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CA3161417A1 - Composite, recycled-plastic, wood-waste, fiberboard-alternative panel - Google Patents

Composite, recycled-plastic, wood-waste, fiberboard-alternative panel

Info

Publication number
CA3161417A1
CA3161417A1 CA3161417A CA3161417A CA3161417A1 CA 3161417 A1 CA3161417 A1 CA 3161417A1 CA 3161417 A CA3161417 A CA 3161417A CA 3161417 A CA3161417 A CA 3161417A CA 3161417 A1 CA3161417 A1 CA 3161417A1
Authority
CA
Canada
Prior art keywords
panel
wood
composite
fiberboard
composition
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CA3161417A
Other languages
French (fr)
Inventor
Myles Peterson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA3161417A1 publication Critical patent/CA3161417A1/en
Pending legal-status Critical Current

Links

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
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • 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
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled 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
    • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • 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
    • B27N3/20—Moulding or pressing characterised by using platen-presses
    • B27N3/203—Moulding or pressing characterised by using platen-presses with heating or cooling means
    • 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
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/30—Polymeric waste or recycled polymer
    • 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
    • C08J2323/04—Homopolymers or copolymers of ethene
    • C08J2323/06—Polyethene
    • 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
    • C08J2323/12—Polypropene
    • 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
    • C08J2497/00—Characterised by the use of lignin-containing materials
    • C08J2497/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/20—Recycled plastic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Landscapes

  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention is a water-resistant, wood-plastic composite panel intended for use as a replacement to traditional fiberboards such as MDF(medium-density fiberboard). The panel consists of wood waste(wood shavings or sawdust) constituting between 15% and 60% of the total mass; shredded recycled polyethylene and polypropylene resins constituting between 40% and 85% of the total mass; and optionally additives including colorants and inhibitors of ultraviolet light, heat, or fire, constituting between 1% and 10% of the total mass. The panel is produced by homogenization of components, which are then added to a mold in one or more layers of any combination of possible components. Once all layers are assembled within the mold, it is heated via induction methods to a temperature between 160 degrees and 200 degrees celsius, and is then formed into a uniform panel using compression molding methods. The mold and panel are then cooled while under compression. Date recue/date received 2021-10-28

Description

Cornposite, Recycled-Plastic, Wood-Waste, Fiberboard-Alternative Panel Field of the invention:
This invention relates to composite fiberboard-alternative panels, comprising plastic polymers and wood, and a process for their production.
Prior Art:
Prior Art fiberboard panels are manufactured from a composite mixture of thermosetting plastic resin, generally constituting between 18% and 35% of the total mass, and a wood component of various shapes and sizes, generally constituting between 65% and 82% of the total mass. A representation of such a product may include a fiberboard disclosed in the Japanese patent 2019-064607.
Fiberboard panels are manufactured primarily from wood or other organic material such as hemp, the fibers of which provide a small amount of strength to the panels. The wood or other organic material is cut into very small pieces, typically between 0.578mm and 0.726mm, as represented in the Canadian patent CA
2675683. This size of wood piece is typically referred to as "wood flour".
These pieces are mixed with a thermosetting plastic resin, which acts to bind the wood pieces together. It should be noted that the resin often does not provide significant water resistance for the panel, resulting in the panels often absorbing water when used in moist environments. This wood and resin mixture is then pressed under intense heat and pressure to produce a dense and rigid panel, which is then cut to size.
Fiberboards, because of their content of fine organic particulate, create significant amounts of potentially-hazardous dust when cut, and absorb significant amounts of any liquid, including paint.
Fiberboard panels are typically not certified for building use purposes in Canada to categorically compete with the likes of plywood, which is significantly stronger than traditional fiberboard. It is important to note that fiberboard is typically prone to breaking, particularly in the corners of a traditional rectangular-shaped board, as the resin is often not capable of resisting stress.
Summary of the Invention:
An object of the present invention is to provide a wood-plastic fiberboard-alternative panel composed of wood waste in the form of shavings and sawdust, and recycled thermoplastic polymer resins, in place of the thermosetting polymer resin used in most fiberboard material.
Date recue/date received 2021-10-28 Another object of the present invention is to provide a wood-plastic fiberboard-alternative panel designed for resistance to water and moisture, by use of a high percentage of non-moisture-absorbing thermoplastic in the composite mixture.
Yet another object of the present invention is to provide a material of comparable physical properties in comparison to other fiberboard panels.
Yet another object of the present invention is to provide a wood-plastic fiberboard-alternative panel that creates significantly lower amounts of dust when cut by methods such as saws.
The present invention comprises a wood and plastic composite material produced in the style of a fiberboard-alternative panel. The panel consists of wood waste in the form of shavings and sawdust, shredded recycled polyethylene and polypropylene resins, and optionally inorganic additives including colorants and inhibitors of ultraviolet light, excessive heat, or fire. The panel is composed of a minimum of one distinct layer. The advantages and features of the present invention will become more apparent upon reading the description of the embodiment of the innovation.
Brief Description of the Drawing Figure 1 shows a front view of an embodiment of a bisected fiberboard-alternative panel, consisting of one layer, in accordance with the embodiment of the present invention.
Detailed Description of the Embodiment The present invention is described in detail with reference to Figure 1.
The invention depicted in Figure 1 consists of a single-layer of wood plastic composite constituting the entire panel. This layer consists of a mixture of wood waste comprising of sawdust or shavings, recycled polyethylene and polypropylene resin shreds, and in some embodiments, may consist of a mixture of additives including colorants and inhibitors of ultraviolet light, excessive heat, or fire. In the depicted embodiment of the present invention, the wood waste constitutes 25%
of the mass of the panel, and the thermoplastic resins constitute 75% of the mass of the panel. In the present invention, the wood waste is held together by the polyethylene and polypropylene resin, which is melted during the manufacturing process..
In all embodiments of the present invention, the panels are manufactured through a process of compression molding, comparable to the manufacturing method used in the Canadian patent application 3126821. The components of the layer(s) are mixed until homogenous, and are then added to a metal mold. The mold is then heated via induction methods to a temperature not less than 160 degrees Date recue/date received 2021-10-28 celsius and not exceeding 200 degrees celsius to melt the recycled thermoplastic polymer resins, and is then formed into a uniform panel using compression molding methods. The compression of the panel is done in a plywood press, providing no less than 200kg/cm2 of force onto the mold. This force densely packs the components of the present invention to produce a panel in a similar fashion to prior art fiberboard panels. The panel is then cooled using induction methods to a temperature not below 20 degrees celsius and not exceeding 45 degrees celsius, under a pressure not less than 200kg/cm2.
Once cooled under pressure, the panels are then removed from the molds, and are cut to the desired shape for the product, and sanded to a nominal thickness to be used as a replacement to prior art panels.
Date recue/date received 2021-10-28

Claims (10)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A water-resistant, composite wood-plastic fiberboard-alternative panel, characterized by:
a. A proportion of wood waste(wood shavings or sawdust), and a proportion of recycled thermoplastic polymer resins, wherein the wood waste is suspended all throughout the thermoplastic.
2. A composite fiberboard-alternative panel, as claimed in Claim 1, consisting of a composition in which the thermoplastic polymer resin is a combination of recycled polyethylene(PE) or polypropylene(PP).
3. A composite fiberboard-alternative panel, as claimed in Claim 1 or Claim 2, consisting of a composition in which the wood waste (wood shavings or sawdust) are between 0.5mm and 8mm in length.
4. A composite fiberboard-alternative panel, as claimed in Claim 1 to 3, consisting of one or more separately-homogenized layers of composite material.
5. A composite fiberboard-alternative panel, as claimed in any one of Claims 1 to 4, consisting of a composition additionally comprising a non-organic additive.
6. A composite fiberboard-alternative panel, as claimed in Claim 5, consisting of a composition in which the non-organic additive is aluminum trihydrate, iron oxide, carbon black or any related carbon additives, titanium dioxide, zinc oxide, calcium carbonate, or any combination thereof in proportions of 1% to 10% of the mass of the composition.
7. A composite fiberboard-alternative panel, as claimed in any one of Claims 1 to 6, consisting of a composition in which the recycled thermoplastic polymer resin represents from 40% to 85% of the mass of the composition.
8. A composite fiberboard-alternative panel, as claimed in any one of Claims 1 to 7, consisting of a composition in which the wood chippings represent from 15% to 60% of the mass of the composition.
9. A composite fiberboard-alternative panel, as claimed in any one of Claims 1 to 8, comprising a thickness of between 3mm and 32mm.
10.A process for producing a composite fiberboard-alternative panel, comprising the steps of:
a. Homogenizing wood-plastic composite material to form a composite panel, as claimed in any one of Claims 1 to 9, to constitute a panel of one or more layers.
b. Adding the previously mentioned wood-plastic composite material to a metal mold to form the desired shape and thickness.
c. Melting the contents of the mold using induction methods, within one or more heated presses, to a temperature no less than 160 degrees celsius and not exceeding 200 degrees celsius, and under pressure reaching not less than 200kg/cm2 during, at minimum, the last part of the heating stage.
Date recue/date received 2021-10-28 d. Cooling the contents of the mold using induction methods, to a temperature between 20 degrees celsius and 45 degrees celsius, under pressure not less than 200kg/cm2.
e. Trimming the cooled contents of the mold, a functional panel, to a nominal size.
f. Sanding the panel to a nominal thickness.
Date recue/date received 2021-10-28
CA3161417A 2021-08-05 2021-10-28 Composite, recycled-plastic, wood-waste, fiberboard-alternative panel Pending CA3161417A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA3126821A CA3126821A1 (en) 2021-08-05 2021-08-05 Recycled-plastic wood-chipping composite sheathing panel
CA3,126,821 2021-08-05

Publications (1)

Publication Number Publication Date
CA3161417A1 true CA3161417A1 (en) 2023-02-05

Family

ID=85128599

Family Applications (2)

Application Number Title Priority Date Filing Date
CA3126821A Abandoned CA3126821A1 (en) 2021-08-05 2021-08-05 Recycled-plastic wood-chipping composite sheathing panel
CA3161417A Pending CA3161417A1 (en) 2021-08-05 2021-10-28 Composite, recycled-plastic, wood-waste, fiberboard-alternative panel

Family Applications Before (1)

Application Number Title Priority Date Filing Date
CA3126821A Abandoned CA3126821A1 (en) 2021-08-05 2021-08-05 Recycled-plastic wood-chipping composite sheathing panel

Country Status (1)

Country Link
CA (2) CA3126821A1 (en)

Also Published As

Publication number Publication date
CA3126821A1 (en) 2023-02-05

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