METHOD FOR MAKING FAUX WOOD MATERIAL WITH MULTILAYER PATTERN EFFECT AND MIXED PLASTIC MATERIAL FOR USE IN THE METHOD

Abstract

A method for making a faux wood material with a multilayer pattern effect and a mixed plastic material for use in the method involve: performing a compounding process on a thermoplastic elastomer material, a hard-segment-structure material and a foaming agent to form the mixed plastic material; performing through an extruder a first foaming process on the mixed plastic material to form a preliminary sheet having a density equal to 10% to 20% of the density of the mixed plastic material and a thickness of 1-4 mm; stacking preliminary sheets up; and performing through a hot-pressing mold a second foaming process on the stacked preliminary sheets to form the faux wood material having a density equal to 40%-50% of the density of the mixed plastic material. Accordingly, through the two foaming processes, a multilayer pattern effect can be presented on the faux wood material due to its density difference.

Claims

1. A method for making a faux wood material with a multilayer pattern effect, comprising: performing a compounding process on a thermoplastic elastomer material, a hard-segment-structure material and a foaming agent to form a mixed plastic material; performing, through an extruder, a first foaming process on the mixed plastic material to form a preliminary sheet having a density equal to 10% to 20% of a density of the mixed plastic material and a thickness of 1-4 mm; stacking a plurality of preliminary sheets including the preliminary sheet up; performing, through a hot-pressing mold, a second foaming process on the stacked preliminary sheets to form the faux wood material having a density equal to 40%-50% of the density of the mixed plastic material, wherein a density of two outer sides of each of the preliminary sheets is different from a density of an inner area of the preliminary sheet so that the faux wood material has a multilayer pattern differing in darkness and lightness.

2. The method according to claim 1, wherein the thermoplastic elastomer material comprises at least one of polyethylene, an ethylene-vinyl acetate copolymer, a styrene-butadiene-styrene block copolymer, a styrene-isoprene-styrene block copolymer, and a styrene-based block copolymer.

3. The method according to claim 1, wherein the hard-segment-structure material comprises at least one of polystyrene, a styrene-acrylonitrile copolymer, an acrylonitrile-butadiene-styrene copolymer, and high-impact polystyrene.

4. The method according to claim 1, wherein the thermoplastic elastomer material constitutes 10% to 90% by weight of the mixed plastic material, the foaming agent constitutes 0.10% to 15% by weight of the mixed plastic material, and the hard-segment-structure material makes up the remaining percentage by weight of the mixed plastic material.

5. The method according to claim 1, wherein the foaming agent is an azo-type chemical foaming agent.

6. The method according to claim 1, wherein the foaming agent is a physical foaming agent.

7. The method according to claim 1, wherein an extrusion temperature of the first foaming process is a decomposition temperature of the foaming agent.

8. The method according to claim 1, wherein the second foaming process has a heating temperature of 160-180? C., a pressing pressure of 100-200 kg/cm.sup.2, and a foaming time of 10-30 minutes.

9. The method according to claim 1, wherein the mixed plastic material further comprises bridging agent.

10. The method according to claim 9, wherein the bridging agent constitutes 0.01% to 2% by weight of the mixed plastic material.

11. The method according to claim 9, wherein the bridging agent is dicumyl peroxide, 2,5-(tert-butylperoxy)-2,5-dimethylhexane, or sulfur.

12. The method according to claim 1, wherein the mixed plastic material further comprises a coloring material.

13. The method according to claim 1, wherein the mixed plastic material further comprises a fire retardant.

14. The method according to claim 1, wherein the mixed plastic material further comprises a blowing promoter that constitutes 0.1% to 10% by weight of the mixed plastic material.

15. The method according to claim 14, wherein the blowing promoter is zinc stearate or zinc oxide.

16. A mixed plastic material for forming a faux wood material with a multilayer pattern effect, comprising: a thermoplastic elastomer material constituting 10% to 90% by weight of the mixed plastic material; a foaming agent constituting 0.1% to 15% by weight of the mixed plastic material; and a hard-segment-structure material.

17. The mixed plastic material according to claim 16, further comprising a bridging agent constituting 0.01% to 2% by weight of the mixed plastic material.

