FIELD OF THE INVENTION

The present invention relates to novel polymer and resin compositions, their use in “vinyl” records (or phonographs), and methods of their manufacture. In particular, the invention relates to new phonograph compositions and processes for making them.

Phonograph records, or often abbreviated to simply a “record”, are media that have been used for the reproduction of sound since the 1890s, with 78s and others dating from the 1940s. Although the discs were originally and commonly made from shellac, in the 1940s polyvinyl chloride (PVC) became the main component, hence the colloquial name “vinyl” for records. The phonograph record was used widely for music reproduction throughout the 20 ^th Century, but in the 1980s digital media, in the form of compact discs (CDs), gained a larger market share, and the record left the mainstream in the early 1990s.

Records have continued to be manufactured and sold on a smaller scale during the 1990s and early 2000s but in recent years have recently enjoyed a significant resurgence. However, in terms of chemical and physical compositions, little has changed over the decades and modern vinyl records are still made with PVC. Although vinyl records are generally strong and do not break easily, they do scratch and acquire a static charge, which then attracts dust, that can be difficult to remove completely. Dust and scratches can cause audio clicks and therefore result in a reduction in acoustic quality during use. They can accelerate wear and tear and ageing over the life of the record. In some cases, this damage can cause the needle to skip over a series of grooves.

There has been much controversy, since the invention of the CD, in the relative quality of CD sound versus LP sound, known as the “analogue versus digital” sound argument. CDs, if correctly handled and stored, can last for many years, but vinyl records need to be handled with care and stored properly. In spite of the inherent flaws associated with vinyl records, such as the lack of portability, records still have enthusiastic support and, in many countries, there has been a growing niche market for records, especially with audiophiles, collectors and DJs. Despite their renaissance, though, little product development has occurred in recent years, and there is a growing need (and desire amongst fans, artists and record labels) to replace or substitute some of the polymers or chemicals used in vinyl, for example PVC, in view of environmental disadvantages. In addition, PVC records can be expensive to manufacture and there is a need to streamline the process and make production quicker and more energy efficient.

The present invention aims to mitigate, alleviate, or solve some of the disadvantages and problems associated with prior vinyl or PVC records.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided a biodegradable, bioplastic or compostable phonograph record (or record for short).

A record, or phonographs (the terms are used interchangeably) is usually a carrier or storage medium for analogue sound. In common parlance these are often referred to as LPs (an abbreviation of Long Player) and are often referred to as vinyl or vinyl record (the “vinyl” being a reference to the main ingredient, PVC). They may be 7-, 10- or 12-inch (17.5, 25 or 30cm) records (in diameter). The record may be designed to be played at 33 1/3 or 45 RPM.

The phonograph or record may thus comprise a data carrier, and may store or carry information, such as sound, in particular in the form of analogue sound (and hence not optical and/or magnetic format).

Usually, the phonograph (or record) will be a playable audio record. It may comprise a flat or planar disc (so generally circular). It will generally be inscribed with, or comprise, a modulated or generally spiral groove. The record may thus have a continuous spiral groove (e.g., with 2 channels, so stereo), usually on each side (of the record). The groove may start at the edge and finish at or near the center. The phonograph record may reproduce audio or sound, for example by vibration of a stylus or needle following a spiral groove, for example when it is rotating, such as on a turntable or deck.

The record may carry an image or embody other special features (these may be called picture discs or specials).

The phonograph (record) is preferably biodegradable and/or compostable (such as under industrial composting conditions). It may be able to decay (in a natural environment) over time.

At its broadest, therefore, the invention relates to a biovinyl record or a biovinyl phonograph (or LP). Preferably the phonograph of the invention comprises (a material which has) one or more biodegradable (or compostable) ingredients or components, bioplastics and/or bio-plastic polymer(s).

Another aspect of the invention comprises a phonograph, or record (made of a material) comprising :

PLA (polylactic acid) and/or polyhydroxyalkanoate (PHA, or a member of the PHA polymer family); and/or

(e.g., glycol-modified) polyethyleneterephthalate, PET or PET-G).

The record may thus comprise an aliphatic-aromatic co-polyester, polyhydroxyalkanoate and optionally one or more mineral fillers (such as magnesium silicate and/or carbonate).

Polylactic acid (PLA) is the preferred aliphatic-aromatic copolyester - PLA is an aliphatic polyester obtainable by converting starch, suitably extracted from a renewable plant resource such as corn, and potato into glucose, which can then be fermented into lactic acid and further polymerized. Preferably the record comprises (a polymer or co-polymer of) PLA+PHA, preferably with more PLA (in the majority, so more than 50%) than PHA (minority, or less than 50%).

The present invention therefore relates to a phonograph (record) which (is made of a material which) does not contain, comprise, or omits or is without either polyvinyl chloride (PVC) and/or polyvinyl acetate (PVA). One or both of these component(s) or polymers may thus be replaced, or substituted, by a biodegradable and/or bio-plastic resin or a compostable) (e.g., resin) composition. At its broadest, the phonograph record may thus have PVC and/or PVA replaced by PLA (polylactic acid). Therefore, one aspect of the invention is a phonograph record that comprises a biodegradable and/or compostable polymer, such as PLA (or PHA), but contains no PVC and/or PVA.

