Composition for sheet using biomass, eco-friendly composite sheet, and fabrication method for thereof

Abstract

The present invention provides a composition for sheet using a biomass, an eco-friendly composite sheet, and fabrication method thereof, where the sheet comprising the composition according to the present invention has eco-friendly characteristics, that is, being recyclable and not harmful to the human body. Further, the sheet according to the present invention is excellent in elongation and hardness and also has good scratch resistance.

Claims

1. A composition for a sheet comprising: 30 to 60 relative parts by weight of an impregnated porous powder, wherein the porous powder is a pulverized herbaceous biomass, and the porous powder of pulverized herbaceous biomass is impregnated with a nano-inorganic filler; 30 to 60 relative parts by weight of a polyolefin resin; and 1 to 40 relative parts by weight of a flow enhancer.

2. The composition of claim 1, wherein the porous powder of pulverized herbaceous biomass comprises any one of bamboo, rice chaff, wheat bran, rice straw, wood flour, and green tea.

3. The composition of claim 1, wherein the porous powder of pulverized herbaceous biomass has an average particle size of 1 m to 45 m.

4. The composition of claim 1, wherein the nano-inorganic filler comprises at least one selected from the group consisting of calcium carbonate, silica, mica, and talc.

5. The composition of claim 4, wherein the nano-inorganic filler has an average particle size of 40 nm to 80 nm.

6. The composition of claim 1, wherein the impregnated porous powder is coated with a vegetable oil/fat or a vegetable fatty acid on the surface thereof.

7. The composition of claim 6, wherein the impregnated porous powder is coated with palm oil.

8. The composition of claim 1, wherein the polyolefin resin is polyethylene resin or polypropylene resin.

9. The composition of claim 1, further comprising compatibilizer or wax.

10. The composition of claim 1 wherein the flow enhancer comprises glass beads.

11. The composition of claim 10, wherein the glass beads have an average particle size of 3 m to 40 m.

12. The composition of claim 1 wherein the flow enhancer comprises an organic peroxide.

13. The composition of claim 12, wherein the organic peroxide comprises at least one organic peroxide selected from the group comprising benzoyl peroxide, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, t-butyl peroxy acetate, t-butyl peroxy benzoate, t-butyl peroxy-2-ethyl hexanoate, t-butyl peroxy isopropyl carbonate, t-butyl peroxy neo-decanoate, methylethyl ketone peroxide, and dicumyl peroxide.

14. A method for preparing the composition for a sheet of claim 1, comprising: pulverizing a herbaceous biomass into a porous powder; impregnating the porous powder of pulverized herbaceous biomass with the nano-inorganic filler; and mixing 30 to 60 relative parts by weight of the impregnated porous powder with 30 to 60 relative parts by weight of the polyolefin resin and 1 to 40 relative parts by weight of the flow enhancer.

15. The method as claimed in claim 14, wherein the porous powder of pulverized herbaceous biomass comprises any one of bamboo, rice chaff, wheat bran, rice straw, wood flour, and green tea.

16. The method as claimed in claim 14, wherein the porous powder of pulverized herbaceous biomass has an average particle size of 1 m to 45 m.

17. The method as claimed in claim 14, wherein the nano-inorganic filler has an average particle size of 40 nm to 80 nm.

18. The method as claimed in claim 14, wherein the impregnated porous powder is coated with vegetable oil/fat or vegetable fatty acid on the surface thereof.

19. The method as claimed in claim 18, wherein the impregnated porous powder is coated at 85 C. to 110 C.

20. The method as claimed in claim 14, wherein the flow enhancer comprises a glass bead having an average particle size of 3 m to 40 m.

21. The method as claimed in claim 14, wherein the impregnated porous powder is dried at 85 C. to 110 C. while mixed together.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1A is a SEM image of mixture of a porous herbaceous biomass and a polyolefin resin according to one embodiment of the present invention.

(2) FIG. 1B is a schematic diagram showing the compatibility between the porous herbaceous biomass A and the polyolefin resin B as shown in FIG. 1A.

(3) FIG. 2A is a SEM image of mixture of a porous herbaceous biomass and a polyolefin resin according to the prior art.

(4) FIG. 2B is a schematic diagram showing the compatibility between the porous herbaceous biomass A and the polyolefin resin B as shown in FIG. 2B.

