合物之小部分包括實質上低百分率之黏合劑,其可選自不含甲醛類之化學物質,諸如二異氰酸酯-二苯甲烷(MDI)或任何以大豆為主之黏合劑。在一較佳具體實例中,黏合劑之重量百分率不大於可模製混合物總重量之5%。該類化學物質可與農業纖維充分混合且改良農業纖維在可模製混合物中之填充。亦添加實質上低百分率之亦用作填充材料的促流劑(諸如小麥粉)以與農業纖維混合以促進可模製混合物之流動,且同時在模製期間填滿纖維細胞之間的空洞空
間。在一較佳具體實例中,促流填充材料之重量百分率少於可模製混合物之10重量%。藉由使用促流填充材料獲得之模製品相對緻密得多且其不會很快隨意自空氣吸收水分且因此其更不會很快翹曲、收縮及黴菌侵襲。本發明之一區別特徵為在可模製混合物中不存在硬化劑、抗衝擊改質劑、脫模劑及共溶劑。因為使用不大於5重量%之高黏度黏合劑且該黏合劑之性質為水分含量低,所以本發明之可模製混合物的水分含量亦相對較低。本發明之可模製混合物的組份易於獲得、簡單且節省成本。總而言之,本發明之可模製混合物的關鍵特徵為:不含甲醛。添加不大於5重量%之高黏度黏合劑,尤其二異氰酸酯-二苯甲烷(MDI)或任何以大豆為主之黏合劑作為可模製混合物組份。使用此高黏度黏合劑可保持模製混合物之總水分含量相對較低。
使用小麥粉替代木薯粉。此主要歸因於木薯粉成本很高且其不含麩質。由於木薯粉不含麩質,因此所製造之產品脆得多。另一方面,小麥粉含有稱為麩質之蛋白質。當揉捏用小麥粉製造之模製品時,麩質分子交聯形成賦予產品彈性結構之亞微觀網。此允許氣泡滯留在完整結構中,產生具有延性質地之充氣最終產品,且因此所製造之產品脆性較低。
並不添加諸如大豆萃取物之脫模劑材料及諸如氯化銨之硬化劑來形成可模製混合物。模具塗有一層市售脫模材料及有液壓頂出系統併入模具及壓力設計中,且又由於可
模製混合物之水分含量相對較低(因為使用不大於5重量%之高黏度黏合劑,尤其MDI或任何以大豆為主之黏合劑),故模製品可易於自模具排出。並不添加諸如氯化銨之硬化劑及諸如大豆萃取物之脫模劑來形成可模製混合物。由於水分含量較低,故模製品在模具中固化之時間短得多。另外,在本發明中並不添加諸如醇之共溶劑來促進固化過程,而當所用之可模製混合物的水分含量高時,使用共溶劑來加速可模製混合物中之水分的汽化過程。
相對輕質。使用諸如油菜稈及/或水稻稈之農業纖維作為基本材料。此等材料比木材或木材相關材料輕幾乎三分之一。
本發明之第二態樣係關於製造模製品及相關部件之方法,其包括以下步驟:提供用於可模製混合物之材料農業纖維、黏合劑及促流填充材料;混合該等所提供之材料以形成可模製混合物;震盪該可模製混合物為壓縮模製作準備;及壓縮模製可模製混合物以形成模製品。
本發明有別於習知模製方法之特徵包括在提供步驟期間可模製混合物之組成及水分含量不同,在混合步驟期間混合及模製週期較短及較簡單,在震盪步驟期間可模製混合物之量分配較均勻且適當,在模製步驟期間由於使用促流填充材料而使可模製混合物的延伸比較高,在模製步驟後不存在熱處理及薰蒸,及較高密度與較輕質,從而可模製較大厚度範圍之模製品。
在圖1中,所主張之製造模製品及相關部件的方法主要藉由4個步驟達成,該等步驟包括提供步驟(100)、混合步驟(120)、震盪步驟(140)及壓縮模製步驟(160)。在提供步驟中,所提供用於形成可模製混合物之農業纖維可為油菜稈、水稻稈或兩者之組合。在一具體實例中,農業纖維原料必須在與其他組份混合形成可模製混合物之前在修整步驟(圖中未示)中修整至範圍為5mm至10mm之長度。接著在乾燥步驟(圖中未示)中乾燥經修整之原料農業纖維以具有少於可模製混合物總重量之8%的水分含量,較佳具有少於可模製混合物總重量之5%的水分含量。