The material used to make the record may be semi-crystalline. This may allow the material to heat up and/or cool quicker or more rapidly, so shortening the manufacturing process. It may also set and/or harden quicker (than PVC).

A further aspect of the invention relates a phonograph (record) which comprises a filler (for example a reinforcing filler, or a substance that can allow or assist the formation of small crystals), preferably wherein such fillers comprise chalk and/or talc and/or magnesium sulphate and/or other natural fillers. This aspect thus provides a phonograph (record) that comprises magnesium silicate, or talc (or chalk). Preferably the magnesium silicate comprises Mg3(SiC>4)10(OH)2

The filler may act as a stabilizer and/or may assist in particle bonding. The magnesium silicate and/or talc (or chalk) particles may be (on average) less than 14pm or 12pm, preferably less than 5pm or 3pm, for example in diameter.

The biodegradable, bio-plastic or compostable polymer and/or resin preferably meets or complies with the EN1342 standard (or equivalent international or national standard, such as ISO or US standard). It may be a polymer resin. Preferably it will replace PVC and/or PVA and/or a plasticizer. The polymer may be plant-based or plant-derived or be based or derived from a raw or natural material (so preferably not synthetic). Preferably it comprises cellulose, such as plant cellulose, and/or sucrose. Suitably, the polymer and/or resin is based on, or derived from, beet, such as sugar beet, alfalfa, corn, cotton, sugar cane, flax, kemp and/or bamboo.

Preferably the polymer and/or resin is mouldable, for example injection mouldable. Suitably, it is thermoplastic. Preferably it can be extruded and/or is therefore suitable for extrusion.

A further aspect of the invention comprises a phonograph record which comprises a mould release (agent).

Suitably the record material comprises e..g. polymer(s) that have antistatic properties Thus the invention also relates to a phonograph that is (e g., inherently) antistatic, or has antistatic properties (or omits a known or conventional antistatic agent).

Usually in the production process, the raw material (usually the polymer composition) is made or formed into a “biscuit” or puck (the terms are used interchangeably). This is then heated and/or compressed. Usually the puck is heated first, up to a temperature of about 180°C, and is then compressed under significant/high pressure. In the present application, it is preferable that the (pressing) temperature is 5-10 or 20% lower than prior art temperatures. For example, in the process of the invention, preferably the temperature of the puck either before, or during, compression is from 150-160°C such as from 135-145°C, preferably from 138-142°C.

This can be achieved by using a resin and/or polymer composition that has a slightly lower softening or melting point (than PVC). Preferably there is thus a shorter pressing time, for example there is a shorter interval of time between pressing consecutive pucks (to make consecutive records) and/or the or each puck is pressed for a shorter period of time. This can vary depending on the pressing or manufacturing machine used (such as Press on Vinyl or Deep Grooves). Suitably the pressing is around 140°C to either form the puck, or to form the record. This can be achieved using a composition with a slightly lower melt and/or flow rate.

It can also result in quicker timing, namely a shorter (pressing) cycle. The puck may be present, or in existence, for a shorter time before being pressed. The reduced pressing temperature may thus reduce energy.

The phonograph record (material) may contain other ingredients and/or components. Preferably it will contain one or more of the following:

(i) one or more colourant(s).

(ii) one or more (e.g., heat) stabilizer(s);

(iii) one or more plasticizer(s).

(iv) one or more lubricant(s) or mould release agent(s); and/or

(v) one or more filler(s) and/or antimicrobial agent(s).

The heat stabilizer preferably comprises a (metal salt of a) fatty acid. The metal(s) can comprise tin and/or lead. Sometimes more than one (type of) stabilizer is included. The stabilizer(s) will usually be in an amount up to 1.5%, such as from 1-2%. Stabilizers can assist to make the polymer and/or resin composition more robust.

The plasticizer may comprise a phthalate ester, for example (an epoxidized) soybean oil. The plasticizer may allow one to alter or change the viscosity of the polymer and/or resin that is to be used to make the phonograph. They may improve the flexibility of the final record and/or the flowability of the polymer resin. It may also be easier to make or match microgrooves in the master disc during the pressing process. The or each plasticizer may be present at less than 1 %, for example from 0.5-1 .5%.

Colourants can also be included. The or each may comprise black, for example carbon black, which may have a carbon content of about 95%. However, other colours can be used, such as yellow, green, orange and/or red. Two or more colorants may be used, in which case one can have or create a marbled effect. Colourants may be up to 0.5%, for example from 0.25-0.75%. Suitable lubricant(s) can comprise (e.g., hard) waxes, for example either natural (montan) or synthetic (for example stearamide) type waxes. The or each lubricant(s) may be present at below 1 %, for example between 0.5-1 .5%.

A lubricant may help or ease the flow of the resin and/or polymer composition, for example during the production or processing stages of manufacture. They may help to reduce friction on the surface of the (phonograph) record. This may reduce heat and disc degradation and/or allow a smoother contact between the record and the stylus.

Thus, the invention at its broadest comprises a phonograph record comprising a biodegradable or compostable polymer (resin). This may be suitable for thermoplastic processing. It may consist of one or more biodegradable polymers.