(5) FIG. 3 is a SEM image of glass bead that is a kind of flow enhancer according to one embodiment of the present invention.

(6) FIGS. 4A and 4B are schematic diagrams showing the principle of the effect of the glass bead added to improve the flowability of the mixture according to one embodiment of the present invention.

(7) FIGS. 5A, 5B and 5C are schematic diagrams showing an eco-friendly composite sheet according to one embodiment of the present invention.

(8) FIG. 6 is a flow chart showing a fabrication method of an eco-friendly composite sheet according to one embodiment of the present invention.

(9) FIG. 7 shows the results of evaluation on the scratch resistance of the sheet according to one embodiment of the present invention.

(10) FIG. 8 shows the results of evaluation on the scratch resistance of the sheet according to another embodiment of the present invention.

BEST MODES FOR CARRYING OUT THE INVENTION

(11) Hereinafter, a detailed description will be given as to the components and technical features of the present invention with reference to the following examples, which are given only to exemplary the contents of the present invention and not intended to limit the scope of the present invention.

Example 1

Preparation of Pretreated Biomass

Experimental Example 1

(12) Cornhusk, a dried porous herbaceous biomass, is pulverized with a ball mill and then grind with an air-jet mill into a powder having an average particle size of 8 m. With respect to the total weight, 40 parts by weight of the porous herbaceous biomass is impregnated with 5 parts by weight of calcium carbonate having an average particle size of 60 nm to prepare an impregnated mixture.

Experimental Example 2

(13) Wheat bran, a dried porous herbaceous biomass, which has a particle size of 19 m, is pulverized with a ball mill and then grind with an air-jet mill into a powder having an average particle size of 8 m. With respect to the total weight, 40 parts by weight of the porous herbaceous biomass is impregnated with 10 parts by weight of calcium carbonate having an average particle size of 60 nm to prepare an impregnated mixture. Subsequently, 1.5 part by weight of palm oil is added as a coating agent to the impregnated mixture, which is then blended at a rate of 60 rpm in a drum dryer at 85 C. for 25 minutes to prepare a surface-coated impregnated mixture.

Comparative Example 1

(14) Rice chaff, a dried porous herbaceous biomass, is pulverized with a ball mill and then grind with an air-jet mill into a powder having an average particle size of 8 m. With respect to the total weight, 40 parts by weight of the porous herbaceous biomass is impregnated with 5 parts by weight of calcium carbonate having an average particle size of 60 nm to prepare an impregnated mixture.

(15) This can be summarized as in the Table 1.

(16) TABLE-US-00001 TABLE 1 Herbaceous nano-inorganic biomass filler Coating agent Experimental Cornhusk, Calcium ESO (Epoxidized Example 1 8 m, carbonate, Soybean Oil, 40 parts by 60 nm, SDB CIZER E-03, weight 5 parts by SAJOHAEPYO weight Corp.) Experimental Wheat bran, Calcium Palm oil, Example 2 8 m, carbonate, 1.5 part by 40 parts by 60 nm, weight weight 10 parts by weight Comparative Rice chaff, Calcium ESO(Epoxidized Example 1 8 m, carbonate, Soybean Oil) 40 parts by 60 nm, weight 5 parts by weight

Example 2

Preparation of Composition for Sheet Including Pretreated Biomass and Evaluation of its Effects

(17) With respect to the total weight, a polypropylene resin (PP B310, manufactured by Honam Petrochemical Corp.) and PE-WAX 102N (as a wax that is a kind of lubricant for plastic) are mixed at a high speed at 85 C. in super-mixer. Subsequently, each impregnated mixture of Experimental Examples 1 and 2 and Comparative Example 1 of Example 1, respectively is added, and then a glass bead (20 nm in diameter) (Brand Name: APS20-215) as a flow enhancer and anhydrous maleic acid as a compatibilizer are added. The resultant mixture is pressurized (4 bar/3 min-cylinder retention time) and heated (190 C. to 210 C.) to prepare a composition for sheet. The specific conditions are presented in Table 2.

