Abstract:
The invention relates to e new environmentally friendly process in which cellular foamed polymer particles selected from the group consisting of cross-linked PVC rigid foam, polyurethane, polyester, polyether and polystyrene are recycled and reused in new extruded acoustics products together with other plastic components.

Description:
[0001]    This application claims benefit of Serial No. 08159101.8, filed 26 Jun. 2008 in Europe and which application is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above disclosed application. 
       FIELD OF INVENTION 
       [0002]    The invention relates to a new environmentally friendly process in which cellular foamed polymer particles selected from the group consisting of cross-linked PVC rigid foam, polyurethane, polyester polyether and polystyrene are recycled and reused in new extruded acoustics products together with other plastic components. 
       BACKGROUND OF THE INVENTION 
       [0003]    When different product are produced from cross-linked PVC rigid foam, materials large amounts are discarded, wherein the discarded material have a density from 40 kg/m 3 . To reduce the volume of the discarded material, the discarded material is grinded and the material will then be packed as small well packed products. By such a process it is possible to reduce the density to about 400 to 1000 kg/m 3 . Additionally, combustion of such materials is not environmentally friendly and influences the climate changes and thereby not an alternative way nowadays. 
         [0004]    The commonly used way to get rid of cross-linked PVC rigid foam, material is to deposit the material. However, the increase in saving our environment also result in an increasing demand to reduce the release of dangerous chlorinated substances and therefore there is a need of replacing old fashioned methods like combustion or deposition due to that they release chlorinated substances into the environment. A global problem is the increasing mountain of waste and the lack of recovery methods that in an ecological way recovers products without using the above mentioned methods. Combustion releases chorine gas which will be captured by a filter in the combustion oven, which is classified as being dangerous deposition material and cannot be destructed. In Sweden for example there are solely three approved plants wherein materials containing chlorine can be combusted. The process is very expensive and non-economic. 
         [0005]    To save the ozone condition it might be that in the near future it will be forbidden to burn PVC globally, which will give rise to new deposited problem which will destroy the environment. Therefore there is a need of developing new environmentally friendly methods in which cross-linked PVC rigid foam, may be recovered and thereby reused. Accordingly there is also a need of developing new improved methods which efficiently can be used to recover cellular plastics, to reduce the large deposit of these plastics which have a low density. 
       SUMMARY OF THE INVENTION 
       [0006]    The invention relates to a new environmentally friendly process in which the above defined cross-linked PVC rigid foams, can be recovered and reused. The process have a number of profits such as no chlorine will be released into the air, and the large amounts of deposited chlorine containing PVC will be reduced and/or eliminated, an increase in the possibility to recover old products containing the PVC. Additionally, new products may be produced from the recovered material and the PVC will be recycled again and again. 
         [0007]    In a first aspect the invention relates to an extruded or pressed acoustic material comprising from about 5 weight-% to about 60 weight-% of cellular foamed polymer particles selected from the group consisting of cross-linked PVC rigid foam, polyurethane, polyester, polyether and polystyrene and a binding agent being having a melting point below 180° C. and optionally cellulose materials, lime, fibres from tree, fibres glass and other synthetic fibres, wherein the total amount of b) is from about 40 weight-% to about 95 weight-%. 
         [0008]    In a second aspect the invention relates to a method producing an extruded or pressed acoustic material comprising the steps of, providing used cellular foamed polymer particles selected from the group consisting of cross-linked PVC rigid foam, polyurethane, polyester, polyether and polystyrene, grinding and/or pulverising said cellular foamed polymer particles, adding at least one binding agent having a melting temperature below 180° C., as homogenising said cellular foamed polymer particles and said binding agent, moulding said cellular foamed polymer particles and binding agent and obtaining an acoustics material as defined above. 
