Foamed Biogranulate Grains

Abstract

A semi-finished product for the production of mouldings is disclosed. The product includes foamed biogranulate grains having a coating. The coating includes an adhesive whereby the biogranulate grains are bondable together in a moulded body. The coating further includes a pesticide. A method of manufacturing a semi-finished product is also disclosed. The foamed biogranulate grains are coated with an adhesive and a pesticide. In a method for producing the moulded body, the semi-finished product is introduced into a press mould and then joined together under the action of heat to form the moulded body.

Claims

1. A semi-finished product for the production of a moulding, comprising foamed biogranulate grains having a coating comprising an adhesive configured such that the biogranulate grains can be bonded to one another in the moulding.

2. The semi-finished product according to claim 1, wherein the adhesive comprises at least one of polylactides, polybutylene adipate terephthalate, and a mixture of polylactides and polybutylene adipate terephthalate; in which a proportion of the polylactides is 0% or more than 1% by weight, or more than 10% by weight, or more than 30% by weight in the adhesive.

3. The semi-finished product according to claim 1, wherein the pesticide comprises at least one of silica, silica gel, diatoms, glass powder, glass splinters, ground silica gel and/or a boron compound, and boric acid and/or essential oils comprising one or more of lavender oil, rosemary oil, citronella, lemon balm, cedar, peppermint, eucalyptus and sandalwood extract.

4. The semi-finished product according to claim 1, wherein the coating comprises at least a first, inner layer and a second, outer layer, such that the pesticide is arranged in the first, inner layer.

5. The semi-finished product according to claim 4, wherein the first, inner layer comprises a mixture of pesticide and adhesive.

6. A method for producing a semi-finished product, comprising the steps of: coating foamed biogranulate grains with a coating comprising an adhesive configured such that the biogranulate grains can be bonded to one another in a molding, and wherein the coating comprises a pesticide.

7. The method according to claim 6, further comprising the steps of: applying the coating in at least one first coating drum; introducing the foamed biogranulate grains into the first coating drum; rotating the first coating drum; and introducing the adhesive and the pesticide.

8. The method according to claim 7, wherein the first coating drum comprises at least one first lance configured to apply the coating outside the biogranulate grains during coating.

9. The method according to claim 7, wherein the first coating drum comprises a second lance and wherein the method further comprises the steps of introducing into the coating drum with the first lance the adhesive and with the second lance the pesticide.

10. The method according to claim 7, wherein the first lance comprises a plurality of openings, arranged and configured such that the adhesive emerges as a liquid jet from the plurality of openings.

11. The method according to claim 9, further comprising the steps of: forming a mixture of the adhesive and the pesticide; and discharging the mixture with the second lance.

12. The method according to claim 7, wherein the step of introducing the adhesive and the pesticide further comprises the steps of: 1. applying the pesticide to the foamed biogranulate grains; and 2. applying the adhesive to the foamed biogranulate grains.

13. (canceled)

14. (canceled)

15. (canceled)

16. A method for producing a moulded body comprising the steps of: coating foamed biogranulate grains with a coating comprising an adhesive configured such that the biogranulate grains can be bonded to one another in moulding, wherein the coating comprises a pesticide to obtain a semi-finished product; introducing the semi-finished product into a press mould; and joining the semi-finished product under the action of heat to form the moulded body.

17. The method according to claim 16, wherein the action of the heat is effected by irradiation, and a radio wave irradiation.

18. (canceled)

19. The method according to claim 16, wherein a proportion of foamed biogranulate grains having an adhesive coating comprises at least 20%, at least 50%, or 100%.

20. The method according to claim 16, further comprising the steps of pressurizing the moulding chamber with a pressure of at least 2 bar, at least 3 bar or at least 5 bar.

21. The method according to claim 16, wherein the adhesive comprises at least one of an organic polymer, an organic copolymer, a mixture of organic polymer and organic copolymer, and wherein the adhesive is biodegradable and/or biobased.

22. The method according to claim 16, wherein the adhesive comprises a hot-melt adhesive and/or a chemically setting adhesive.

23. The method according to claim 16, further comprising the steps of adding at least one of a heat transfer medium, a liquid, and water to the foamed biogranulate grains having an adhesive coating during welding by means of electromagnetic waves.

