WO2004000529A1 - Method for producing parts from high-grade lignocellulose fiber-filled thermoplastics - Google Patents

Method for producing parts from high-grade lignocellulose fiber-filled thermoplastics Download PDF

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Publication number
WO2004000529A1
WO2004000529A1 PCT/EP2003/006595 EP0306595W WO2004000529A1 WO 2004000529 A1 WO2004000529 A1 WO 2004000529A1 EP 0306595 W EP0306595 W EP 0306595W WO 2004000529 A1 WO2004000529 A1 WO 2004000529A1
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WIPO (PCT)
Prior art keywords
fibers
filled
thermoplastic
lignocellulose
fiber
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PCT/EP2003/006595
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German (de)
French (fr)
Inventor
Maik Ziegler
Jürgen BRUNNING
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Fagerdala Deutschland Gmbh
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Publication date
Priority claimed from DE2002128191 external-priority patent/DE10228191A1/en
Application filed by Fagerdala Deutschland Gmbh filed Critical Fagerdala Deutschland Gmbh
Priority to AU2003250844A priority Critical patent/AU2003250844A1/en
Publication of WO2004000529A1 publication Critical patent/WO2004000529A1/en

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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
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
    • 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
    • B27N3/08—Moulding or pressing
    • 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
    • B27N3/08—Moulding or pressing
    • B27N3/28—Moulding or pressing characterised by using extrusion presses
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • 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
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • 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
    • 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
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • 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
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10—Homopolymers or copolymers of propene

Definitions

  • the invention relates to a method for producing plastic
  • Molded parts consisting of a thermoplastic matrix and 60 to 98% by weight of lignocellulose fibers.
  • plastic moldings with a high fiber content.
  • components made of polymers as a matrix in connection with fibers as a filler or for reinforcement are manufactured.
  • Glass or carbon fibers are mainly used for high-strength components.
  • components for the automobile interior are known, whereby these are often manufactured from thermosets and natural fibers in the pressing process.
  • Wood fibers in connection with polypropylene are also increasingly used in the automotive sector.
  • the maximum proportion of wood fiber in the extrusion process in the manufacture of panels and semi-finished products is 50%. Further applications can also be found in landscaping and in the furniture industry, whereby the fiber-matrix adhesion and thus the quality and strength of the components are reduced as the degree of filling increases.
  • DE 199 34 871 describes an embodiment of an extrusion tool for shaping polymers with approximately 90% wood fiber content. The premixing and composition of the is also problematic
  • DE 198 52 067 describes the composition of natural fiber reinforced plastics using hemp fibers
  • US 76685 describes a process which includes the premixing and the subsequent extrusion of wood-filled thermoplastics with filler contents of up to 75%.
  • the adhesion between natural fibers and matrix polymer is also increased when adding thermoplastics and natural fibers by adding silanes, maleic anhydride or isocyanates and dimeric alkyl ketene.
  • maleic anhydride the anhydride group reacts with the hydroxyl groups of the cellulose fibers.
  • a non-polar bond is attached to the fiber, which in turn is soluble in a non-polar plastic matrix and thus increases the adhesive strength.
  • the current process for achieving high fill levels for plastics filled with natural fibers and ensuring fiber-matrix adhesion is associated with a high expenditure of time, energy and costs.
  • the natural fibers are dried extensively and are often treated chemically with bactericides and fungicides.
  • New processes for the digestion and separation of lignocellulosic fibers into the constituents lignin and cellulose can be used for the preparation and extraction of various fiber constituents such as lignin, which subsequently enable thermoplastic processing; however, complex process steps are also necessary here.
  • the invention is therefore based on the object of providing a method by which inexpensive, high-quality molded parts with high strength can be produced, which are made of thermoplastic materials
  • lignocellulose fiber content 60% to 98%, preferably wood fibers and polypropylene.
  • This object is achieved according to the invention by a process for the production of moldings from filled thermoplastic material with a filler content of at least 60% by weight, in which lignocellulose fibers are used as filler, which are mixed with the thermoplastic and processed by extrusion of the mixture, and in which the processed mixture is pressed in a shaping tool.
