WO2008117947A1 - Double extrusion panel manufacturing system and method using waste plastic materials - Google Patents

Double extrusion panel manufacturing system and method using waste plastic materials Download PDF

Info

Publication number
WO2008117947A1
WO2008117947A1 PCT/KR2008/001488 KR2008001488W WO2008117947A1 WO 2008117947 A1 WO2008117947 A1 WO 2008117947A1 KR 2008001488 W KR2008001488 W KR 2008001488W WO 2008117947 A1 WO2008117947 A1 WO 2008117947A1
Authority
WO
WIPO (PCT)
Prior art keywords
extruder
plastic panel
plastic
raw material
waste
Prior art date
Application number
PCT/KR2008/001488
Other languages
French (fr)
Inventor
Jeong A Shin
Original Assignee
Jhan Co., Ltd.
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 Jhan Co., Ltd. filed Critical Jhan Co., Ltd.
Publication of WO2008117947A1 publication Critical patent/WO2008117947A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0013—Extrusion moulding in several steps, i.e. components merging outside the die
    • B29C48/0014—Extrusion moulding in several steps, i.e. components merging outside the die producing flat articles having components brought in contact outside the extrusion die
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/34—Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/916—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means using vacuum
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0027—Cutting off
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/904—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article using dry calibration, i.e. no quenching tank, e.g. with water spray for cooling or lubrication
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • 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