18. The mixed plastic material according to claim 17, wherein the bridging agent is dicumyl peroxide, 2,5-(tert-butylperoxy)-2,5-dimethylhexane, or sulfur.

19. The mixed plastic material according to claim 16, further comprising a blowing promoter that constitutes 0.1% to 10% by weight of the mixed plastic material.

20. The mixed plastic material according to claim 19, wherein the blowing promoter is zinc stearate or zinc oxide.

21. The mixed plastic material according to claim 16, wherein the thermoplastic elastomer material comprises at least one of polyethylene, an ethylene-vinyl acetate copolymer, a styrene-butadiene-styrene block copolymer, a styrene-isoprene-styrene block copolymer, and a styrene-based block copolymer.

22. The mixed plastic material according to claim 16, wherein the hard-segment-structure material comprises at least one of polystyrene, a styrene-acrylonitrile copolymer, an acrylonitrile-butadiene-styrene copolymer, and high-impact polystyrene.

23. The mixed plastic material according to claim 16, further comprising a coloring material.

24. The mixed plastic material according to claim 16, further comprising a fire retardant.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present disclosure will become more fully understood from the following detailed description and accompanying drawings.

[0033] FIG. 1 is a flowchart of the method according to certain embodiments in the present disclosure.

[0034] FIG. 2 is a photographic copy illustrating a multilayer pattern effect of a faux wood material according to certain embodiments in the present disclosure.

[0035] FIG. 3 is a photographic copy illustrating another multilayer pattern effect of a faux wood material according to certain embodiments in the present disclosure.

DETAILED DESCRIPTION

[0036] The present disclosure is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Like numbers in the drawings indicate like components throughout the views. As used in the description herein and throughout the claims that follow, unless the context clearly dictates otherwise, the meaning of a, an, and the includes plural reference, and the meaning of in includes in and on. Titles or subtitles can be used herein for the convenience of a reader, which shall have no influence on the scope of the present disclosure.

[0037] The accompanying drawings are schematic and may not have been drawn to scale. The terms used herein generally have their ordinary meanings in the art. In the case of conflict, the present document, including any definitions given herein, will prevail. The same thing can be expressed in more than one way. Alternative language and synonyms can be used for any term(s) discussed herein, and no special significance is to be placed upon whether a term is elaborated or discussed herein. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms is illustrative only, and in no way limits the scope and meaning of the present disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given herein. Numbering terms such as first, second or third can be used to describe various components, materials, objects, or the like, which are for distinguishing one component/material/object from another one only, and are not intended to, nor should be construed to impose any substantive limitations on the components, materials, objects, or the like. Directional terms (e.g., front, rear, left, right, upper/top and/or lower/bottom) are explanatory only and are not intended to be restrictive of the scope of the present disclosure.

[0038] As may be used herein, the term substantially refers to, for example, a value, or an average of values, in an acceptable deviation range of a particular value recognized or decided by a person of ordinary skill in the art, taking into account any specific quantity of errors related to the measurement of the value that may resulted from limitations of a measurement system or device. For example, substantially may indicate that the value is within, for example, ?5%, ?3%, ?1%, ?0.5% or ?0.1%, or one or more standard deviations, of the particular value.

[0039] Certain aspects of the present disclosure are directed to a method for making a faux wood material with a multilayer pattern effect and a mixed plastic material for use in the method, which enable the faux wood material with both dark and light colors to be made of the mixed plastic material of a single color, and simulate the wood properties and multilayer grain patterns of real wood. In certain embodiments, referring to FIG. 1, the method for making the faux wood material includes the following steps:

[0040] Step (101): A composite material formed by a thermoplastic elastomer material and a hard-segment-structure material goes through a compounding process together with a foaming agent in order for the composite material and the foaming agent to form a mixed plastic material. The thermoplastic elastomer material can constitute 10% to 90% by weight of the mixed plastic material, and the foaming agent can constitute 0.1% to 15% by weight of the mixed plastic material, with the hard-segment-structure material making up, for example but not limited to, the remaining percentage by weight of the mixed plastic material. If the mixed plastic material includes another ingredient, the percentage by weight of the hard-segment-structure material will be changed accordingly. In certain embodiments, the mixed plastic material can further include a bridging agent that constitutes 0.01% to 2% by weight of the mixed plastic material. In certain embodiments, the mixed plastic material can include a coloring material (e.g., a color masterbatch) and/or a fire retardant in order for the end product to have the color and/or effect desired by the manufacturer. In certain embodiments, the mixed plastic material can include a blowing promoter that constitutes 0.1% to 10% by weight of the mixed plastic material to facilitate decomposition of the foaming agent and increase foaming efficiency. In any of the foregoing cases, the percentage by weight of the hard-segment-structure material will be reduced according to the percentage(s) by weight of the additional material(s).