  • the extrusion pressures for gentle processing can be between 40 and 450 bar, preferably they are in the range of around 100 bar and are realized using planetary roller extruders.
  • the pressures for the final shaping are essential for the component strength and must be correspondingly higher between 100 bar and 5000 bar, preferably in the range around 1000 bar.
  • these compression pressures achieve an at least partial digestion of the fibers and thus an at least partial separation of the lignin portion from the natural fibers.
  • the thermoplastic properties of the deposited lignin result in a of the fibers and a connection to the thermoplastic components as well as an increased fluidity of the composite material.
  • the thermoplastic properties of the lignin in conjunction with the synthetic thermoplastic thus act as a binder and contribute to increased fiber-matrix adhesion after the compression molding process has been completed.
  • composite components is possible using the pressing process.
  • other composite partners can preferably be molded from the same base material as the polymer matrix in a foamed and unfoamed version.
  • An inexpensive lignocellulose-filled base body can thus be manufactured in one production step with soft foamed and / or textile decorative materials.
  • An advantageous variant is the use of lignocellulosic fibers with a moisture content of the fibers greater than 3% and pressures around 1000 bar during the pressing process and 100 bar during the previous preparation process.
  • the moisture of the wood fibers in connection with an overpressure can support a disintegration of the fibers and thus an at least partial separation of the lignin portion of the natural fibers and a subsequent better wettability.
  • plunge edge tools Another variant is the use of plunge edge tools.
  • the tool filling process takes place when the tool is not completely closed.
  • the internal pressure of the mold can be regulated via a subsequent post-compression by closing the tool after the filling process, which likewise leads to the effect described in connection with the pressing presses and increases the strength of the plastic moldings obtained.
  • adhesion promoters such as silanes, anhydrides, isocyanates or alkyl ketene during the process or a pretreatment of the fibers with adhesion promoters and / or copolymerization with a non-polar polymer, preferably polyolefin, causes a reaction with the hydroxyl groups of the cellulose fibers and thus better solubility and increased fiber - Matrix liability.
  • An advantage of this process is primarily the possibility of producing components with a high proportion of lignocellulose fibers, preferably wood fibers, in the strand laying process, which are significantly less expensive than pure wooden components or also pure plastic components.
  • the shape of the components can be selected almost arbitrarily via the tool design, which in comparison to solid wooden molded parts enables rational production of components without post-processing.
  • the highly filled plastics are characterized by similar properties to wood, have high strength and can be seen above all as an inexpensive alternative to solid wood parts. In this way, components such as hat racks, sun visors, pillar trims, door side trims, instrument panels, sports and leisure equipment, etc. can be manufactured.
  • the introduction of decorative or functional materials for the stiffness-imparting wood-filled thermoplastics into the shaping tool can be implemented particularly advantageously.
  • wood fibers with a moisture of 2-10% are added to a polypropylene granulate or powder.
  • the mixture is achieved via manual premixing or via premixed pellets or through metering devices or for fiber addition via a forced feed in a planetary roller extruder.
  • the mixture (extrudate) extruded at a pressure of approximately 100 bar is subsequently fed into a press tool and, if necessary, with other network partners, e.g. Decorative materials, pressed to a shaped body at a pressure of about 1000 bar.

Abstract

The invention relates to a method for producing shaped parts, which are comprised of a thermoplastic matrix and of a filler portion consisting of at least 60 % lignocellulose fibers. In order to increase the adhesion between the fibers and the matrix, the lignocellulose fibers are mixed with the thermoplastic, processed by extruding the mixture, and the processed mixture is then molded inside a shaping tool.

Description

Verfahren zur Herstellung von Bauteilen aus hochgradig lignocellulosefaser-gefüllten Thermoplasten Process for the production of components from highly lignocellulosic fiber-filled thermoplastics
Die Erfindung betrifft ein Verfahren zur Herstellung von Kunststoff-The invention relates to a method for producing plastic
Formteilen, die aus einer thermoplastischen Matrix und 60 bis 98 Gew.-% Lignocellulosefasern bestehen.Molded parts consisting of a thermoplastic matrix and 60 to 98% by weight of lignocellulose fibers.
