MULTI-LAMINATE PLASTIC CARRIER PLATE AND METHOD FOR THE PRODUCTION THEREOF

Abstract

The present disclosure relates to a multi-laminate plastic carrier plate having a plurality N of A-B-A layer sequences, wherein the A layer includes a first thermoplastic resin and the B layer includes a second thermoplastic resin, and wherein the first thermoplastic resin is a virgin plastic and the second plastic is a recycled plastic, and wherein 250N2, preferably 200N3, preferably 125N4, still more preferably 100N5.

Claims

1. A multi-laminate plastic support material having a plurality N of A-B-A layer sequences, wherein the A layer includes a first thermoplastic resin and the B layer includes a second thermoplastic resin, and wherein the first thermoplastic resin is a virgin plastic and the second plastic is a recycled plastic, and wherein 250N2, preferably 200N3, preferably 125N4, still more preferably 100N5.

2. The multi-laminate plastic support material according to claim 1, wherein the recycled thermoplastic resin of the B layer includes an amorphous polyethylene terephthalate (PET).

3. The multi-laminate plastic support material according to claim 1, wherein the B layer includes a filler material besides the thermoplastic resin, wherein the filler material is preferably selected from the group consisting of chalk, non-asbestos silicate, preferably magnesium silicate, sawdust, expanded clay, volcanic ash, pumice, aerated concrete, in particular includes inorganic foams, cellulose or an expanding agent.

4. The multi-laminate plastic support material according to claim 3, wherein the proportion of filler material is in a range between 1 wt % and 60 wt % relative to the total weight of the material that forms the B layer.

5. The multi-laminate plastic support material according to claim 1, wherein the thermoplastic resin of the A layer includes a glycol-modified polyethylene terephthalate (PET-G).

6. The multi-laminate plastic support material according to claim 1, wherein the layer thickness of the B layer has a value between 100% and 3000% of the layer thickness of the A layer.

7. The multi-laminate plastic support material according to claim 1, wherein the plastic support material has a shrinkage of 0.25% at 80 C. according to ISO 23999.

8. The multi-laminate plastic support material according to claim 1, wherein at least a part of the film-like multilayer composites with the layer sequence A-B-A is stretched biaxial.

9. A method for producing a multi-laminate plastic support material including the steps: a) Producing a first film-like multilayer composite with the layer sequence A-B-A, wherein the A layer contains a first thermoplastic resin, and the B layer contains a second thermoplastic resin; b) Placing a plurality N of first film-like multilayer composites with the layer sequence A-B-A one on top of the other to form a layer stack, wherein 250N2, preferably 200N3, preferably 125N4, more preferably still 100N5; c) Compressing the layer stack using the effects of pressure and temperature; and d) Cooling the compressed layer stack.

10. The method according to claim 9, wherein the film-like multilayer composite with the layer sequence A-B-A is produced by feeding the first and second thermoplastic resins into a feedblock and extruding them through a sheet extrusion die.

11. The method according to claim 9, wherein at least a part of the film-like multilayer composites with the layer sequence A-B-A is stretched biaxially before being placed one on top of the other to form the layer stack.

12. The method according to claim 9, wherein after the compression in step c) the multi-laminate plastic support material is cooled to a temperature 40 C. and subsequently heated to a temperature above the glass transition temperature of the plastic, in particular to a temperature in a range between 90 C. and 110 C.

13. The method according to claim 12, wherein the multi-laminate plastic support material is heated for a period from 0.5 to 5 minutes, preferably 1 to 4 minutes, in particular 1.5 to 3 minutes to a temperature above the glass transition temperature of the plastic.

14. A decorative panel including a support board, a decoration arranged on the support board, a covering layer arranged over the decoration and optionally corresponding locking means on at least two side edges of the panel, wherein the support board is a multi-laminate support board according to claim 1 and the decorative panel undergoes shrinkage 0.25% at 80 C. for 6 h according to ISO 23999.

Description

DRAWINGS

[0124] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0125] In the following text, the disclosure will be explained further with reference to the figures and an exemplary embodiment.

[0126] FIG. 1 shows a schematic representation of a variant of a multi-laminate plastic support material according to the disclosure; and

[0127] FIG. 2 illustrates the method workflow for producing a film-like multilayer composite with the layer sequence A-B-A for a multi-laminate plastic support material according to the disclosure.

