MOULDED ARTICLE

Abstract

The invention relates to a moulded article (3) comprising a basic material (1), wherein the basic material (1) contains a wax, and also a filler, wherein the filler comprises or consists of a mineral filler and/or a fibrous material, wherein the wax is contained in the basic material (1) with a content of between 3% by weight and 60% by weight, wherein the filler is contained in the basic material (1) with a content of between 40% by weight and 97% by weight, wherein the moulded article (3) comprises a moulded element (2), and wherein the moulded element (2) comprises or consists of a fibrous material. The invention also relates to a process for producing a moulded article (3).

Claims

1. A molded article, comprising a base material (1), wherein the base material (1) contains a wax and a filler, wherein the filler comprises or consists of a mineral filler and/or a fibrous material, wherein the base material (1) contains between 3 wt.-% and 60 wt.-% of the wax, and wherein the base material (1) contains between 4 wt.-% and 97 wt.-% of the filler, characterized in that the molded article (3) comprises a shaping element (2), wherein the shaping element (2) comprises or consists of a fiber material.

2. The molded article according to claim 1, characterized in that the wax is one or more of the following group: vegetable wax, such as carnauba wax; candelilla wax; rice wax; castor wax; sunflower wax; sugarcane wax, animal wax, such as wool wax and beeswax, mineral wax, such as paraffin wax, montan wax, synthetic wax, such as stearin.

3. The molded article according to claim 1, characterized in that the wax is a Fischer-Tropsch wax, in particular a CO.sub.2 wax.

4. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) is selected from one or more of: natural fibers, in particular cellulose fibers; synthetic fibers, textile fibers; paper fibers; recycled fibers.

5. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) is or comprises a natural fiber, which is selected from one or more of: bagasse; wood; cotton; hemp; flax; kenaf; coconut; pineapple; palm; banana; water hyacinth; sea grass; bamboo; reed; grass; straw.

6. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) is or comprises a synthetic fiber, which is selected from one or more of: viscose; nylon; polyester; aramid; polyethylene.

7. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) is or comprises a paper material, which is optionally selected from one or more of: stone paper; grass paper; bamboo paper.

8. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) is present as fiber netting, felt or fabric.

9. The molded article according to claim 1, characterized in that the shaping element (2) is or comprises a fibrous molded part.

10. The molded article according to claim 1, characterized in that the fiber material of the shaping element (2) and the fibrous material of the base material (1) comprise the same fiber component.

11. The molded article according to claim 1, characterized in that the shaping element (2) has a sealing layer (5) on its surface.

12. The molded article according to claim 11, characterized in that the sealing layer (5) is selected from one or more of the following: SiO.sub.x layer; hybrid polymer layer, in particular organic-inorganic hybrid polymer layer; biopolymer layer; dispersion coating; wax layer, such as vegetable wax, animal wax, mineral wax, synthetic wax, biomass wax; metal layer; plastic layer.

13. The molded article according to claim 1, characterized in that the shaping element (2) has a decorative element on its surface, optionally on the sealing layer (5), which is not meltable at the melting temperature of the molded article (3).

14. A method for producing a molded article (3), comprising the steps of: providing a shaping element (2), which comprises or consists of a fiber material, in a negative mold (4) of the molded article (3), introducing a molding material into the negative mold (4), wherein the molding material contains a wax and a filler, wherein the filler comprises or consists of a mineral filler and/or a fiber, wherein the molding material contains between 3 wt.-% and 60 wt.-% of the wax, and wherein the molding material contains between 40 wt.-% and 97 wt.-% of the filler, and cooling the molding material for forming the molded article (3).

15. The method according to claim 14, characterized in that the introduction of the molding material is done by one or more of: shell casting; injection molding; transfer molding; extrusion; deep-drawing; calendering; rotational molding; pressure bag molding; compression molding.

16. The method according to claim 14, characterized in that the method additionally comprises: applying a sealing layer (5) to the shaping element (2).

Description

[0062] In the following, the present invention is described in detail by means of exemplary embodiments.

[0063] In the figures:

[0064] FIG. 1 shows a schematic sectional view of a first exemplary embodiment of an inventive molded article;

[0065] FIG. 2 shows a schematic sectional view of a second exemplary embodiment of an inventive molded article;

[0066] FIG. 3 shows a schematic sectional view of a third exemplary embodiment of an inventive molded article;

[0067] FIG. 4 shows a schematic sectional view of a fourth exemplary embodiment of an inventive molded article;

[0068] FIG. 5 shows a schematic sectional view of a negative mold for producing a fifth exemplary embodiment of an inventive molded article; and

[0069] FIG. 6 shows a schematic sectional view of a fifth exemplary embodiment of an inventive molded article.

[0070] FIG. 1 shows a schematic sectional view of a first exemplary embodiment of an inventive molded article 3. In this embodiment, the molded article 3 is formed as a cream pot. The base material 1 consists of 70 wt.-% calcium carbonate as mineral filler, 5 wt.-% cellulose fibers as fibrous material and 25 wt.-% carnauba wax as wax/organic binder.