[0041] Based on actual product requirements and manufacturing process requirements, the thermoplastic elastomer material can be of polymer compounds, and can include at least one of polyethylene (PE), an ethylene-vinyl acetate (EVA) copolymer, a styrene-butadiene-styrene (SBS) block copolymer, a styrene-isoprene-styrene block copolymer, and a styrene-based block copolymer; the hard-segment-structure material can be of polymer compounds, and can include at least one of polystyrene (PS), a styrene-acrylonitrile (SAN) copolymer, an acrylonitrile-butadiene-styrene (ABS) copolymer, and high-impact polystyrene (HIPS); the foaming agent can be a chemical foaming agent (e.g., an azo-type chemical foaming agent) or a physical foaming agent (e.g., sodium bicarbonate); the bridging agent can be dicumyl peroxide, 2,5-(tert-butylperoxy)-2,5-dimethylhexane, or sulfur; and the blowing promoter can be, but is not limited to, zinc stearate or zinc oxide. Moreover, the present disclosure is not limited to the thermoplastic elastomer material and the hard-segment-structure material forming a composite material before going through the compounding process together with the foaming agent, as the individual ingredients (i.e., the thermoplastic elastomer material, the hard-segment-structure material, and the foaming agent) can also be added into the compounding machine one by one, as long as those ingredients can form the desired mixed plastic material.

[0042] Step (102): An extruder is used to perform a first foaming process (also referred to as a foam extrusion process or a microcellular foaming process) on the mixed plastic material. In certain embodiments, the extrusion temperature of the first foaming process is the decomposition temperature of the foaming agent, such as but not limited to a temperature in the range from 160? C. to 180? C. The duration of the first foaming process depends on the extrusion speed and extrusion pressure, both of which can be adjusted according to the type of the extruder and product requirements in order to change the foamed state of the mixed plastic material. The foam resulting from this step (i.e., the mixed plastic material in an expanded state) can have a density equal to 10% to 20% of the density of the mixed plastic material and a thickness of 1-4 mm so as to form a preliminary sheet.

[0043] Step (103): A plurality of preliminary sheets are stacked up according to a required product thickness.

[0044] Step (104): A hot-pressing mold is used to perform a second foaming process on the stack of preliminary sheets. In certain embodiments, the second foaming process uses a heating temperature of 160-180? C. and a pressing pressure of 100-200 kg/cm.sup.2, and the foaming time is 10-30 minutes. The parameters of the second foaming process, however, are not limited to those stated above. In certain embodiments, the parameters of the second foaming process can be adjusted according to product requirements. The foam resulting from this step (i.e., the stack of preliminary sheets in an expanded state) can have a density equal to 40%-50% of the density of the mixed plastic material so as to form a faux wood material.

[0045] Referring again to FIG. 1, the method according to the present disclosure is so designed that the first foaming process involves only microcellular foaming to form a preliminary sheet. The first foaming process is intended mainly to provide the preliminary sheet with dark and light colors that are slightly different from each other. More specifically, the forming (i.e., foaming) process of the preliminary sheet gives the two outer sides of the preliminary sheet a relatively high density and hence a relatively dark color, and the same forming process gives the inner area of the preliminary sheet (i.e., the area close to the center of the preliminary sheet) a relatively low density and hence a relatively light color. As a result, two colors that differ in darkness/lightness (that is, two visual effects of the same color that vary in darkness/lightness) are naturally formed. During the second foaming process, the stack of a plurality of preliminary sheets is foamed under a high temperature and high pressure without the colors of each preliminary sheet blending with those of another, and this allows the resulting faux wood material to show a natural multilayer pattern effect as illustrated in FIG. 2 and FIG. 3, which present photos of faux wood materials made according to the present disclosure.

[0046] The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.

[0047] The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope.