KR100552418B1 - Plastic panel manufacturing method and plastic panel - Google Patents

Abstract

Disclosed are a plastic panel manufacturing method and a plastic panel using the same. The moisture of the coir extracted from coconut is removed and dried to produce a coir polymer. The resulting polymer is impregnated in a synthetic resin and gelled. Gel polymers and synthetic resins are compressed into an extruder to form plastic panels. Compression-generated plastic panels undergo more than one cooling process to prevent shrinkage of the panels. Therefore, by containing the coir in the plastic panel, it is possible to improve the durability and strengthen the strength of the plastic panel.

Plastic, coconut, coir, strength

Description

Plastic panel and manufacturing method of the same}

1 is a side cross-sectional view of a typical coconut,

2 is a flow chart showing a manufacturing method of a plastic panel according to the present invention;

3A to 3C are cross-sectional views showing an embodiment of a plastic panel before cooling produced by the plastic panel manufacturing method according to the present invention;

4a to 4c is a cross-sectional view showing an embodiment of a plastic panel manufactured by the plastic panel manufacturing method according to the present invention,

5 is a rear view showing an embodiment of a plastic panel manufactured by the plastic panel manufacturing method according to the present invention, and

6 is a perspective view showing an embodiment of a plastic panel manufactured by the plastic panel manufacturing method according to the present invention.

The present invention relates to a plastic panel manufacturing method and a plastic panel using the same, and more particularly, to a plastic panel manufacturing method containing a fiber component of coconut and a plastic panel using the same.

Coconut (coconut) is a fruit of the Coconut Palm Tree (Coconut Palm Tree) as shown in Fig. 1 (epicarp) 110, mesopore (120), endothelial (endocarp) 130 and endosperm (140) as shown in FIG. ). Referring to FIG. 1, the surgical skin 110 is a thick solid line, the middle skin 120 is an oblique line, the inner skin 130 is a point, and the inner oil 140 is represented by a triangle. Surgical epithelium 110 is smooth as the outer shell of the coconut, the inner mesoderm 120 is a fiber layer of 2cm to 5cm in thickness. This fibrous layer is called a coir. The length of the coir is about 0.7 mm and the width is about 20 μm. Coir is water and air resistant and has good elasticity, flexibility and moisture resistance. Due to this property, the rind 120 is used for raw materials such as fibers, ropes, and mats. The inner skin 130, also called the shell, is hard and has a thickness of 2 mm to 6 mm. The inner skin 130 of the pulp is useful for manufacturing industrial activated carbon. The inner oil 140 has a thickness of 10 mm to 20 mm and is used as coconut oil, spices, or the like.

Hereinafter, a method of manufacturing plastic using a conventional coconut coir will be described.

Plastics using a conventional coir impregnates the resin in a natural state, which serves as a reinforcing material. The resin uses a thermosetting resin according to the use characteristics of the plastic. Thermosetting is a property that the material does not melt but hardens when secondary heat is applied to the molded material. As the thermosetting resin, a semiconductive material such as rubber is used. Coir impregnated with the thermosetting resin uses a natural state and thus maintains a sparse tissue layer. Therefore, it is compressed to a predetermined thickness to have different strengths depending on the use characteristics of the plastic. That is, conventionally, coconut coir plastics are manufactured by compressing a coir impregnated with a thermosetting resin to a predetermined thickness by pressing and then curing.

The strength of the plastic depends on the degree of compression. In other words, the degree of compression is determined by the use of the plastic. The less the number of compressions, the lower the strength of the plastic, and the thicker panels are produced. Thick plate panels have more voids as they enter relatively from the surface of the panel. On the other hand, the more the number of compression is, the thinner the panel is manufactured. The thin panel has a higher strength than the thick panel because the entire panel is almost uniform in structure. Thin panel is used for various building materials such as interior and exterior materials for building.

However, the strength of the plastic using the conventional coir is determined only by compression as described above. Plastics whose strength is determined by compression recovery are weak in durability, which lowers the strength of the plastic. Also, plastics released as finished products are likely to shrink due to voids formed inside the plastic. This is because the voids may shrink when an external pressure such as a large amount of load is applied to the plastic in which the voids are formed. In addition, when manufacturing the plastic using the thermosetting resin it is impossible to recycle.

The technical problem to be achieved by the present invention is to provide a plastic panel manufacturing method for reinforcing a plastic panel using a coir as a reinforcement of plastic and a plastic panel using the same.