Es ist bekannt, Kunststoffforrnkörper mit hohem Faseranteil herzustellen. Mittels Extrusions-, Press- oder Spritzgießverfahren werden dabei Bauteile aus Polymeren als Matrix in Verbindung mit Fasern als Füllstoff oder zur Verstärkung gefertigt. Für hochfeste Bauteile werden im wesentlichen Glas- oder Kohlefasern eingesetzt. Im Bereich der hochgefüllten naturfaserverstärkten Kunststoffe sind Bauteile für den Automobilinnenraum bekannt, wobei diese häufig aus Duromeren und Naturfasern im Pressverfahren hergestellt werden. Auch Holzfasern in Verbindung mit Polypropylen werden im Automobilbereich immer häufiger eingesetzt. Der maximale Holzfaseranteil im Extrusionsverfahren bei der Fertigung von Platten und Halbzeugen liegt hier bei 50 %. Weitere Anwendungen sind auch im Landschaftsbau und in der Möbel-Industrie zu finden, wobei hier mit steigendem Füllgrad die Faser-Matrix-Haftung und damit Qualität und Festigkeit der Bauteile reduziert wird.It is known to produce plastic moldings with a high fiber content. By means of extrusion, pressing or injection molding processes, components made of polymers as a matrix in connection with fibers as a filler or for reinforcement are manufactured. Glass or carbon fibers are mainly used for high-strength components. In the field of highly filled natural fiber reinforced plastics, components for the automobile interior are known, whereby these are often manufactured from thermosets and natural fibers in the pressing process. Wood fibers in connection with polypropylene are also increasingly used in the automotive sector. The maximum proportion of wood fiber in the extrusion process in the manufacture of panels and semi-finished products is 50%. Further applications can also be found in landscaping and in the furniture industry, whereby the fiber-matrix adhesion and thus the quality and strength of the components are reduced as the degree of filling increases.
Die Füllgrade beim Extrusions- und Spritzgießprozess sind begrenzt. Mit konventionellen Extrusionswerkzeugen lassen sich nur maximale Füllgrade von ca. 50% Naturfaseranteil erreichen.The filling levels in the extrusion and injection molding process are limited. Conventional extrusion tools can only achieve maximum fill levels of around 50% natural fiber.
Eine vollständige Formgebung bei höheren Füllgraden lässt sich nur unter Einsatz spezieller Extrusionswerkzeuge erzielen. DE 199 34 871 beschreibt eine Ausführung eines Extrusionswerkzeuges zur Formgebung von Polymeren mit ca. 90 % Holzfaseranteil. Problematisch ist ebenfalls die Vormischung und Zusammensetzung derComplete shaping at higher fill levels can only be achieved using special extrusion tools. DE 199 34 871 describes an embodiment of an extrusion tool for shaping polymers with approximately 90% wood fiber content. The premixing and composition of the is also problematic
Werkstoffkomponenten. DE 198 52 067 beschreibt die Zusammensetzung naturfaserverstärkter Kunststoffe unter Einsatz von Hanffasern, und US 76685 beschreibt ein Verfahren welches das Vormischen und die anschließende Extrusion holzgefüllter Thermoplaste mit Füllstoffgehalten bis zu 75 % beinhaltet.Material components. DE 198 52 067 describes the composition of natural fiber reinforced plastics using hemp fibers, and US 76685 describes a process which includes the premixing and the subsequent extrusion of wood-filled thermoplastics with filler contents of up to 75%.
