Recording disc

Abstract

The present invention relates to a phonograph record (AKA a vinyl record, or vinyl, or an LP) which is biodegradable, compostable and / or comprises a bioplastic. The record has a resin or polymer composition (or a biodegradable plastic) primarily made of polylactic acid (PLA) with some polybutylene adipate terephthalate (PBAT) which is plant based or derived, for example from raw materials. This can replace the PVC used in prior art records, making the record cheaper and easier to manufacture and reducing the environmental impact. The record can meet the EU compostable standard EN13432.

Description

[0001] RECORDING DISC FIELD OF THE INVENTIONThe present invention relates to novel polymer and / or resin compositions, and theiruse in vinyl records (or phonographs). In particular, the invention relates to new phonograph compositions and processes for making them.Phonograph records or discs are media that have been used for the reproduction ofsound 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 recordingdiscs. The phonograph record was used widely for music reproduction throughout the 20thCentury, but in the 1980’s 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 continued to be manufactured and sold on a smaller scale during the 1990’sand early 2000’s but have recently enjoyed a significant resurgence. However, interms of chemical and physical compositions, little has changed over the decades andmodern vinyl records are still made with PVC. Although vinyl records are generallystrong and do not break easily, they do scratch and acquire a static charge, which thenattracts dust, that can be difficult to remove completely. Dust and scratches can causeaudio clicks and therefore result in a reduction in acoustic quality during use. They canaccelerate wear and tear and ageing over the life of the record. In some cases, damage can cause the needle to skip over a series of grooves.There has been much controversy, since the invention of the CD, as to the relativequality of CD sound quality vs LP sound quality, often known as the “analogue versusdigital!” 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 theinherent flaws associated with vinyl records, such as portability, records still haveenthusiastic support and, in many countries, there has been a growing niche marketfor records, especially with audiophiles, collectors and DJs.Despite their renaissance, though, little product development has occurred in recentyears, 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 examplePVC, in view of environmental disadvantages. The present invention aims to mitigate, alleviate, or solve a number of the disadvantages and problems associated with prior vinyl or PVC records.SUMMARY OF THE INVENTIONAccording to a first aspect of the invention, there is provided a phonograph record (or“record” for short) comprising one or more of the following: -a) A plant based polymer;b) Natural minerals (such as to reduce flex);c) An impact modifier;d) A colourant with no or low toxicity;e) A bioplastic polymer;f) Calcium carbonate (CaCO3), such as (or other) filler;g) Polylactic acid (PLA), suitably at an amount of from 55% by weight (or 70 mole%); h) A poly alkylene (e.g. adipate) terephthalate polymer, such as polybutyleneadipate terephthalate (PBAT); and / ori) Both PLA and PBAT.Phonographs (or records)When referring to records, or phonographs (the terms are used interchangeablyherein) we mean a phonograph record (or format), usually a carrier or storage medium of or 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, in prior art records). The phonograph may thus comprise a data carrier or record, and may store or carryinformation, such as sound, in particular in the form of analogue sound (and hence notan optical and / or magnetic format). Usually, the phonograph (or record) will be aplayable audio record. It may be a flat or planar disc (and generally circular). It willgenerally be inscribed with, or comprise, a modulated and / or (generally) spiral groove.The record may carry an image or embody other special features (these are often called picture discs or specials). 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. BiovinylAt its broadest, therefore, the invention relates to a biovinyl record or a biovinylphonograph (or LP). Preferably the phonograph of the invention comprises one ormore biodegradable (or compostable) ingredients or components, bioplastics and / orbio-plastic polymer(s). Said polymer may be present at from 50, 60 or 70% and / or maybe up to 65, 70 or 85%, such as from 55 to 65 %. The polymer may be (sourced orderived from) from sugar cane, such as sugar beet, wheat, corn and / or cassava. The phonograph (record) is preferably biodegradable and / or compostable (such asunder industrial composting conditions). It may (be able to) decay 0r compost (e.g. ina natural environment) over time. PolymersThe phonograph (or record) can comprise PLA (polylactic acid) and / or a poly alkylene(e.g. adipate) terephthalate, such as PBAT (poly butylene adipate terephthalate). Itmay comprise other polymers such as poly hydroxy alkanoate (PHA, or a member ofthe PHA polymer family) and / or (e.g. glycol-modified) polyethylene terephthalate, PETor PET-G). The