         [0009]    Thereby it is for the first time possible to produce light weight extruded or pressed acoustic materials, such as plates from reused cellular foamed polymer particles together with other discarded plastic materials and optionally glass wool. Acoustic materials which have increased acoustic properties compared to earlier materials. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0010]    The invention relates to new acoustic materials suitable to be used in all places were there is a need to reduce noise, such as floors, walls, roof as well as different noise walls which are found for example in close connection with railways. The new improved material being an extruded or pressed acoustic material comprising from about 5 weight-% (w.p.) to about 60 weight-% (w.p.) of cellular foamed polymer particles selected from the group consisting of cross-linked PVC rigid foam, polyurethane, polyester, polyether and polystyrene and a binding agent being having a melting point below 180° C. and optionally cellulose materials, lime, fibres from tree, fibres glass and other synthetic fibres, wherein the total amount of b) is from about 40 weight-% to about 95 weight-%. It is the cellular foamed polymer particles that give the material the acoustic properties. 
         [0011]    The extruded or pressed acoustic material may comprise the cellular foamed polymer particles in an amount from about 10 weight-% to about 50 weight-%, such as from about 10 weight-% to about 40 weight-% or from about 30 weight-% to about 50 weight-%. Specific examples include 15, 20, 25, 30, 35, 40, 45 or 50 weight-%. 
         [0012]    The different materials may be obtained from different sources such as material that have not been used during the manufacturing of other products and which needs to be discarded, such as during the production of wing for wind power, small and large boats and ferries etc or other PVC rests that contains chlorine and may be extruded with soft PVC materials such as old floor plates, PVC cables as well as other materials containing PVC such as floor carpets, borders, tiles etc, wherein said recovered PVC material may be grinded to a size varying from 0.1-5 mm and then be used as a recovered granulate. For example cross-linked PVC rigid foam has a low specific weight about 40 kg/m 3  which prior to use will be grinded to a size of 0.001-1 mm. Another example being cellular foamed polymer products based on polyvinyl chloride. 
         [0013]    When the cellular foam polymer material is homogenised a binding agent is added to the cellular foam polymer material, said binding agent having a melting temperature being below 180° C., such as below 170° C. The cellular foam polymer and binding agent is either moulded together either cold or warm moulding or extruded together. Together, all the ingredients are mixed together by an extrude machine or pressed by moulding to a homogenous mixture prior to that the mixture is moulded, wherein the homogenous mixture will be moulded into a hard and stabile product. In some cases the materials may be melted into flakes or granulate/agromerate prior to the materials are extruded or pressed into a product. The moulding may be performed with or without heat If the materials are to be heat moulded together the temperature will be selected such as being below 180° C. so that the binding agent will melt and bind to cellular foam polymer having a higher melting temperature and thereby a hard rigid product is produced. Prior to that the moulding step will be performed the components are homogenised. If the materials are extruded the different components are mixed prior to that the components are extruded together. However, independent on which method is used the cellular foam polymer is mixed with a binding agent, which melts at a temperature below 170° C., such as 120-180° C. 
         [0014]    Examples of binding agents include soft PVC materials, such as PVC that can be formed into products. Said soft PVC has a melting point below 180° C. Other binding agents may be PE (polyeten), LDPE &amp; LLDPE, (polyethylene) HDPE (high density polyethylene) PS (polystyrene), ABS (acrylonitrile butadiene styrene), EPS (polystyrene), PET (polyethylene), i.e., PVC materials that does not contain chlorine. These materials have a lower melting point than cellular foam polymer and the two materials may therefore be extruded together into new products. Another group of binding agents are cellulose materials, lime, fibres from tree, fibres glass or other synthetic fibres. 
         [0015]    Soft PVC may be used for the recovering of cellular foamed polymer particles in a size of up to about 5 mm. However, if a specific cellular foamed polymer particles sold under the trade mark divenylcell is used it may be used in a size of from 0.001 to 1 mm. Examples of suitable machines to be used in the invention are extruder, calander or belt press or any other suitable machines. 
         [0016]    To increase the acoustic properties or the disclosed material even more glass wool may be added in an amount up to about 30 weight-% of glass wool, such as 10, 15, 20, 25 or 30 weight-%. 
       EXAMPLE 
     Example 1 
       [0017]    Plates produced by recovered PVC with heat moulding. One cellular foamed polymer particle that was used in the example was Divenylcell™. 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                 No 
                   