繼農業纖維原料之乾燥步驟後為稱量步驟(圖中未示)以稱量適量之實質上乾燥農業纖維,隨後與其他組份混合形成可模製混合物。在一具體實例中,實質上乾燥農業纖維之重量百分率介於可模製混合物總重量之85%-95%之間。在提供步驟中,亦提供黏合劑來形成可模製混合物。在一具體實例中,該黏合劑為二異氰酸酯-二苯甲烷(MDI)。或者,黏合劑可為任何以大豆為主之黏合劑。在一具體實例中,可模製混合物中所用之以大豆為主之黏合劑可為大豆粉。黏合劑之重量百分率不大於可模製混合物總重量之5%。此黏合劑具有高黏度,水分含量低且不含甲醛。在提供步驟中,亦提供促流填充材料來形成可模製混合物。在一具體實例中,該促流填充材料為小麥粉。促流填充材料少於可模製混合物之10重量%。在一較佳具體實例中,在提供步驟中提供包括農業纖維、黏合劑及促流填充材料之3
種主要材料來形成可模製混合物,但在同一提供步驟中不提供硬化劑、抗衝擊改質劑、共溶劑及脫模劑。在一具體實例中,對於形成可模製混合物,並不在提供步驟中提供諸如氯化銨之硬化劑、諸如大豆萃取物之脫模劑、諸如醇之共溶劑及諸如棕櫚纖維之抗衝擊改質劑。
在圖1中,在稱量步驟(圖中未示)中稱量實質上乾燥農業纖維後,在混合步驟(120)中將85重量%-95重量%之實質上乾燥農業纖維(諸如油菜稈、水稻稈或油菜稈與水稻稈之組合)與其他組份混合形成可模製混合物。在一具體實例中,該混合步驟為兩步混合步驟。在兩步混合步驟之第一部分中,將85重量%-95重量%之實質上乾燥農業纖維與少於10重量%之促流填充材料(諸如小麥粉)於混合機(圖中未示)中混合。在一具體實例中,該混合機帶有水平旋轉葉片(4個安裝於水平軸上之葉片)且其以約20rpm至30rpm旋轉。在兩步混合步驟之第一部分中,當在混合機中攪拌農業纖維時,將少於10重量%之小麥粉引入攪拌農業纖維中。在兩步混合步驟之第二部分中,亦藉由噴霧(圖中未示)將不大於5重量%之黏合劑(諸如二異氰酸酯-二苯甲烷(MDI)或任何以大豆為主之黏合劑)引入混合機中。在一具體實例中,用壓力噴嘴於約5巴至8巴之壓力下將不大於5重量%之MDI噴入農業纖維與促流填充材料之攪拌混合物中。在另一具體實例中,用壓力噴嘴於約5巴至8巴之壓力下將不大於5重量%之以大豆為主的黏合劑(諸如大豆粉)噴入農業纖維與促流填充材料之
攪拌混合物中。在混合步驟中,使農業纖維、促流填充材料及黏合劑之混合物保持攪拌直至摻合該混合物形成可模製混合物為止。在一具體實例中,混合步驟之整個旋轉週期耗時少於3分鐘。
在圖1中,在完成混合步驟(120)後,可模製混合物準備在震盪步驟(140)中將可模製混合物饋送至模具中。在該震盪步驟中,將可模製混合物裝載至中型散裝容器(Intermediate Bulk Container,IBC)(圖中未示)中且接著經由稱料漏斗(圖中未示)排放至裝料台(圖中未示)上之饋料盤中。接著使裝滿可模製混合物之饋料盤自裝料台轉移至進行壓縮模製(160)之壓製區域(圖中未示)。在一具體實例中,可模製混合物已在將可模製混合物經由稱料漏斗自IBC排放至饋料盤中的整個過程中經震盪。在另一具體實例中,含有可模製混合物之饋料盤亦已在將可模製混合物自饋料盤裝載至底部模具之空腔之進行壓縮模製的壓製區域的整個過程中經震盪。
在圖1中,震盪(140)可模製混合物後,可模製混合物準備在壓縮模製步驟(160)中經受壓縮。壓縮模製步驟係以單一壓縮衝程執行。在一具體實例中,壓縮模製步驟在介於200-230℃之間的溫度下進行。在一具體實例中,在介於200-230℃之間的溫度下經由內熱轉移加熱模具。在介於0.30kg/mm2至0.40kg/mm2之間的壓力下壓縮可模製混合物1.5分鐘至2.5分鐘。壓縮模製後,將模製品排出模具且接著轉移至鄰接於壓製區域之填充區域。在自模具排出
