Composite material

Patent metadata

Field	Value
Publication number	US-9908982-B2
Application number	US-201514714379-A
Country	US
Kind code	B2
Filing date	May 18, 2015
Priority date	Sep 5, 2014
Publication date	Mar 6, 2018
Grant date	Mar 6, 2018

Abstract

The present application relates to a natural fiber plastic composite product comprising thermoplastic polymer and dried deinking sludge containing cellulose fibers and minerals in foamed form. The present application also relates to a method for preparing the natural fiber plastic composite product.

First claim

The invention claimed is:

1. A natural fiber plastic composite product consisting of
10-70% by weight of a thermoplastic polymer;
30-90% by weight of dried deinking sludge containing organic material in the range of 25-45% by weight, minerals in the range of 55-75% by weight, and ink;
a foaming agent; and
optionally, minor amounts of colorants, UV stabilizers, coupling agents, lubricants, and incidental impurities;
wherein the organic material comprises cellulose fibers in the range of 10-30% by weight based on the weight of the dried deinking sludge, and
wherein the composite product is in foamed form.

2. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer comprises polyolefin.

3. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer has a melting temperature of at least 200° C.

4. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer comprises a thermoplastic polymer selected from the group consisting of polystyrene, polyamide, polytetrafluoride, polyethylene terephthalate and polycarbonate.

5. A natural fiber plastic composite product comprising a first layer and a second layer, the first layer forming at least a part of the surface of the product, wherein
the first layer comprises thermoplastic polymer and cellulose based particles, and
the second layer comprises the foamed natural fiber plastic composite product of claim 1 .

6. A composite product containing the natural fiber plastic composite product of claim 1 , wherein the composite product is a building element, a decking board, a façade panel, a railing, a fence, a cover strip, a noise barrier, a pole, a frame, a board or panel, a furniture, or a part of a furniture.

7. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer comprises polypropylene or polyethylene.

8. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer has a melting temperature of at least 220° C.

9. The natural fiber plastic composite product of claim 1 , wherein the thermoplastic polymer is in an amount in the range of 30-45% by weight and the dried deinking sludge is in the range of 55-70% by weight.

10. A method for preparing a natural fiber plastic composite product consisting of
10-70% by weight of a thermoplastic polymer;
30-90% by weight of dried deinking sludge containing organic material in the range of 25-45% by weight, minerals in the range of 55-75% by weight, and ink;
a foaming agent; and
optionally minor amounts of colorants UV stabilizers coupling agents lubricants and incidental impurities;
wherein the composite product is in foamed form,

the method comprising
mixing the thermoplastic polymer, the dried deinking sludge, the foaming agent, and, optionally, the colorants, UV stabilizers, coupling agents, lubricants, and incidental impurities to provide a mixture,
heating the mixture above the melting temperature of the thermoplastic polymer,
foaming the mixture, and
forming the mixture into the composite product.

11. The method of claim 10 , wherein the thermoplastic polymer comprises polyolefin.

12. The method of claim 10 , wherein the thermoplastic polymer has a melting temperature of at least 200° C.

13. The method of claim 10 , wherein the mixture is heated to a temperature in the range of 200−360° C.

14. The method of claim 10 , wherein the thermoplastic polymer comprises a thermoplastic polymer selected from the group consisting of polystyrene, polyamide, polytetrafluoride, polyethylene terephthalate and polycarbonate.

Assignees

• Upm Kymmene Corp

Inventors

• Peltola Piia

Classifications

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title

• C08L23/06

  Polyethylene · CPC title

• C08J9/0066

  Use of inorganic compounding ingredients · CPC title

• C08J9/02

  using blowing gases generated by the reacting monomers or modifying agents during the preparation or modification of macromolecules · CPC title

• C08L23/12 Primary

  Polypropene · CPC title