In order to solve the above technical problem, the plastic panel manufacturing method according to the present invention comprises the steps of drying the coir (coir) of coconut at a predetermined range of temperature to produce a coir polymer; Impregnating the coir polymer with the synthetic resin by heating and blending the produced coir polymer and the synthetic resin within a predetermined range of temperature; Compressing the blended coir polymer and the synthetic resin to a predetermined strength to produce a panel; And cooling the compression-generated panel to a predetermined cooling temperature.

More specifically, the temperature range for drying the coir in the coir polymer production step is 180 ℃ to 200 ℃. The coir dried in the coir polymer production step maintains a water content less than or equal to 300 ppm (Parts Per Million).

The temperature range for heating the coir polymer and the synthetic resin in the compounding step is 220 ℃ to 230 ℃. In addition, the blending step is a gel (gel) by blending the Coir polymer and the synthetic resin in a ratio of 4: 6. In the compounding step, the synthetic resin is a resin produced by blending polycarbonate and ABS resin in a ratio of 3: 7.

Preferably, the panel produced in the panel generation step forms one or more voids on the side. In addition, the panel generated in the panel generation step forms one or more grooves on one surface. The cooling step cools the compression-produced panel at least once, and when the cooling step is performed, each of the cooling temperatures corresponding to each cooling step is lowered step by step.

On the other hand, the plastic panel according to the present invention comprises the steps of drying and pulverizing the coir (coir) of coconut at a predetermined range of temperature to produce a coir polymer; Impregnating the polymer into the synthetic resin by heating and blending the produced coir polymer and the synthetic resin within a predetermined range of temperature; Compressing the blended coir polymer and the synthetic resin to a predetermined strength to produce a panel; And cooling the compression-generated panel to a predetermined cooling temperature.

More specifically, the temperature range for drying the coir in the coir polymer production step is 180 ℃ to 200 ℃. The coir dried in the coir polymer production step maintains a water content less than or equal to 300 ppm (Parts Per Million).

In addition, the temperature range for heating the coir polymer and the synthetic resin in the blending step is 220 ℃ to 230 ℃. In the blending step, the coir polymer and the synthetic resin are blended in a ratio of 4: 6 to gel. In the compounding step, the synthetic resin is a resin produced by blending polycarbonate and ABS resin in a ratio of 3: 7.

Preferably, the panel produced in the panel generation step forms one or more voids on the side. In addition, the panel generated in the panel generation step forms one or more grooves on one surface. The cooling step cools the compression-produced panel at least once, and when the cooling step is performed, each of the cooling temperatures corresponding to each cooling step is lowered step by step.

According to the present invention it is possible to enhance the durability and strength of the panel by manufacturing a plastic panel using a coir of coconut.

Hereinafter, the present invention will be described in more detail with reference to the given drawings.

2 is a flowchart illustrating a method of manufacturing a plastic panel according to the present invention.

The plastic panel according to the present invention can be processed to have a height of 6 mm to 60 mm, that is, a thickness. In the following, panel production having a thickness of 13 mm is described as an embodiment.

In the method of manufacturing a plastic panel according to the present invention, a plastic panel is manufactured using a coir fiber component of coconut. Referring to Figure 2, the manufacturing method of the plastic panel according to the present invention extracts the coir from the shell of the main material coconut. The extracted coir is used as a reinforcement to reinforce the plastic panel. The extracted coir is crushed after removing moisture. The moisture is removed from the coir is dried and pulverized within a predetermined range of temperature to produce a polymer (S210). A polymer refers to a molecule having a very high molecular weight, such as a molecule such as rubber or protein.

At this time, appropriate conditions for drying the coir are as follows. First, the temperature range for drying the coir is preferably 180 ° C. to 200 ° C., and is preferably dried by applying hot air. 1 hour is suitable for drying 200 kg-300 kg of coir. In addition, the degree of drying to maintain the moisture content of the Coir polymer less than 300ppm (Parts Per Million).

After drying the coir, when the coir polymer is produced, the produced polymer and the synthetic resin are heated and blended within a predetermined range of temperatures. That is, the coir polymer is impregnated in the synthetic resin (S220). At this time, the coir polymer maintaining a water content of 300 ppm or less is impregnated and blended to achieve perfect dispersion. Synthetic resin uses a high molecular compound, such as xenoy, polyethylene (PE), polypropylene (PP), etc., produced by combining polycarbonate (PC) and A.B.S. in a ratio of 3: 7 or 2: 8. In this invention, it is preferable to use the genoa produced by mix | blending polycarbonate (PC) and A.B.S. in the ratio of 3: 7.