Definitions

  • the present invention relates to a double extruded panel made from waste plastic, which is used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse. More particularly, the present invention relates to a manufacturing system of a double extruded panel and a method thereof.
  • a manufacturing system of a double extruded panel and a method thereof By mixing waste plastic, wood powder, and vermiculite, and forming a floor covering by double extruding in a shape of an inner body and outer body, a plastic panel having improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat may be produced. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area.
  • Korean Patent No. 645935 applied by the inventor discloses a manufacturing system of a floor covering of a cargo container for an aircraft, ship, and truck, wherein the floor covering includes an outer element having a hollow formed in a planar sheet and foam filler injected into the hollow of the outer element.
  • This manufacturing system includes: an extruder for mixing and melting a raw material supplied in a powder form from a hopper through a hot screw cage, and for extruding the melt raw material towards a head; a foam extruder disposed parallel and adjacent to the extruder, for foaming a raw material supplied in a powder form from a hopper through a hot screw cage, and extruding the foamed material into the head of the extruder through its head and a connection pipe; a dice for receiving the raw material supplied by the head of the extruder, forming an outer body having a hollow in a planar sheet, and filling the hollow of the outer body with the foamed material supplied by the foam extruder; a sizing unit installed following the dice, for pressing and fixing the outer body extruded by the dice and the foamed material; and a water cooling means following the sizing unit, for hardening the outer body and foamed material fixed by the sizing unit.
  • Korean Patent No. 645935 has the following disadvantages.
  • the thickness of a floor covering becomes uneven, because the supply of raw material for forming an inner body and outer body is performed unevenly. Phenomenon of bowing of the floor covering is also generated, because the center part of the inner body and outer body becomes thinner than both sides of the inner body and outer body due to the uneven supply of raw material. Further, the quality of the floor covering is reduced, because air bubbles are generated while melting and extruding the raw material through the d ice, and thereby the cohesion between the inner body and the outer body is partially split while vacuuming. Disclosure of Invention Technical Problem
  • the present invention provides a manufacturing system of a double extruded panel and a method thereof.
  • a plastic panel By mixing waste plastic, wood powder, and vermiculite, and forming a floor covering by double extruding in a shape of an inner body and outer body, a plastic panel may be produced with improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area.
  • the double extruded panel made from waste plastic according to the present invention is used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse.
  • the manufacturing system of a double extruded panel includes: a raw material mixer for mixing waste materials recycled by a crusher conventionally used for crushing waste plastic and vinyl, wood powder, wood powder, chaff, vermiculite, glass fiber, and foaming agent; a first extruder and a second extruder for melting mixed raw materials supplied from the raw material mixer to hoppers by using planar heaters cir- cumferentially wound in a predetermined distance, and for extruding the mixed raw material towards head units by using transport screws; a double extruder for forming an inner body with a raw material extruded through the head unit of the first extruder and an outer body with a raw material extruded through the head unit of the second extruder, which is configured with a plurality of rectangular blocks such that a plastic panel is formed by controlling a feeding rate of the outer body with a plurality of adjusting bolts installed widthwise at its upper and lower surfaces; a cooler having a vacuum unit installed at its front inner side for smoothening the surface
  • a plastic panel may be produced with improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area.
  • plastic panel such as a floor covering, shelf, exterior panel, interior panel, and molding flask, may be formed efficiently by configuring the double extruder with a plurality of blocks and replacing a block having a discharge hole with one having a desired size. Further, the shock absorption and durability of the plastic panel may be improved by forming the plastic panel in a shape of an inner body and outer body and an environment-oriented product may be produced by recycling the waste plastic repeatedly.
  • FIG. 1 is a layout drawing showing a manufacturing system for extruding a plastic panel according to the present invention.
  • FIG. 2 is a plan view of the raw material extruders of FIG. 1 for supplying raw materials in double extruding a plastic panel.
  • FIG. 3 is a plan view of the double extruder and cooler of FIG. 1 for extruding and cooling the plastic panel.
  • FIG. 4 is a sectional view of the extruder and vacuum unit of FIG. 1 for double extruding the plastic panel.
  • FIG. 5 is a partial perspective view showing the double extruder and the vacuum unit of FIG. 1 for smoothening the surface of the extruded plastic panel.
  • FIG. 6 is a detailed view of the drawing unit of FIG. 1 for drawing the extruded plastic panel.
  • FIG. 7 is a detailed view of the cutter of FIG. 1 for cutting the extruded plastic panel.
  • FIG. 8 is a perspective view showing the extruded plastic panel cut in a predetermined length.
  • FIG. 9 is a flow chart showing a manufacturing process of a plastic panel according to the present invention.
  • a manufacturing system for double extruding a construction material or a floor covering by using waste plastics includes: a raw material mixer 1 for mixing waste materials recycled by a crusher conventionally used for crushing waste plastic and vinyl, wood powder, wood powder, chaff, vermiculite, glass fiber, and foaming agent; a first extruder 2 and a second extruder 2' for melting mixed raw material supplied from the raw material mixer 1 to hoppers 3 and 3' by using planar heaters 4 and 4' circumferentially wound in a predetermined distance, and for extruding the mixed raw material towards head units 6 and 6' by using transport screws 5 and 5'; a double extruder 7 for forming an inner body 8 with the raw material extruded through the head unit 6 of the first extruder 2 and an outer body 9 with the raw material extruded through the head unit 6' of the second extruder 2', wherein the double extruder 7 is configured with a plurality of rectangular blocks such that
  • the double extruder 7 includes a plurality of blocks having discharge holes 10 formed at its front side for extruding an inner body 8 and an outer body 9, a head unit 6 of the first extruder 2 and a head unit 6' of the second extruder 2' formed respectively in its rear center and at its side, and a plurality of adjusting bolts 20 formed width wise at one side of its upper surface for controlling the feeding rate of the raw material.
  • the cooler 11 includes a rectangular pressure housing open towards its upper side, an inlet 14 formed at its one side, an outlet 15 formed at the other side, a rectangular vacuum unit 12 installed adjacent to the inner side of the inlet 14 of the cooler 11, and a plurality of guides 16 installed following the vacuum unit 12 for guiding and cooling the plastic panel 30.
  • a method of manufacturing a double extruded panel by using waste plastic includes: mixing raw materials for a waste plastic panel by agitating crushed waste plastic or waste vinyl, wood powder or chaff, vermiculite, glass fiber, and foaming agent with a raw material mixer; supplying the raw materials mixed by the raw material mixer to hoppers of a first extruder and a second extruder, melting the supplied raw material, and extruding the melt raw material with a transport screw; forming a plastic panel with a double extruder configured to form an inner body with the raw material supplied from the first extruder and an outer body with the raw material supplied from the second extruder; smoothening the upper and lower surfaces of the formed plastic panel with a vacuum unit; cooling the smoothened plastic panel with cooling water; drawing the cooled plastic panel with a drawing unit having upper and lower rollers; cutting the drawn plastic panel according to a product specification; and inspecting and packing the cut plastic panel.
  • the plastic panel includes 50 - 70wt% (weight percent) crushed waste plastic powder containing one of waste plastic and waste vinyl, 10 - 20wt% wood powder or chaff, 10 - 20wt% glass fiber, 9.8wt% vermiculite, and 0.1 - 0.2wt% foaming agent.
  • Step 1 Composing and mixing raw materials of plastic panel
  • a motor installed at a side of the mixing tank of the raw material mixer 1 rotates a propeller located in the mixing tank such that the raw materials are uniformly mixed.
  • Distribution of raw materials is stabilized by agitating the raw materials in the mixing tanks of the raw material mixer, and therefore, uniform foam is generated in the following extrusion process.
  • the powder of waste plastic and waste vinyl is not a form of fine particles like wheat flour but a form of grains.
  • Step 2 Melting and extruding raw material with first and second extruders
  • the mixed raw materials are supplied through the hopper 3 of the first extruder 2 and the hopper 3' of the second extruder 2' and transported to the head units 6 and 6' installed at the end of the transport screws 5 and 5'.
  • a plurality of planar heaters 4 and 4' are installed at the circumference of the transport screw in a shape of a ring, and the melt plastic raw material is transported by the transport screws. Because a foaming agent is mixed in the raw materials, foam is generated while the raw materials melt.
  • the transport screw continuously extrudes the melt raw material towards the head units 6 and 6' to supply the raw materials to the double extruder 7.
  • the melting temperature of the plastic raw material may vary, because the collected waste plastic materials include a hard material and a soft material.
