• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of forming a thermoplastic composite material in a paper machine, the method comprising the steps of: forming a suspension of fibrous material in water, contacting said fiber suspension with at least one additive, said additive being introduced into said fiber suspension, wherein said additive or in the bridges, to thereby form an intermediate suspension, to, after the formation of the transition suspension, introduce a plastic material into said transition suspension, to thereby form a suspension of plastic / carrier composite. Fig. 6 selected for publication
    公开号:SE1400228A1
    申请号:SE1400228
    申请日:2014-05-08
    公开日:2015-11-09
    发明作者:Kaj Backfolk
    申请人:Stora Enso Oyj；
    IPC主号:
    专利说明:

    US 6,103,155 describes a wet forming process for producing a fiber reinforced thermoplastic resin sheet with no or reduced curvature.
    This sheet is prepared by feeding a thermoplastic resin and a reinforcing fiber into a dispersion tank, to which an aqueous medium containing a surfactant or a thickener is added in a predetermined ratio. The mixture is stirred to prepare a dispersion as a material mixture. This mixture is then pumped to a web forming portion, where the dispersion is discharged on an endless wire belt, while the vacuum and filtration process, the discharge speed of the dispersion on the belt and the speed of said wire belt are controlled to provide a fiber orientation which is advantageous.
    WO2012 / 122224 A1 describes another method for forming a wet web, in which hydrogen bonds between the natural fibers are inhibited and bonds between the fibers and the plastic particles are promoted. In this process, the size of the powdered plastic particles and the use of a compatibility enhancer are essential to provide a homogeneous mixture of natural fibers and plastic materials. WO2012 / 122224 A1 describes that the natural fiber, plastic, liquid and compatibilizer are fed to a mixing tank, and that the mixture is stirred overnight. This mixture can then be diluted to a so-called headbox concentration and fed to a conventional flat wire machine to form a web which is pressed and dried to form composite sheets of thermoplastic.
    Thus, there is a need for a simplified process for forming a thermoplastic composite material.
    Summary An object of the present invention is to provide an improved method for forming a thermoplastic composite material based on a web forming technique and more precisely a method for reducing the contact between fibers and thus preventing strong fiber-fiber bonding and / or flocculation in the composite. or the intermediate. Another object of the present invention is to improve the dewatering and dosing of fillers in the composite material. The invention is defined by the appended independent claims.
    Embodiments are described in the appended dependent claims and in the following description and drawings.
    According to a first aspect, there is provided a method of forming a thermoplastic composite material, the method comprising the steps of: forming a suspension of fibrous material in water, contacting said fiber suspension with at least one additive, said additive being introduced into said fiber suspension, whereby said additive reacts to form a precipitating product on or in the fibers, to thereby form a transition suspension, to, after the formation of the intermediate suspension, introduce a plastic material into said intermediate suspension, to thereby form composite material.
    This method allows a fast, simple and efficient way to produce a wood / plastic composite material. The process allows precipitated pigment particles to form on the surface of the fibers adjacent to, or near or in the production line, which ensures a more even distribution of fillers, improves the dewatering of the wet web, reduces costs and prevents excessive fiber-fiber bonds and flocs that can affect fiber distribution in the composite web. An uncontrolled distribution of fillers and fibers can lead to variations in product quality or impaired physical, optical or mechanical properties of the product. This thermoplastic fabric can also be used as an intermediate product to make a stock mixture, or for direct pressing of the web or sheets into a molded product. In the latter case, it is of fundamental importance that the distribution of fibers and fillers is evenly distributed.
    Alternatively, the thermoplastic composite material may comprise a fabric formed in a fibrous web machine. This allows the composite material to be formed in a conventional paper machine, which is cost effective.
    The weave material may also be formed in a machine comprising a wire for dewatering said wet web or stock composition.
    According to one embodiment, the plastic material may comprise any of a plastic particulate material, a plastic fiber material, or a mixture thereof.
