Method For Preparing Panels Made of a Composite of Cork and Polyethylene

Abstract

The present invention relates to a process for preparation of polyethylene-cork composite panels comprising the steps of: mixing 10-64% of cork granulate and 36-90% of polyethylene granulate at room temperature, and feeding a press with this mixture; compressing this mixture in the press with a compression force in the range of 300-450 kN, at a temperature in the range of 160-200 C. and for a hot compression time between 24-180 seconds; and cooling to room temperature, with a compression force between 350-450 kN, for a cold compression time between 32 and 240 seconds; to obtain panels with a thickness between 3 and 5 mm. The invention further relates to a polyethylene-cork composite panel and also to use thereof in the construction industry, particularly as cover board core.

Claims

1. Process for preparation of polyethylene-cork composite panels characterized by comprising the steps of: a) mixing 10-64% of cork granulate and 36-90% of polyethylene granulate at room temperature, and feeding a press with this mixture; b) compressing the mixture of step a) in the press with a compression force in the range of 300-450 kN, at a temperature in the range of 160-200 C. and for a hot compression time between 24-180 seconds; c) cooling to room temperature, with a compression force between 350-450 kN, for a cold compression time between 32 and 240 seconds; to obtain panels with a thickness between 3 and 5 mm, provided that: for a thickness of 3 mm and temperature of step b) of 160 C., the minimum value of the hot compression time is 180 seconds; and for a thickness of 3 mm when the mixture has 60% or more of cork, the temperature value of step b) is 200 C.

2. Process for preparation of polyethylene-cork composite panels according to claim 1, wherein step a), up to 20% of paraffin is further added.

3. Process for preparation of polyethylene-cork composite panels according to claim 2, wherein step a) 10 to 34% of a filler selected from the group comprising calcium carbonate, talc, magnesium hydroxide, kaolin, natural and synthetic fibres, among others, and mixtures thereof, is further added.

4. Process for preparation of polyethylene-cork composite panels according to claim 3, wherein the filler is calcium carbonate.

5. Process for preparation of polyethylene-cork composite panels according to claim 1, wherein the polyethylene granulate of step a) comprises 20 to 32% of a filler selected from the group comprising calcium carbonate, talc, magnesium hydroxide, kaolin, natural and synthetic fibres, among others, and mixtures thereof.

6. Process for preparation of polyethylene-cork composite panels according to claim 5, wherein the filler is calcium carbonate.

7. Process according to claim 1, wherein the mixing is carried out with cork granulate having a particle size in the range of 0.5-1 mm.

8. Process according to claim 1, wherein the mixing is carried out with polyethylene granulate having a particle size in the range of 0.3-1 mm.

9. Process for preparation of polyethylene-cork composite panels according to claim 1, wherein: in step a) 37% of cork granulate and 63% of polyethylene granulate are mixed; in step b) the temperature is 180 C. and the hot compression time is 72 seconds; in step c) the cold compression time is 96 seconds; to obtain a panel having a thickness of 5 mm.

10. Process for preparation of polyethylene-cork composite panels according to claim 2, wherein: in step a) 50% of cork granulate, 63% of polyethylene granulate and 4% of paraffin are mixed; in step b) the temperature is 160 C. and the hot compression time is 180 seconds; in step c) the cold compression time is 240 seconds; to obtain a panel having a thickness of 3 mm.

11. Process for preparation of polyethylene-cork composite panels according to claim 3, wherein: in step a) 31.5% of cork granulate, 54.9% of polyethylene granulate, 3.6% of paraffin and 10% of calcium carbonate are mixed; in step b) the temperature is 190 C. and the hot compression time is 90 seconds; in step c) the cold compression time is 120 seconds; to obtain a panel with a thickness of 5 mm.

12. Process for preparation of polyethylene-cork composite panels according to claim 5, wherein: in step a) 25% of cork granulate, 43% of polyethylene granulate with 32% of incorporated calcium carbonate are mixed; in step b) the temperature is 190 C. and the hot compression time is 120 seconds; in step c) the cold compression time is 160 seconds; to obtain a panel with a thickness of 5 mm.