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0089] The drawings used to explain the embodiments show:

[0090] FIG. 1a a schematic representation of a sectional view of a foamed biogranulate grain with a coating comprising two layers;

[0091] FIG. 1b a schematic representation of a sectional view of a foamed biogranulate grain with a coating comprising three layers;

[0092] FIG. 2 a schematic representation of a longitudinal section through a coating drum for coating foamed biogranulate grains, with two lances;

[0093] FIG. 3 a schematic representation of a longitudinal section through a cascade of a first and a second coating drum for coating foamed biogranulate grains, each comprising a lance;

[0094] FIG. 4a a schematic representation of a cross-section through an insulating element with a layer and;

[0095] FIG. 4b a schematic representation of a cross-section through an insulation element with two layers. FIG. 2

[0096] In the figures, the same components are given the same reference symbols.

PREFERRED EMBODIMENTS

[0097] FIG. 1a shows a schematic diagram of a sectional view of a foamed biogranulate grain 11 with a coating comprising two layers, thus forming a semi-finished product 10. In the present case, the foamed biogranulate grain 11 is puffed maize, preferably puffed industrial maize, which is first comminuted (cut into small pieces, preferably 0.7 mm to 4 mm). The grains are then sorted according to size (for example by sieving techniques) and puffed or foamed. A first layer of an adhesive comprising a pesticide is then applied to the foamed biogranulate grain 11. The adhesive is a mixture made of PLA and PBAT (for example Novamont®) and the pesticide is ground silica gel. Both were mixed in an extruder and then applied as a melt to the puffed maize. Furthermore, a tank melter with an agitator can be provided for this purpose, in which Novamont® and the silica gel are mixed and then applied to the puffed maize via a pump. A tank melter can be provided for each of the two coatings. After a cooling process to cool the layer 12, a second coating with the same adhesive is applied to seal the silica gel from the outside air. This prevents the silica gel from absorbing moisture during storage and thus losing its effect. Then it is cooled down again. The cooling takes place via nitrogen supply.

[0098] FIG. 1b shows another variant of a semi-finished product 15, essentially analogous to FIG. 1a. The present semi-finished product 15 comprises puffed maize as foamed biogranulate grain 16. The first, inner layer 17 of the semi-finished product 15 is Novamont®, the second, middle layer 18 is silica gel and the outer layer 19, or sealing layer, is Novamont®.

[0099] FIG. 2 shows a schematic representation of a longitudinal section through a coating drum 20, for coating foamed biogranulate grains, with two lances 21 and 22. This means that both layers 12 and 13 can be applied to the puffed maize with a single coating drum 20, without having to feed a lance with different products.

[0100] FIG. 3 shows a schematic representation of a longitudinal section through a cascade of a first coating drum 30 and a second coating drum 40, for coating foamed biogranulate grains, each comprising a lance 31 and 41 respectively. The puffed maize is coated with the Novamont, which contains silica gel, in the first coating drum 30 by means of the lance 31. The still hot intermediate product is then fed into the second coating drum 40 via a downcomer. The falling strand cools the intermediate product so that no lumps form due to the grains sticking together. Subsequently, a Novamont layer is applied by means of the lance 41 of the second coating drum 40, which forms a sealing layer and enables a long shelf life of the semi-finished product 10.

[0101] FIG. 4a shows a schematic representation of a cross-section through an insulating element 50 with a layer 51 made of the semi-finished product 10. For this purpose, the semi-finished product 10 was inserted into a press mould. Due to the choice of adhesive, the semi-finished product 10 is particularly free-flowing, so that the transport of the semi-finished product 10 into the press mould can be automated using conventional means for transporting bulk materials, for example conventional injectors for granulates. Subsequently, the semi-finished product 10 is subjected to radio waves under pressure so that the adhesive of the individual grains bonds and forms a moulded body. The insulation element 50 can be used for building insulation, as a packaging material (shock absorber), furniture construction, etc.

[0102] FIG. 4b shows a schematic representation of a cross-section through an insulation element 60 with two layers 61 and 62. The two layers 61 and 62 differ in grain size distribution. This makes it possible to achieve particularly effective sound insulation. The insulation element 60 can be manufactured in the same way as the insulation element 50. In particular, the multiple layers can be achieved in a single manufacturing step by successively feeding semi-finished product 10 with different grain sizes into the mould and then bonding the whole thing under heating. Alternatively, several insulation panels with different grain sizes can be bonded together to form a single insulation element 60.

[0103] In summary, it can be stated that according to the invention a semi-finished product is created which is characterised by good durability and optimal flowability. Furthermore, a particularly efficient manufacturing process is provided for the semi-finished product and, finally, a particularly dimensionally stable moulded body is achieved, which is also characterised by very good durability due to the pesticide additives.