    The method may further comprise introducing said at least one additive into a liquid flow of a short circulation of a fiber web forming process in a fiber web machine, in an in-line manufacturing process for forming said reaction product on or in the fibers. in the fiber suspension.
    By using an in-line production method, a method is provided which allows an efficient mixing in the wet end of the paper machine. The in-line production process also allows a direct precipitation of a filler such as PCC on or in the fibers of the suspension.
    Alternatively, the additive may be introduced into the fiber suspension in, for example, a mixing tank prior to introduction into the paper machine, or a headbox of a fiber web machine. According to yet another alternative, the fiber suspension, additives and plastic materials are all mixed in the headbox.
    According to an alternative of the first aspect of the invention, the method, when there are two or more additives, may further comprise allowing them to react with each other to form the precipitate product on or in the fibers.
    It has surprisingly been found that the use of carbonization on fibers solves the aforementioned problems and prevents strong fiber-fiber flocks and bonds in a wet forming of a thermoplastic web. By using predetermined conditions, it is possible to precipitate fillers (or other inorganic material) on the fibers and thus prevent strong interaction between fibers.
    According to one embodiment, the precipitating product may comprise a crystallized filler, or mixtures thereof, and wherein the additives are carbon dioxide and lime milk, said carbon dioxide and lime milk being fed to the short circulation separately or simultaneously, said precipitating product or filler being precipitated on or in fiber , to thereby form the intermediate suspension, which comprises precipitated calcium carbonate on or in said fibers.
    The filler may in fact be crystalline, semi-crystalline or amorphous.
    By precipitating PCC on the fibers, it is possible to further improve dewatering and reduce the cost of the thermoplastic composite.
    According to yet another embodiment, a coupling agent can be introduced into the transition suspension at the same time as, or substantially immediately after, the introduction of said additive.
    The introduction of a coupling agent can improve the adhesion between the plastic material and the fiber and thus improve the properties of the composite material. Said coupling agent can also be used to control the morphology and / or chemistry of the fillers. According to an alternative embodiment of the first aspect, the method may comprise the step of, before the step of contacting said fiber suspension with at least one additive, dividing said fiber suspension into two separate flows: a first flow which is then brought into contact with said additive and a second flow which is then reintroduced into the transition suspension.
    In addition, according to this alternative, it may be possible to precipitate PCC only on a fraction, such as ground or fibrillated fiber or nanofibers, while large (normal) fibers remain untreated by the process. Alternatively, the fraction of larger (normal) fiber is treated with the process, which fraction is later mixed with untreated ground / fibrillated fibers or nanofibers.
    The fiber used in the first aspect of the invention may be any of an organic fiber such as natural lignocellulosic fiber, wood fiber, bleached sulfate fiber, dissolving pulp fiber, microfibrillated cellulose, or inorganic fibers such as glass fibers, metal fibers, plastic fibers, heat treated fibers. The liquid flow may comprise at least one of the following components: suspension of fresh fiber pulp (long fiber pulp, short fiber pulp, mechanical pulp, chemical mechanical pulp, chemical pulp, microfiber pulp, nanofiber pulp), suspension of recycled pulp (recycled pulp, reject, fiber fraction suspension from the filter) additives and filtrates containing solids.
    The plastic material can be any of a plastic selected from the group consisting of polyethylene (PE), polypropylene (PP), ethylene-propylene copolymer, polycarbonate (PC), polystyrene (PS), polyethylene terephthalate (PET), polylactic acid (PLA), polyhydroxybutylate, acrylonitrile. butadiene-styrene copolymer (ABS), styrene-acrylonitrile copolymer (SAN), polyoxymethylene (POM), biodegradable thermoplastics, starch-based thermoplastics, their derivatives and / or mixtures thereof.
    Alternatively, any suitable plastic material can be used.
    Plastic materials obtained from bio-raw materials can also be used.