At this time, the heating temperature of the coir polymer and the synthetic resin is appropriately 220 ℃ ~ 230 ℃. In addition, it is preferable to blend 300 kg of Coir polymer and synthetic resin per hour. It is appropriate to mix the synthetic resin and the Coir polymer at a ratio of 6: 4, so that the two components blended are in a gel state.

The blended Coir polymer and synthetic resin are extruded by a predetermined strength to generate a panel (S230). For example, the two blended ingredients are mixed once again and then extruded using an extruder such as T-dies. The core coir polymer and the synthetic resin are passed through the T-dies to produce a compressed panel having a thickness of 15 mm as shown in Figure 3a.

The coir polymer and the synthetic resin blended in a gel state have thermoplastic properties by secondary heating in step S220. Thermoplastic refers to the secondary processing of the material when the secondary heat is applied to the molded material. Materials having thermoplasticity include PP, PE PVC and the like. The thermoplastic coir polymer and the synthetic resin may be formed of various types of plastic panels such as FIGS. 3A to 3C.

3A to 3C are cross-sectional views showing an embodiment of a plastic panel after passing through T-dies as a plastic panel manufactured by the plastic panel manufacturing method according to the present invention.

Referring to FIGS. 3A-3C, the panel produced through the T-dies has a width of 900 mm and a thickness of 15 mm. In particular, the panel passed through the T-dies as shown in Figure 3b may form one or more voids on the side. In addition, the panel passing through the T-dies as shown in Figure 3c may form one or more grooves on one surface. These panels can be used in various ways depending on the type of T-dies. Panels with voids are excellent in thermal insulation and durable. In addition, the panel in which the gap is formed and the panel in which the groove is formed have a strong strength in a direction perpendicular to the direction in which the gap and / or the groove is formed.

The panel produced by compression through an extrusion machine such as T-dies performs a cooling process at a predetermined temperature (S240). Compressed panels perform one or more cooling cycles, and the number of cooling cycles can be optionally specified. Each time the cooling process is performed, the appropriate cooling temperature is lowered step by step. In the embodiment, when the first panel is cooled, the optimum temperature is 8 ° C, the second temperature is 5 ° C, and the third temperature is preferably 3 ° C. By cooling the panel at least once at such an appropriate temperature, shrinkage of the finished panel can be prevented. It is also possible to smooth the product surface of the panel and to activate the release of gases.

4A to 4C are cross-sectional views of panels formed when the panels of FIGS. 3A to 3C are first cooled to a cooling temperature of 8 ° C. When the panel compressed to a thickness of 15 mm is first cooled to a temperature of 8 ° C., the thickness of the panel is shrunk to 13 mm as shown in FIGS. 4A to 4C. In addition, as shown in FIG. 5, the rear surface of the panel may form a groove portion having a lattice pattern. Such grid pattern can be processed while secondary cooling the panel produced as shown in Figure 4c, it is maintained by secondary aging. 4A, 4B, 4C and 5, the panel can produce about 6 tons per day.

Plastic panels manufactured by performing the steps S210 to S240 require the appropriate conditions for each step. The appropriate conditions presented in the examples in each step can be represented as shown in [Table 1].

dry Combination Cooling  Temperature 180 ℃ ~ 200 ℃ (hot air) 220 ℃ ~ 230 ℃ (heating) 1st cooling: 8 ℃ 2nd cooling: 5 ℃ 3rd cooling: 3 ℃ An appropriate amount per hour (200kg ~ 300kg) / 1 hour 300kg / 1 hour · Moisture content 300 ppm · · Compounding ratio (synthetic resin: coir) · 6: 4 ·

FIG. 6 is an embodiment of a plastic panel having a cross section of FIG. 4A. The plastic panel produced by the manufacturing method according to the present invention can have a specification as shown in [Table 2].

division Production standard thickness 6 mm to 60 mm Length infinity width 500 mm to 1300 mm

Referring to FIG. 6 and Table 2, the panel manufactured by the present invention has a thickness of 13 mm, a length of 1800 mm, and a width of 900 mm. I can make it.

Table 3 shows a comparison of the specific gravity of the plastic panel of the present invention prepared by performing a conventional synthetic resin, plywood and S210 to S240 step.

