Method for laminating plastic profiles produced from mixed polymers

Abstract

A method for laminating profile and plate materials produced from processed mixed plastic waste and other plastic surfaces comprises steps of collecting and processing of mixed plastic waste for recycling for making profile and plate materials and lamination of profile and plate materials produced from processed mixed plastic waste, wherein the lamination of profile and plate materials produced from processed mixed plastic waste comprises stabilizing the profile temperature before lamination; determining the surface quality; making the surface quality of profile suitable by propane gas treatment of the profile; heating the profile surface before the lamination process; heating the adhesive right before the lamination; applying the adhesive to the laminate surface; carrying out the lamination process; and directing the laminated profiles for storying.

Claims

1. A method for laminating profile and plate materials produced from processed mixed plastic waste and other plastic surfaces comprises collecting and processing of mixed plastic waste for recycling for making profile and plate materials and lamination of profile and plate materials produced from processed mixed plastic waste, wherein the lamination of profile and plate materials produced from processed mixed plastic waste comprises the following steps: stabilizing the profile temperature before lamination and preparing the surface of plastic profile or plate materials to be laminated; determining the surface quality before starting the lamination process; making the surface quality of profile suitable by changing the surface quality of the profile to be laminated; heating the surface to be laminated before the lamination process; heating the adhesive right before the lamination; applying the adhesive to the laminate surface; carrying out the lamination process; and directing the laminated profiles for storying.

2. The method according to claim 1, wherein the laminated plastic surface is prepared upon heat treatment such that the temperature of the cross-section of the laminated surface is achieved in the range from +15 C. to +22 C.

3. The method according to claim 1, wherein when making the surface quality of the laminated surface suitable, the adherence of the laminated surface is at least 40 mN/m before lamination.

4. The method according to claim 1, wherein plasma, corona or gas treatment is used to change the surface quality.

5. The method according to claim 1, wherein propane-based flame is used to change the surface quality.

6. The method according to claim 1, wherein the temperature of the laminated surface is, before adhesion, brought to the range of 45-55 C. when changing the surface quality.

7. The method according to claim 1, wherein the process of surface treatment in the step of changing the surface quality is carried out 5-10 seconds before the adhesion process.

8. The method according to claim 1, wherein heat treatment of the adhesive is carried out in the range of 120-137 C.

9. The method according to claim 1, wherein acrylate laminate is used for lamination.

10. The method according to claim 1, wherein polymethylmethacrylate laminate is used for lamination.

11. The method according to claim 1, wherein polyurethane adhesive is used as an adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0011] The method for laminating profile and plate materials produced from processed mixed plastic waste as well as other plastic surfaces comprises the following steps: [0012] mixed plastic waste is collected and processed for recycling as profile and plate materials; [0013] stabilizing the profile temperature before lamination and plastic surface of profile or plate materials to be laminated are prepared; [0014] before starting the lamination process, the surface quality of the laminated surface is determined; [0015] making the surface quality of profile suitable by propane gas treatment of the profile; [0016] the laminated surface is heated before the lamination process; [0017] right before the lamination, the adhesive is heat-treated; [0018] applying the adhesive to the laminate surface; [0019] carrying out the adhesion (lamination) process; [0020] directing the laminated profiles for storying.

[0021] In order to use the method of the present invention for laminating the products produced from processed mixed plastic waste, the corresponding mixed plastic waste are first collected and processed for recycling as profile and plate materials.

[0022] Then the plastic surface of the profile or plate material to be laminated is prepared such that the temperature of the cross-section of the laminated surface is from +15 C. to +22 C. for ensuring adhesion and avoiding delamination, if the profile is cold or too hot, the process will not function.

[0023] Before the lamination process, the surface quality is determined where testers of determination of surface adherence level are used. According to the present invention, the adherence of the laminated surface is at least 40 mN/m before the lamination.

[0024] For changing the surface quality, plasma, corona or gas treatments are used, for example, wherein best results gives gas treatment. As a flame, for instance, a propane-based flame is used, which ensures sufficient heat treatment of the surface for guaranteeing adherence (which, for example, plasma treatment and chemical treatment do not allow), wherein the ratio of the mixture of air and propane is preferably 25:1 and the flow rate of the mixture is 220 l per minute. As such, the surface adherence of the laminated profile is more than 40 according to the scale of the testers. The propane flame is used 45-50 mm away from the profile surface, because a smaller distance damages the surface and a greater distance does not change the surface quality enough.

[0025] Before adhesion, the temperature of the laminated surface is brought to the range of 45-55 C. by changing the surface quality with propane flame.

[0026] The process of surface treatment in the step of changing the surface quality is carried out 5-10 seconds before the adhesion process.

[0027] Right before lamination, heat treatment and application of adhesive, polyurethane-based adhesive or some other hot-melt adhesive is carried out, wherein the resistance to cold or heat thereof is between at least 40 C. to 150 C. Heat treatment of the adhesive is carried out in the range 120-137 C., for instance, at 120-125 C. when using acrylate coating, at 120-137 C. when using polymethylmethacrylate laminate for laminating vertical surfaces. Then the adhesion (lamination) process is carried out, for example, with profiles of cross-section from 70 mm15 mm to 150 mm100 mm with a rate of 14-16 m/min, wherein polyurethane adhesive is used as an adhesive, for example, and electron beam cured decor surfaces are used for lamination which ensures resistance to scratches and bending of the laminate over the edge of the laminated surface.

[0028] Polyurethane adhesive is elastic between the laminate and the plastic profile to be laminated which allows stretching and the polyurethane adhesive itself is able to shrink and expand in the same range as the laminated surface.

[0029] Angular radiuses of the profiles are at least R5 depending on the bending properties of the laminate. For instance, laminate used on the terrace boards is rigid and, therefore, profiles with rounded angles are preferred. For instance, flexible laminate is used with window profiles and in such a case, steeper angle of the profiles is preferred.

[0030] The flow rate of the heat-treated adhesive is between 60-70 g/m.sup.2.