Die Haftung zwischen Naturfasern und Matrixpolymer wird bei der Verbindung von Thermoplasten und Naturfasern auch durch Zugabe von Silanen, Maleinsäureanhydrid oder Isocyanaten und dimeren Alkylketenen gesteigert. Bei Maleinsäureanhydrid reagiert die Anhydridgruppe mit den Hydroxylgruppen der Cellulosefasem. So wird eine unpolare Bindung an die Faser angebracht, die wiederum in einer unpolaren Kunststoff-Matrix löslich ist und damit die Haftfestigkeit erhöht. Die aktuellen Verfahren zur Erzielung hoher Füllgrade bei Naturfaser-gefüllten Kunststoffen und eine Gewährleistung der Faser- Matrixhaftung ist jedoch mit einem hohen Aufwand an Zeit, Energie und Kosten verbunden. Insbesondere werden die Naturfasern aufwendig getrocknet und häufig chemisch mit Bakteriziden und Fungiziden behandelt.The adhesion between natural fibers and matrix polymer is also increased when adding thermoplastics and natural fibers by adding silanes, maleic anhydride or isocyanates and dimeric alkyl ketene. With maleic anhydride, the anhydride group reacts with the hydroxyl groups of the cellulose fibers. A non-polar bond is attached to the fiber, which in turn is soluble in a non-polar plastic matrix and thus increases the adhesive strength. However, the current process for achieving high fill levels for plastics filled with natural fibers and ensuring fiber-matrix adhesion is associated with a high expenditure of time, energy and costs. In particular, the natural fibers are dried extensively and are often treated chemically with bactericides and fungicides.
Der Einsatz von Pressverfahren, wie sie häufig für naturfaserverstärkte Duroplaste eingesetzt werden, zeichnet sich durch hohe Taktzeiten und eine Begrenzung in der Formgebung aus. Im Extrusionsverfahren lassen sich mit speziellen Werkzeugen Werkstoffe mit Holzfaseranteil von über 90 % herstellen, hierbei handelt es sich jedoch um Profile oder Halbzeuge, die ebenfalls nur eine begrenzte Formgebung zulassen. Formteile mit Naturfaseranteilen über 50% lassen sich im Spritzgießverfahren bislang nur mit erhöhtem Aufwand und unter Einsatz von Haftvermittlern zur Vorbehandlung der Fasern zur Erhöhung der Faser-Matrix-Haftung herstellen.The use of pressing processes, as they are often used for natural fiber reinforced thermosets, is characterized by high cycle times and a limitation in shape. In the extrusion process, special tools can be used to produce materials with a wood fiber content of over 90%, but these are profiles or semi-finished products that also only allow a limited shape. Molded parts with natural fiber proportions above 50% have so far only been able to be produced in an injection molding process with increased effort and with the use of adhesion promoters for pretreating the fibers in order to increase the fiber matrix adhesion.
Neue Verfahren zum Aufschluss und Separieren von Lignocellulosefasern in die Bestandteile Lignin und Cellulose können zur Aufbereitung und Gewinnung verschiedener Faserbestandteile wie beispielsweise Lignin herangezogen werden, die im Anschluß eine thermoplastische Weiterverarbeitung ermöglichen; jedoch sind hier ebenfalls aufwendige Prozeßschritte notwendig. Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren bereitzustellen, mit dem kostengünstige, qualitativ hochwertige Formteile mit hoher Festigkeit herstellbar sind, die aus thermoplastischen Kunststoffen inNew processes for the digestion and separation of lignocellulosic fibers into the constituents lignin and cellulose can be used for the preparation and extraction of various fiber constituents such as lignin, which subsequently enable thermoplastic processing; however, complex process steps are also necessary here. The invention is therefore based on the object of providing a method by which inexpensive, high-quality molded parts with high strength can be produced, which are made of thermoplastic materials
Verbindung mit einem Lignocellulosefaseranteil von 60 % bis 98 % bestehen, wobei vorzugsweise Holzfasern und Polypropylen eingesetzt werden.There is a connection with a lignocellulose fiber content of 60% to 98%, preferably wood fibers and polypropylene.
Diese Aufgabe wird erfindungsgemäß gelöst durch ein Verfahren zur Herstellung von Formteilen aus gefülltem thermoplastischem Kunststoff mit einem Füllstoffgehalt von mindestens 60 Gew.-%, bei dem als Füllstoff Lignocellulosefasern verwendet werden, die mit dem Thermoplasten vermischt und durch Extrusion des Gemischs aufbereitet werden, und bei dem das aufbereitete Gemisch in einem formgebenden Werkzeug verpreßt wird.This object is achieved according to the invention by a process for the production of moldings from filled thermoplastic material with a filler content of at least 60% by weight, in which lignocellulose fibers are used as filler, which are mixed with the thermoplastic and processed by extrusion of the mixture, and in which the processed mixture is pressed in a shaping tool.
