Title of Invention: Moulding made from or including an environmentally acceptable material, a process for manufacturing the same, and the use of said moulding
Abstract: A novel, bio-degradable molding based on particles of a plant fiber material, preferably wood and/or cellulose, in particular recycled fiber material, as well as other additives, which are integrated preferably with starch and/or protein into a matrix of at least one biogenic material which has been reduced at high temperature and pressure to a molten state and undergone thermoplastic treatment, and a process for manufacturing the molding and uses thereof. The molding is substantially free of pores and the particles are at least partially impregnated with at least one resin acid (where appropriate mixed with at least one fatty acid, in particular from tall oil and/or natural resins) and preferably also with at least one fat, oil and/or wax; the total water content of the molding is no greater than 18 wt %, preferably 3-16 wt %, and in particular 4-12 wt %, while its preferred density is 0.8-1.25 t/m.sup.3.
Detailed Description: Part PAC: EXAMPLE 1
Part PAL: Process stage 1
Part PAR: Composition of the molding substance for manufacturing the pre-mouldings (e.g., granulate)
Part TBL: ______________________________________ %-wt Components ______________________________________ 58.47 wood chips (e.g., top-layer chips from chip board manufacture) 23.39 corn meal, finely ground (average particle size 0.4-0.8 millimeters) 10.55 resin acid (Sacocell 309, from Krems Chemie) 2.92 hardened plant fat, melting temperature: 45 degrees Celsius 2.92 glycerine 1.75 quick-drying linseed oil ______________________________________
Part PAR_2: One hundred kg of long wood shavings, 0.2-5 millimeters long, are thoroughly mixed in a heatable mixer with 5 kg of hardened plant fat at 65 degrees Celsius, so that the wood absorbs the molten-liquid fat completely.
Part PAR_3: Subsequently, 40 kg of very finely ground corn meal with a fat content of 2.5%-wt. is mixed in.
Part PAR_4: This dry mixture is placed in an extruder, with the various liquids or liquid phases being metered in at different locations on the extruder housing.
Part PAR_5: The resin acid components (Sacocell 309 is a derivative of abietinic acid), emulsified in water and with a solids content of 50%-wt, is introduced shortly after the entry point; the glycerine is introduced at the middle, and the linseed oil is introduced before the last mixing zone.
Part PAR_6: Extrusion and separation are carried out in such a way that a granulate of approximately 2.5-3 millimeters results, and so that expansion is prevented by low gas temperature, low pressure, and a large, unobstructed nozzle area (larger number of nozzle apertures).
Part PAR_7: Extruder: CM 45 Cincinnati Milcron Screw type: SK 400 Nozzle: 20 round apertures, 2.5 millimeters.
Part PAR_8: Extrusion parameters: Screw speed: 70 rpm Throughput: 103 kg/hour Torque: 30% (SME approximately 0.05 kWh/ kg) Mass pressure: 30 bar Mass temperature: 105 degrees Celsius Granulation in the nozzle-cut process to form spherical granulate.
Part PAR_9: The granulate obtained in this manner is conditioned to a total water content of 14%-wt by adjusting the air humidity, and in this state it is passed to an injection-molding machine for further processing.
Part PAL_2: Process stage 2:
Part PAR_10: Injection molding machine: Engel, ES 330/80 HL
Part PAR_11: The injection molding machine is so operated that the entry section is kept cool (approximately 30 degrees Celsius) and the mass temperature does not exceed 165 degrees Celsius during the injection molding process. The injection molding mold is intensely cooled so that it does not exceed a temperature of 20 degrees Celsius even in the case of short cycle times.
Part PAR_12: Expansion is prevented or suppressed by using greater injection entry cross-sections and smaller injection velocities in the first phase of the injection process.
Part PAR_13: A higher and pressure during the injection molding process causes the fat components to leave the wood fraction and, in conjunction with the cold mold, this results in problem-free separation from the mold. The work pieces obtained in this way (cylinders, 5 centimeters high and 4 millimeters diameter, which are about the color of ash have a smooth surface, the wood fraction being partially visible.