(18) TABLE-US-00002 TABLE 2 PE- Glass WAX bead PP 102N Impregnated (flow Compat- resin (wax) mixture enhancer) ibilizer Experimental 45.5 4 45 parts by 5 Silane, Example 3 weight of 0.5 Experimental Example 1 Experimental 39.3 4 51.5 parts 5 Anhydrous Example 4 by weight of maleic acid, Experimental 0.2 Example 1 Comparative 45.5 4 45 parts by None Silane, Example 2 weight of 0.5 Comparative Example 1 (Unit: part by weight)

(19) Evaluation of Melt Mass Flow (Melt Flow Index: MI)

(20) The composition for sheet using a biomass is prepared in the same manner as described in Experimental Example 4, while the content of the glass bead having an average particle size of 3 m to 40 m is varied. The measurement results in regards to the melt mass flow (melt flow index (MI)) are presented in Table 3.

(21) TABLE-US-00003 TABLE 3 Glass bead Test conditions (part by Temp. ( C.)/ Results Sample weight) load (g) g/10 min Method Comparative 0 190/2,160 3.33 ASTM D Example 3 1238 Experimental 5 190/2,160 6.6 ASTM D Example 5 1238 Experimental 10 190/2,160 9.0 ASTM D Example 6 1238 Experimental 15 190/2,160 15.2 ASTM D Example 7 1238 Experimental 50 190/2,160 2.0 ASTM D Example 8 1238

(22) In this regard, the MI determination is performed according to a known method (Tinius Olsen Testing Machine Co., Inc.: MWLD-600).

(23) According to Table 3, it is apparent that the flowability of the composition for sheet increases with an increase in the content of the glass bead. But, the flowability deteriorates when the content of the glass bead is 50 parts by weight.

Example 3

Fabrication of Eco-Friendly Composite Sheet and Evaluation of its Effects

(24) Fabrication of Eco-Friendly Single-Layered Composite Sheet With respect to the total weight, 42 parts by weight of a polypropylene resin (PP B310, manufactured by Honam Petrochemical Corp.) and 8 parts by weight of ethylene vinyl acetate (EVA) are mixed together as a base resins, and 50 parts by weight of the composition for sheet according to Experimental Example 3 or 4 is added to the base resin mixture to prepare a composition for extrusion, which is then extruded into an eco-friendly single-layered composite sheet.

(25) The above-prepared single-layered composite sheet and a single-layered composite sheet using the composition for sheet according to Comparative Example 2 in place of Experimental Example 3 or 4 are evaluated in regards to the scratch resistance. The results of evaluation are presented in FIGS. 8 and 9, respectively. It can be seen that the composite sheets using the composition of Experimental Example 3 or 5 are superior in the scratch resistance to the composite sheet using the composition of Comparative Example 2.

(26) Fabrication of Eco-Friendly Multi-Layered Composite Sheet

(27) With respect to the total weight, 40 parts by weight of a polypropylene resin (PP B310, manufactured by Honam Petrochemical Corp.) and 10 parts by weight of a high-density polyethylene resin (HDPE 7000F, manufactured by Lotte Chemical Corp.) are mixed together as a base resins. To the base resin mixture is added 50 parts by weight of the composition for sheet according to Experimental Example 3 or 4 to prepare a composition for extrusion, which, as is shown in FIG. 5A, is then extruded to form the first layer 100. With respect to the total weight, 35 parts by weight of a polypropylene resin (PP B310, manufactured by Honam Petrochemical Corp.) and 5 parts by weight of a linear low-density polyethylene resin (L/LDPE UL614, manufactured by Lotte Chemical Corp.) are mixed together as base resins. To the base resin mixture is added 60 parts by weight of the composition for sheet according to Experimental Example 3 or to prepare a composition for extrusion, which is then, as shown in FIG. 5B extruded to form the second layer 200. Subsequently, the first and the second layers, 100 and 200 respectively, are laminated according to the side feed block type integrated direct extrusion method to fabricate a multi-layered eco-friendly composite sheet as shown in FIG. 5C.

(28) The multi-layered eco-friendly composite sheet is formed through the vacuum forming method to fabricate a carbon dioxide (CO2) reduced eco-friendly bio-tray. The process has no difficulty in employing the vacuum forming method, and the bio-tray thus prepared satisfies the defined properties.

(29) The present invention has been described with reference to the particular illustrative embodiments, which are not intended to limit the scope of the present invention but susceptible to many changes and modifications without departing from the scope and spirit of the present invention. Further, specific situations and materials can be adopted in the specification of the present invention by changes and modifications without departing from the substantial scope of the present invention. The scope of the present invention is not limited to the specific embodiments disclosed as the best modes planned to realize the present invention but includes all the embodiments according to the claims of the present invention.