                 Moulding 
                   
                 Cool- 
               
               
                 of 
                   
                 time 
                 Temp. 
                 ing 
               
               
                 plate 
                 Contents of PVC waste 
                 [min/sek] 
                 [° C.] 
                 [min] 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 PVC 
                 10-20 
                 min 
                 160-180 
                 10 
               
               
                   
                 Polyvinyl chloride waste + 
               
               
                   
                 remains of metallic about 100% 
               
               
                 2 
                 Polyvinyl chloride/soft PVC 
                 5-10 
                 min 
                 130-180 
                 10 
               
               
                   
                 waste about 50% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 waste about 50% 
               
               
                 3 
                 Granulate of soft PVC/Polyvinyl 
                 25 
                 min 
                 140-180 
                  5 
               
               
                   
                 chloride about 100% 
               
               
                 4 
                 Granulate of soft PVC/Polyvinyl 
                 10-25 
                 min 
                 140-180 
                  5 
               
               
                   
                 chloride about 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 40% 
               
               
                 5 
                 Granulate of soft PVC/Polyvinyl 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 chloride included calcium 
               
               
                   
                 carbonate about 70% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                 6 
                 Granulate of soft PVC/Polyvinyl 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 chloride included calcium 
               
               
                   
                 carbonate about 80% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                 7 
                 Soft PVC/Polyvinyl chloride 
                 10-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 about 70% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                 8 
                 Granulate and soft PVC/Polyvinyl 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 chloride included fibre wood; 
               
               
                   
                 about 80% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                   
               
             
          
         
       
     
         [0018]    Different moulding times influences the thickness of the different plates from 3-15 mm. 
       Example 2 
       [0019]    Plates produced by recovered PVC by moulding without heat. 
         [0000]    
       
         
               
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                 No 
                   
                 Moulding 
                   
               
               
                 of 
                   
                 time 
                 Temp. 
               
               
                 plate 
                 Contents of PVC waste 
                 [sek] 
                 [° C.] 
               
               
                   
               
             
             
               
                 1 
                 PVC Polyvinyl chloride waste + remains 
                 10-20 
                 without 
               
               
                   
                 of metallic about 100% 
                   
                 heating 
               
               
                 2 
                 Polyvinyl chloride/soft PVC waste 
                  5-10 
                 without 
               
               
                   
                 about 50% 
                   
                 heating 
               
               
                   
                 Cross-linked PVC rigid foam waste about 
               
               
                   
                 50% 
               
               
                 3 
                 Granulate of soft PVC/Polyvinyl chloride 
                 25 
                 without 
               
               
                   
                 about 100% 
                   
                 heating 
               
               
                 4 
                 Granulate of soft PVC/Polyvinyl chloride 
                 10-25 
                 without 
               
               
                   
                 included calcium carbonate/fibre wood 
                   
                 heating 
               
               
                   
                 about 60% 
               
               
                   
                 Cross-linked PVC rigid foam about 40% 
               
               
                 5 
                 Granulate of soft PVC/Polyvinyl chloride 
                  5-25 
                 without 
               
               
                   
                 included calcium carbonate about 50% 
                   
                 heating 
               
               
                   
                 Cross-linked PVC rigid foam about 50% 
               
               
                 6 
                 Granulate of soft PVC/Polyvinyl chloride 
                     5-25 s 
                 without 
               
               
                   
                 included calcium carbonate/fibre wood 
                   
                 heating 
               
               
                   
                 about 80% 
               
               
                   
                 Cross-linked PVC rigid foam about 20% 
               
               
                 7 
                 Soft PVC/Polyvinyl chloride about 70% 
                 10-25 
                 without 
               
               
                   