13. Composite panel comprising polyethylene and cork, characterized by having a density between 800-900 kg/m.sup.3, flat tensile strength higher than 1.3 MPa, water absorption of less than 3% and hardness between 45 and 65 Shore D.

14. Use of polyethylene-cork composite panels according to claim 13 as cover board core.

15. Use of polyethylene-cork composite panels obtained by the process according to claim 1, as cover board core.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0048] The present invention relates to a process for preparation of polyethylene-cork composite panels.

[0049] In the context of the present description, the term comprising should be understood as including, among others. As such, said term should not be interpreted as consisting only of.

[0050] By cork granulate is meant, in the context of the present description, cork fragments whose particle size is comprised between 0.2 to 1 mm, preferably between 0.5 to 1 mm, with a moisture content between 0 and 10% and a density between 200 and 320 kg/m.sup.3.

[0051] In the context of the present invention, polyethylene granulate means micronized polyethylene, with or without fillers, whose particle size is comprised between 0.3 and 1 mm, with a moisture content between 0 and 5% and a intrinsic density between 930 and 1100 kg/m.sup.3. Preferably, the polyethylene may be recycled polyethylene.

[0052] Still within the context of the present invention, by room temperature is meant a temperature in the range between 10 C. and 40 C.

[0053] In the present invention, press means a mechanical device which compresses a material by applying a force that compresses the granulate mixture to a predefined target thickness. Those skilled in the art, on the basis of the teachings of the present invention, will know to use any press, either continuous or discontinuous, for example a (Double Belt Press) DBP-like continuous plate press. For example, a speed of 2 m/min and a hot mat zone of 6 meters correspond to a compression time of 180 seconds.

[0054] In the present invention, by hot compression time is meant the time that the mixture of cork granulate and polyethylene granulate remains in the press at a temperature in the range between 160 C. and 200 C.

[0055] In the present invention, by cold compression time is meant the time that the mixture of cork granulate and polyethylene granulate remains in the press until it reaches room temperature.

[0056] Unless expressly stated otherwise, the percentages mentioned in the present description and claims refer to percentages by mass.

[0057] It should be noted that any X value in the present description must be interpreted as an approximate value of the actual X value, as such approximation to the actual value would reasonably be expected by the person skilled in the art due to experimental and/or measurement conditions which introduce deviations from the real value.

[0058] Unless otherwise noted, the ranges of values given in the present description are intended to provide a simplified and technically accepted way to indicate each individual value within the respective range. By way of example, the expression 1 to 2 or between 1 and 2 means any value within this range, for example 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0. All values mentioned in the present description must be interpreted as approximate values, for example the reference to 160 C. means about 160 C..

[0059] The process of the present invention provides a particularly suitable mode for the production of cork and polymer composite panels, overcoming the problems identified in the prior art with respect to cover board cores and simultaneously enabling the use of cork granulate and polymer granulate without the need to previously preparing a mixed granulate of cork and polymer.

[0060] Polyethylene is a simple and easily obtainable polymer. However, its melting point is close to 135 C. and therefore it is difficult to handle due to melting when working at temperatures comprised in a range between 160 C. and 200 C., resulting in a excessive fluidity that does not allow panels with the desired properties. For this reason, the use of PVC has been preferred over the use of polyethylene.

[0061] Moreover, the difference in particle sizes between the cork and polyethylene individual granulate also creates homogeneity problems in a mixture of these, as the raw materials are stratified when exposed to temperatures in the above mentioned range and therefore the production of panels from individual granulates is impracticable.

[0062] Surprisingly, it has been found that by mixing cork granulate and polyethylene granulate with similar particle sizes, a heterogeneous solid mixture is obtained which upon feeding into a press at temperatures in the range of 160 C. to 200 C. for a period of time between 24 and 180 seconds, followed by a cooling period for a period of time between 32 and 240 seconds, allows for a homogeneous composite panel with a uniform distribution of raw materials, without complete melting of the polyethylene and thus overcoming the drawbacks of the prior art.