[0071] A shaping element 2 made of pressed cellulose fibers is arranged on the inside of the molded article 3. The shaping element 2 is in direct contact with the base material 1. A sealing layer 5 of SiO.sub.2, which was applied by a vapor deposition method, is arranged on the opposite surface of the shaping element 2. The inner surface 13 of the molded article 3 is formed by the sealing layer 5.

[0072] On its open side, the molded article 3 has a threaded projection 12 with a threaded element 8 arranged thereon. A standing ring 7 is arranged on the opposite closed side of the molded article 3. The outer surface 6 of the molded article 3 is uncoated.

[0073] FIG. 2 shows a schematic sectional view of a second exemplary embodiment of an inventive molded article 3. The base material 1 consists of 70 wt.-% calcium carbonate as mineral filler, 5 wt.-% cellulose fibers as fibrous material and 25 wt.-% carnauba wax as wax/organic binder. The molded article 3 is designed as a lid for the cream pot of FIG. 1. Therefore, the molded article 3 has a threaded element 8 that is designed to engage with the threaded element 8 of the molded article 3 of FIG. 1.

[0074] A shaping element 2 made of pressed cellulose fibers is arranged as a circular plate on the inside of the molded article 3 of the second embodiment. The shaping element 2 is in direct contact with the base material 1. As in the first exemplary embodiment, the shaping element 2 is coated on its surface with an SiO.sub.2layer as a sealing layer 5. The outer surface 6 of the molded article 3 is uncoated.

[0075] When the lid of the second exemplary embodiment is completely screwed onto the cream pot of the first exemplary embodiment, the threaded projection 12 applies a pressure on the shaping element 2 so that a seal effect is obtained.

[0076] FIG. 3 shows a schematic sectional view of a third exemplary embodiment of an inventive molded article 3. This molded article 3 is also designed as a cream pot, but with a tapered outer surface. The base material 1 consists of 80 wt.-% calcium carbonate as mineral filler, 3 wt.-% cellulose fibers as fibrous material and 17 wt.-% rice wax as wax/organic binder.

[0077] A threaded element 8 is arranged at the open end of the molded article 3 to be able to close the container with a suitable lid. This lid may be similar to the molded article 3 of the second exemplary embodiment in terms of geometry.

[0078] In contrast to the above described exemplary embodiments, the inner surface 13 of the molded article 3 of the third exemplary embodiment is uncoated. On the outer surface, a shaping element 2 made of paper is arranged. The shaping element 2 is printed on the visible surface.

[0079] FIG. 4 shows a schematic sectional view of a fourth exemplary embodiment of an inventive molded article 3, which is formed as a container. In this exemplary embodiment, a shaping element 2 made of bagasse is surrounded by a base material 1 on all sides. The base material 1 consists of 80 wt.-% calcium carbonate as mineral filler and 20 wt.-% carnauba wax as wax/organic binder. Both the inner surface 13 and the outer surface 6 of the container expose the uncoated base material 1.

[0080] FIG. 5 shows a schematic sectional view of a negative mold 4 for producing a fifth exemplary embodiment of an inventive molded article 3. The negative mold 4 is suitable for injection molding. Details are not shown to simplify the view.

[0081] The negative mold 4 is designed to be hinged open and has an injection opening 10 into which a molding mass can be introduced. A molding space 9 extends inside the negative mold 4, in which a shaping element 2 made of recycled cardboard is arranged in this view. The shaping element 2 is held in the correct position within the molding space 9 by holding elements 11. The shaping element 2 has a water-impermeable sealing layer 5 of ormocer material (hybrid polymer material) on its inside.

[0082] When a molding mass is introduced into the negative mold 4 through the injection opening 10, it penetrates only into the area that is around the shaping element 2. This allows a molded article 3 to be formed as shown in FIG. 6. Excess molding mass can escape via the outlet opening 14.

[0083] The molded articles 3 of the exemplary embodiments described above were produced with similar conditions.

[0084] The molded article 3 produced in this way is in the form of a bottle. The base material 1 consists of 80 wt.-% calcium carbonate as mineral filler, 3 wt.-% cellulose fibers as fibrous material and 17 wt.-% rice wax as wax/organic binder. This material mixture is not blowable. In order to nevertheless be able to form a hollow body with little process effort, the shaping element 2 is used as a basic mold which remains on the molded article 3 even after demolding. In addition to preserving a cavity, the shaping element 2 also fulfils the other properties of the invention described above.

[0085] Thus, the manufactured bottle has a sealing layer 5 of ormocer material on its inner surface 13, and the outer surface 6 is uncoated. On the opening side, a threaded element 8 is provided to enable the bottle to be tightly closed with a screw cap. After demolding, the molded article 3 is cut off above the threaded element 8 to remove the cavities created by the holding elements 11.

List of Reference Signs

[0086] 1 Base material [0087] 2 Shaping element [0088] 3 Molded article [0089] 4 Negative mold [0090] 5 Sealing layer [0091] 6 Outer surface [0092] 7 Standing ring [0093] 8 Threaded element [0094] 9 Molding space [0095] 10 Injection opening [0096] 11 Holding element [0097] 12 Threaded projection [0098] 13 Inner surface [0099] 14 Outlet opening