present invention thus provides a phonograph (record) 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, orsubstituted, suitably 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 byPLA (polylactic acid), optionally with PLA and / or PBAT. Therefore, the phonographrecord can comprise a biodegradable and / or compostable polymer, such as PLA (orPHA), but may contain (substantially) no PVC and / or PVA.PLA This polymer may be the main or largest component or ingredient in the record. It may the major polymer component. Suitably the PLA polymer is present at from 45, 50, 55or 65% and / or may be up to 75, 80 or 85 or 95%, such as from 50 or 55 up to 65, 70or 80% (by weight).PBATThis is suitably a biodegradable (e.g. random) (co)-polymer, especially a copolyesterof adipic acid, 1,4-butanediol and terephthalic acid. However, it may comprise a polyalkylene (e.g. adipate) terephthalate polymer, such as polybutylene adipate terephthalate (PBAT). Suitably the butylene and / or terephthalate component is from 23, 25 or 30% to 35, 38 or 40%.This polymer may be the second largest component or ingredient in the record. It maythe minor polymer component (thus PLA is usually present at a larger amount thanPBAT). Suitably the PBAT is present at from 15 or 20% and / or up to 30 or 35 %, suchas from 23 to 28 %.Suitably the ratio of PLA:PBAT is 2:1 to 4:1, such as 2.5:1 to 3.5:1, optimally about FillersThe phonograph (record) can comprise a filler, for example a reinforcing filler, or asubstance that can allow or assist the formation of small crystals. The filler may becrystalline and / or birefringent.The preferred filler comprises calcium carbonate (CaCO3), but it maybe chalk and / ortalc. The filler (e.g. calcium carbonate and / or talc) may be present at from 10 to 30%,such as from 15 to 20 or 25%, optimally from 15 or 18% to 20 or 23%. However, inother embodiments the filler (suitably calcium carbonate and / or talc) may be presentat lesser amounts, such as from 2 to 16%, suitably from 5 to 11%, optimally from 7 to10%.The phonograph (record) can (also) comprise magnesium silicate and / or talc.Preferably the magnesium silicate comprises Mg3(SiO4)10(OH)2.. It or the talc may bepresent at from 2 to 16%, such as from 4 to 11%, optimally from 6 to 9%.The filler may act as a stabilizer and / or may assist in particle bonding. The particles(e.g. magnesium silicate, calcium carbonate and / or talc) particles may be (on average)less than 18, 12 or 10µm. Preferably they are more than 5µm or 3µm (for example, indiameter). Most particles will suitably be less than 10 µm and / or at least 1 µm or500nm. The phonograph record in some embodiments may contains a filler, other than chalk, that suitably comprises talc, magnesium silicate, or preferably magnesium silicate hydrate (or hydrated magnesium silicate). It is thought that the talc or magnesium silicate can provide stability and / or may help with the bonding of other particles. It may also provide an antistatic effect. BiodegradabilityThe biodegradable, bio-plastic or compostable polymer and / or resin preferably meetsor 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 rawmaterial (preferably natural materials rather than synthetic). Preferably it comprisescellulose, such as plant cellulose and / or sucrose. Suitably, the polymer and / or resin isbased 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 suitablefor extrusion. Said polymer may be present at from 75 to 95 %, such as from 80 to 85%. Acoustics The records of the invention have good or wide frequency range, or the ability to play audio at a wide frequency range. This can range from treble to bass.Anti-static (s)Suitably the polymer(s) used have antistatic properties Thus the invention also relatesto a phonograph that is (e.g. inherently) antistatic and / or has antistatic properties (oromits a known or conventional antistatic agent). The phonograph may 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 agents 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. Antistatics 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 depleteor reduce the electric charge.ManufactureUsually 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). Thisis then heated and / or compressed. Usually the puck is heated first, up to a temperatureof about 180°C, and is then compressed under significant / high pressure. In the presentapplication, it is preferable that the (pressing) temperature is 5-10 or 20% lower thanprior art temperatures. For example, in the process of the invention, preferably thetemperature of the puck either before, or during, compression is from 150-160°C suchas from 135-145°C, preferably from 138-142°C. This can be achieved by using a resin and / or polymer composition that has a slightlylower softening point than in the prior art. Preferably there is thus a shorter pressingtime, for example there is a shorter interval of time between pressing consecutivepucks and / or the or each puck is pressed for a shorter period of time. This can varydepending on the pressing or manufacturing machine used (such as Press On Vinyl or DeepGrooves). Suitably the pressing is around 140°C to either form the puck, or to form the phonograph. 