[0063] The composite has excellent physicochemical and mechanical properties and has high intrinsic resistance, suitable to its application. Moreover, the panels obtained by the process of the present invention have a low density compared to prior art panels, since the cork is not compressed as after extrusion.

[0064] Thus, the process of the invention proves to be an excellent improvement over the processes known and used in the art, for their simplicity of execution, because there is no thermal/mechanical degradation of the cork and quality of the final product, due to the maintenance of cork density.

[0065] Next, the process for preparation of polyethylene-cork composite panels is described in detail.

[0066] The process of the present invention comprises the steps of: [0067] a) mixing 10-64% of cork granulate and 36-90% of polyethylene granulate at room temperature, and feeding a press with this mixture; [0068] b) compressing the mixture of step a) in the press with a compression force in the range of 300-450 kN, at a temperature in the range of 160200 C. and for a hot compression time between 24-180 seconds; [0069] c) cooling to room temperature, with a compression force between 350-450 kN, for a cold compression time between 32 and 240 seconds; [0070] to obtain panels with a thickness between 3 and 5 mm, [0071] provided that: [0072] for a thickness of 3 mm and temperature of step b) of 160 C., the minimum value of the hot compression time is 180 seconds; and [0073] for a thickness of 3 mm when the mixture has 60% or more of cork, the temperature value of step b) is 200 C.

[0074] Preferably in the mixture of step a), the cork granulate has a particle size in the range of 0.5-1.0 mm and the polyethylene granulate has a particle size in the range of 0.3-1.0 mm.

[0075] In one embodiment of the invention, in the mixture of step a), paraffin is further added. The paraffin is liquid at room temperature, stable and resistant to chemical changes at the temperature ranges in which the process of the invention occurs and has thermoplastic properties, whereby it functions as a binding agent and promotes the composite homogeneity. The use of paraffin is preferred when the particle size of polyethylene and cork are different.

[0076] In another embodiment of the present invention, the mixture may further incorporate a filler, as another additional component.

[0077] In another embodiment, the polyethylene granulate may undergo a pre-treatment with the introduction of a filler which provides it improved stability.

[0078] The filler, whether incorporated in the mixture as one of its ingredients or pre-incorporated in the polyethylene granulate, is selected from the group comprising calcium carbonate, but it may be talc, magnesium hydroxide, kaolin, natural and synthetic fibres, among others, and mixtures thereof. Preferably, the filler is calcium carbonate (CaCO.sub.3).

[0079] The percentage of filler present in the polyethylene granulate is about 10 to 34% of the total mixture of step a), preferably 30% of the total mixture.

[0080] Furthermore, it has been found that the use of a polyethylene granulate with an incorporated filler, without addition of paraffin, provides composite panels with an improved stability.

[0081] Also in step a), the mixture is fed into the press. In this step, an adjustable spatula or doctor blade may be used which limits the quantity of the feeded mixture to obtain panels having the thickness between 2 and 5 mm and density between 800 and 900 kg/m.sup.3.

[0082] In step b), the mixture is compressed in the press with a pressure in the range of 300-450 kN, preferably 350-400 kN. Compression occurs at a temperature in the range of 160 C. to 200 C., preferably 170 C. to 200 C. The compression time is comprised between 24 and 180 seconds, preferably between 72 and 180 seconds.

[0083] In step c), the mixture is allowed to cool down in the press at a pressure of 350-450 kN, preferably 400-450 kN, for a period of time between 32 and 240 seconds, obtaining panels with thickness between 2 and 5 mm.

[0084] The present invention also relates to polyethylene-cork composite panels having a high dimensional stability, thickness comprised between 3 and 5 mm, density between 800-900 kg/m.sup.3, tensile strength (EN 319) higher than 1.3 MPa, water absorption of less than 3% and hardness between 45 and 65 Shore D, and its use as cover board core.

EXAMPLES

[0085] Next, the results of the tests performed on composite panels obtained by the process of the present invention, as well as the description thereof, are shown.

[0086] Mechanical Tests

[0087] In order to perform the mechanical tests, it is necessary to cut test pieces, the number of which depends on the test, and with a size appropriate to the subject test. Table 1 lists the quantities of test pieces required and their dimensions according to the test.