    According to an alternative embodiment, the plastic / fiber composite suspension can be dewatered and pressed into a product in or after the paper machine. The web or sheet can also be laminated to provide a composite product.
    According to another embodiment, the plastic / fiber composite suspension can be dewatered, dried and optionally used as a stock mixture and then extruded to form a product. According to yet another embodiment, the suspension of plastic / fiber composite can be dewatered in a mold after which an object is formed.
    According to another alternative embodiment, the plastic / fiber composite suspension can be transferred to a headbox of a fiber web machine.
    According to this embodiment, said mixture of plastic / fiber composite can furthermore be fed out on a wire portion of a fiber weaving machine, in order thereby to form a plastic / fiber composite web material.
    According to a second aspect of the present invention, there is provided a plastic / fiber composite material obtained by the method of the first aspect.
    The plastic / fiber composite material or the thermoplastic composite material thereby has improved properties compared with previously known composites.
    Brief description of the drawings.
    Embodiments of the present solution will now be described by way of example, with reference to the accompanying schematic drawings.
    Fig. 1 schematically shows an arrangement of a short circulation according to the prior art.
    Fig. 2 schematically shows an arrangement of a short circulation according to an embodiment of the invention.
    Figures 3a-b schematically show an arrangement of a short circulation according to an alternative embodiment of the invention.
    Fig. 4 schematically shows an arrangement of a short circulation according to yet another alternative embodiment of the invention.
    Fig. 5 schematically shows an arrangement of a short circulation according to yet another alternative embodiment of the invention.
    Fig. 6 shows a schematic flow chart of the present invention.
    Figures 7a and 7b are schematic side views of a conventional paper machine. Description of Embodiments Definition of Precipitated Calcium Carbonate (PCC) Almost all PCC is produced by direct carbonation of slaked lime, known as the calcium hydroxide process. The lime is quenched with water to form Ca (OH) 2 and, to form the precipitated calcium carbonate (insoluble in water), the quenched lime is combined with the (trapped) carbon dioxide.
    PCC can then be used in the paper industry as a filler or pigmentation, as a mineral or coating material, or in plastic or barrier layers. It can also be used as a filler in plastics or as an additive in home care products, toothpastes, foods, medicines, paints, inks, etc.
    Definition of in-line process for precipitated calcium carbonate By "in-line production" is meant that the precipitated calcium carbonate (PCC) is produced directly in the flow of papermaking stock, ie the captured carbon dioxide is combined with quenched lime milk in-line, instead of being produced separately from In addition, separate production of PCC requires the use of retention chemicals to cause PCC to be adsorbed or fixed to the fibers. PCC process is described, for example, in WO2011 / 110744.
    Fig. 1 shows a previously known method for in-line production of precipitated calcium carbonate as described in US2011 / 0000633 and a schematic process arrangement for a paper machine 2. The backwater F is fed to e.g. a mixing tank or filtrate tank 4, to which various fiber components are added for the preparation of papermaking stock. , fiber fraction from the filter for fiber recovery), regenerated cellulose, dissolving pulp, suspension of additives and filtrates containing solid to the mixing tank and led therefrom by a mixing pump 14 to a vortex cleaner 16, where heavier particles are separated. The acceptance from the vortex cleaning leads to a gas separation tank 18, where air and / or other gases are removed from the papermaking stock. The papermaking stock 10 is then transported to a feed pump 20 for the headbox, which pumps the papermaking stock to a so-called headbox screen 22, where large particles are separated from the papermaking stock. The acceptance fraction is fed to the paper machine 2 through its headbox. However, the short circulation of fiber web machines that produce less demanding end products does not need to have a vortex cleaner, gas separation plant and / or headbox.
    In the prior art processes, the PCC production is carried out in the short circulation of the paper machine, before the vortex cleaning plant 16.
    The carbon dioxide (C02) is injected on the pressure side of the vortex cleaner and the lime milk (MoL) is injected a few meters after the carbon dioxide has dissolved in the same pipe.