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 cycle. The puck may be present or in existence for a shorter time before being pressed. The reduced pressing temperature may thus save energy. Other componentsThe phonograph record may contain other ingredients and / or components. Preferablyit 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).StablizersHeat stabilizers can be included and preferably comprise a metal salt of a fatty acid.The metals can comprise tin and / or lead. Sometimes more than one (type of) stabilizeris included. Stabilizers can assist to make the polymer and / or resin composition morerobust. The stabilizer(s) will usually be in an amount up to 1.5%, such as from 1-2%. Plasticiser One can include a plasticizer. This may comprise a phthalate ester, for example (anepoxidized) soybean oil.ColourantsColorants can also be included. They 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, inwhich case one can have or create a marbled effect.Preferably the colourant is black, or green, or a marbling effect colorant. Suitablemixes of colorants may be black, grey marble, green or marbling green and / or white. Colorants may be up to 0.5%, for example from 0.25-0.75%. A black colourant may comprise a black (e.g. organic) dyestuff and / or carbon black (pigment). LubricantsSuitable lubricants can comprise (e.g. hard) waxes, for example either natural(montan) or synthetic (for example stearamide) type waxes. 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. Lubricants may be present at below 1%, for example between 0.5-1.5%. PlasticiserPlasticizers may be present at less than 1%, for example from 0.5-1.5%.The plasticizer may allow one to alter or change the viscosity of the polymer and / orresin that is to be used to make the phonograph. They may improve the flexibility ofthe final record and / or the flowability of the polymer resin. It may also be easier tomake or match microgrooves in the master disc during the pressing process. Mould release agent A further aspect of the invention comprises a phonograph record which comprises a mould release. CompostabilityThe phonograph record comprises 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 indeed 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 formulation may be as much as 69%.Preferably the polymer or composition is easy flowing. It may be suitable forprocessing by (injection) moulding. It may thus produce a final item (such as a record)that is biodegradable. Preferably the composition can be converted by sheet filmextrusion and / or is extrudable. The absence of a plasticiser, in some embodiments,may allow the material to be more easily processed. Density Preferably the biopolymer or composition will have a density of from 1.3-1.4, such as around 1.35g / cm2. Preferably the bulk density will be from 800-900, such as from 850- 870kg / m3. The moisture content is preferably below 0.2wt%.Preferably the biopolymer or composition is suitable for injection moulding. It may alsobe suitable for sheet film extrusion, such as thermoforming and / or blown film extrusion.Preferably the composition, and therefore the record, is recyclable. Preferably it canbe coloured, for example with a master batch.Suitably the phonograph is compostable, recyclable, and / or can be incinerated.Suitably it complies with the EN13432 standard. Other parametersSuitably, if the biodegradable polymer(s) were made into a blown film, they will havetensile strength of 30-40, such as from 53-35, MPa. It may have a Young’s modulusof from 2-3, such as 2.3-2.5 GPa. They may have a Flexural modulus of from 2-3, suchas from 2.5-2.6 GPa.They may have an Oxygen permeability of 45-55, such as from 48-52, cm3(M2d bar).Preferably, in terms of thermal properties, it has a softening temperature of from 50-70°C, such as from 55-60°C.Suitable source (s)Preferably the bioplastic is derived, or based on, sugar and / or a starch. It maypreferably comprise sucrose. Preferably the composition comprises BIOPLASTGS2189, made by Biotec in Emmerich am Rhein, Germany, or equivalent material. A further aspect of the invention relates to a phonograph record which does not containchalk, in other words it is chalk-free or chalk is omitted. The chalk can be replaced orsubstituted by talc and / or magnesium silicate, as described earlier.ManufactureUsually during the production process, the (resin or) polymer (composition) will bemixed with a second polymer and / or resin composition (often called a master batch). Thus, in a preferred embodiment, the BIOPLAST GS2189 (or equivalent) is mixed with the master batch, to create the composition to be used to form 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 12µm or less than 5µm, preferably or less than 3µm. 