TABLE-US-00001 TABLE 1 Number of test pieces and their dimensions (width and length), for each test. Test piece Test No. of test pieces dimensions, mm Ultimate tensile 5 50.8 50.8 strength, radial section Water absorption 3 25.4 76.2 Density depends on material 50.8 101.6 thickness

[0088] Ultimate Tensile Strength Test

[0089] Of all the tests, the ultimate tensile strength test is the most important since it studies the strength of the material when subjected to transverse or radial forces so as to elongate until breakage. For this, a tensometer is used.

[0090] Given the purpose of the composite, it is not relevant to measure the ultimate tensile strength at cross-section. In this way, the ultimate tensile strength was measured in a more suitable way to the product, which applies a force in the radial section of the test piece, in order to determine the binding force between the components (binding between the cork and the thermoplastic).

[0091] This test is termed flat-tensile strength (FTS) according to EN 319. For this test it is necessary to weigh and measure the thickness of the test pieces at three points in order to calculate an average thickness. The width and length are also measured for the area calculation, as this influences the value of the strength. The test pieces are then glued, with an appropriate adhesive, to the metal parts of the equipment.

[0092] This test uses an appropriate software that indicates the peak strength as well as the elongation, and the value of the area and the average thickness of each of the test pieces are inserted at the beginning of the test.

[0093] Water Absorption

[0094] The water absorption test aims to evaluate the behaviour of the material when subjected to possible disturbances, determining variations in weight and thickness.

[0095] Thus, the test pieces are pre-weighed, the thicknesses are measured at three points on the test piece and its average thickness is determined. At the end of the tests, the test pieces are again weighed and the thickness is measured again at the initial points, once again obtaining a final average thickness. The weight and thickness variations of each test piece are calculated, respectively, by Equation 4 and Equation 5.

[00001]$\begin{array}{cc}.Math..Math.P\left(\%\right)=\frac{P_f-P_i}{P_i}.Math.100& \left(4\right)\\ .Math..Math.e\left(\%\right)=\frac{e_f-e_i}{e_i}.Math.100& \left(5\right)\end{array}$

wherein, P.sub.i is the initial weight of the test piece (g), P.sub.f the final weight of the test piece (g), e.sub.i the initial average thickness (mm) and e.sub.f the final average thickness (mm).

[0096] The water absorption test was run according to applicant's internal methods, based on the VDA 675 301 guideline.

[0097] In this test, the test pieces are placed in a water container so they are fully immersed for 24 hours. At the end of this time, the test pieces are dried and the weighing and thickness measurement are again made at the initial points. Once these measurements have been made, they are placed on the laboratory bench, exposed to the lab conditions, for a period of 24 hours. After this time, a new weighing and a new thickness measurement are carried out in the respective points. The calculations of the weight and thickness variation are made by the same equations of the previous tests, Equation 4 and Equation 5, respectively.

[0098] Determination of the Hardness

[0099] Hardness is a parameter that measures the deformation strength of a solid material, related to the binding force of the atoms. For different materials, different scales are used, and the shore scale is suitable for polymers. For the subject material, the appropriate scale is shore D.

[0100] This test measures the penetration of a specific indenter when forced into the material under specific conditions. The hardness of the material depends on the modulus of elasticity and viscoelastic behaviour thereof.

[0101] A durometer was used to perform this test. Determination of the hardness is made for a minimum thickness of 6 mm. Since the agglomerated panels have a thickness of less than 6 mm, it was necessary to use an extra teste piece, so that when overlapped they had a thickness of more than 6 mm.

[0102] Determination of the Density

[0103] Density is a very important property, given its influence on mechanical properties. The density test was carried out according to ASTM F 1315.

[0104] The density is a measurement of the ratio of mass to volume and is therefore easily determined by measuring the mass of the teste piece on an analytical weighing scale and by a thickness gauge.

[0105] The calculation of the density is obtained by:

[00002]$\begin{array}{cc}\left(\frac{g}{{\mathrm{cm}}^2}\right)=\frac{W.Math.10}{T.Math.A}& \left(6\right)\end{array}$

Wherein, W is the weight of the test piece, in grams, T is the average thickness, in mm, and A is the area of the test piece, in cm.sup.2.