  • the waste vinyl is supplied to the hoppers in a state of soil contamination, and does not need to be sorted and washed. Because the vermiculite in the composition is similar to stone powder and soil, the waste vinyl and waste plastic contaminated by soil do not give any influence to forming a plastic panel 30.
  • Step 3 Forming plastic panel with double extruder
  • the plastic panel 30 is formed in the double extruder 7 by forming the raw material supplied from the first extruder 2 as an inner body 8 and the raw material supplied from the second extruder 2' as an outer body 9.
  • the double extruder includes a plurality of blocks and each block may be dismantled or replaced if necessary.
  • a discharge hole 10 for extruding the inner body 8 and outer body 9 is formed at a side of the double extruder 7.
  • the head unit 6 of the first extruder 2 is connected to the rear center of the double extruder 7 such that the raw materials that are extruded through the transport screw 5 form the inner body 8.
  • the head unit 6' of the second extruder 2' is connected to a side of the double extruder 7 such that the raw materials that are extruded through the transport screw 5' form the outer body 9.
  • Air bubbles that are generated while forming the inner body 8 and outer body 9 in the double extruder 7 are exhausted towards an exhaust hole along the connection line between the blocks, and thereby deformation and burning of the product due to the air bubbles are prevented.
  • the thickness of the plastic panel 30 may be controlled by replacing the discharge hole 10 according to the requirements.
  • Step 4 Smoothening and cooling formed plastic panel with vacuum unit
  • the vacuum unit is formed with a double pressure housing and has a space for transporting the plastic panel 30 in a length direction.
  • Inner plates of the vacuum unit 12 having a plurality of fine pores face the upper and lower surface of the plastic panel 30.
  • An external case is formed at the outside of the inner plates maintaining a predetermined distance. Therefore, the upper and lower surfaces of the plastic panel 30 passing through the transport space of the vacuum unit are smoothened by sucking the air through an air suction hole formed at the upper and lower surface of the external case.
  • the plastic panel 30 smoothened by the vacuum unit 12 is transported by a drawing unit 17 and hardened by cooling water of the cooler 11 while being guided by the guides 16.
  • the plastic panel 30 is located between the upper and lower rollers of the drawing unit 17 and transported by the rotation of the upper and lower rollers.
  • the distance between the upper and lower rollers may be adjusted according to the desired thickness of the plastic panel 30 by using cylinders installed at the upper and lower rollers.
  • Step 6 Cutting, inspecting, and packing plastic panel
  • the plastic panel 30 hardened by the cooler 11 and drawn by the drawing unit 17 is cut in a predetermined length according to a product specification by a cutter installed following the drawing unit 17.
  • Support bars 19a and 19b are installed at the upper part of the cutter 19 and cutting operation of the plastic panel 30 is performed by a circular saw installed in the cutter 19 and traversing in the length direction. While the plastic panel 30 is cut with the circular saw, the plastic panel 30 is fixed by pressing with the support bars of the cutter 19, and the cutter 19 moves along the rails 19c. The traversing speed of the cutter 19 is synchronized with the drawing speed of the drawing unit. After the plastic panel is cut, the cutter 19 returns to its initial position along the rails 19c.
  • the plastic panel 30 is then inspected, packed, and shipped according the product specification.
  • the finished plastic panels are used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse.
  • a plastic panel is produced by using a double extruder, and raw materials for the inner body 8 and the outer body 9 of the plastic panel may be prepared in the same composition or in different compositions.
  • the inner body 8 may be formed with a waste plastic material and the outer body 9 covering the inner body 8 may be formed with a virgin material.
  • connection means may be provided at both sides of the plastic panel 30 for easy assembly of the plastic panels.
  • the plastic panel provides excellent shock absorption and a strength required to be used as a floor covering.
  • FIG. 1 is a drawing of a layout showing a manufacturing system for extruding a plastic panel according to the present invention.
  • the manufacturing system includes: a raw material mixer 1 for mixing and homogenizing waste plastic materials by agitating; a first extruder 2 and a second extruder 2' for melting the mixed raw material supplied from the raw material mixer 1 through hoppers 3 and 3' by using planar heaters 4 and 4', and for extruding the melt raw material by using transport screws 5 and 5'; a double extruder 7 for forming a plastic panel from the raw materials extruded by the first and second extruders; a cooler 11 for smoothening the surface of the plastic panel by using vacuum and hardening the plastic panel by water cooling; and a cutter 19 for cutting the plastic panel in a predetermined length according a product specification.
  • the above manufacturing system may be automated, and thereby labor costs can be saved and the product control can be performed efficiently.
  • FIG. 2 is a plan view of the raw material extruders of FIG. 1 for supplying raw materials when double extruding a plastic panel.
  • the double extruder is configured with a first extruder 2 and a second extruder 2' to form a plastic panel having a double structure.
  • the first extruder 2 and the second extruder 2' are configured respectively with hoppers 3 and 3', planar heaters 4 and 4', transport screw 5 and 5', and head units 6 and 6'.
  • the raw materials melt and foamed by the extruders 2 and 2' are extruded towards the head units 6 and 6' by the transport screw 5 and 5'.
  • the head unit 6 of the first extruder 2 is connected to the rear center part of the double extruder 7 to form an inner body 8 and the head unit 6' of the second extruder 2' is connected to a side of the double extruder 7 to form an outer body 9.
  • the double extruder is configured with a plurality of blocks and the inner body 8 and the outer body 9 are formed and extruded by heating the blocks with electric power.
  • FIG. 3 is a plan view of the double extruder and cooler of FIG. 1 for extruding and cooling a plastic panel.
  • the plastic panel formed by the double extruder 7 is smoothened by sucking the air from the upper and lowers surfaces of the plastic panel and cooling with water, and transported to the following drawing unit.
  • the cooler 11 includes a rectangular pressure housing open towards its upper side, an inlet 14 formed at its one side, an outlet 15 formed at the other side, a rectangular vacuum unit 12 installed adjacent to the inner side of the inlet 14 of the cooler 11, and a plurality of guides 16 installed following the vacuum unit 12 for guiding and cooling the plastic panel 30.
  • FIG. 4 is a sectional view of the extruder and vacuum unit of FIG. 1 for double extruding a plastic panel.
  • the raw material extruded by the first extruder 2 is supplied to the center part of the double extruder 7 to form an inner body 8 and the raw material extruded by the second extruder 2' is supplied to the circumference of the inner body 8 to form an outer body 9.
  • the inner body 8 and the outer body 9 are extruded separately by the double extruder. However, after extrusion, the inner body 8 and the outer body 9 adhere to each other, and form a single plastic panel 30.
  • adjusting bolts 20 are disposed widthwise at the upper and lower surfaces of the double extruder 7 to control the amount of raw material to be supplied. Uneven supply of the raw material is prevented by controlling the amount of raw material with the adjusting bolts 20, and thereby the outer body 9 is formed in a uniform thickness.
  • FIG. 5 is a partial perspective view showing the double extruders and the vacuum unit of FIG. 1 for smoothening the surface of the extruded plastic panel.
  • a vacuum unit installed adjacent to the inlet of the cooler smoothens the surface of the plastic panel formed by the double extruder 7 and fixes the inner body 8 and the outer body 9 together.
  • FIG. 6 is a detailed view of the drawing unit 17 of FIG. 1 for drawing the extruded plastic panel.
  • the drawing unit 17 draws the plastic panel from the outlet 15 of the cooler 11 and transports the plastic panel 30 to the cutter 19.
  • the drawing unit includes upper and lower rollers, and the plastic panel is drawn by rotating the rollers.
  • FIG. 7 is a detailed view of the cutter 19 of FIG. 1 for cutting the extruded plastic panel.
  • the cutter 19 cuts the plastic panel transported by the drawing unit 17 into a predetermined length according to a product specification.
  • FIG. 8 is a perspective view showing the extruded plastic panel cut in a predetermined length.
  • the plastic panel is formed in a shape of an inner body and outer body by the double extruder 7, and may be used for a floor covering, exterior or interior panel for construction, and support panel. According to the present invention, plastic panels having various thicknesses may be produced by replacing the block containing a discharge hole 10 in the double extruder 7.
  • FIG. 9 is a flow chart showing a manufacturing process of a plastic panel according to the present invention.
  • the manufacturing process includes: composing and mixing raw materials of plastic panel; melting and extruding raw material with first and second extruders; forming plastic panel with double extruder; smoothening and cooling formed plastic panel with vacuum unit; drawing plastic panel; and cutting, inspecting, and packing plastic panel.
  • plastic panel such as a floor covering, shelf, exterior panel, interior panel, and molding flask
  • a double extruder with a plurality of blocks and replacing a block having a discharge hole with one having a desired size. Accordingly, the plastic panel can be used generally in the industry and forest can be conserved by substituting the plastic panel for wood.
  • the shock absorption and durability of the plastic panel may be improved by forming the plastic panel in a shape of an inner body and outer body and the plastic panel may be substituted for wood that are used as a floor covering of a container and a truck, in which damages are frequently occurred due to repeated high loads and shocks, and absorption of oil and rain water. Accordingly, an owner of a truck can save cost for replacing damaged floor coverings.