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 or green,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 is a sugar-based biopolymer. This cancomprise up to 60% of the composition that is to be heated and / or pressed into a record.Suitably the record will be comprised of heated and / or compressed (crushed) pellets.Suitably there will be 90% biodegradation within 180 days. This parameter is usuallymeasured in the presence of microorganisms (bacteria and fungi) under industrialcomposting 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, byusing a x2mm2 mesh, for example at temperatures of around 40°C.Polymer components 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 is what is known as a Master Batch (MB). This may comprise a colourant and / or a lubricant and / or plasticizer and / or one or more agents that modulate or change the thermoplastic flow or properties of the material. It 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 it 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 then be able to heat the mixed components, or the precursor, and 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. 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 asfrom 7-3%, preferably around 5%. 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 betuned or adapted to a specific manufacturing machine or press.The bioplastic resin or record precursor is suitably melted. It may then be extruded toform the puck or biscuit. The puck or biscuit may then be placed between a plate anda stamper. The biscuit is then compressed, or pressed, at high pressure. A blade may be used to sheer off the excess bioplastic or material, thus producing a record. The bioplastic resin or precursor may also be used in record manufacturing machines (such as the machines of Green Vinyl Records). Record sizeThe record may be 7 inch, 10 inch, or 12 inch (as imperial measurements are oftenused to denote size, usually diameter). 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. 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 120-150⁰C.Suitably, the biodegradable polymer is based on, or may comprise the widely availablecommercial biopolymer GS2189 (or equivalent). This may optionally contain a filler,for example chalk (as a known filler) and / or (preferably) talc. Suitably, this biopolymerwill replace PVC, PBA, and / or a plasticizer in a traditional vinyl composition. Suitablythe biopolymer will comprise up to 50, up to 60, or up to 70% of the composition. Suitably it will be derived from sugar beet and / or maize. Disc componentsThe GS2189, or biopolymer, may comprise or be the first component of the record. Itmay 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 alower level of surface noise. It is thought that the talc might give stability and / or mayhelp with the bonding of other particles.The second component may be the master batch. This may include carbon blackstabilizers and / or fillers. 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 hasa water content of less than 12, 10 or 5 weight %, based on the total weightcomposition of the mixture. The epoxide group-containing polymer (as an additive to production of the polymermaterials containing starch) may increase in tensile strength, for example, have aDIN53455 of 5-60, in particular 10-40, N / mm2. It may have an elongation at break inaccordance 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 / ormaze 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. Poly ester (optional)The polyester suitably comprises an aliphatic-aromatic co-polyester, an aliphaticpolyester, 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 0⁰C, in particular less than -4⁰C, more preferably less than -10⁰C. The polyesters are preferably thermoplastic.Preferably, a co-polyester, in particular a random co-polyester, may be used as thealiphatic-aromatic polyester, for example based on at least adipic acid. Preferably thisis 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 polybutylenesuccinate (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. Epoxide (optional)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, acrylicester 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 %. Water, etc. Suitably the water content is less than 10 weight %, such as less than 7 weight %, more preferably less than 5%, and ideally less than 1 weight %. The polymer material may have thermoplastic properties, and thus can be thermoplastically processed. Other suitable polymers in include P-BAT (polybutylene terephthalate). Starch (optional) The polymer composition may contain less than 10 weight % or low molecularstructures, the starch portion of the polymer material (if present) may be at least 34weight %, and a film produced by the polymer material as an elongation at break inaccordance with DIN53455 of at least 200%. If starch is present then suitably it will me amorphous and molecularly dispersed within the polymer (s), such as within the PLA. Suitably the polymer material does not contain any glycerol and / or sorbitol.Preferably the starch proportion of the polymer material, if present, is at least 35%,preferably at least 39%. The polymer material can contain a polyester (e.g. as another constituent) and, ifpresent, may preferably be in an amount less than 75%, suitably less than 55% byweight. Aspects of the invention The invention aims to provide a more efficient process for pressing or manufacturinga record. Existing manufactures consume a considerable amount of energy in themanufacturing 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 createsa master lacquer disc. This disc (usually aluminium with nitrocellulose lacquer) is thenelectroplated, 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 createthe 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 thistime the stampers are heated with steam (this requires a boiler room to generate allthe 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 maybequicker (or less), too. This means that in the invention the entire process formanufacturing 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 ofthe record. The amount of static electricity can be measured, for example using acoulombmeter (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 1µC / m2. 