[0106] The average thickness is calculated taking into account the measurement made in five points of the test piece.

[0107] In the preparation of the panels to be tested, the amount of material per m.sup.2 to be fed into the press is directly dependant on the desired density and final thickness.

[0108] For example, if a material of 900 kg/m.sup.3 of density and 5 mm of thickness is desired, 4.5 kg is required, i.e.,

1 m.sup.20.005 m900 kg/m.sup.3=4.5 kg

TABLE-US-00002 Minimum and maximum temperature limit (cont.) operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 1 1% paraffin T = 160 C. DNW 62% PE t.h. = 72 s 37% cork t.c. = 96 s th = 5 mm 2 1% paraffin T = 160 C. DNW 62% PE t.h. = 103 s 37% cork t.c. = 140 s th = 5 mm 3 1% paraffin T = 160 C. DNW 62% PE t.h. = 103 s 37% cork t.c. = 140 s th = 3 mm 4 1% paraffin T = 160 C. >1.3 45-65 24 h = <3% 62% PE t.h. = 180 s 24 h + 24 h @ 37% cork t.c. = 240 s RT = <1% th = 3 mm 5 1% paraffin T = 160 C. DNW 62% PE t.h. = 180 s 37% cork t.c. = 240 s th = 5 mm 6 4% paraffin T = 160 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 5 mm 7 4% paraffin T = 180 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 5 mm 8 4% paraffin T = 180 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 3 mm 9 4% paraffin T = 160 C. >1.3 45-65 24 h = <3% 46% PE t.h. = 180 s 24 h + 24 h @ 50% cork t.c. = 240 s RT = <1% th = 3 mm 10 4% paraffin T = 160 C. DNW 46% PE t.h. = 180 s 50% cork t.c. = 240 s th = 4 mm 11 4% paraffin T = 160 C. DNW 46% PE t.h. = 120 s 50% cork t.c. = 160 s th = 3 mm 12 4% paraffin T = 170 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 5 mm 13 4% paraffin T = 170 C. >1.3 45-65 24 h = <3% 56% PE t.h. = 180 s 24 h + 24 h @ 40% cork t.c. = 240 s RT = <1% th = 3 mm 14 4% paraffin T = 170 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 4 mm 15 4% paraffin T = 170 C. DNW 56% PE t.h. = 120 s 40% cork t.c. = 160 s th = 3 mm 16 4% paraffin T = 160 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 3 mm 17 4% paraffin T = 170 C. >1.3 45-65 24 h = <3% 56% PE t.h. = 144 s 24 h + 24 h @ 40% cork t.c. = 192 s RT = <1% th = 3 mm 18 1% paraffin T = 180 C. >1.3 45-65 24 h = <3% 62% PE t.h. = 180 s 24 h + 24 h @ 37% cork t.c. = 240 s RT = <1% th = 5 mm 19 20% T = 180 C. >1.3 45-65 24 h = <3% paraffin t.h. = 180 s 24 h + 24 h @ 49.9% PE t.c. = 240 s RT = <1% 29.1% cork th = 5 mm 20 63% PE T = 190 C. DNW 37% cork t.h. = 90 s t.c. = 120 s th = 3 mm 21 63% PE T = 200 C. >1.3 45-65 24 h = <3% 37% cork t.h. = 120 s 24 h + 24 h @ t.c. = 160 s RT = <1% th = 3 mm 22 63% PE T = 200 C. >1.3 45-65 24 h = <3% 37% cork t.h. = 120 s 24 h + 24 h @ t.c. = 160 s RT = <1% th = 5 mm 23 4% paraffin T = 200 C. >1.3 45-65 24 h = <3% 36% PE t.h. = 120 s 24 h + 24 h @ 60% cork t.c. = 160 s RT = <1% th = 3 mm 24 4% paraffin T = 200 C. DNW 36% PE t.h. = 120 s 60% cork t.c. = 160 s th = 5 mm 29 20% T = 200 C. >1.3 45-65 24 h = <3% paraffin t.h. = 120 s 24 h + 24 h @ 49.9% PE t.c. = 160 s RT = <1% 29.1% cork th = 5 mm DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00003 Variation of paraffin percentage (keeping cork-PE ratio) operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 1 1% paraffin T = 160 C. DNW 62% PE t.h. = 72 s 37% cork t.c. = 96 s th = 5 mm 2 1% paraffin T = 160 C. DNW 62% PE t.h. = 103 s 37% cork t.c. = 140 s th = 5 mm 3 1% paraffin T = 160 C. DNW 62% PE t.h. = 103 s 37% cork t.c. = 140 s th = 3 mm 4 1% paraffin T = 160 C. >1.3 45-65 24 h = <3% 62% PE t.h. = 180 s 24 h + 24 h @ 37% cork t.c. = 240 s RT = <1% th = 3 mm 5 1% paraffin T = 160 C. DNW 62% PE t.h. = 180 s 37% cork t.c. = 240 s th = 5 mm 18 1% paraffin T = 180 C. >1.3 45-65 24 h = <3% 62% PE t.h. = 180 s 24 h + 24 h @ 37% cork t.c. = 240 s RT = <1% th = 5 mm 19 20% T = 180 C. >1.3 45-65 24 h = <3% paraffin t.h. = 180 s 24 h + 24 h @ 49.9% PE t.c. = 240 s RT = <1% 