Abstract

The present invention relates to a double extruded panel made from waste plastic, which is used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse. The plastic panel includes 50 - 70wt% crushed waste plastic powder containing one of waste plastic and waste vinyl, 10 - 20wt% wood powder or chaff, 10 - 20wt% glass fiber, 9.8wt% vermiculite, and 0.1 - 0.2wt% foaming agent. According to the present invention, cost of recycling waste plastic and waste vinyl is reduced and environmental pollution is prevented by recycling waste plastic and waste vinyl. Various types of plastic panel, such as a floor covering, shelf, exterior panel, interior panel, and molding flask, may be formed efficiently by configuring the double extruder with a plurality of blocks and replacing a block having a discharge hole with one having a desired size. Further, shock absorption and durability of the plastic panel may be improved by forming the plastic panel in a shape of an inner body and outer body and an environment-oriented product may be produced by recycling the waste plastic repeatedly.

Description

Description
DOUBLE EXTRUSION PANEL MANUFACTURING SYSTEM AND METHOD USING WASTE PLASTIC MATERIALS
Technical Field
[1] The present invention relates to a double extruded panel made from waste plastic, which is used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse. More particularly, the present invention relates to a manufacturing system of a double extruded panel and a method thereof. By mixing waste plastic, wood powder, and vermiculite, and forming a floor covering by double extruding in a shape of an inner body and outer body, a plastic panel having improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat may be produced. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area. Background Art
[2] Although various floor coverings and construction materials made from waste plastic have been developed, most of the products made from the waste plastic has poor physical properties, and thereby are not commercialized yet.
[3] In the case of forming a floor covering or a construction material only with waste plastic, treatment for increasing a strength of the product may result in low shock absorption of the product and treatment for increasing shock absorption of the product may result in a low strength of the product. In order to improve shock absorption and durability, PVC (poly vinyl chloride) is added to the waste plastic when forming a floor covering or a construction material. However, this method has a disadvantage that other physical properties are deteriorated. In particular, collected waste plastic must first be sorted manually, must be washed and dried to remove impurities such as soil. Therefore, this may require high labor cost.
[4] Korean Patent No. 645935 applied by the inventor discloses a manufacturing system of a floor covering of a cargo container for an aircraft, ship, and truck, wherein the floor covering includes an outer element having a hollow formed in a planar sheet and foam filler injected into the hollow of the outer element. This manufacturing system includes: an extruder for mixing and melting a raw material supplied in a powder form from a hopper through a hot screw cage, and for extruding the melt raw material towards a head; a foam extruder disposed parallel and adjacent to the extruder, for foaming a raw material supplied in a powder form from a hopper through a hot screw cage, and extruding the foamed material into the head of the extruder through its head and a connection pipe; a dice for receiving the raw material supplied by the head of the extruder, forming an outer body having a hollow in a planar sheet, and filling the hollow of the outer body with the foamed material supplied by the foam extruder; a sizing unit installed following the dice, for pressing and fixing the outer body extruded by the dice and the foamed material; and a water cooling means following the sizing unit, for hardening the outer body and foamed material fixed by the sizing unit. However, Korean Patent No. 645935 has the following disadvantages. The thickness of a floor covering becomes uneven, because the supply of raw material for forming an inner body and outer body is performed unevenly. Phenomenon of bowing of the floor covering is also generated, because the center part of the inner body and outer body becomes thinner than both sides of the inner body and outer body due to the uneven supply of raw material. Further, the quality of the floor covering is reduced, because air bubbles are generated while melting and extruding the raw material through the d ice, and thereby the cohesion between the inner body and the outer body is partially split while vacuuming. Disclosure of Invention Technical Problem
[5] In order to solve the above problems, the present invention provides a manufacturing system of a double extruded panel and a method thereof. By mixing waste plastic, wood powder, and vermiculite, and forming a floor covering by double extruding in a shape of an inner body and outer body, a plastic panel may be produced with improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area. Technical Solution
[6] The double extruded panel made from waste plastic according to the present invention is used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse.
[7] The manufacturing system of a double extruded panel includes: a raw material mixer for mixing waste materials recycled by a crusher conventionally used for crushing waste plastic and vinyl, wood powder, wood powder, chaff, vermiculite, glass fiber, and foaming agent; a first extruder and a second extruder for melting mixed raw materials supplied from the raw material mixer to hoppers by using planar heaters cir- cumferentially wound in a predetermined distance, and for extruding the mixed raw material towards head units by using transport screws; a double extruder for forming an inner body with a raw material extruded through the head unit of the first extruder and an outer body with a raw material extruded through the head unit of the second extruder, which is configured with a plurality of rectangular blocks such that a plastic panel is formed by controlling a feeding rate of the outer body with a plurality of adjusting bolts installed widthwise at its upper and lower surfaces; a cooler having a vacuum unit installed at its front inner side for smoothening the surface of the plastic panel formed by the double extruder, and filled with cooling water through a plurality of guides installed following the vacuum unit; a drawing unit having rollers for drawing the plastic panel hardened by the cooler; and a cutter having a circular saw installed movably for cutting the plastic panel drawn by the drawing unit in a predetermined length.
[8] By using the double extruded panel manufacturing system according to the present invention, a plastic panel may be produced with improved shock absorption, durability, flame retardancy, and resistance to distortion due to heat. Additionally, environmental pollution may be prevented by recycling waste plastic and waste vinyl discarded in an industrial area and a farm area.
Advantageous Effects
[9] According to the present invention, cost of recycling waste plastic and waste vinyl may be reduced and the environmental pollution is prevented by recycling waste plastic and waste vinyl. Various types of plastic panel, such as a floor covering, shelf, exterior panel, interior panel, and molding flask, may be formed efficiently by configuring the double extruder with a plurality of blocks and replacing a block having a discharge hole with one having a desired size. Further, the shock absorption and durability of the plastic panel may be improved by forming the plastic panel in a shape of an inner body and outer body and an environment-oriented product may be produced by recycling the waste plastic repeatedly. Brief Description of the Drawings
[10] FIG. 1 is a layout drawing showing a manufacturing system for extruding a plastic panel according to the present invention.
[11] FIG. 2 is a plan view of the raw material extruders of FIG. 1 for supplying raw materials in double extruding a plastic panel.
[12] FIG. 3 is a plan view of the double extruder and cooler of FIG. 1 for extruding and cooling the plastic panel.
[13] FIG. 4 is a sectional view of the extruder and vacuum unit of FIG. 1 for double extruding the plastic panel.
[14] FIG. 5 is a partial perspective view showing the double extruder and the vacuum unit of FIG. 1 for smoothening the surface of the extruded plastic panel.
[15] FIG. 6 is a detailed view of the drawing unit of FIG. 1 for drawing the extruded plastic panel.
[16] FIG. 7 is a detailed view of the cutter of FIG. 1 for cutting the extruded plastic panel.
[17] FIG. 8 is a perspective view showing the extruded plastic panel cut in a predetermined length.
[18] FIG. 9 is a flow chart showing a manufacturing process of a plastic panel according to the present invention.
[19] <Reference numbers in the drawings>
[20] 1: raw material mixer 2: first extruder
[21] 2': second extruder 4, 4': planar heater
[22] 5, 5': transport screw 6, 6': head unit
[23] 7: double extruder 8: inner body
[24] 9: outer body 10: discharge hole