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 about140°C. Suitably, in the invention, the record is made from material that has a meltingpoint 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 opressing a record in a mould; ando packaging the record within 2, 3, or 4 hours (such as within 10, 15 or 20hours) 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: oheating the material (such as to form a “puck” or “biscuit”) so that it (atleast partially) melts; ooptionally, pre-heating the mould;o heating and pressing the (e.g. molten) material in the mould underpressure; ocooling the material and / or mould;e) releasing the (pressed) material, such as from the mould, to thereby forma record; f) optionally, repeating stage (a), such as with fresh or new material (toform 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 (orhigher) 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 becausethe 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. Preferred features and characteristics of one aspect of the invention are applicable to another aspect mutatis mutandis.The mould is pre-heated (such as in b) then the length of this pre-heating is for a time(bt) 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 inthe press or mould, suitably under high pressure, c2t, in seconds). Preferably c2t isless than 1.0 or 0.5 seconds, and optimally zero (0).Length of time spent cooling the mould and / or material (usually the material willalready have been pressed in the mould, and preferably at high pressure; et, inseconds), Preferably, dt, is 6-11 seconds, such as 7-10 seconds, optimally 8-9seconds. Time between heating the mould and / or the material in the press, suitably underpressure (thus in between steps c) and d). This is often called a “dwell” time. This issuitably 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 exampleallowing 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 orabout 11-15 seconds. Suitably steps c and d last from 14, 15 or 16 seconds to 17, 18or 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. Preferred features and / or characteristics of one aspect of the invention are applicable to another aspect mutatis mutandis. 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, B, & CA polymer master batch (MB) in the form of pellets (composition DP 990) was mixedwith pelleted GS2189 original (Example A, can be sourced from Biotec in Emmericham Main, Germany). The pellets were mixed in a screw mixer on site, with green andwhite colourings. A record was then pressed using the combined pelleted materialusing a WarmTone LP pressing machine.The process was then repeated with GS 2891 alternative (B) and GS 2819 BB (as C).The components for each of these 4 compositions (and the Material names) is listed in the Table 1 below (page 19).Examples 2A, B & CA master batch carbon black (DP 990) was mixed with the 3 GS2189 materials (similarto Example 1). Both materials were in the form pellets and were mixed as described.The colourants were black and white in the final records.Example 3 This used a master batch carbon (DP 990) and GS2189, with a filler (chalk). The records produced had a better sound quality.Examples 4A, B & CExample 1 was repeated, except there was no added chalk, and an additional mouldrelease was included at 1%.Examples 5A, B & CThis used the same composition as Example 2, but there was no chalk. Instead, talcwas used as the filler, with a particle size of 5 microns.Example 6 This repeated Example 2, using a homogeneous mix, with small pellets. Example 7 A polymer composition was manufactured with the following components. 19.1% Calcium Carbonate a maximum particle size of 16.48 microns 75.6% PLA and 24.4% PBAT Plus a minor amount of mineral oil or hydrocarbon wax. Particles were <10 microns (with a lower size of <1 micron). Test Pressing of the composition into records: 16.65% Calcium Carbonate and Talc (the carbon black will have been lost). 9% Calcium Carbonate and 7.65% TalcSo 84.35% of the material is polymer, 75.5% PLA and 24.5% PBATPlus a minor amount of mineral oil or hydrocarbon wax. The Calcium Carbonate and Talk (combined) had a maximum particle size of 12 microns. Particles were <10 microns (lower size <1 micron). Examples 8 to 11 Four polymer compositions were manufactured, each having the components as described in Table 1, namely: GS 2189 original GS 2189 alternative DP 990 test pressing GS 2189.BB (biobased)7% talc or Calcium Carbonate with a maximum particle size of 15 microns - particleswere mainly <10 microns (with a lower size of <1 micron). Each of the 4 compositions were then pelleted and then pressed into records, and tested as described in Example 14: 42 U egrio ag s Onn u s S mi(sofT N EID )3 s E e RlkO TivG a Cih a A Atd NICC(L B P P d a T E