Part PAR_14: The properties of the mouldings so obtained are similar to those of wood and they can be finished by conventional wood-working methods such as drilling, sawing, sanding, slicing, cutting, gluing, dowelling, screwing, lacquering, coating, etc. Their resistance to corrosion is very similar to that of wood and for this reason it differs from such behavior as seen in the case of plastic.
Part PAR_15: Clear differences from wood can be seen in the high density (0.8-1.25 t/m.sup.3) and in the isotropic structure. Resistance to water without surface treatment is only slightly lower than in the case of wood mouldings. Mechanical properties, in particular, strengths, are comparable to those of wood although, in contrast to wood, there is no shrinkage due to growth rings or knots.
Part PAR_16: The surface hardness of the new mouldings obtained by using the above-described composition corresponds to that of commercially available hard PVC. Their workability corresponds to that of wood, although without the disadvantages displayed by thermo-plastifiable plastics, i.e., glazing and plugging of tools (sand paper, saws, files, drills, etc.). At the same time, the amount of dust that is created during cutting operations is significantly less than is the case with wood or conventional wood-based materials.
Part PAC_2: EXAMPLE 2
Part PAL_3: Process stage 1
Part PAR_17: Composition of a molding substance for manufacturing a pre-molding granulate
Part TBL_2: ______________________________________ %-wt Components ______________________________________ 50.95 compacted, recycled, pourable pulp 25.40 very finely ground rice meal (average particle size 0.4 to 0.8 millimeters) 12.70 resin acid (Sacocell 309, Krems Chemie) 6.85 linseed oil 90P (Lechner & Crebert) 4.11 glycerine ______________________________________
Part PAR_18: In contrast to Example 1, all of the linseed oil is mixed into the recycled pulp at room temperature, with the rice meal being mixed in at the same time. The resin acid component (Sacocell 309 is a derivative of abietinic acid) in aqueous solution and with a solid content of 50%-wt is introduced just after the entry point; the glycerine is introduced at the middle. There is no introduction of a component just before the last mixing zone. In all other respects, work is carried out analogously to Example 1, and this also applies to process step 2.
Part PAR_19: In contrast to those obtained as in Example 1, the granulate or pre-moldings obtained are not colored brown by the wood content. They can be colored as desired by the appropriate additives.
Part PAR_20: The mechanical properties are improved compared to those described in Example 1, and in certain areas they exceed those of wood to a considerable degree; for example, their compression resistance is considerably greater.
Part PAR_21: Only resistance to water is somewhat less without surface treatment, although this promotes biodegradablity under certain suitable ambient conditions, e.g., during composting.
Part PAC_3: EXAMPLE 3
Part PAL_4: Process stage 1
Part PAR_22: Composition of a molding substance for manufacturing a pre-molding granulate
Part TBL_3: ______________________________________ %-Wt Components ______________________________________ 56.60 pourable pulp fibers 12.58 potato starch 12.58 bone lime 9.44 resin acid (Sacocell 309) 3.77 ethylene glycol 3.77 linseed oil 90P (Lechner & Crebert) 1.26 glutaraldehyde ______________________________________
Part PAR_23: As has been described in Example 1, the cellulose fibers are coated with linseed oil; then the bone line and potato starch are mixed in and the dry mixture is placed into the extruder. Resin acid, glycol, and glutaraldehyde are introduced into the extruder housing at different points, the glutar aldehyde being added just before the last mixing zone, shortly before the extruder outlet.
Part PAL_5: Process stage 2
Part PAR_24: The pre-molding granulate obtained from process stage one was processed in the injection-molding machine under the conditions described for Example 1.
Part PAR_25: Because of the linseed oil stored in the cellulose fibers, which is partially expressed as a result of the high injection pressure, as has been described in the preceding examples, separation from the mold could be effected without any difficulty. The glutaraldehyde that is used denatures the bone lime so that the work pieces were hardened and became resistant to water. This entails the advantage that the mouldings so obtained are made completely water resistant without any surface treatment. However, biological breakdown during composting then takes place somewhat slower.