後,不使模製品經受用於殺死任何活害蟲之熱處理及薰蒸。
圖2中給出混合及震盪可模製混合物之一實施例。在該實施例中,中型散裝容器(IBC)(81)位於獨立裝料台(85)之頂部。可模製混合物(圖中未示)可經由排料螺桿(圖中未示)排放至稱料漏斗(82)中且接著進一步以逐列方式排放至饋料盤(83)中。完成排放後,接著將饋料盤沿盤移動路徑(84)轉移至進行壓縮模製步驟之壓製區域(88)。藉由液壓機(86)將轉移至模具(87)中之壓製區域之可模製混合物壓縮成模製品。
圖3中給出饋料盤之一實施例。在該實施例中,饋料盤(310)之俯視圖展示其可具有1.4×1.2×0.2公尺(長×寬×高)之平均尺寸且可分成35至49個隔室以滿足裝載不同重量之可模製混合物以模製成在產品之不同部分具有不同輪廓及厚度之產品的需求。每一隔室(320)設計成裝載不同重量之可模製混合物。此確保將適量之可模製混合物均勻地裝載至模具中之預定位置以優化模製結果及材料利用率。其亦有助於促進模製程序提供最大延伸比且使模製品能夠在產品之不同部分具有不同輪廓及厚度。隔室之組合根據模製品之複雜性及尺寸而變化。為了促進在模製步驟期間農業纖維在模具中之流動,藉由薄鋼板(圖中未示)以十字形方式建構饋料盤之隔板以形成所需隔室。
圖3中所給出之實施例展示饋料盤之仰視圖具有一片焊接於鋼隔板底面之金屬絲網(330)。整個鋼隔板連接於安裝有振動器之旋轉棒(圖中未示)。鋼隔板以及焊接之金
屬絲網可用於在將可模製混合物自饋料盤排放至模具之壓製區域(圖中未示)的整個過程中於水平方向上震盪。接著當將饋料盤轉移至模具之壓製區域時,藉由於水平方向上滑動而打開安裝於饋料盤底部之閘門(340)。
在焊接之金屬絲網上方,將如圖4中所示之另外4個振動器(410)安裝於饋料盤之4個角上,該4個角亦在排放及裝載可模製混合物的整個過程中同時沿垂直方向震盪。
在圖5之下半部分中,在壓縮模製步驟之前,藉助於由具有振動器(圖5中未示)之旋轉棒及如上文所述之饋料盤之4個角上的另外4個振動器(550)所產生之水平與垂直振動運動將可模製混合物(530)以均勻分散方式排放至底部模具(560)之空腔中。由於當使用習知方法時,在無任何震盪之情況下將可模製混合物自習知饋料盤(510)裝載至底部模具中始終形成***堆積(520),故將此種震盪特徵併入本發明中。另一方面,本發明之饋料盤(540)必須藉由底面之4個角上的另外4個振動器(550)來調平以在將可模製混合物自饋料盤裝載至底部模具之壓製區域中時能夠實現震盪。該特徵可達成實現最優模製結果,亦即最小模製壓力、最少材料使用。該特徵亦使可模製混合物能夠自由流動至可藉由延伸比確定之所需高度。在可模製混合物裝滿底部模具之空腔後,可使饋料盤返回至原始位置以進行再裝填。
圖6中給出用於模製之液壓頂出系統的說明。在該實
施例中,液壓頂出器(630)位於底部模具之壓製區域的下方。在一具體實例中,在介於200-230℃之間的溫度下於壓製區域中模製可模製混合物。頂部(610)與底部(620)模具皆裝備有各種鋼管(圖中未示)。熱油經電加熱且在模具內之油路中循環。由於經由模製中之熱傳遞來加熱模具,因此其可達成較低能量損失。
在一具體實例中,在介於0.30kg/mm2至0.40kg/mm2之間的壓力下於壓製區域中壓縮可模製混合物1.5分鐘至2.5分鐘。壓縮模製以單一壓縮衝程執行。無需反覆打開及關閉模具,亦無需熨燙來釋放過量水分以防止可能的模具***,因為本發明之可模製混合物具有相對低的水分含量。壓縮後,用液壓系統(630)使模製部件排出底部模具。將機械取置系統(圖中未示)併入饋料系統中以取出模製部件且將模製部件轉移至鄰接於壓製區域之填充區域(圖中未示)。因為模製品已在模製程序中經受高溫及高壓,所以不需要用於殺死模製品中之活害蟲的進一步加熱及薰蒸步驟。
圖7說明在模製步驟中之壓縮前後模具中之模製部件的截面。該圖之上半部分展示在壓縮模製步驟之前底部模具(740)空腔中之可模製混合物(720)的截面,而該圖之下半部分展示在壓縮模製步驟後頂部模具(780)與底部模具(790)之間的空腔中之模製品(760)之一部分的截面。在一具體實例中,以0.30kg/mm2至0.40kg/mm2之壓力將頂部模具(780)壓在底部模具(790)之空腔中的可
模製混合物上以形成模製品(760)。將可模製混合物壓縮模製成模製品之一部分為無需反覆打開及關閉模具之單一壓縮衝程。在一具體實例中,在介於200-230℃之間的溫度下,壓縮後之可模製混合物沿密封模具之水平模製空腔向上流動。可測定模製品(760)之一部分沿密封模具之水平模製空腔的高度(750)。由將壓縮後模製部件(760)在密封模具之水平模製空腔中的高度(750)除以壓縮前可模製混合物(720)在底部模具(740)之空腔中的高度(710)來獲得可模製混合物之延伸比。該比率反映在模製期間可模製混合物之向上流動能力。
由於高延伸比及高密度,模製部件可具有波紋狀之複雜輪廓,諸如圖8中所示之托板(830)之流槽(810)及板條(820)。在不經任何後熱處理及薰蒸之情況下,模製品可供使用或可反覆使用。
雖然本發明已用實施例至較佳具體實例來描述,但顯而易見,在不脫離本文所附申請專利範圍之範疇或精神的情況下,熟習此項技術者可作其他改變及修改。
工業適用性
本發明提供一種可模製混合物及基於所主張之可模製混合物來製造模製品及相關部件之方法。所主張之可模製混合物可應用於建構材料及製造諸如托板及相關部件之模製品的領域。所主張之製造方法可應用於製造具有更佳品質之建構產品或模製品。
81‧‧‧中型散裝容器(IBC)
82‧‧‧稱料漏斗
83‧‧‧饋料盤
84‧‧‧盤移動路徑
85‧‧‧獨立裝料台
86‧‧‧液壓機
87‧‧‧模具
88‧‧‧壓製區域
100‧‧‧提供步驟
120‧‧‧混合步驟
140‧‧‧震盪步驟
160‧‧‧壓縮模製步驟
310‧‧‧饋料盤
320‧‧‧隔室
330‧‧‧金屬絲網
340‧‧‧閘門
410‧‧‧振動器
510‧‧‧習知饋料盤
520‧‧‧***堆積
530‧‧‧可模製混合物
540‧‧‧饋料盤
550‧‧‧振動器
560‧‧‧底部模具
610‧‧‧頂部模具
620‧‧‧底部模具
630‧‧‧液壓頂出器/液壓系統
710‧‧‧高度
720‧‧‧可模製混合物
740‧‧‧底部模具
750‧‧‧高度
760‧‧‧模製品/模製部件
780‧‧‧頂部模具
790‧‧‧底部模具
810‧‧‧流槽
820‧‧‧板條
830‧‧‧模製品/托板
圖1展示製造封閉模製品之流程圖。
圖2為用於在整個自IBC排放可模製混合物過程中震盪可模製混合物直至將可模製混合物裝載至模具中之裝置的圖示。
圖3展示震盪步驟中所用之饋料盤的俯視圖及仰視圖。
圖4為饋料盤之放大圖像,其展示每一角上用於在震盪步驟期間震盪可模製混合物之額外振動器。
圖5展示本發明中用於將可模製混合物裝載至底部模具之壓製區域的具有震盪特徵之饋料盤(下半部分)的設計與無震盪特微之習知饋料盤(上半部分)的設計之比較。
圖6為模製步驟中壓製區域處之模具及液壓機的放大圖像。
圖7展示在模製步驟中之壓縮前後具有可模製混合物之頂部及底部模具之截面。
圖8展示本發明之模製托板的側面預期圖。
810‧‧‧流槽
820‧‧‧板條
830‧‧‧模製品/托板
Claims (12)