In the past, replacements for PVC that have been suggested have included silicone, EVA (ethylene vinyl acetate), polyolefins, elastomers and polyurethanes. However, although all these PVC substitutes have been used, none of them are biodegradable, or constitute a bioplastic, or are compostable.

Preferably, the biopolymer or resin composition (or the record) comprises a plasticiser- free thermoplastic material. This may contain or comprise biologically sourced raw materials. The bio-based carbon share of the composition may be as much as 69%.

Preferably the polymer or composition is easy or free flowing. It may be suitable for processing by (injection) moulding. It may thus produce a final item (such as a record) that is biodegradable.

Preferably the biopolymer or composition will have a density of from 1 .3-1 .4, such as around 1.35, g/cm ² . Preferably the bulk density will be from 800-900, such as from 850-870, kg/m ³ . The moisture content is preferably below 0.2 wt%.

Preferably the composition, and therefore the record (material), is recyclable. Suitably it can be printable by flexographic and/or offset printing, for example without pretreatment. Preferably it can be coloured, for example with a master batch. Suitably the phonograph or record (material) is compostable, recyclable and/or can be incinerated. Suitably it complies with the EN 13432 standard.

Suitably, if the biodegradable polymer(s) were made into a blown film, they would have tensile strength of 30-40, such as from 53-35, MPa. It may have a Young’s modulus of from 2-3, such as 2.3-2.5 GPa. They may have a Flexural modulus of from 2-3, such as from 2.5-2.6 GPa.

They may have an Oxygen permeability of 45-55, such as from 48-52, cm ³ (M2d bar).

Preferably, in terms of thermal properties, it has a softening temperature of from 50- 70°C, such as from 55-60°C.

Preferably the bioplastic is derived, or based on, a sugar and/or a starch. It may preferably comprise sucrose. Preferably the composition comprises BIOPLAST GS2189, made by Biotec in Emmerich am Rhein, Germany, or equivalent material.

In some instances, the phonograph record may not contain chalk, in other words it is chalk-free, or where chalk is omitted. The chalk can be (fully or partly) replaced or substituted by talc and/or magnesium silicate, as described earlier.

Usually during the production process, the resin or polymer composition will be mixed with a second polymer and/or resin composition called a master batch. Thus, in a preferred embodiment, the BIOPLAST GS2189 (or equivalent, such as DP 990 from Colloids, UK) is mixed with the master batch, to create the material that forms the biscuit or puck, ready to be heated and/or compressed.

At its broadest, therefore, the invention relates to a phonograph record, or a polymer and/or resin composition, comprising a bioplastic (or biodegradable) polymer and, optionally (a filler comprising) talc and/or magnesium silicate. Preferably the resin comprises PLA (polylactic acid). If talc is included, then the diameter of the talc or magnesium silicate particles, or the grain size, is less than 12pm or less than 5pm, preferably or less than 3pm. Suitably the record comprises a polymer (e.g. PLA) that is nucleated by the (talc or) filler, of has (talc or) a filler that can nucleate ta (constituent) polymer (e.g. the PLA). The talc or filer may be (semi) crystalline. It may allow the polymer(s) to recrystallise faster.

Preferably the composition additionally comprises a colourant, such as black, green, white, red, or a marbling effect colorant. Suitable (mixes of) colourants may be black, grey marble, green or marbling green and/or white.

Suitably the polymer and/or resin composition comprises a sugar-based biopolymer. This can comprise up to 60% of the composition) that is to be heated and/or pressed into a record).

The phonograph record preferably contains a filler, other than chalk, that suitably comprises talc, magnesium silicate, or preferably magnesium silicate hydrate (or hydrated magnesium silicate). The talc or magnesium silicate may provide stability and/or may help with the bonding of other particles. It may also provide an antistatic effect.

Suitably the record will be comprised of heated and/or compressed (crushed) pellets. Preferably the phonograph will be 90% biodegradation within 180 days. This parameter is usually measured in the presence of microorganisms (bacteria and fungi) under industrial composting conditions. The conditions will usually be at a temperature of about 50°C, e.g., with a relatively high humidity.

Preferably the record will have a standard of 90% disintegration within 12 weeks, by using a x2mm ² mesh, for example at temperatures of around 40°C.

Suitably the phonograph will comprise two main ingredients and/or components. A first ingredient or component is suitably the biodegradable polymer, or polymers, or bioplastic polymer or a biodegradable resin or resin composition. If a filler is present, then preferably this is comprised in the first component.

A second component may be what is known in the art as a Master Batch (MB). This may comprise a colourant and/or a lubricant and/or plasticizer and/or one or more agents that may modulate or change the thermoplastic flow or properties of the material.

The record may also comprise a mould release agent, for example to assist in release of the pressed material (a record) from the pressing mould.

During the phonograph or record production process, the two components are usually mixed first. Suitably, each component is in the form of a pellet or pellets, although they can be in the form of a powder. The second component, the master batch, can sometimes be a liquid.