Part PAC_4: EXAMPLE 4 (Comparative Example)
Part PAR_26: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_4: ______________________________________ %-Wt Components ______________________________________ 48.31 wood shavings 32.24 corn meal 10.49 resin acid (Sacocell 309) 4.76 glycerine 4.20 linseed oil ______________________________________
Part PAR_27: The amount of linseed oil is unacceptably high when wood shavings are used as the fibre material, so that the separation of oil could be observed on the surface of the work pieces so obtained. It is obvious that, using this receipe, the upper limit for linseed oil had been exceeded.
Part PAC_5: EXAMPLE 5 (Comparative Example)
Part PAR_28: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_5: ______________________________________ %-Wt Component ______________________________________ 56.47 wood shavings 24.22 ground corn 12.28 resin acid (Sacotan 85, Krems Chemie) 4.76 glycerine 2.27 linseed oil ______________________________________
Part PAR_29: Sacotan 85 is a resin acid derivative with a low melting point. The glycerine used in this example is a crude glycerine from raps-methylester (rme) plants. Using this composition, once again, a higher proportion of wood fibre was tried with a simultaneously reduced quantity of starch. It was shown that both the manufacture of pre-molding granulate as well as the injection molding of the mouldings proceeded without any problems. An upper limit for the amount of wood in the end mixture was not nearly reached in this instance.
Part PAC_6: EXAMPLE 6
Part PAR_30: The same procedure as in Example 2 was followed, using the following recipe:
Part PA1: 49.03 straw PA1 32.74 ground corn PA1 11.52 resin acid (sacotan 85) PA1 4.76 glycerine PA1 1.95 linseed oil
Part PAR_31: The pre-moldings or pre-molding-granulate can be manufactured without any problem. However, the mechanical stability and strength of the mouldings that are obtained using this mixture are somewhat reduced.
Part PAC_7: EXAMPLE 7
Part PAR_32: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_6: ______________________________________ %-Wt Components ______________________________________ 49.42 wood shavings 32.95 ground corn 9.61 resin acid (Sacocell 309) 4.76 glycerine 1.63 linseed oil 1.63 naturally modified resin ("Weich-Harz," Krems Chemie) ______________________________________
Part PAR_33: In contrast to Example 2, the extrusion parameters used in the first stage of the process were modified in that the mass temperature was approximately 115 degrees Celsius. This brings about an improved disintegration of the starch components and, as a consequence of this, improved flow of the molding mass during injection molding during the second stage of the process. The expansion behavior was somewhat more difficult to manage when this was done.
Part PAR_34: In addition to the components known from Example 2, resin acids from natural, modified resin were included in the recipe. Polyol-abietinic acid ester, such as the "Weich-Harz," manufactured by Krems Chemie, which was used and which essentially contains diethylenelycol abietinic acid ester, was intended as an additional--and, compared to glycerine, essentially less moisture-dependent--softener and as an emulsifier for larger quantities of linseed oil.
Part PAR_35: The differences in the mouldings compared to the mouldings as in Example 2 were slight. The effects of natural, modified resin as an emulsifier are only fully effective in the case of greater additions of linseed oil.
Part PAC_8: EXAMPLE 8
Part PAR_36: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_7: ______________________________________ %-Wt Components ______________________________________ 50.28 wood shavings 33.55 ground corn 9.74 resin acid (Sumatra Dammar, Worlee) 4.67 glycerine 1.67 linseed oil ______________________________________
Part PAR_37: This mixture was selected in order to test the effects of a non-derivatised natural hard resin. The solid hard resin was added to the dry mixture in ground form.
Part PAR_38: In addition to minor problems at the extruder entry point, separation of the finished injection molded mouldings from the mold was not as satisfactory as had been expected. Because of this experience, the use of prepared natural resins or their resin acids seems to be more useful on account of the their better-defined characteristics.
Part PAC_9: EXAMPLE 9 (Comparative Example)
Part PAR_39: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_8: ______________________________________ %-Wt Components ______________________________________ 57.14 wood shavings 38.10 ground corn 4.76 glycerine ______________________________________
Part PAR_40: Under conditions considered normal for the present invention, no mouldings could be produced from this mixture. The unsatisfactory flow behavior of the molding mass did not permit proper filling of the injection molding mold. Separation from the mold of the incompletely formed mouldings was not acceptable. The addition of resin acids and/or fatty acids (both components are contained, for example, in tall oil) was thus shown to be an essential component of the recipe.