Classification importance Conventional synthetic resin 0.93 to 0.97 Plywood 0.75 Plastic panel according to the invention 0.6 to 0.7

According to Table 3, the compressive strength of the plastic panel according to the present invention shows an improved specific gravity compared to the conventional synthetic resin and the conventional compression panel. In other words, the plastic panel according to the present invention has the same specific area and high specific gravity as compared with the conventional synthetic resin and plywood. As a result, it is possible to use a lighter plastic panel than conventional synthetic resin and plywood.

According to the plastic panel manufacturing method and the plastic panel using the same according to the present invention, the strength of the plastic panel can be improved by using a fiber component, that is, a coir, contained in the hull of coconut. In addition, by manufacturing a plastic panel using a thermoplastic resin, it is possible to form voids on the side of the panel or to form grooves on one surface of the panel. For this reason, it is possible to have strong durability in the direction perpendicular to the space | gap or groove part formed in the plastic panel. And since the thickness of the plastic panel can be set arbitrarily, it can be utilized in various fields such as building interior and exterior materials, insulation materials, sound absorbing materials. Furthermore, the plastic produced using the thermoplastic resin and the natural fiber can be recycled 100%, thereby preventing environmental pollution. In addition, by using a natural material such as coir as a reinforcing material it is possible to simplify the complex manufacturing process and to reduce the cost.

Although the present invention has been described in detail through the representative embodiments, those skilled in the art to which the present invention pertains can make various modifications without departing from the scope of the present invention with respect to the embodiments described above. Will understand. Therefore, the scope of the present invention should not be limited to the described embodiments, but should be defined by the claims below and equivalents thereof.

Claims (18)

Drying and pulverizing a coir of coconut to maintain a moisture content of at least less than or equal to 300 ppm (Parts Per Million) to produce a coir polymer; Impregnating the coir polymer with the synthetic resin such that the coir polymer and the synthetic resin are in a gel state by heating and blending the produced coir polymer and the synthetic resin; Extruding the coir polymer and the synthetic resin with an extrusion machine to produce a panel having at least one void formed therein; And Cooling the panel produced by the extruder at least once; plastic panel manufacturing method comprising a. The method of claim 1, The method of producing a plastic panel, characterized in that the temperature range for drying the coir in the coir polymer production step is 180 ℃ to 200 ℃. delete The method of claim 1, The temperature range for heating the coir polymer and the synthetic resin in the compounding step is a plastic panel manufacturing method, characterized in that 220 ℃ to 230 ℃. The method of claim 1, The blending step is a plastic panel manufacturing method, characterized in that for blending the coir polymer and the synthetic resin in a ratio of 4: 6. The method of claim 1, In the compounding step, the synthetic resin is a plastic panel manufacturing method, characterized in that the resin produced by blending polycarbonate and ABS resin in a ratio of 3: 7. delete The method of claim 1, The panel produced in the panel generating step is a plastic panel manufacturing method, characterized in that to form one or more grooves on one surface. The method of claim 1, When the cooling step is performed, each of the cooling temperature corresponding to each of the cooling step is a plastic panel manufacturing method characterized in that the step is lowered.    Drying and pulverizing a coir of coconut to maintain a moisture content of at least less than or equal to 300 ppm (Parts Per Million) to produce a coir polymer; Impregnating the coir polymer with the synthetic resin such that the coir polymer and the synthetic resin are in a gel state by heating and blending the produced coir polymer and the synthetic resin; Extruding the coir polymer and the synthetic resin with an extrusion machine to produce a panel having at least one void formed therein; And Cooling the panel produced by extrusion by the extruder at least once; plastic panel manufactured by performing. The method of claim 10, Plastic panel, characterized in that the temperature range for drying the coir in the coir polymer production step is 180 ℃ to 200 ℃. The method according to claim 10 or 11, wherein The coir dried in the coir polymer production step is a plastic panel, characterized in that to maintain a moisture content less than or equal to at least 300ppm (Parts Per Million: ppm). The method of claim 10, The temperature range for heating the coir polymer and the synthetic resin in the compounding step is a plastic panel, characterized in that 220 ℃ to 230 ℃. The method of claim 10, The compounding step is a plastic panel, characterized in that for blending the coir polymer and the synthetic resin in a ratio of 4: 6. The method of claim 10, In the compounding step, the synthetic resin is a plastic panel, characterized in that the resin produced by blending polycarbonate and ABS resin in a ratio of 3: 7. The method of claim 10, The panel generated in the panel generation step is characterized in that the plastic panel, characterized in that to form one or more voids on the side. The method of claim 10, The panel produced in the panel generation step is characterized in that the plastic panel, characterized in that to form one or more grooves on one surface. delete

Images