    However, it is conceivable that this PCC production could take place closer to the headbox, or that the distance between the injectors is very small, so that carbon dioxide and lime milk are in fact injected in the same place in the short circulation. This is due to the requirements of the final product and the design of the paper machine.
    When two or more additives are fed into the short circulation, they are preferably reacted with each other, which means that they are fed into the short circulation in a manner which allows the additives to react, in the case of lime milk and carbon dioxide so that precipitated calcium carbonate is formed on or in the fibers as a reaction product.
    According to one embodiment of the present invention, an in-line PCC process is combined with the dosing of fibers into the in-line PCC process.
    In one embodiment of the present invention, lime milk, carbon dioxide and fiber mixture are injected separately into the short circulation and fiber web of the paper machine.
    In an alternative embodiment, the fiber mixture is provided e.g. in the preparation of papermaking stock and is thus present in the papermaking stock and the carbon dioxide and lime milk are injected separately or simultaneously in the short circulation. In all the embodiments described above, it should be understood that the order of injection of the additives, i.e. lime milk, carbon dioxide, fiber mixture and possibly other additives can be made in a different order or at a different stage in the short circulation. It is conceivable that the injection takes place very close to the headbox, or that the dosing of fiber mixture takes place before the addition of the carbon dioxide, or that the distances between the "injection points" are shorter or longer than described above. 10 15 20 25 30 35 9 Thus, the fiber mixture, lime milk and carbon dioxide can be injected into the short circulation at substantially the same injection point.
    The point or points where injection takes place thus form a "PCC reaction zone".
    In one embodiment of the present invention, shown in Fig. 2, lime milk, carbon dioxide and fiber mixture are injected separately into the short circulation and fiber web of the paper machine.
    In an alternative embodiment, shown in Figures 3a and 3b, the fibers are provided e.g. in the preparation of papermaking stock and is thus present in the papermaking stock and the carbon dioxide and lime milk are injected separately or simultaneously into the short circulation.
    In yet another alternative embodiment, shown in Fig. 4, the lime milk and the bran are mixed before the injection into the short circulation and the carbon dioxide is injected separately from this mixture.
    In yet another alternative embodiment, shown in Fig. 5, the fibers are mixed with other additives and this mixture is injected separately from the lime milk and carbon dioxide.
    Alternatively, other fillers may be used, such as silicate, calcium silicate, or other types of fillers based on alkaline earth carbonates, such as magnesium carbonate.
    The first additive may be sodium silicate and the second additive an acidic medium, thereby forming silica.
    The first additive may be calcium hydroxide, CaOH, the second additive may be carbon dioxide, CO 2, and a third additive may be sodium silicate, to thereby form calcium silicate.
    The first additive may be another hydroxide of an alkaline earth metal (eg MgOH) and the second additive may be carbon dioxide, CO2, to thereby form other types of fillers based on alkaline earth carbonates, such as e.g. magnesium carbonate.
    Fig. 6 shows an overview of the method. In step A, a fibrous material suspension is provided. This suspension may comprise any of the aforementioned fibers. The fluid suspension is then contacted with one or more additives, either as an in-line process or in a batch operation. In step B, the intermediate suspension formed comprises the fibers and additives, wherein the additives may be a precipitating product, such as PPC, which has been formed on the fibers of the fiber suspension. In step C, the intermediate suspension is brought into contact with a plastic material, which may be any of the aforementioned materials. The resulting material is a suspension comprising a composite of plastic and fiber, which can then be further treated, for example as described below.
    If the process is an in-line production process, all these steps can be performed more or less simultaneously. However, it is preferred that the intermediate suspension, i.e. the precipitating product, is formed before the plastic material is added. In the in-line production process, the formation of the intermediate suspension can take place very quickly, which provides a very efficient way of forming the plastic / fiber composite.