Part PAC_10: EXAMPLE 10 (Comparative Example)
Part PAR_41: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_9: ______________________________________ %-Wt Components ______________________________________ 50.96 wood shavings 33.98 ground corn 10.36 resin acid (Sacocell 309) 4.76 glycerine ______________________________________
Part PAR_42: The granulates for the pre-molding can be produced without any problem. In contrast to this, separation from the mold at the injection molding machine varies from poor to unacceptable. There was also undesirable expansion. The lack of the oil component, in particular, clearly has a negative effect.
Part PAC_11: EXAMPLE 11 (Comparative Example)
Part PAR_43: The same procedure as in Example 2 was followed, using the following recipe:
Part TBL_10: ______________________________________ %-Wt Components ______________________________________ 47.50 wood chips 31.70 ground corn 11.43 resin acid (Sacocell 309) 4.76 glycerine 4.61 sodium chloride ______________________________________
Part PAR_44: It is true that, in this example, the addition of sodium chloride reduced the expansion processes, but it did not eliminate them completely. Above and beyond this, separation from the mold was poor because of the lack of linseed oil. Giver a mixture of this kind, the concentration of the additives that suppress expansion, must be increased, and/or still others must be included, in order to bring about effective suppression of expansion.
Part PAC_12: EXAMPLE 12
Part PAR_45: An especially preferred embodiment of the present invention contains the following:
Part TBL_11: ______________________________________ %-Wt Components ______________________________________ 50.5 wood shavings (0.05-35 millimeters long, 0.05-3 millimeters thick) 28.0 fine ground corn 10.8 resin acid (Sacocell 309) 6.9 glycerine 1.9 linseed oil 1.9 naturally modified resin ("Weich-Harz," Krems Chemie) ______________________________________
Part PAR_46: The same procedure as in Example 2 was followed, with the following differences:
Part PAR_47: All of the linseed wall and the "Weich-Harz" (diethyleneglycol abietinic acid ester) were mixed into the wood shavings at room temperature, the corn meal being mixed in at the same time. Shortly before the point at which the mass enters the extruder, the resin acid component (Sacocell 309) was pumped into the extruder in the form of an aqueous emulsion.
Part PAR_48: The pre-mouldings-granulates obtained after the extrusion process are dried to a total water content of 5%-wt and then acted upon by the appropriate quantity of glycerine, this glycerine being completely resorbed by the granulate within a few hours.
Part PAR_49: In the second stage of the process, the mass can be processed at a temperature of 110-200 degrees Celsius, preferably, however, between 150-170 degrees Celsius. In contrast to the preceding examples, the injection mold was not cooled; rather, it was conditioned to a maximum of 90 degrees Celsius, preferably 80 degrees Celsius, when, because of the selected recipe and method of processing, problem-free separation from the mold nevertheless took place.
Part PAR_50: The injection speed can be selected within a relatively wide range without any loss of quality, and compared to different injection speeds, the process proved to be stable and robust. However, it is recommended that a higher dwell pressure be set within the context of the closing force relationship in order to eliminate any partial expansion that may possibly occur during injection.
Part PAR_51: Tempering to at most 90 degrees Celsius clearly has positive effects on the quality of the surface and the mechanical strength of the mouldings in comparison to those produced by according to the preceding examples.


{'bibliographic_information': "{'Patent Number': '059391928', 'Series Code': '8', 'Application Number': '5869021', 'Application Type': '1', 'Art unit': '174', 'Application Filing Date': '19960212', 'Title of Invention': 'Moulding made from or including an environmentally acceptable material, a process for manufacturing the same, and the use of said moulding', 'Issue Date': '19990817', 'Number of Claims': '60', 'Exemplary Claim Number(s)': '1', 'Primary Examiner': 'Weisberger; Richard'}", 'source_file': './grant/1999/pftaps19990817_wk33.txt', 'source_data': 'USPTO-Grant'}