29.1% cork th = 5 mm 20 63% PE T = 190 C. DNW 37% cork t.h. = 90 s t.c. = 120 s th = 3 mm 21 63% PE T = 200 C. >1.3 45-65 24 h = <3% 37% cork t.h. = 120 s 24 h + 24 h @ t.c. = 160 s RT = <1% th = 3 mm 22 63% PE T = 200 C. >1.3 45-65 24 h = <3% 37% cork t.h. = 120 s 24 h + 24 h @ t.c. = 160 s RT = <1% th = 5 mm 29 20% T = 200 C. >1.3 45-65 24 h = <3% paraffin t.h. = 120 s 24 h + 24 h @ 49.9% PE t.c. = 160 s RT = <1% 29.1% cork th = 5 mm 36 0% paraffin T = 180 C. >1.3 45-65 24 h = <3% 63% PE t.h. = 72 s 24 h + 24 h @ 37% cork t.c. = 96 s RT = <1% th = 5 mm DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00004 Variation of cork percentage (keeping paraffin percentage and adjusting PE percentage) operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 6 4% paraffin T = 160 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 5 mm 7 4% paraffin T = 180 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 5 mm 8 4% paraffin T = 180 C. DNW 35% PE t.h. = 180 s 61% cork t.c. = 240 s th = 3 mm 9 4% paraffin T = 160 C. >1.3 45-65 24 h = <3% 46% PE t.h. = 180 s 24 h + 24 h @ 50% cork t.c. = 240 s RT = <1% th = 3 mm 10 4% paraffin T = 160 C. DNW 46% PE t.h. = 180 s 50% cork t.c. = 240 s th = 4 mm 11 4% paraffin T = 160 C. DNW 46% PE t.h. = 120 s 50% cork t.c. = 160 s th = 3 mm 12 4% paraffin T = 170 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 5 mm 13 4% paraffin T = 170 C. >1.3 45-65 24 h = <3% 56% PE t.h. = 180 s 24 h + 24 h @ 40% cork t.c. = 240 s RT = <1% th = 3 mm 14 4% paraffin T = 170 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 4 mm 15 4% paraffin T = 170 C. DNW 56% PE t.h. = 120 s 40% cork t.c. = 160 s th = 3 mm 16 4% paraffin T = 160 C. DNW 56% PE t.h. = 180 s 40% cork t.c. = 240 s th = 3 mm 17 4% paraffin T = 170 C. >1.3 45-65 24 h = <3% 56% PE t.h. = 144 s 24 h + 24 h @ 40% cork t.c. = 192 s RT = <1% th = 3 mm 23 4% paraffin T = 200 C. >1.3 45-65 24 h = <3% 36% PE t.h. = 120 s 24 h + 24 h @ 60% cork t.c. = 160 s RT = <1% th = 3 mm 24 4% paraffin T = 200 C. DNW 36% PE t.h. = 120 s 60% cork t.c. = 160 s th = 5 mm DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00005 Type of cork used (variation of density and particle size) operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 25 35% low T = 180 C. DNW density t.h. = 180 s cork 0.5-1 mm t.c. = 240 s 4% paraffin th = 3 mm 61% PE 26 35% low T = 200 C. DNW density t.h. = 180 s cork 0.5-1 mm t.c. = 240 s 4% paraffin th = 5 mm 61% PE 27 35% high T = 180 C. >1.3 45-65 24 h = <3% density t.h. = 120 s 24 h + cork 1-2 mm t.c. = 160 s 24 h @ 4% paraffin th = 5 mm RT = <1% 61% PE 30 100% PE T = 160 C. DNW t.h. = 120 s t.c. = 160 s th = 5 mm 31 100% PE T = 180 C. >1.3 45-65 24 h = <3% t.h. = 120 s 24 h + t.c. = 160 s 24 h @ th = 5 mm RT = <1% 32 35% Cork T = 180 C. >1.3 45-65 24 h = <3% with t.h. = 180 s 24 h + 0.2-0.6 mm t.c. = 240 s 24 h @ 4% paraffin th = 5 mm RT = <1% 61% PE DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00006 Density of final panel Hardness operation FTS (shore Water Abs. Test Formulation conditions (MPa) D) (%) 34 4% paraffin T = 180 C. >1.3 45-65 24 h = <3% 35% cork t.h. = 120 s 24 h + 24 h @ 61% PE t.c. = 160 s RT = <1% Formulation th = 5 mm with 600 kg/m.sup.3 35 4% paraffin T = 180 C. >1.3 45-65 24 h = <3% 35% cork t.h. = 120 s 24 h + 24 h @ 61% PE t.c. = 160 s RT = <1% Formulation th = 5 mm with 1100 kg/m.sup.3 DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00007 Variation of filler percentage in polyethylene granulate operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 40 25% cork T = 190 C. >1.3 45-65 24 h = <3% 43% PE t.h. = 120 s 24 h + 24 h @ 32% CaCO.sub.3 t.c. = 160 s RT = <1% th = 5 mm 41 30% cork T = 190 C. >1.3 45-65 24 h = <3% 50% PE t.h. = 90 s 24 h + 24 h @ 20% CaCO.sub.3 t.c. = 120 s RT = <1% th = 5 mm DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