Vorteilhafte Ausführungsformen dieses Verfahrens sind zusätzlich durch die Merkmale der Patentansprüche 2 bis 18 gekennzeichnet.Advantageous embodiments of this method are additionally characterized by the features of claims 2 to 18.
Die Verfahrensschritte des Aufbereitens und Verpressens sind sowohl im Spritzgießverfahren, Strangablegeverfahren und im Pressverfahren aufbereiteter und ggf. vorgewärmter extrudierter Halbzeuge möglich.The process steps of preparation and pressing are possible both in the injection molding process, strand laying process and in the press process processed and, if necessary, preheated extruded semi-finished products.
Ein Feuchtigkeitsanteil der Lignocellulosefasern zwischen 2 und 8 Gew.-%, vorzugsweise 4 Gew.-%, bewirkt nicht nur eine verbesserte Anbindung der Fasern an die Polymermatrix sondern verbessert insbesondere die Gleiteigenschaften während des Extrusionsvorganges.A moisture content of the lignocellulose fibers of between 2 and 8% by weight, preferably 4% by weight, not only brings about an improved connection of the fibers to the polymer matrix, but in particular improves the sliding properties during the extrusion process.
Die Extrusionsdrücke können für eine schonende Aufbereitung zwischen 40 und 450 bar liegen, vorzugsweise liegen sie im Bereich um 100 bar und werden über Planetwalzenextruder realisiert. Die Pressdrücke für die endgültige Formgebung hingegen sind wesentlich für die Bauteilfestigkeit und müssen entsprechend höher zwischen 100 bar und 5000 bar, vorzugsweise im Bereich um 1000 bar, liegen. Durch diese Preßdrücke wird bei Lignocellulosefasern ein zumindest teilweiser Aufschluß der Fasern und damit eine zumindest teilweise Separation des Lignin- Anteils von den Naturfasern erreicht. Die thermoplastischen Eigenschaften des abgeschiedenen Lignins bewirken so eine Benet- zung der Fasern und eine Anbindung an die thermoplastischen Bestandteile sowie eine erhöhte Fließfähigkeit des Werkstoffverbundes. Die thermoplastischen Eigenschaften des Lignins in Verbindung mit dem synthetischen Thermoplasten wirken so als Binder und tragen zu einer erhöhten Faser-Matrix-Haftung nach Abschluß des Formpreßvorganges bei.The extrusion pressures for gentle processing can be between 40 and 450 bar, preferably they are in the range of around 100 bar and are realized using planetary roller extruders. The pressures for the final shaping, on the other hand, are essential for the component strength and must be correspondingly higher between 100 bar and 5000 bar, preferably in the range around 1000 bar. With lignocellulosic fibers, these compression pressures achieve an at least partial digestion of the fibers and thus an at least partial separation of the lignin portion from the natural fibers. The thermoplastic properties of the deposited lignin result in a of the fibers and a connection to the thermoplastic components as well as an increased fluidity of the composite material. The thermoplastic properties of the lignin in conjunction with the synthetic thermoplastic thus act as a binder and contribute to increased fiber-matrix adhesion after the compression molding process has been completed.
Die Fertigung von Verbundbauteilen ist im Pressverfahren möglich. So können weitere Verbundpartner vorzugsweise aus dem gleichen Grundwerkstoff wie die Polymermatrix in geschäumter und ungeschäumter Ausführung mit verpresst werden. Ein kostengünstiger lignocellulosegefüllter Grundkörper kann somit mit weichen geschäumten und/oder textilen Dekorwerkstoffen in einem Fertigungsgang gefertigt werden.The production of composite components is possible using the pressing process. For example, other composite partners can preferably be molded from the same base material as the polymer matrix in a foamed and unfoamed version. An inexpensive lignocellulose-filled base body can thus be manufactured in one production step with soft foamed and / or textile decorative materials.