                 Cross-linked PVC rigid foam about 30% 
                   
                 heating 
               
               
                 8 
                 Granulate and soft PVC/Polyvinyl chloride 
                  5-25 
                 without 
               
               
                   
                 included fibre wood/calcium carbonate 
                   
                 heating 
               
               
                   
                 about 80% 
               
               
                   
                 Cross-linked PVC rigid foam about 20% 
               
               
                   
               
             
          
         
       
     
         [0020]    Different moulding times influences the thickness of the different plates from 3-15 mm. 
       Example 3 
       [0021]    Plates produced by recovered PVC by moulding with or without heat. 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
               
                 No 
                   
                 Moulding 
                   
                 Cool- 
               
               
                 of 
                 Contents of PVC waste and other 
                 time 
                 Temp. 
                 ing 
               
               
                 plate 
                 plastic without PVC 
                 [sek] 
                 [° C.] 
                 [min] 
               
               
                   
               
             
             
               
                 1 
                 PVC 
                 10-20 
                 180-200 
                 10 
               
               
                   
                 Polyvinyl chloride/cross-linked 
               
               
                   
                 PVC rigid foam about 70% 
               
               
                   
                 LDPE about 30% 
               
             
          
           
               
                 1A 
                 PVC 
                   
                   
                 without 
                 — 
               
               
                   
                 Polyvinyl chloride/cross-linked 
                   
                   
                 heating 
               
               
                   
                 PVC rigid foam about 70% 
               
               
                   
                 LDPE about 30% 
               
               
                 2 
                 Cross-linked PVC rigid foam 
                 5-10 
                 min 
                 130-180 
                 10 
               
               
                   
                 waste about 50% 
               
               
                   
                 LDPE about 50% 
               
               
                 2A 
                 Cross-linked PVC rigid foam 
                   
                   
                 without 
                 — 
               
               
                   
                 about 50% 
                   
                   
                 heating 
               
               
                   
                 LDPE/PET about 50% 
               
               
                 3 
                 Granulate of soft PVC/Polyvinyl 
                 25 
                 min 
                 140-180 
                  5 
               
               
                   
                 chloride about 100% 
               
               
                   
                 PS/EPS about 40% 
               
               
                 3A 
                 Granulate of soft PVC/Polyvinyl 
                   
                   
                 without 
                 — 
               
               
                   
                 chloride about 60% 
                   
                   
                 heating 
               
               
                   
                 PS/EPS about 40% 
               
               
                 4 
                 Granulate of soft PVC/Polyvinyl 
                 10-25 
                 min 
                 140-180 
                  5 
               
               
                   
                 chloride/Cross-linked PVC rigid 
               
               
                   
                 foam about 60% 
               
               
                   
                 EPS about 20% 
               
               
                   
                 HDPE about 20% 
               
               
                 4A 
                 Granulate of soft PVC/Polyvinyl 
                   
                   
                 without 
                 — 
               
               
                   
                 chloride/Cross-linked PVC rigid 
                   
                   
                 heating 
               
               
                   
                 foam about 60% 
               
               
                   
                 EPS about 20% 
               
               
                   
                 HDPE about 20% 
               
               
                 5 
                 Soft PVC/Polyvinyl chloride 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 included calcium carbonate about 
               
               
                   
                 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                   
                 PET about 10% 
               
               
                 5A 
                 Soft PVC/Polyvinyl chloride 
                   
                   
                 without 
                 — 
               
               
                   
                 included calcium carbonate about 
                   
                   
                 heating 
               
               
                   
                 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                   
                 PET about 10% 
               
               
                 6 
                 Granulate of soft PVC/Polyvinyl 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 chloride about 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                   
                 PP about 20% 
               
               
                 6A 
                 Granulate of soft PVC/Polyvinyl 
                   
                   
                 without 
                 — 
               
               
                   
                 chloride about 60% 
                   
                   
                 heating 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                   
                 PP about 20% 
               
               
                 7 
                 Soft PVC/Polyvinyl chloride 
                 10-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 about 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                 7A 
                 HDPE about 10% 
                   
                   
                 without 
                 — 
               
               
                   
                   
                   
                   
                 heating 
               
               
                 7A 
                 Soft PVC/Polyvinyl chloride 
               
               
                   
                 about 60% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 30% 
               
               
                   
                 HDPE about 10% 
               
               
                 8 
                 Soft PVC/Polyvinyl chloride 
                 5-25 
                 sek 
                 130-180 
                 2-5 
               
               
                   
                 included fibre wood about 70% 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                   
                 LDPE/HDPE about 10% 
               
               
                 8A 
                 Soft PVC/Polyvinyl chloride 
                   
                   
                 without 
                 — 
               
               
                   
                 included fibre wood about 70% 
                   
                   
                 heating 
               
               
                   
                 Cross-linked PVC rigid foam 
               
               
                   
                 about 20% 
               
               
                   
                 LDPE/HDPE about 10% 
               
               
                   
               
             
          
         
       
     
       Example 4 
       [0022]    1. Plate A: 70-90% PP+10-30% cross-linked PVC rigid foam 
         [0023]    2. Plate B: 70-90% PVC+10-30% cross-linked PVC rigid foam 
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Total weight of the plates 
               
             
          
           
               
                   
                 Plate (mm) 
                 Weight (g) 
               
               
                   
                   
               
               
                   
                 A1 328.68 × 328.49 × 5.02 
                 501.54 
               
               
                   
                 A2 328.54 × 323.36 × 5.03 
                 501.83 
               
               
                   
                 A3 323.81 × 323.63 × 5.04 
                 501.38 
               
               
                   
                 A4 323.73 × 323.79 × 5.04 
                 507.52 
               
               
                   
                 A5 323.70 × 323.73 × 5.04 
                 504.66 
               
               
                   
                 B1 300.63 × 210.18 × 12.43 
                 787.77 
               
               
                   
                 B2 311.37 × 210.47 × 12.41 
                 833.70 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Density of the plates 
               
             
          
           
               
                   
                   
                 Mean value for the density 
               
               
                   
                 Plate 
                 (g/cm3) 
               
               
                   
                   
               
               
                   
                 A 
                 0.944 
               
               
                   
                 B 
                 1.033 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Pull strength 
               
             
          
           
               
                   
                 Plate 
                 Pull strength (MPa) 
               
               
                   
                   
               
               
                   
                 A 
                 7.758-8.750 
               
               
                   
                 B 
                 6.909-7.589 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Hardness 
               
             
          
           
               
                   
                 Plate 
                 Hardness (HB) 
               
               
                   
                   
               
               
                   
                 A 
                 118-408 
               
               
                   
                 B 
                 116-219 
               
               
                   
                   
               
             
          
         
       
     
         [0024]    The values are in Brinell scale (HB) 
       Example 5  
       [0025]    Acoustic product 
         [0026]    Product 1 
         [0027]    Polyvinyl chloride/soft PVC waste about 50% 
         [0028]    Cross-linked PVC rigid foam waste about 20% 
         [0029]    Glass wool waste about 30% 
         [0030]    Product 2 
         [0031]    ABS waste 60% 
         [0032]    Cross-linked PVC rigid foam waste about 20% 
         [0033]    Glass wool waste about 20% 
         [0034]    Product 3 
         [0035]    HDPE waste about 60% 
         [0036]    EPS waste about 25% 
         [0037]    Glass wool waste about 15% 
         [0038]    Product 4 
         [0039]    Polyvinyl chloride PVC waste included calcium carbonate about 60% 
         [0040]    Cross-linked PVC rigid foam waste about 25% 
         [0041]    Glass wool waste about 15% 
         [0042]    Addition of glass wool increases the acoustic effect and decreases the weight of the acoustic material.