Suitably, the two components are mixed, for example in a suitable mixer. If both components are in the form of pellets, then the mixer may be a twin screw or screw mixer. The mixer may be able to heat the mixed components (or the precursor) and so suitably heat the material, so that it becomes flowable, or thermoplastic. It can then form the “biscuit” or puck, which can then be subjected to heat and/or pressure, in order to form the final phonograph or record.

The phonograph may, if necessary, comprise one or more anti-static agents. This may comprise carbon black. However, with certain polymers (such as PLA) these may be, or reduce, antistatic in which case no additional antistatic agent may be necessary. Alternatively, it may comprise magnesium silicate, or for example talc, suitably in particles with a (mean) diameter of less than 5, or less than 3, microns.

The records of the invention may have good anti-static properties. This is thought to be due to either the addition of magnesium silicate, such as talc, or the (biodegradable) polymers used. The usual measurement for antistatic is by the equation Q(charge) = Cm(capacitance) x V(voltage), the capacitance usually set at the measuring distance of 100mm.

Suitably the first component (with or without filler) will comprise 80-99%, such as from 85-96%, such as from 90-95% of the record. The second (e.g., master batch) component will usually provide the remainder, and this may vary from 10-2%, such as from 7-3%, preferably around 5%. The records of the invention have also been found to have good or wide frequency range, or the ability to play audio at a wide frequency range. This can range from treble to bass.

The composition of the record allows it to be tunable, or adaptable, to certain conditions for processes. For example, the composition may allow the record to be tuned or adapted to a specific manufacturing machine or press.

The record material (e.g. bioplastic resin or record precursor) is suitably melted. It may then be extruded to form the puck or biscuit. The puck or biscuit may then be placed between a plate and a stamper. The biscuit is then compressed, or pressed, at high pressure. A blade may be used to sheer off the excess material, thus producing a record. One can use record manufacturing machines (such as the machines of Green Vinyl Records).

The record may contain one or more antistatic agent(s). This may be provided in the second component, and thus the master batch may be antistatic, or have antistatic properties. Usually, static or electricity is undesirable for records, as this can attract dust and other particulates, which can impair acoustic properties. The master batch or the record may comprise one or more antistatic additives, to create an antistatic (second) component.

Antistatics (or master batches) may comprise one or more molecules that may be able to migrate to the surface. The or each antistatic agent may be able to draw or attract (e.g., airborne) water or water molecules, for example onto the surface of the record. This may deplete or reduce the electric charge.

The record may comprise one or more lubricants and or glidant(s). These may improve the flow and or processing of the pellets and/or powders, for example a powder or pellet blend. Suitable compounds include magnesium stearate, colloidal silica and/or talc. The phonograph may therefore have a relatively low static charge. It may comprise one or more compostable biopolymers, including polylactic acid (PLA), polyhydroxyalkanoate (PHA), and optionally in addition related biopolymers. Additional agents include a (e.g., non-toxic) mould release, one or more colorings or coloring agents, and optionally one or more natural mineral filler or filler materials. The temperature range for heating and/or pressing may be from 120-150°C.

Suitably, the biodegradable polymer is based on, or may comprise the widely available commercial biopolymer GS2189 (or equivalent). This may optionally contain a filler, for example chalk (as a known filler) and/or (preferably) talc. Suitably, this biopolymer will replace PVC, PBA, and /or a plasticizer in a traditional vinyl composition. Suitably the biopolymer will comprise up to 50, up to 60, or up to 70% of the composition. Suitably it will be derived from a renewable biomass, typically from fermented plant starch like corn, casava, sugar beet (pulp) or cane and/or maize.

The GS2189, or biopolymer, may comprise or be the first component of the record. It may comprise talc, or other fine particles of a filler. This is suitably under 5microns. It has been found that this can provide a record which has better sound quality, and a lower level of surface noise. It is thought that the talc might give stability and may help with the bonding of other particles.

The second component may be the master batch. This may include a carbon black stabilizer(s) and/or filler(s). Suitably, this second component is entirely biodegradable.

The biodegradable or bioplastic polymer is preferably made by the following method. First, a mixture is produced containing 1-75 weight % of starch or a starch derivative, 10-85 weight % of a polyester and 0.01-7% of an epoxide group-containing polymer.

The mixture can be homogenised, for example by supplying thermal or mechanical energy. The water content of the mixture can then be adjusted, suitably so that it has a water content of less than 12, 10 or 5 weight %, based on the total weight composition of the mixture.

The epoxide group-containing polymer (as an additive to production of the polymer materials containing starch) may increase in tensile strength, for example, have a DIN53455 of 5-60, in particular 10-40, N/mm ² . It may have an elongation at break in accordance with DIN53455 of 100 to 1 ,000%, in particular from 200 to 800%.

The starch may comprise (native) potato starch, tapioca starch, rice starch and/or maze starch. Preferably, the biopolymer will contain 5% by weight, in particular 10- 75% by weight, preferably 15-70% by weight, more preferably 25-55% by weight and most preferably 34-51 % by weight of the starch and/or starch derivative.

The polyester suitably comprises an aliphatic-aromatic co-polyester, an aliphatic polyester, aromatic polyester, PHA, PLA, PHB and/or PHBB.