    According to an alternative, the method provides for a division of material or suspension flows, so that in step A, before the fiber suspension is brought into contact with at least one additive, the fiber suspension is divided into two separate flows: a first flow which is then contacted with said additive, and a second flow which is then reintroduced into the intermediate suspension. In addition, according to this alternative, it may be possible to precipitate PCC only on a fraction such as nanofibers, while large (normal) fibers remain untreated by the process.
    In the present invention, various types of plastic material can be used to form the thermoplastic composite material. Such materials include the aforementioned materials, but may also include a fiber type of thermoplastic material or a mixture of two or more thermoplastic materials. The material may also contain a coupling agent which improves the adhesion between fibers or between fiber fillers and plastics.
    Alternatively, the additive may be introduced into the fiber suspension in, for example, a mixing tank prior to introduction into the paper machine, or a headbox of a fiber web machine. According to yet another alternative, the fiber suspension, additives and plastic materials are all mixed in a headbox of a paper machine.
    According to one embodiment, a thermoplastic web according to the present invention can be manufactured in a conventional type of paper machine.
    An example of such a paper machine 60 is shown in Figs. 7a and 7b, Fig. 7b being a continuation of Fig. 7a.
    Fig. 7a illustrates a forming portion 65 or the so-called wet end of the paper machine, and a pressing or wet pressing portion 66. In the headbox 62, a stock mixture or suspension 4 is usually provided and prepared.
    The stock mixture 64 can, for example, be heated to a desired temperature, or run through strainers to remove contaminants, etc. In the headbox 62 different types of papermaking additives or chemical aids can also be added to the stock mixture, for example, but not limited to additives such as retention chemicals, fillers and surfactants or polymers.
    In the present invention, the mixture of plastic-fiber composite can be transferred to the headbox 62.
    Other types of additives that can be added to the wet end or an adhesive press can be additives such as starch, PVOH, CMC, or latex (SB, SA), crosslinkers, optical brighteners or colorants, biocides, fixatives, lubricants, preservatives, dispersants, etc.
    The stock suspension 64, which contains the mixture of plastic-fiber composite, is provided on a wire 63 in the forming portion 65. A wet web 63 is thereby formed on the wire. An arrow 64 indicates the direction of the fabric or machine direction.
    After the forming portion 65, the fabric passes through a press portion 66, or wet press portion. The pressing operation can be performed by passing the wet fabric 63 through a series of nips, which are formed by rollers 67 which press against each other and which are assisted by press blankets 68 which suck up the squeezed water from the fabric.
    After the wet pressing operation, the web or sheet material 63 can be passed through a drying section 69. The drying can be performed in many different ways, but one way is to use drying cylinders 70 and steam. After the drying portion 69, the web or sheet 63 can pass through a calendering portion and a series of calenders (heavy steel rollers) 72 to make the sheet smoother and finally rolled up on a roll or roll 73.
    权利要求:
    Claims (15)
    [1]
    A method of forming a thermoplastic composite material, the method comprising the steps of: forming a suspension of fibrous material in water, contacting said fiber suspension with at least one additive, said additive being introduced into said fiber suspension, whereby said additive reacts to form a precipitating product on or in the fibers, to thereby form a transition suspension, to, after the formation of the intermediate suspension, introduce a plastic material into said transition suspension, to thereby form a composite material.
    [2]
    The method of claim 1, wherein the thermoplastic composite material comprises a web material formed in a fibrous web paper machine.
    [3]
    A method according to claim 1 or 2, wherein the plastic material comprises any of a plastic particulate material, a plastic fiber material, or a mixture thereof.
    [4]
    A method according to any one of the preceding claims, wherein the method comprises introducing said at least one additive into a liquid stream in a short circulation in a fibrous web forming process of a fibrous web machine, in an in-line manufacturing process to form said reaction product on or in the fibers of the fiber suspension.