- 一種製造模製品之方法,其包含以下步驟:a.提供農業纖維、黏合劑及含麩質促流填充材料;b.先使該農業纖維與該促流填充材料混合,然後再與該黏合劑混合以形成可模製混合物;c.震盪該可模製混合物為壓縮模製作準備;d.壓縮模製該可模製混合物以形成模製品,其中該混合進一步包含在介於5巴至8巴之間的壓力下將該黏合劑噴入含該促流填充材料之該農業纖維中,其中該黏合劑為用量為不大於該可模製混合物之5重量%的二異氰酸酯-二苯甲烷或以大豆為主之黏合劑。
- 如申請專利範圍第1項之方法,其中該促流填充材料為小麥粉,其少於該建構模製混合物之10重量%。
- 如申請專利範圍第1項之方法,其中該混合在不存在硬化劑、抗衝擊改質劑、共溶劑及脫模劑之情況下進行且不含甲醛。
- 如申請專利範圍第1項之方法,其中該震盪進一步包含經由排料螺桿將該可模製混合物排放至稱料漏斗中且接著進一步排放至分成至少35個隔室之饋料盤中。
- 如申請專利範圍第7項之方法,其中繼該排放後將該可模製混合物自該饋料盤轉移至同時水平及垂直振動或震盪運動之模具中,為壓縮模製作準備。
- 如申請專利範圍第1項之方法,其中該壓縮模製以單一壓縮衝程且在整個模製程序中無任何壓力釋放機構之情 況下執行,其中該總模製時間少於1分鐘。
- 如申請專利範圍第9項之方法,其中該單一壓縮衝程在延伸比為1至10及在整個模製程序中無任何壓力釋放機構之情況下執行,其中該總模製時間少於1分鐘。
- 如申請專利範圍第1項之方法,其中該壓縮模製係於攝氏200至230度之溫度下執行,其中製造出托板作為該壓縮模製之結果。
- 如申請專利範圍第1項之方法,其中該壓縮模製係於0.30至0.40kg/mm2之壓力下執行,其中製造出托板作為該壓縮模製之結果。
- 一種由申請專利範圍第1項至第9項中任一項之方法所製造之可模製混合物,其中該可模製混合物中不存在硬化劑、抗衝擊改質劑、共溶劑及脫模劑。
- 如申請專利範圍第10項之可模製混合物,其中該黏合劑不含甲醛。
- 如申請專利範圍第10項之可模製混合物,其中該促流填充材料為小麥粉,其少於該可模製混合物之10重量%。
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CN105171889A (zh) * | 2015-05-22 | 2015-12-23 | 中国装饰股份有限公司 | 地板压制设备 |
US20220242007A1 (en) * | 2016-03-21 | 2022-08-04 | Bondcore öU | Composite wood panels with corrugated cores and method of manufacturing same |
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US20130234356A1 (en) | 2013-09-12 |
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EP2321371B1 (en) | 2016-09-07 |
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AU2008357242B2 (en) | 2012-02-23 |
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US20110024932A1 (en) | 2011-02-03 |
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