Suitable polyesters can be biodegradable in accordance with EN13432 and/or have a glass transition temperature (Tg) of less than 0°C, in particular less than -4°C, more preferably less than -10°C. The polyesters are preferably thermoplastic.

Preferably, a co-polyester, in particular a random co-polyester, may be used as the aliphatic-aromatic polyester, for example based on at least adipic acid. Preferably this is a co-polyester or random co-polyester, based on at least 1 , 4-butanediol, adipic acid and/or terephthalic acid.

Suitable polyesters are aliphatic esters such as polyhydroxyvalerate, polyhydroxybutyrate-hydroxyvalerate and polycaprolactone.

Other suitable aliphatic polyesters are based on succinate, such as polybutylene succinate (PDS), polybutylene succinate adipate (PDSA) and polyethylene succinate (PES). The polyester content is suitably from 20-85, such as 30-80, preferably 40-80% by weight.

The polymer material may also suitably contain an epoxide group containing polymer, for example with a molecular weight of 1 ,000 and 2,500, in particular 3,000 to 10,000.

Suitable preferred epoxide group containing polymers are disclosed in EP-A-2203511 , the contents of which are hereby incorporated by reference. Suitable epoxide group containing polymers can be based on styrene, ethylene, acrylic ester and/or methacrylic ester. The epoxide group containing polymer may be present at from 0.01 to 5, such as 0.05 to 3, more preferably 0.1 to 2 weight %.

Suitably the water content is less than 10 weight %, such as 7 weight %, more preferably less than 5%, and ideally less than 1 weight %.

Other suitable polymers in include P-BAT (polybutylene terephthalate).

The polymer material may have thermoplastic properties, and thus can be thermoplastically processed. The polymer composition may contain less than 10 weight % or low molecular structures, the starch portion of the polymer material is at least 34 weight %, and a film produced by the polymer material as an elongation at break in accordance with DIN53455 of at least 200%.

Suitably the polymer material does not contain any glycerol and/or sorbitol.

Preferably the starch proportion of the polymer material is at least 35%, preferably at least 39%.

The polymer material can contain a polyester as another constituent, preferably in an amount less than 75%, suitably less than 55% by weight.

The invention aims to provide a more efficient process for pressing or manufacturing a record. Existing manufacture consume a considerable amount of energy in the manufacturing or pressing process.

The process usually starts with the original audio music that is to be reproduced on a record. Using a master lacquer machine (such as a lathe or a cut lacquer) one creates a master lacquer disc. This disc (usually aluminium with nitrocellulose lacquer) is then electroplated, for example with silver and/or nickel. This results in a metal stamper, which is a negative image of the record to be created. There are usually two stampers, one for the A side and one for the B side of the record. The stamper is used to create the record. The material for the record is usually made of pellets. These are heated, usually by steam, so that they melt, or partially melt. In prior art systems, the pellets would have been heated to about 300-350°C. This creates a puck or biscuit. This molten material is then squeezed at high pressure between two plates, or metal stampers, that are normally pre-heated with steam. The pressing takes about 30 seconds, and during this time the stampers are heated with steam (this requires a boiler room to generate all the steam). The stampers are then cooled, using cold water, in order to release the pressed record from between the stampers. The edge or flashing is then trimmed (as there will be a rough edge) to produce the record. The off-cuts or trimmings are usually recycled.

In the invention the temperature needed to melt the material (to form the puck or biscuit) can be a little higher, but the pressing time and heat during the pressing phases is lower, so the processing time is quicker. Plus, the time for cooling maybe quicker (or less), too. This means that in the invention the entire process for manufacturing or creating the record is considerably quicker.

Suitably the record of the invention has (substantially) no static or is static free. Static electricity usually results from charge (both positive and/or negative) on the surface of the record. The amount of static electricity can be measured, for example using a coulombmeter (often using the equation Q=CmV). Suitably, the static level will be less than 100, preferably less than 70, and optimally less than 50 nanocoulombs (nC).

The (amount of) static can also be measured in terms of kilovolts (kV). Suitably, this is below 1.0, such as 0.5, optimally less than 0.2 kV. Suitably, the voltage (per distance) (kV/cm) is less than 4, optimally less than 2. In these measurements, 3kV/cm can be equivalent to 1 pC/m ² .

Suitably, the record comprises or consists of a material that has a lower melting point than PVC. Thus, prior art records are made from material with a melting point of about 140°C. Suitably, in the invention, the record is made from a material that has a melting point of at least 160°C, preferably 180°C, optimally at least 200°C.

Preferably, the record is made of a material which does not warp, or does not distort, or does not bend. Suitably, it will not twist or curve, or come (or bend) out of shape. Suitably, the record will have flexural stiffness (Mpa) of at least 100, preferably at least 400, optimally at least 800. Suitably, the record will be made of material that has a tensile strength (Mpa) of at least 24, such as least 30, preferably at least 35, and optimally at least 40.

Suitably, the record will be made of a material which allows the record to be packaged (such as placed in a sleeve) within at least 2, such at least 3, preferably at least 4 hours after pressing or manufacture. By this time, the record of the invention will be fully cooled and set.

The invention thus additionally relates to a method of packaging a (e.g. newly pressed) record, the method comprising a) pressing a record in a mould; and b) packaging the record within 2, 3, or 4 hours (such as within 10, 15 or 20 hours) of pressing the record (resulting from step a).

The invention also relates to a process or method for producing (or making or manufacturing) a record, suitably comprising pressing (or compressing) a material in a mould. The process suitably comprises: a) heating the material (such as to form a “puck” or “biscuit”) so that it (at least partially) melts; b) optionally, pre-heating the mould; c) heating and pressing the (e.g. molten) material in the mould under pressure; d) cooling the material and/or mould; e) releasing the (pressed) material, such as from the mould, to thereby form a record; f) optionally, repeating stage (a), such as with fresh or new material (to form another record)

Suitably, c) may comprise two pressing steps. The first pressing step (c1 ) may be under low (or lower) pressure. The second pressing step (c2) may be under high (or higher) pressure. In prior art methods c2 is present. In the invention c2 may be omitted, Thus there may be only one heating step, usually under low pressure. This is because the material used for the record in the invention is softer, more viscous, and thus requires less pressure to push/compress the material into the mould and so form the grooves.

There are a number of parameters involved in the above process.

If the mould is pre-heated (such as in b) then the length of this pre-heating is for a time (bf) in seconds. Suitably, bt is one or about one second long, suitably between 0.5 and 1.5 seconds.

Length of time of heating the mould and/or material during pressing (for example, while the puck is in the press or mould, suitably under low pressure, c1t, in seconds. Preferably, c1t, is 6-11 seconds, such as 7-10 seconds, optimally 7 or 8 to 9 seconds.

Length of time for heating the mould and/or material (again, usually with the puck in the press or mould, suitably under high pressure, c2t, in seconds). Preferably c2t is less than 1 .0 or 0.5 seconds, and optimally zero (0).

Length of time spent cooling the mould and/or material (usually the material will already have been pressed in the mould, and preferably at high pressure; et, in seconds), Preferably, dt, is 6-11 seconds, such as 7-10 seconds, optimally 8-9 seconds.

Time between heating the mould and/or the material in the press, suitably under pressure (thus in between steps c) and d). This is often called a “dwell” time. This is suitably less than 1.0 or 0.5 seconds, or zero (0). Thus, there may be no gap or wait time.

The process is usually repeated to produce a second record, as in step f. Thus, after the final step of releasing the pressed material, the process may be repeated, starting (again) with step a, with fresh/new material (and so to produce second or further) record. The time therefore between e and a, which is often a cooling cycle, for example allowing the water to remain or sit in the mould, before being ejected, or pushed out, such as with steam (to heat in n step b), fat, in seconds (also called a dwell time). Preferably, fat or Interval 1 , or dwell 1 is 0, or there is no gap, or wait time). Preferably, the total heating time (in step c, c1t, is from 5, 6 or 7 seconds to 8, 9 or 10 seconds), optimally about 6-9 or about 7-8 seconds. Suitably the cooling time, dt, is from 6, 7 or 8 seconds to 15, 12, 10, 9 or 8 seconds, optimally from about 10 — 16 or about 11-15 seconds. Suitably steps c and d last from 14, 15 or 16 seconds to 17, 18 or 19 seconds.

The entire record manufacturing process may only take 20-25 seconds per record (the prior art processes could be 30-35secs).

The heating in steps a, b and/or c maybe (solely) via electric heaters (rather than using steam). This can avoid the need for boilers (to generate steam).

The overall process is thus much shorter and may be as much as 30% more efficient than prior art processes. It may thus allow more records to be produced in a shorter period of time, thus reducing costs.

The invention will now be described by reference to the following examples, which are intended to be purely illustrative, and are not intended to be limiting.

Examples 1A and B

A master batch (MB) from Colloids in the form of pellets was mixed with pelleted GS2189 obtained from Biotec in Emmerich am Main in Germany.

In a second set just GS 2189 pellets were used.

The pellets were mixed in a screw mixer on site, with green and white colourings.

The record thus had a polymer blend of PLA+PHA, with more PLA (more than 50%) than PHA (less than 50%).

The PLA was obtained by converting starch, extracted from a renewable plant resource (corn and potato) into glucose, which was then fermented into lactic acid and polymerized. Example 2

A master batch containing carbon black (obtained from Colloids) was mixed with GS2189. Both ingredients were pellets and were mixed as described in Example 1. The colourants were black and white.

Example 3

This used a master batch carbon from Colloids and GS2189, with a filler (chalk). The records produced had a slightly better sound quality.

Example 4

Example 1 was repeated, except there was no added chalk, and an additional mould release was included.

Example 5

This used the same composition as Example 2, but there was no chalk, instead, talc was used as the filler, particle size 5 microns.

Examples 6A and B

This repeated Example 2, using a homogeneous mix, with small pellets.

Secondly pellets, with black, using a polymer blend of PLA+PHA, with more PLA (60%) than PHA (less than 40%) were mixed in a screw mixer.

Source: master batch (MB) from Colloids, UK (DP 990) and pelleted GS2189 obtained from Biotec in Emmerich am Main in Germany.