[0128] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0129] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0130] FIG. 1 shows a schematic representation of a variant of a multi-laminate plastic support material 100 according to the disclosure. The multi-laminate plastic material 100 includes a plurality N of A-B-A layer sequences 110. In the schematic embodiment shown, the number of A-B-A layer sequences is 4 (N=4). In general, the number of A-B-A layer sequences 110 may be between 3 and 250 (250N2). The A layer includes a first thermoplastic resin and the B layer includes a second thermoplastic resin. The first thermoplastic resin is preferably a virgin plastic and the second plastic a recycled plastic. The thermoplastic resins are preferably polyethylene terephthalates. These are available in large quantities particularly as recycled material from the recycling of food packaging. The thermoplastic resin of the A layer is preferably a glycol-modified polyethylene terephthalate (PET-G). Surprisingly, it was found that the glycol-modified PET can function as a sealing and/or adhesive layer between the A-B-A multilayer composites. The A-B-A layer sequence 110 may have a total layer thickness between 100 m and 2000 m. In this case, it may be provided that the layer thickness of the B layer has a value between 100% and 3000% of the layer thickness of the A layer. In other words, the B layer may have the same layer thickness as an A layer or it may be up to 30 times thicker than said A layer. In particular, it may be provided that largest part of the total layer thickness of the multilayer composite A-B-A is provided by the B layer. Accordingly, it may be provided for example that the layer thickness of the B layer constitutes 50% of the total layer thickness of the multilayer composite, preferably 60%, particularly 70% and more preferably 90% of the total layer thickness. The thermoplastic resin of the B layer may preferably be a plastic that is modified with filler materials, such as talcum for example, in particular a PET. The multi-laminate plastic support material 100 according to the disclosure may be made into a film stack 120 by stacking film-like multilayer composites 110 one on top of the other, wherein the stack is then compressed together under the effects of pressure and temperature. The pressure to supply during the compression according to the disclosure may be in a range from 0.5 MPa to 25 MPa, preferably in a range from 1 MPa to 15 MPa. The target temperature in the core of the film stack may preferably be set in a range between 65 C. and 140 C., in particular in a range between 80 C. and 120 C. This ensures good bonding between the individual three-layer film-like multilayer composites 110. For the compression process, a preheating of the three-layer film-like multilayer composites 110 may be provided to 80 to 135 C. for example. Suitable heat sources for this may be for example a heated roller, hot air, an IR radiator, in particular an NIR radiator or a microwave radiator or combination of these. The compression may take place for example in a dual-band press, so that and endless material is produced in a continuous process. It may be provided that the exposed surfaces of the A layer are pre-treated with a corona treatment before the film-like multilayer composites 110 are stacked to form the film stack 120. After the compression of the film stack 120 to form the multi-laminate plastic support material according to the disclosure, it can be cooled down and cut to the desired size.

[0131] FIG. 2 illustrates the method workflow for producing a film-like multilayer composite with the layer sequence A-B-A for a multi-laminate plastic support material according to the disclosure. According to the disclosure, it may be provided that a film-like multilayer composite with the layer sequence A-B-A is produced by co-extrusion using a feedblock 220 and sheet extrusion die 230. This process may make use of two co-rotating twin-screw extruders 210, 211 for example. A main extruder 210 may be used to produce the material for the middle layer B, and it may be provided that this extruder has two lateral feeds. These lateral feeds may be used for mixing filler materials. The second twin-screw extruder 211 may be used to produce the thermoplastic resin for two A-type layers. This extruder may also be equipped with lateral feeds to enable mixing of additional constituents. In order to be able to remove any moisture and/or monomers from the polyester melts in the extruder, provision may be made to install a high-vacuum venting system in both twin-screw extruders. The polymer melts from both extruders 210, 211 may be introduced into a feedblock 220 separately from one another. While the melt from the main extruder 210 forms the type B middle layer, the material from the co-extruder 211 is directed above and below the middle layer B and forms the two type A outer layers. The three-layer melt may then be passed through a sheet extrusion die 230. This die serves to create a uniform layer distribution over the entire intended film width. A number of different variants may be implemented for the cooling process which is carried out subsequently. For example, the melt may be cooled by means of a calender roller system. A chill roll may also be used. In this context, an air knife and a vacuum chamber may fulfil the function of ensuring that the melt lies evenly on the chill roll.

[0132] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are inter-changeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.