    [5]
    A method according to any one of the preceding claims, wherein the method, when there are two or more additives, further comprises allowing them to react with each other to form the precipitate product on or in the fibers.
    [6]
    A method according to any one of the preceding claims, wherein the precipitating product comprises a crystallized filler, and wherein the additives are carbon dioxide and lime milk, said carbon dioxide and lime milk being fed to the short circulation separately or simultaneously, wherein said precipitating product or filler is precipitated on or in the fibers of the fiber suspension, to thereby form the transition suspension, which comprises precipitated calcium carbonate on or in said fibers.
    [7]
    A method according to any one of the preceding claims, wherein a coupling agent is introduced into the transition suspension at the same time as, or substantially immediately after, the introduction of said additive.
    [8]
    A method according to any one of the preceding claims, wherein said method, prior to the step of contacting said fiber suspension with at least one additive, further comprises dividing said fiber suspension into two separate flows: a first flow, which is then contacted with said additive, as well as a second flow, which is then reintroduced into the transition suspension.
    [9]
    A method according to any one of the preceding claims, wherein the fiber is an organic fiber such as natural fiber, wood fiber, bleached sulphate fiber, dissolving pulp fiber, microfibrillated cellulose, or inorganic fibers such as glass fibers, metal fibers, plastic fibers, heat treated fibers, or wherein the liquid stream comprises at least one the following components: suspension of fresh fiber pulp (long fiber pulp, short fiber pulp, mechanical pulp, chemical mechanical pulp, chemical pulp, microfiber pulp, nanofiber pulp), suspension of recycled pulp (recycled pulp, reject, fiber fraction from the filter for fiber recovery), suspension of additive and filtrate content.
    [10]
    A method according to any one of the preceding claims, wherein the plastic material is a plastic selected from the group of polyethylene (PE), polypropylene (PP), ethylene-propylene copolymer, polycarbonate (PC), polystyrene (PS), polyethylene terephthalate (PET), polylactic acid (PLA). ), polyhydroxybutylate, acrylonitrile-butadiene-styrene copolymer (ABS), styrene-acrylonitrile copolymer (SAN), polyoxymethylene (POM), biodegradable thermoplastics, starch-based thermoplastics, their derivatives and / or mixtures thereof.
    [11]
    A method according to any one of the preceding claims, wherein the plastic / fiber composite suspension is dewatered and pressed into a product in the paper machine. 14
    [12]
    A method according to any one of claims 1-10, wherein the plastic / fiber composite suspension is dewatered and then extruded to form a product. 5
    [13]
    A method according to any one of claims 1-10, wherein the plastic / fiber composite suspension is dewatered in a mold after which an article is formed.
    [14]
    A method according to any one of claims 1-10, wherein said suspension of plastic / fiber composite is transferred to a headbox of a fiber weaving machine.
    [15]
    Plastic / fiber composite material obtained by the process according to any one of claims 1-14.
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    SE1400228A|SE538770C2|2014-05-08|2014-05-08|Process for making a thermoplastic fiber composite material and a fabric|SE1400228A| SE538770C2|2014-05-08|2014-05-08|Process for making a thermoplastic fiber composite material and a fabric|
    EP15788962.7A| EP3140455B1|2014-05-08|2015-05-06|A method of making a thermoplastic fiber composite material and web|
    US15/309,286| US11078626B2|2014-05-08|2015-05-06|Method of making a thermoplastic fiber composite material and web|
    RU2016147926A| RU2683092C2|2014-05-08|2015-05-06|Method of making thermoplastic fiber composite material and web|
    PCT/IB2015/053297| WO2015170262A1|2014-05-08|2015-05-06|A method of making a thermoplastic fiber composite material and web|
    CA2946494A| CA2946494A1|2014-05-08|2015-05-06|A method of making a thermoplastic fiber composite material and web|
    CN201580024210.7A| CN106460339B|2014-05-08|2015-05-06|Method for manufacturing thermoplastic fiber composite and web|
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