Example 7 - Tests & Validation This involved comparative testing of: g) bioplastic LP of the invention (c.f. Examples 1 to 6); and h) Conventional P\/C LP

1. Physical & Mechanical Properties

1 . Strength - ductile + tensile - Hardness

2. Degradation - Exposure tests - 50 degrees + 85 humidity

3. Durability - friction and wear tests - diamond tip

4. Scratch resistance

5. Antistatic properties

2. Sustainability

1. Non-toxicity - REACH regulations cover safety in chemicals - ISO standards etc from Biome and Colloids.

3. Sound - advice from acoustics team -

1. Noise floor

2. Frequency response

The testing plan included comparative physical and sounds testing (tensile & ductile strength; degradation of materials, frequency response etc e.g., from extended usage, light, moisture; noise floor (DB); scratch resistance; anti-static properties; environmental performance/minimum impacts).

Diamond Black was used as the pressing plant.

Summary of Testing Results

The physical and sound properties of novel environmentally friendly bioplastic LPs were tested (with the National Physical Laboratory, NPL). The testing involved:

- Accelerated ageing

- Mechanical testing

- Scratch resistance

- Acoustic performance Accelerated Ageing Tests used a standard PVC LP, and two bioplastic LP from adjusted mixes, with each specimen aged in an environmental oven for 1 month at a temperature of 50 °C and Humidity of 50% rh.

Mechanical Testing used Flexure Testing, which conformed to ISO 178:2019 (Plastics - Determination of flexural properties) for Specimens of 10 x 60 mm Span with a Load of 250 N at a displacement rate of 1 mm/min, using both standard and Accelerated Aged samples for both the standard PVC LP, and the two bioplastic LP from adjusted mixes.

The conclusions of these tests were:

• Flexure modulus of bioplastics is approx. 10% lower than PVC.

• Modulus of both PVC and Bioplastics decreased after ageing by approx. 15%

• PVC and bioplastics behaved in ductile manner up to high strains.

Scratch Resistance Tests using all samples were scratched perpendicularly across the audio tracks using a 5um radius diamond tip. The NPL built scratch tester used 1 mm constant load traces (50/100/150/200mN), with 4mm long ramped load 10- 200mN, to observe the damage with load and compare unaged and environmentally aged samples.

The conclusions of these tests were:

• The two bioplastic samples (1 BAC & 22) behave similarly, with less effect of aging than for PVC.

• PVC seems harder, although it seems more affected by ageing.

• Track breakage occurs with 1 BAC, 22 at a much lower load than for PVC as indicated in the loading data.

Example 8

MBP9D0329 - BLACK

Processing Started with 25kg trial using MBP9D0329. Started processing the polymer at 160°C, but the extruded puck had flashing and overfilled due to GS2189 being so soft at this temperature. Temperatures were then reduced to 120°C, which produced a slightly firmer puck with less overfill. The final temperature settings used for MBP9D0329; Feeder-^ Nozzle = 130°C - 120°C - 120°C.

The dimensions around the edge of the record were thinner than usually achieved with PVC, causing some early issues with the edging of the records, leaving a jagged edge. This improved with optimization of the machine settings.

Colour

Table states approximate levels of MBX used in first MBP9D0285 Black Trial.

Initially the black masterbatch was weighed out incorrectly and produced a grey marbled-effect record. This was rectified to include the intended amount of masterbatch, and the record became a deeper black in colour but still with a noticeable marbled effect.

The darkest colour was achieved with MBP9D0285 with the least amount of marbling (Run 5). It was noted that with increased carbon black content, the pucks became firmer. Sound

The grey marbled record was listened to first and achieved a good sound. The sound quality decreased with the increased concentration of carbon black in the final product.

MBP6D0329 - GREEN

Processing

The machine settings had to be changed again slightly for the green masterbatch. The machine settings are below.

To run the green at 3% and 4% the temperatures were as follows: feed nozzle = 140°C - 140°C - 120°C.

When 4% antimicrobial MBP1 L0227 and MBP6D0329 was pressed for the last batch, the temp settings were altered to the following for best results: feed nozzle = 130°C - 140°C - 130°C.

Colour The MBP6D0329 samples were run in batches of 5kg and MBX concentrations for this are exact.

The records produced from Run 1 (3% MBP6D0329) were very marbled and so the concentration of masterbatch was increased for the next batch of records.

The marble effect was still very prominent with the increased let down rate, but the overall colour achieved was slightly darker.

CBP6D0335 compound was trialled, this did slightly reduce the marbling effect but still did not produce one solid base colour. This may be due to contamination of the press from the previous samples. A larger sample size of the compound is required to test the colour consistency.

The last trial used 4% MBP6D0329 with 4% of the antimicrobial masterbatch, the visual result of this was similar to Run 2 and Run 4, although there was perhaps more off-white colour present in the marbling.

Sound

Records produced from Run 2 and Run 5 were tested for sound. The green records had a noticeable improvement in sound when compared to the black records. There was no obvious difference in sound between samples from Run 2 and Run 5, leading to the conclusion that the antimicrobial additive does not affect the sound.

Surface Resistivity

The samples were tested by Colloids Knowsley branch using a SR110 hand-held meter to measure surface resistance. A Keithly SR Meter was used to determine surface resistivity. Results are shown in the table below.