TABLE-US-00008 Variation of filler percentage in the mixture operation FTS Hardness Water Abs. Test Formulation conditions (MPa) (shore D) (%) 45 31.5% cork T = 190 C. >1.3 45-65 24 h = <3% 54.9% PE t.h. = 90 s 24 h + 3.6% paraffin t.c. = 120 s 24 h @ 10% CaCO.sub.3 th = 5 mm RT = <1% 46 28% cork T = 190 C. >1.3 45-65 24 h = <3% 49% PE t.h. = 180 s 24 h + 3% paraffin t.c. = 240 s 24 h @ 20% CaCO.sub.3 th = 5 mm RT = <1% DNWdid not work; Ttemperature; RTroom temperature; t.h.hot compression time; t.c.cold compression time; ththickness

[0109] The panels of the present invention thus show advantages over prior art panels namely: [0110] low density of the cork panel with thermoplastic (when compared to material obtained by extrusion or pultrusion) [0111] machining ability (when compared to cork) [0112] intrinsic resistance suitable to the application [0113] physico-mechanical properties suitable for use as cover board core

[0114] The process of the present invention has enormous advantages when compared with prior art technologies, namely: [0115] no thermal/mechanical degradation of cork, by avoiding extrusion/pultrusion processes; [0116] the process steps are simple and do not include prior steps to simultaneously granulate, in the same granule, the cork and the polymer; [0117] enables a high throughput, from one to several m.sup.2/minute; [0118] easily adaptable to the production of large panels.