[25] 11: cooler 12: vacuum unit
[26] 13: guide 14: inlet
[27] 15: outlet 16: guide
[28] 17: drawing unit 18: roller
[29] 19: cutter 20: adjusting bolt
[30] 30: plastic panel
Best Mode for Carrying Out the Invention
[31] According to an exemplary embodiment of the present invention, a manufacturing system for double extruding a construction material or a floor covering by using waste plastics includes: a raw material mixer 1 for mixing waste materials recycled by a crusher conventionally used for crushing waste plastic and vinyl, wood powder, wood powder, chaff, vermiculite, glass fiber, and foaming agent; a first extruder 2 and a second extruder 2' for melting mixed raw material supplied from the raw material mixer 1 to hoppers 3 and 3' by using planar heaters 4 and 4' circumferentially wound in a predetermined distance, and for extruding the mixed raw material towards head units 6 and 6' by using transport screws 5 and 5'; a double extruder 7 for forming an inner body 8 with the raw material extruded through the head unit 6 of the first extruder 2 and an outer body 9 with the raw material extruded through the head unit 6' of the second extruder 2', wherein the double extruder 7 is configured with a plurality of rectangular blocks such that a plastic panel 30 is formed by controlling the feeding rate of the outer body 9 with a plurality of adjusting bolts 20 installed widthwise at its upper and lower surfaces; a cooler 11 having a vacuum unit 12 installed at its front inner side for smoothening the surface of the plastic panel 30 formed by the double extruder 7, and filled with cooling water through a plurality of guides 16 installed following the vacuum unit 12; a drawing unit 17 having rollers 18 for drawing the plastic panel 30 hardened by the cooler 11; and a cutter 19 having a circular saw installed movably for cutting the plastic panel 30 drawn by the drawing unit 17 in a predetermined length.
[32] Preferably, the double extruder 7 includes a plurality of blocks having discharge holes 10 formed at its front side for extruding an inner body 8 and an outer body 9, a head unit 6 of the first extruder 2 and a head unit 6' of the second extruder 2' formed respectively in its rear center and at its side, and a plurality of adjusting bolts 20 formed width wise at one side of its upper surface for controlling the feeding rate of the raw material.
[33] Preferably, the cooler 11 includes a rectangular pressure housing open towards its upper side, an inlet 14 formed at its one side, an outlet 15 formed at the other side, a rectangular vacuum unit 12 installed adjacent to the inner side of the inlet 14 of the cooler 11, and a plurality of guides 16 installed following the vacuum unit 12 for guiding and cooling the plastic panel 30.
[34] According to another exemplary embodiment of the present invention, a method of manufacturing a double extruded panel by using waste plastic includes: mixing raw materials for a waste plastic panel by agitating crushed waste plastic or waste vinyl, wood powder or chaff, vermiculite, glass fiber, and foaming agent with a raw material mixer; supplying the raw materials mixed by the raw material mixer to hoppers of a first extruder and a second extruder, melting the supplied raw material, and extruding the melt raw material with a transport screw; forming a plastic panel with a double extruder configured to form an inner body with the raw material supplied from the first extruder and an outer body with the raw material supplied from the second extruder; smoothening the upper and lower surfaces of the formed plastic panel with a vacuum unit; cooling the smoothened plastic panel with cooling water; drawing the cooled plastic panel with a drawing unit having upper and lower rollers; cutting the drawn plastic panel according to a product specification; and inspecting and packing the cut plastic panel.
[35] Preferably, the plastic panel includes 50 - 70wt% (weight percent) crushed waste plastic powder containing one of waste plastic and waste vinyl, 10 - 20wt% wood powder or chaff, 10 - 20wt% glass fiber, 9.8wt% vermiculite, and 0.1 - 0.2wt% foaming agent.
[36] Hereinafter, the method of manufacturing a double extruded panel by using waste plastic is described in more detail.
[37]
[38] Step 1 : Composing and mixing raw materials of plastic panel
[39] Composition of 50 - 70wt% powder of crushed waste plastic and waste vinyl, 10 -
20wt% wood powder or chaff, 10 - 20wt% glass fiber, 9.8wt% vermiculite, and 0.1 - 0.2wt% foaming agent is mixed by agitating with a raw material mixer 1. [40] A motor installed at a side of the mixing tank of the raw material mixer 1 rotates a propeller located in the mixing tank such that the raw materials are uniformly mixed.
[41] Because the shrinkage and strength of each component vary, the raw materials must be mixed uniformly such that each component is not distributed on one side.
[42] Distribution of raw materials is stabilized by agitating the raw materials in the mixing tanks of the raw material mixer, and therefore, uniform foam is generated in the following extrusion process.
[43] The powder of waste plastic and waste vinyl is not a form of fine particles like wheat flour but a form of grains.
[44]
[45] Step 2: Melting and extruding raw material with first and second extruders
[46] The mixed raw materials are supplied through the hopper 3 of the first extruder 2 and the hopper 3' of the second extruder 2' and transported to the head units 6 and 6' installed at the end of the transport screws 5 and 5'. A plurality of planar heaters 4 and 4' are installed at the circumference of the transport screw in a shape of a ring, and the melt plastic raw material is transported by the transport screws. Because a foaming agent is mixed in the raw materials, foam is generated while the raw materials melt.
[47] The transport screw continuously extrudes the melt raw material towards the head units 6 and 6' to supply the raw materials to the double extruder 7.
[48] The temperature of the planar heater 4 and 4' installed at the transport screw 5 and
5' may vary according to the composition of plastic raw material supplied through the hoppers 3 and 3'. That is, the melting temperature of the plastic raw material may vary, because the collected waste plastic materials include a hard material and a soft material.
[49] The waste vinyl is supplied to the hoppers in a state of soil contamination, and does not need to be sorted and washed. Because the vermiculite in the composition is similar to stone powder and soil, the waste vinyl and waste plastic contaminated by soil do not give any influence to forming a plastic panel 30.
[50]
[51] Step 3 : Forming plastic panel with double extruder
[52] The plastic panel 30 is formed in the double extruder 7 by forming the raw material supplied from the first extruder 2 as an inner body 8 and the raw material supplied from the second extruder 2' as an outer body 9.
[53] The double extruder includes a plurality of blocks and each block may be dismantled or replaced if necessary.
[54] A discharge hole 10 for extruding the inner body 8 and outer body 9 is formed at a side of the double extruder 7. The head unit 6 of the first extruder 2 is connected to the rear center of the double extruder 7 such that the raw materials that are extruded through the transport screw 5 form the inner body 8. The head unit 6' of the second extruder 2' is connected to a side of the double extruder 7 such that the raw materials that are extruded through the transport screw 5' form the outer body 9.
[55] Air bubbles that are generated while forming the inner body 8 and outer body 9 in the double extruder 7 are exhausted towards an exhaust hole along the connection line between the blocks, and thereby deformation and burning of the product due to the air bubbles are prevented.
[56] Because the double extruder 7 is configured in blocks, the thickness of the plastic panel 30 may be controlled by replacing the discharge hole 10 according to the requirements.
[57]
[58] Step 4: Smoothening and cooling formed plastic panel with vacuum unit
[59] While transporting the plastic panel 30 through the inlet 14 and the vacuum unit 12 of the cooler 11, the upper and lower surfaces of the plastic panel 30 are smoothened by sucking air from the upper and lower parts of the vacuum unit 12.
[60] The vacuum unit is formed with a double pressure housing and has a space for transporting the plastic panel 30 in a length direction. Inner plates of the vacuum unit 12 having a plurality of fine pores face the upper and lower surface of the plastic panel 30. An external case is formed at the outside of the inner plates maintaining a predetermined distance. Therefore, the upper and lower surfaces of the plastic panel 30 passing through the transport space of the vacuum unit are smoothened by sucking the air through an air suction hole formed at the upper and lower surface of the external case.
[61] The plastic panel 30 smoothened by the vacuum unit 12 is transported by a drawing unit 17 and hardened by cooling water of the cooler 11 while being guided by the guides 16.
[62]
[63] Step 5: Drawing plastic panel
[64] The plastic panel 30 hardened by the cooling water of the cooler 11 is further transported by the drawing unit 17 installed following the outlet 15 of the cooler 11.
[65] The plastic panel 30 is located between the upper and lower rollers of the drawing unit 17 and transported by the rotation of the upper and lower rollers.
[66] The distance between the upper and lower rollers may be adjusted according to the desired thickness of the plastic panel 30 by using cylinders installed at the upper and lower rollers.
[67]
[68] Step 6: Cutting, inspecting, and packing plastic panel
[69] The plastic panel 30 hardened by the cooler 11 and drawn by the drawing unit 17 is cut in a predetermined length according to a product specification by a cutter installed following the drawing unit 17.
[70] Support bars 19a and 19b are installed at the upper part of the cutter 19 and cutting operation of the plastic panel 30 is performed by a circular saw installed in the cutter 19 and traversing in the length direction. While the plastic panel 30 is cut with the circular saw, the plastic panel 30 is fixed by pressing with the support bars of the cutter 19, and the cutter 19 moves along the rails 19c. The traversing speed of the cutter 19 is synchronized with the drawing speed of the drawing unit. After the plastic panel is cut, the cutter 19 returns to its initial position along the rails 19c.
[71] After cutting, the plastic panel 30 is then inspected, packed, and shipped according the product specification. The finished plastic panels are used as a floor covering for a room, container, truck, aircraft, and ship, and pallets of a warehouse.
[72] According to the present invention, a plastic panel is produced by using a double extruder, and raw materials for the inner body 8 and the outer body 9 of the plastic panel may be prepared in the same composition or in different compositions.
[73] For example, the inner body 8 may be formed with a waste plastic material and the outer body 9 covering the inner body 8 may be formed with a virgin material.
[74] The plastic panel according to the present invention may be further processed if necessary. For example, connection means may be provided at both sides of the plastic panel 30 for easy assembly of the plastic panels.
[75] Further, by producing a plastic panel with a double extruder in a shape of an inner body and outer body according to the present invention, the plastic panel provides excellent shock absorption and a strength required to be used as a floor covering.
[76]
[77] Hereinafter, exemplary embodiments of the present invention are described in more detail referring to the attached drawings.
[78] FIG. 1 is a drawing of a layout showing a manufacturing system for extruding a plastic panel according to the present invention. The manufacturing system includes: a raw material mixer 1 for mixing and homogenizing waste plastic materials by agitating; a first extruder 2 and a second extruder 2' for melting the mixed raw material supplied from the raw material mixer 1 through hoppers 3 and 3' by using planar heaters 4 and 4', and for extruding the melt raw material by using transport screws 5 and 5'; a double extruder 7 for forming a plastic panel from the raw materials extruded by the first and second extruders; a cooler 11 for smoothening the surface of the plastic panel by using vacuum and hardening the plastic panel by water cooling; and a cutter 19 for cutting the plastic panel in a predetermined length according a product specification.
[79] The above manufacturing system may be automated, and thereby labor costs can be saved and the product control can be performed efficiently.
[80] FIG. 2 is a plan view of the raw material extruders of FIG. 1 for supplying raw materials when double extruding a plastic panel. The double extruder is configured with a first extruder 2 and a second extruder 2' to form a plastic panel having a double structure. The first extruder 2 and the second extruder 2' are configured respectively with hoppers 3 and 3', planar heaters 4 and 4', transport screw 5 and 5', and head units 6 and 6'. The raw materials melt and foamed by the extruders 2 and 2' are extruded towards the head units 6 and 6' by the transport screw 5 and 5'. The head unit 6 of the first extruder 2 is connected to the rear center part of the double extruder 7 to form an inner body 8 and the head unit 6' of the second extruder 2' is connected to a side of the double extruder 7 to form an outer body 9.
[81] The double extruder is configured with a plurality of blocks and the inner body 8 and the outer body 9 are formed and extruded by heating the blocks with electric power.
[82] FIG. 3 is a plan view of the double extruder and cooler of FIG. 1 for extruding and cooling a plastic panel. The plastic panel formed by the double extruder 7 is smoothened by sucking the air from the upper and lowers surfaces of the plastic panel and cooling with water, and transported to the following drawing unit.
[83] Referreing to Figs. 1 and 3, the the cooler 11 includes a rectangular pressure housing open towards its upper side, an inlet 14 formed at its one side, an outlet 15 formed at the other side, a rectangular vacuum unit 12 installed adjacent to the inner side of the inlet 14 of the cooler 11, and a plurality of guides 16 installed following the vacuum unit 12 for guiding and cooling the plastic panel 30.
[84] FIG. 4 is a sectional view of the extruder and vacuum unit of FIG. 1 for double extruding a plastic panel. The raw material extruded by the first extruder 2 is supplied to the center part of the double extruder 7 to form an inner body 8 and the raw material extruded by the second extruder 2' is supplied to the circumference of the inner body 8 to form an outer body 9.
[85] The inner body 8 and the outer body 9 are extruded separately by the double extruder. However, after extrusion, the inner body 8 and the outer body 9 adhere to each other, and form a single plastic panel 30.
[86] Additionally, adjusting bolts 20 are disposed widthwise at the upper and lower surfaces of the double extruder 7 to control the amount of raw material to be supplied. Uneven supply of the raw material is prevented by controlling the amount of raw material with the adjusting bolts 20, and thereby the outer body 9 is formed in a uniform thickness.
[87] FIG. 5 is a partial perspective view showing the double extruders and the vacuum unit of FIG. 1 for smoothening the surface of the extruded plastic panel. A vacuum unit installed adjacent to the inlet of the cooler smoothens the surface of the plastic panel formed by the double extruder 7 and fixes the inner body 8 and the outer body 9 together.
[88] FIG. 6 is a detailed view of the drawing unit 17 of FIG. 1 for drawing the extruded plastic panel. The drawing unit 17 draws the plastic panel from the outlet 15 of the cooler 11 and transports the plastic panel 30 to the cutter 19.
[89] The drawing unit includes upper and lower rollers, and the plastic panel is drawn by rotating the rollers.
[90] FIG. 7 is a detailed view of the cutter 19 of FIG. 1 for cutting the extruded plastic panel. The cutter 19 cuts the plastic panel transported by the drawing unit 17 into a predetermined length according to a product specification.
[91] FIG. 8 is a perspective view showing the extruded plastic panel cut in a predetermined length. The plastic panel is formed in a shape of an inner body and outer body by the double extruder 7, and may be used for a floor covering, exterior or interior panel for construction, and support panel. According to the present invention, plastic panels having various thicknesses may be produced by replacing the block containing a discharge hole 10 in the double extruder 7.
[92] FIG. 9 is a flow chart showing a manufacturing process of a plastic panel according to the present invention. The manufacturing process includes: composing and mixing raw materials of plastic panel; melting and extruding raw material with first and second extruders; forming plastic panel with double extruder; smoothening and cooling formed plastic panel with vacuum unit; drawing plastic panel; and cutting, inspecting, and packing plastic panel. Industrial Applicability
[93] By recycling waste plastic and waste vinyl according to the present invention,
[94] 1) Cost of processing waste materials may be reduced and environmental pollution may be prevented.
[95] 2) Various types of plastic panel, such as a floor covering, shelf, exterior panel, interior panel, and molding flask, may be formed efficiently by configuring a double extruder with a plurality of blocks and replacing a block having a discharge hole with one having a desired size. Accordingly, the plastic panel can be used generally in the industry and forest can be conserved by substituting the plastic panel for wood.
[96] 3) The shock absorption and durability of the plastic panel may be improved by forming the plastic panel in a shape of an inner body and outer body and the plastic panel may be substituted for wood that are used as a floor covering of a container and a truck, in which damages are frequently occurred due to repeated high loads and shocks, and absorption of oil and rain water. Accordingly, an owner of a truck can save cost for replacing damaged floor coverings.

Claims

Claims
[1] A manufacturing system for double extruding a construction material or a floor covering by using waste plastics comprising: a raw material mixer 1 for mixing waste materials recycled by a crusher conventionally used for crushing waste plastic and vinyl, wood powder, wood powder, chaff, vermiculite, glass fiber, and foaming agent; a first extruder 2 and a second extruder 2' for melting the mixed raw material supplied from the raw material mixer 1 through hoppers 3 and 3' by using planar heaters 4 and 4' circumferentially wound in a predetermined distance, and for extruding the mixed raw material towards head units 6 and 6' by using transport screws 5 and 5'; a double extruder 7 for forming an inner body 8 with the raw material extruded through the head unit 6 of the first extruder 2 and an outer body 9 with the raw material extruded through the head unit 6' of the second extruder 2', wherein the double extruder 7 is configured with a plurality of rectangular blocks such that a plastic panel 30 is formed by controlling the feeding rate of the outer body 9 with a plurality of adjusting bolts 20 installed widthwise at its upper and lower surfaces; a cooler 11 having a vacuum unit 12 installed at its front inner side for smoothening the surface of the plastic panel 30 formed by the double extruder 7, and filled with cooling water through a plurality of guides 16 installed following the vacuum unit 12; a drawing unit 17 having rollers 18 for drawing the plastic panel 30 hardened by the cooler 11 ; and a cutter 19 having a circular saw installed movably for cutting the plastic panel 30 drawn by the drawing unit 17 in a predetermined length.
[2] The manufacturing system of claim 1, wherein the double extruder 7 comprises a plurality of blocks having discharge holes 10 formed at its front side for extruding the inner body 8 and outer body 9, a head unit 6 of the first extruder 2 and a head unit 6' of the second extruder 2' formed respectively in its rear center and at its side, and a plurality of adjusting bolt 20 formed widthwise at one side of its upper surface for controlling the feeding rate of the raw material.
[3] The manufacturing system of claim 1, wherein the cooler 11 comprises a rectangular pressure housing open towards its upper side, an inlet 14 formed at its one side, an outlet 15 formed at the other side, a rectangular vacuum unit 12 installed adjacent to the inner side of the inlet 14 of the cooler 11, and a plurality of guides 16 installed following the vacuum unit 12 for guiding and cooling the plastic panel 30. [4] A method of manufacturing a double extruded panel by using waste plastics comprising: mixing raw materials of a waste plastic panel by agitating crushed waste plastic or waste vinyl, wood powder or chaff, vermiculite, glass fiber, and foaming agent with a raw material mixer; supplying the raw materials mixed by the raw material mixer to hoppers of a first extruder and a second extruder, melting the supplied raw material, and extruding the melt raw material with a transport screw; forming a plastic panel with a double extruder configured to form an inner body with the raw materials supplied from the first extruder and an outer body with the raw materials supplied from the second extruder; smoothening the upper and lower surfaces of the formed plastic panel with a vacuum unit; cooling the smoothened plastic panel with cooling water; drawing the cooled plastic panel with a drawing unit having upper and lower rollers; cutting the drawn plastic panel according to a product specification; and inspecting and packing the cut plastic panel. [5] The method of claim 4, wherein the plastic panel comprises 50 - 70wt% crushed waste plastic powder containing one of waste plastic and waste vinyl, 10 -
20wt% wood powder or chaff, 10 - 20wt% glass fiber, 9.8wt% vermiculite, and
0.1 - 0.2wt% foaming agent.
PCT/KR2008/001488 2007-03-28 2008-03-17 Double extrusion panel manufacturing system and method using waste plastic materials WO2008117947A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR20070030575A KR100789957B1 (en) 2007-03-28 2007-03-28 Double extrusion panel manufacturing system and method using waste plastic materials
KR10-2007-0030575 2007-03-28

Publications (1)

Publication Number Publication Date
WO2008117947A1 true WO2008117947A1 (en) 2008-10-02

Family

ID=39216114

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/KR2008/001488 WO2008117947A1 (en) 2007-03-28 2008-03-17 Double extrusion panel manufacturing system and method using waste plastic materials

Country Status (2)

Country Link
KR (1) KR100789957B1 (en)
WO (1) WO2008117947A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102975444A (en) * 2012-03-08 2013-03-20 张耀中 Multilayer structure floor board for cargo container and multilayer structure floor board body manufacturing method
GB2519249A (en) * 2014-01-07 2015-04-15 Environmental Technology Evolution Ltd Process and apparatus for manufacturing a multilayer article
CN108467558A (en) * 2018-06-28 2018-08-31 多稳（太仓）智能科技有限公司 A kind of plastics firework barrel and preparation method thereof

Families Citing this family (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100975976B1 (en) 2008-06-10 2010-08-13 주식회사 세데코 Siding for house and making apparatus and process
KR100897836B1 (en) 2008-06-20 2009-05-19 양명주 Extrusion molding apparatus and the extrusion molding method structured multi-floor inside frame
KR100949685B1 (en) * 2008-12-30 2010-03-26 주식회사 알씨씨 Device for manufacturingthe synthetic resin plate having forming layer
KR101129076B1 (en) * 2009-09-10 2012-03-23 현대산업개발 주식회사 One touch constructing method and its apparatus in celing using engineering plastic
KR101237993B1 (en) 2009-12-03 2013-02-26 주식회사 피앤씨 Double composite synthetic resin composition and panel therefrom
KR101188737B1 (en) 2010-01-08 2012-10-10 주식회사 피앤씨 Double extrusion panel manufacturing system and method using waste plastic materials, and double extrusion panel
KR101135630B1 (en) 2010-02-03 2012-04-17 주식회사 피앤씨 Tree piece puts in on the center of double extrusion panel manufacturing system and method using waste plastic materials, and double extrusion panel
KR101188738B1 (en) * 2010-03-15 2012-10-15 주식회사 피앤씨 The panel and manufacturing system double extrusion panel using waste plastic materials of one in two out
KR101192018B1 (en) * 2010-05-28 2012-10-16 이재식 Pattern all style manufacturing method
KR101166899B1 (en) 2010-08-27 2012-07-19 양명주 The extrusion molding device having dice structured multi-extrusing stage and the extrusion moding method of synthetic resins plank
KR101379284B1 (en) 2011-11-04 2014-03-28 양명주 The extrusion molding device having dice structured multi-extrusing stage and the extrusion moding method of synthetic resins plank
KR101166370B1 (en) 2011-12-14 2012-07-23 (주) 웹스 A profile manufacturing system and a method for manufacturing the same
KR101452199B1 (en) 2014-02-06 2014-10-22 미르하이텍 주식회사 Pallet
KR101491073B1 (en) 2014-08-18 2015-02-10 주식회사 성지기공 Method for PDF panel and its using the manufactured PDF panel
KR101676753B1 (en) * 2016-02-25 2016-11-16 장석기 A method for manufacturing and execution of works with a deck
KR102022023B1 (en) 2016-07-27 2019-09-19 주식회사 레인보우 Method and system manufacturing double extrusion panel for construction
KR101885770B1 (en) 2016-11-04 2018-08-06 박성민 Method and system manufacturing of multiple holes panel extrusion synthetic resins for construction
KR101849984B1 (en) 2016-12-12 2018-04-24 이강준 extruder having pollution preventing cover
KR102133076B1 (en) * 2017-11-01 2020-07-13 경동산업 주식회사 Eco type interior and exterior material and its manufacture facility and method
KR102080268B1 (en) 2018-06-22 2020-02-21 한뫼공업(주) Double extruded multiple holes panel manufacturing device of outer join synthetic resins
KR102070681B1 (en) * 2019-06-18 2020-01-29 (주)애니우드 Bio-synthetic Wood Made of Waste Plastics And a Method of Manufacturing the Same
KR102266410B1 (en) * 2019-11-05 2021-06-18 주식회사 에이피글로벌 Hole forming guide rod Cooling System of Waste synthetic resin Panel extrusion equipment

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5088910A (en) * 1990-03-14 1992-02-18 Advanced Environmental Recycling Technologies, Inc. System for making synthetic wood products from recycled materials
US5480602A (en) * 1994-06-17 1996-01-02 Nagaich; Laxmi Extruded particle board
US5516472A (en) * 1993-11-12 1996-05-14 Strandex Corporation Extruded synthetic wood composition and method for making same
JP2003155825A (en) * 2001-09-04 2003-05-30 Nkk Corp Plastic board using spent plastic as raw material and its manufacturing method
US6605245B1 (en) * 1997-12-11 2003-08-12 Boise Cascade Corporation Apparatus and method for continuous formation of composites having filler and thermoactive materials
KR20030096210A (en) * 2003-12-04 2003-12-24 조팔수 Manufacturing method of pallet using waste synthetic resin and chip of timber, and manufactured pallet

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100397351B1 (en) * 2002-10-16 2003-09-13 주식회사 지앤씨 A Process of Soundproofing Panel by Compounded Waste Resin
KR200376522Y1 (en) 2004-11-16 2005-03-11 최창호 Construction panel and producing apparatus of the same
KR100749880B1 (en) * 2005-09-23 2007-08-16 장기운 Regeneration device of waste-vinyl plastics

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5088910A (en) * 1990-03-14 1992-02-18 Advanced Environmental Recycling Technologies, Inc. System for making synthetic wood products from recycled materials
US5516472A (en) * 1993-11-12 1996-05-14 Strandex Corporation Extruded synthetic wood composition and method for making same
US5480602A (en) * 1994-06-17 1996-01-02 Nagaich; Laxmi Extruded particle board
US6605245B1 (en) * 1997-12-11 2003-08-12 Boise Cascade Corporation Apparatus and method for continuous formation of composites having filler and thermoactive materials
JP2003155825A (en) * 2001-09-04 2003-05-30 Nkk Corp Plastic board using spent plastic as raw material and its manufacturing method
KR20030096210A (en) * 2003-12-04 2003-12-24 조팔수 Manufacturing method of pallet using waste synthetic resin and chip of timber, and manufactured pallet

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102975444A (en) * 2012-03-08 2013-03-20 张耀中 Multilayer structure floor board for cargo container and multilayer structure floor board body manufacturing method
CN102975444B (en) * 2012-03-08 2015-07-15 张耀中 Multilayer structure floor board for cargo container and multilayer structure floor board body manufacturing method
GB2519249A (en) * 2014-01-07 2015-04-15 Environmental Technology Evolution Ltd Process and apparatus for manufacturing a multilayer article
GB2550770A (en) * 2014-01-07 2017-11-29 Environmental Tech Evolution Limited Process and apparatus for manufacturing a multilayer article
GB2550770B (en) * 2014-01-07 2018-11-14 Environmental Tech Evolution Limited Process for manufacturing a multilayer article
CN108467558A (en) * 2018-06-28 2018-08-31 多稳（太仓）智能科技有限公司 A kind of plastics firework barrel and preparation method thereof

Also Published As

Publication number Publication date
KR100789957B1 (en) 2008-01-02

Similar Documents

Publication Publication Date Title
WO2008117947A1 (en) Double extrusion panel manufacturing system and method using waste plastic materials
KR101188737B1 (en) Double extrusion panel manufacturing system and method using waste plastic materials, and double extrusion panel
EP2565004B1 (en) Method of manufacturing composite pellets for extrusion, and composite pellets thus produced
EP2114648B1 (en) Wood-plastic composites using recycled carpet waste and methods of manufacturing
US8617330B2 (en) Process and installation for the production of stiff recyclable sandwich-type polymeric panels, without the use of adhesives, and the panel produced
EP2601151A2 (en) Composite building materials and methods of manufacture
US20120088853A1 (en) Molding material for extrusion foam molding, process for producing same, woody molded foam produced from the molding material, and process and apparatus for producing the woody molded foam
KR102022023B1 (en) Method and system manufacturing double extrusion panel for construction
WO2015104541A1 (en) Process and apparatus for manufacturing a multilayer article
EP2764969B1 (en) A process for the preparation of a recycled composite material
KR101135630B1 (en) Tree piece puts in on the center of double extrusion panel manufacturing system and method using waste plastic materials, and double extrusion panel
KR100824752B1 (en) Method and apparatus for making an sawdust thermoplastic board
Gardner et al. Extrusion of wood plastic composites
KR101546907B1 (en) The multi-extruded resin panel manufacturing equipment and manufacturing method
JPH09123169A (en) Thermoplastic resin synthetic material with plastic bottle as material, manufacture thereof, thermoplastic resin molding using the material and manufacture thereof
US11673308B2 (en) WPC extrusion profile and apparatus and method for manufacturing the same
KR101188738B1 (en) The panel and manufacturing system double extrusion panel using waste plastic materials of one in two out
RU2597908C1 (en) Composition of roofing-construction material
CN211762820U (en) Casting film machine production equipment
KR100818342B1 (en) The compression forming systems duplication of plastics panel
JP3672616B2 (en) Hollow resin molded plate having reinforcing profile, and method and apparatus for molding hollow resin molded plate
JPH08118452A (en) Method and apparatus for extrusion molding of hollow resin panel
CN114262504A (en) Preparation method and system of high-temperature-resistant PET film
JP3140715B2 (en) Foam composite molding
AU717587B3 (en) An apparatus for recycling waste composite materials

Legal Events

Date Code Title Description
DPE2 Request for preliminary examination filed before expiration of 19th month from priority date (pct application filed from 20040101)
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 08723525

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

32PN Ep: public notification in the ep bulletin as address of the adressee cannot be established

Free format text: NOTING OF LOSS OF RIGHTS PURSUANT TO RULE 112(1) EPC AS PER OUR COMMUNICATION DATED 07.12.09 (EPO FORM 1205A)

122 Ep: pct application non-entry in european phase

Ref document number: 08723525

Country of ref document: EP

Kind code of ref document: A1