The technician testing the sample determined that all 3 samples were insulative with no discernible difference between the surface resistance or the surface resistivity results.

Scratch Resistance

Scratch resistance test was performed using a TQC hardness Pen (SP0015).

This was performed at increasing pressures; 6, 12, 18, 24 and 30N.

Permanent anti-static effect can be created throughout the record to prevent dust settling on the surface.

Supplementary Test Pressing Trials

Subsequently, further test pressing trials were undertaken at the pressing plants Deep Grooves (Netherlands) and Press on Vinyl (Middlesbrough) with sound quality and manufacturing efficiency improvements being achieved to confirm the consistency of the materials combinations, product quality and manufacturing processes for commercial production.

Example 9

3 different variations of the PLA based material of the invention were tested (c.f. Examples 1 to 6). Approximately 2500 records were pressed. They were compared with prior art PVC records.

The objective of these tests was to observe how the PLA based record material reacted to the pressing process and to determine the settings and parameters at which this material worked best.

A summary of the progress regarding the sound and mechanical characteristics of the record material • It was possible to make a good physical record with the PLA based material, that reproduced sound accurately in terms of the dynamic frequency range being a true and uncompromised reflection of the source audio.

• Whilst there were no limitations with regard to frequency range; there was some a low-level background noise.

• The current level of background was equivalent to that of a standard ‘picture disc’. It did not distract from the music and was a viable, commercial product.

• The records produced were flat and hard-wearing, comparable and better in this regard to PVC.

• The material gave improved sound and mechanical characteristics (meaning how the material responds mechanically through a typical record press machine).

A summary of the observations of the manufacturing process using the new record material

• It required a higher average temperature (than PVC), in the extruder to produce a flow rate that will enable an evenly formed ‘puck’.

• The rate at which the extruded material cooled, was sometimes higher;

• However, once the puck was in the press itself; it required significantly less heat, pressure and energy to form a viable record. On average about a third less heating and cooling than PVC.

Further observations of note are that records produced with this material: a) were static free. b) were less prone to warping in both the pressing process and after cooling. c) could be safely packaged within 2-4 hours after pressing, without fear of post-press warping as the record had fully cooled and set. Overview of the pressing process as it relates to the common variables and parameters shared across different record pressing machines.

• All the record presses utilised a combination of steam and cold water injected moulds, under pressure to produce records.

• All pressing processes started with the extrusion of a ‘puck’, which was then placed in the press where the hot, semi-molten puck was compressed between two ‘stampers’ (negative imprints of the A and B side of a record).

• In the press, the stampers sat on moulds which were injected with steam which helped to enable the spread of the material in to the grooves whilst being compressed, followed by an injection of cold water which helped to firm up the pressed record, so that it could then be removed from the press once opened.

• The record was then removed from the press, and the excess trimmed, before being left to cool for typically a minimum of 12-24 hours for PVC, but only 2-4 hours for the new PLA-derived material.

• The range of temperatures typically used when pressing with PVC was between 125-140C in the extruder and 10 bars of steam pressure (approx. 115C) in the press itself, followed by an injection of water to the mould at a temperature range of 20-24C at 8-10 bar pressure.

• For PVC, the range of hydraulic ‘Ram’ pressure required (that is to say, the pressure in the press when the two moulds are compressed together with the puck/material in between); typically ranged between 1900 psi (131 bar) to 2400 psi (165 bar).

Summary of observed differences in required temperatures and pressure required for PLA material compared to PVC.

In general, within the extruder, more heat and screw speed was needed with the PLA material in order to get the material flowing smoothly.

PVC averaged a required extruder temperature of 130C and a screw speed of 35rpm The PLA material required an initial temperature of 145 and a screw speed of 50rpm. Once the PLA material was flowing and continuous viable pucks were being made; it was possible to reduce the extruder temperature and screw speed to around 140C and 45rpm.

In the press, the PLA material required significantly less heat and cooling when compared to PVC.

Whereas PVC averaged between 10-14 seconds heat cycle (at 10 bar pressure) and a similar 11-15 second cooling cycle (at 20-24c), the PLA material only required 7-8 seconds heat and 8-9 seconds cooling.

Whilst there were some minor mechanical differences between press machines from different manufacturers, all cycled steam and cold water. The common process shared by all models and makes of presses are listed below; this allowed the capture of common data when using the PLA material on any press.

The common features were:

Extruder:

• 3 heating zones, plus a ‘die-zone’ (nozzle); each with a set point temperature.

• RPM speed of the screw (inside the extruder barrel); which drives the material as it melts.

Press:

• A minimum of two heating ‘phases’:

• 1 . Pre-heat cycle - prior to the material being in the press; and

• 2. A heat cycle when the material is in the press under pressure.

• A cooling cycle that starts whilst the material is in the press and under pressure.

Some different models of presses may have these heat and cooling cycles subdivided and may also include ‘dwell’ periods between each cycle. The data given below is based on the observed settings using three different models of presses, namely:

1. Phoenix Alpha AD12

2. Viryl Technologies WarmTone; and

3. M-Tech Allegro 2.

Summary of parameters for best results when using PLA based material (when compared to PVC):