Development of Process for Producing Metal/Plastic Composite Tile Using Wasted Plastics

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A fluidized bed coater was manufactured by installing a fluidized bed column (90 mm i.d., 400 mm height, quartz glass) in a electromagnetic induction coil (wave frequency : 4MHz, maximum electromagnetic wave power output : 40kW) for preparing composite iron particles covered with plastic particles. Tile-shaped composite moldings were prepared using the composite particles as raw material. The following results were obtained.(1) Preparation of composite particles and evaluation of their properties1-1) In the case where epoxy resin particles are used as plastic material, composite particles are produced successfully above the power output of 4kW.The diameter of composite particles increases linearly with the power output. The geometric standard deviation of particle size ranges from 1.1 to 1.2 independent of the size of iron particles and power output.1-2) The diameter of iron/ epoxy resin composite particles increases with the size of epoxy resin particles at the same power output.1-3) The diameter of composite particles with polyethylene is larger than epoxy resin at the same ion power output.(2) Preparation of composite moldings and evaluation of their propertiesComposite moldings were prepared by shaping composite particles in a mold (40×10×10mm) with a heating and pressurizing machine. Molding temperatures were kept at about the melting points of plastics. The following findings were obtained by measuring the density, bending strength and compressive strength of the moldings.2-1) Iron/ epoxy resin and iron/ polyethylene composite moldings are successfully manufactured as ordered mixtures.2-2) The density of composite moldings can be controlled by adjusting electromagnetic wave power output in the coating process.2-3) In the case of iron/ polyethylene composite moldings, plastic deformation can be suppressed under larger compressive load, and consequently the strain produced in the molding can be made smaller than that in pure polyethylene moldings.