Eine vorteilhafte Variante ist der Einsatz von Lignocellulosefasern mit einer Feuchte der Fasern größer 3 % und Drücken um 1000 bar beim Pressvorgang und 100 bar beim vorhergehenden Aufbereitungsverfahren. Über die Feuchtigkeit der Holzfasern in Verbindung mit einem Überdruck kann ein Aufschluss der Fasern und damit eine zumindest teilweise Separation des Lignin-Anteils der Naturfasern und eine anschließende bessere Benetzbarkeit unterstützt werden.An advantageous variant is the use of lignocellulosic fibers with a moisture content of the fibers greater than 3% and pressures around 1000 bar during the pressing process and 100 bar during the previous preparation process. The moisture of the wood fibers in connection with an overpressure can support a disintegration of the fibers and thus an at least partial separation of the lignin portion of the natural fibers and a subsequent better wettability.
Eine weitere Variante ist der Einsatz von Tauchkantenwerkzeugen. Der Werkzeugfüllvorgang erfolgt bei nicht komplett geschlossenem Werkzeug. Über eine anschließende Nachverdichtung durch Schließen des Werkzeuges im Anschluß an den Füllvorgang kann der Werkzeuginnendruck geregelt werden, was ebenfalls zu dem im Zusammenhang mit den Preßdrücken beschriebenen Effekt führt und die Festigkeit der erhaltenen Kunststoff-Formkörper erhöht.Another variant is the use of plunge edge tools. The tool filling process takes place when the tool is not completely closed. The internal pressure of the mold can be regulated via a subsequent post-compression by closing the tool after the filling process, which likewise leads to the effect described in connection with the pressing presses and increases the strength of the plastic moldings obtained.
Eine Zugabe von Haftvermittlern wie Silanen, Anhydriden, Isocyanaten oder Alkylketenen während des Prozesses oder ein Vorbehandeln der Fasern mit Haftvermittlern und/oder Copolymerisation mit einem unpolaren Polymer, vorzugsweise Polyolefin, bewirkt eine Reaktion mit den Hydroxylgruppen der Cellulosefasem und damit eine bessere Löslichkeit und erhöhte Faser- Matrixhaftung. Vorteilhaft bei diesem Verfahren ist in erster Linie die Möglichkeit, Bauteile mit hohem Anteil an Lignocellulosefasern, vorzugsweise Holzfasern, im Strangablegeverfahren herzustellen, die wesentlich preisgünstiger als reine Holzbauteile oder auch reine Kunststoffbauteile sind. Die Formgebung der Bauteile ist über die Werkzeuggestaltung nahezu beliebig wählbar, womit im Vergleich zu massiven Holzformteilen eine rationelle Fertigung von Bauteilen ohne Nachbearbeitung ermöglicht wird. Die hochgefüllten Kunststoffe zeichnen sich durch ähnliche Eigenschaften wie Holz aus, weisen eine hohe Festigkeit auf und sind vor allem als preiswerte Alternative zu Massivholzteilen zu sehen. Auf diese Weise können Bauteile wie Hutablagen, Sonnenblenden, Säulenverkleidungen, Türseitenverkleidungen, Instrumententafeln, Sport- und Freizeitgeräte etc. gefertigt werden. Die Einbringung von dekorativen oder funktionellen Werkstoffen zum steifigkeitsgebenden holzgefüllten Thermoplasten in das formgebende Werkzeug ist dabei besonders vorteilhaft umsetzbar.An addition of adhesion promoters such as silanes, anhydrides, isocyanates or alkyl ketene during the process or a pretreatment of the fibers with adhesion promoters and / or copolymerization with a non-polar polymer, preferably polyolefin, causes a reaction with the hydroxyl groups of the cellulose fibers and thus better solubility and increased fiber - Matrix liability. An advantage of this process is primarily the possibility of producing components with a high proportion of lignocellulose fibers, preferably wood fibers, in the strand laying process, which are significantly less expensive than pure wooden components or also pure plastic components. The shape of the components can be selected almost arbitrarily via the tool design, which in comparison to solid wooden molded parts enables rational production of components without post-processing. The highly filled plastics are characterized by similar properties to wood, have high strength and can be seen above all as an inexpensive alternative to solid wood parts. In this way, components such as hat racks, sun visors, pillar trims, door side trims, instrument panels, sports and leisure equipment, etc. can be manufactured. The introduction of decorative or functional materials for the stiffness-imparting wood-filled thermoplastics into the shaping tool can be implemented particularly advantageously.
Ausführungsbeispielembodiment
Einem Polypropylen-Granulat oder -pulver werden 60-98 Gew.-% Holzfasern mit einer Feuchte von 2-10 % zugegeben. Die Mischung wird über manuelles Vormischen oder über vorgemischte Pellets oder durch Dosiereinrichtungen bzw. für die Faserzugabe über eine Zwangszuführung in einem Planetwalzenextruder, erreicht. Das bei einem Druck von etwa 100 bar extrudierte Gemisch (Extrudat) wird nachfolgend in ein Presswerkeug eingegeben und ggf. mit weiteren Verbundpartnern, z.B. Dekormaterialien, bei einem Druck von etwa 1000 bar zu einem Formkörper verpresst. 60-98% by weight of wood fibers with a moisture of 2-10% are added to a polypropylene granulate or powder. The mixture is achieved via manual premixing or via premixed pellets or through metering devices or for fiber addition via a forced feed in a planetary roller extruder. The mixture (extrudate) extruded at a pressure of approximately 100 bar is subsequently fed into a press tool and, if necessary, with other network partners, e.g. Decorative materials, pressed to a shaped body at a pressure of about 1000 bar.

Claims

Patentansprüche claims
1. Verfahren zur Herstellung von Formteilen aus gefülltem thermoplastischem Kunststoff mit einem Füllstoffgehalt von mindestens 60 Gew.-%, dadurch gekennzeichnet, daß als Füllstoff Lignocellulosefasern verwendet werden, die mit dem Thermoplasten vermischt und durch Extrusion des Gemischs aufbereitet werden, und daß das aufbereitete Gemisch in einem formgebenden Werkzeug verpreßt wird.1. A process for the production of moldings made of filled thermoplastic material with a filler content of at least 60 wt .-%, characterized in that lignocellulose fibers are used as filler, which are mixed with the thermoplastic and prepared by extrusion of the mixture, and that the processed mixture is pressed in a shaping tool.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Aufbereitung und Förderung der lignocellulosefasergefüllten Thermoplaste über einen Extruder und/oder eine Zahnradpumpe erfolgt.2. The method according to claim 1, characterized in that the processing and conveying of the lignocellulose fiber-filled thermoplastics is carried out via an extruder and / or a gear pump.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Aufbereitung der lignocellulosefaser-gefüllten Thermoplaste über einen Planetwalzenextruder erfolgt.3. The method according to claim 1 or 2, characterized in that the preparation of the lignocellulose fiber-filled thermoplastics is carried out via a planetary roller extruder.
4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass der lignocellulosefaser-gefüllte Thermoplast mittels Strangablegeverfahren aufbereitet und verpreßt wird.4. The method according to any one of claims 1 to 3, characterized in that the lignocellulosic fiber-filled thermoplastic is processed and pressed by means of the strand laying process.
5. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass der lignocellulosefaser-gefüllte Thermoplast mittels Spritzgießverfahren aufbereitet und verpresst wird.5. The method according to any one of claims 1 to 3, characterized in that the lignocellulose fiber-filled thermoplastic is processed and pressed by means of injection molding.
6. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass Halbzeuge aus extrudierten, lignocellulosefaser-gefüllten Thermoplasten mittels Preßverfahren aufbereitet und verpresst werden.6. The method according to any one of claims 1 to 3, characterized in that semi-finished products made of extruded, lignocellulosic fiber-filled thermoplastics are processed and pressed by means of pressing processes.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Extrusion bei einem Druck zwischen 40 und 450 bar durchgeführt wird, vorzugsweise im Bereich um 100 bar. 7. The method according to any one of claims 1 to 6, characterized in that the extrusion is carried out at a pressure between 40 and 450 bar, preferably in the range around 100 bar.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Veφressen bei einem Druck zwischen 100 bar und 5000 bar durchgeführt wird, vorzugsweise im Bereich um 1000 bar.8. The method according to any one of claims 1 to 7, characterized in that the Veφressen is carried out at a pressure between 100 bar and 5000 bar, preferably in the range around 1000 bar.
9. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass die Lignocellulosefasern eine Feuchte von 2 bis 8 Gew.-%, vorzugsweise 4 Gew.-9. The method according to any one of claims 1 to 8, characterized in that the lignocellulose fibers have a moisture content of 2 to 8% by weight, preferably 4% by weight.
%, enthalten.%, contain.
10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass die Mischung aus Lignocellulosefasern und Thermoplaste in Form von Pellets zugeführt wird.10. The method according to any one of claims 1 to 9, characterized in that the mixture of lignocellulose fibers and thermoplastics is supplied in the form of pellets.
11. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, dass der Thermoplast ein Polyolefin, insbesondere ein Polypropylen, ist.11. The method according to any one of claims 1 to 10, characterized in that the thermoplastic is a polyolefin, in particular a polypropylene.
12. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass weitere Verbundpartner beim Pressverfahren, vorzugsweise aus dem gleichen Grundwerkstoff wie die aus dem thermoplastischen Kunststoff gebildete Polymermatrix, in geschäumter und/oder ungeschäumter Form mit verpresst werden.12. The method according to any one of claims 1 to 11, characterized in that other composite partners in the pressing process, preferably made of the same base material as the polymer matrix formed from the thermoplastic, are also pressed in a foamed and / or non-foamed form.
13. Verfahren nach einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, dass dem Gemisch ein Haftvermittler, der aus der Gruppe der Silane, Maleinsäureanhydrid, Isocyanate und/oder dimeren Alkylketene ausgewählt wird, zugegeben wird.13. The method according to any one of claims 1 to 12, characterized in that an adhesion promoter, which is selected from the group of silanes, maleic anhydride, isocyanates and / or dimeric alkylketenes, is added to the mixture.
14. Verfahren nach einem der Ansprüche 1 bis 13, dadurch gekennzeichnet, dass die Lignocellulosefasern im wesentlichen Holzfasern sind.14. The method according to any one of claims 1 to 13, characterized in that the lignocellulosic fibers are essentially wood fibers.
15. Verfahren nach einem der Ansprüche 1 bis 14, dadurch gekennzeichnet, dass die Lignocellulosefasern mit Haftvermittler modifiziert sind.15. The method according to any one of claims 1 to 14, characterized in that the lignocellulose fibers are modified with an adhesion promoter.
16. Verfahren nach einem der Ansprüche 1 bis 15, dadurch gekennzeichnet, dass als Thermoplaste Copolymerisate aus Haftvermittlern und Polyolefinen eingesetzt werden. 16. The method according to any one of claims 1 to 15, characterized in that copolymers of adhesion promoters and polyolefins are used as thermoplastics.
17. Verfahren nach einem der Ansprüche 1 bis 16, dadurch gekennzeichnet, dass ein Tauchkantenwerkzeug eingesetzt wird, welches bei geöffnetem Spalt befüllt wird und anschließend mechanisch bzw. hydraulisch durch Schließen des Werkzeuges den notwendigen Druck erzeugt bzw. regelt.17. The method according to any one of claims 1 to 16, characterized in that a plunge edge tool is used which is filled when the gap is open and then generates or regulates the necessary pressure mechanically or hydraulically by closing the tool.
18. Verfahren nach einem der Ansprüche 1 bis 17, dadurch gekennzeichnet dass für die Werkzeuge ein poröses Material verwendet wird, welches ein Entgasen der Restfeuchte ermöglicht. 18. The method according to any one of claims 1 to 17, characterized in that a porous material is used for the tools, which enables the residual moisture to be degassed.
PCT/EP2003/006595 2002-06-24 2003-06-23 Method for producing parts from high-grade lignocellulose fiber-filled thermoplastics WO2004000529A1 (en)

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DE2002128191 DE10228191A1 (en) 2001-12-21 2002-06-24 Production of formed parts from thermoplastic with a high wood fibre content, e.g. hat racks, door panels or sports equipment, involves processing the plastic-fibre mixture in an extruder and compression-moulding the extrudate

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