H R %0 %5 %5 AGI% H Y E2-6-2- S B W 51 55 513- 1 N OI: L T 1AIA N 9 E R 8 l L EGI1 a B T A A S 2inE S g T M D Giro 52 ) ice d n e ) nasaicn d acrblid a egrino a s egro m n g i(u sinsofm ni(s ) e 3 m TivlO u lcA Ait kd a Ca atL B P P d h a CC(%0 %5 % 2 5 -6-2% %0 5 - 1 55 513- 11- 7 et9 v se g 8it1 at / 0in2nr9 s e 9 s S GltP a Derp 62 ) ice d n e ) nasicaca n drb a egra lidgrino m n g s e i(u sino sofm ni(s ) e 3 m TivlkO u lcA AitatL B d a C P P d h a a CC(% % 0 5 % 1-65 -2- % %0 7 55 513- 11- 7 B B )d 9 e 8 s 1 a 2 b SoiGb( myrtareldcu l e d u a o d p v a n u mer,,t ,s A n L m,e a g)rere dete oPbrc,ta srtula v s a a aa stwee,detg e s s o s u h s m a o a s w a c a s wf(w d eictl) i en nonalceeb d a egr rino amrate m n gefi(u siog b e v se muivilcA Atd atL H P P d a % % % 0 5 1-65 -2- % 7 55 513- 1Examples 12 and 13A polymer composition was manufactured with the following components. Raw Material 18.1% Calcium Carbonate (from ash analysis). 14.9% Calcium Carbonate (as calculated by XRF) Average is 16.5 % Calcium Carbonate, so 83.5% of composition is organic / polymerbased from natural sources74.6% of this is PLA 25.4% of this is PBAT Plus a minor amount of mineral oil or hydrocarbon wax.The Calcium Carbonate filler examined had a maximum particle size of 16.48micronsMost of the particles were <10 microns (with a lower size of <1 micron). This wasthen used in a pressing, or pressed as is.Test Pressing of the composition into records.15.65% Calcium Carbonate and Talc (the carbon black will have been lost).8% Calcium Carbonate and 7.65% Talc (plus others).Hence about 84.35% of the material is polymer .75.5% of this is PLA 24.5% of this is PBAT Plus a minor amount of mineral oil or hydrocarbon wax.The Calcium Carbonate and Talk (combined) had a maximum particle size of 12microns. Most particles were <10 microns (and there is a lower size <1 micron).Example 14 - Tests & ValidationThis involved comparative testing of: ^bioplastic LP of the invention; and^ Conventional PVC LP (prior art)1. Physical & Mechanical Properties1. Strength – ductile + tensile - Hardness2. Degradation - Exposure tests – 50 degrees + 85 humidity3. Durability – friction and wear tests – diamond tip4. Scratch resistance5. Antistatic properties2. Sustainability1. Non-toxicity – REACH regulations cover safety in chemicals – ISOstandards etc from Biome and Colloids. 3. Sound – advice from acoustics team –1. Noise floor2. Frequency responseThe testing plan included comparative physical and sounds testing (tensile & ductilestrength; 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).Composition was as detailed in previous Examples. Optimal was Master batch DP990, Diamond Black as the pressing plant.Summary of Testing Results The physical and sound properties of novel environmentally friendly bioplastic LPswere tested (with the National Physical Laboratory, NPL). The testing involved:- Accelerated ageing- Mechanical testing- Scratch resistance- Acoustic performanceAccelerated Ageing Tests used a standard PVC LP, and two bioplastic LPs of theinvention from previous mixes as described, with each specimen aged in anenvironmental oven for 1 month at a temperature of 50 ⁰C 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 Loadof 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 LPs. 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 strainsScratch Resistance Tests using all samples were scratched perpendicularly acrossthe audio tracks using a 5um radius diamond tip. The NPL built scratch tester used 1mm 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 (1BAC & 22) behaved similarly, with less effect ofaging than compared with PVC^ PVC seemed a little harder, and seemed more affected by ageing^ Track breakage occurs with 1BAC, 22 at a much lower load than for PVCExample 15MBP9D0329 - BLACKProcessing This started with a 25kg trial using MBP9D0329. Started processing the polymer at160°C, but the extruded puck had flashing and overfilled due to GS2189 being softat this temperature. Temperatures were then reduced to 120°C, which produced aslightly firmer puck with less overfill. The final temperature settings used forMBP9D0329; Feeder→ Nozzle = 130°C - 120°C - 120°C.The dimensions around the edge of the record were thinner than usually achieved withPVC, causing some early issues with the edging of the records, leaving a jagged edge.This improved with optimization of the machine settings. Colour The Table above gives approximate levels of MBX used in first MBP9D0285 Black Trial. Initially the black masterbatch produced a grey marbled-effect record. This wasrectified 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. Thesound quality decreased with the increased concentration of carbon black in thefinal product.MBP6D0329 - GREENProcessing 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 MBP1L0227 and MBP6D0329 was pressed for the lastbatch, 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 thepress from the previous samples. A larger sample size of the compound is requiredto 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 perhapsmore 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. Therewas 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 determinesurface resistivity. Results are shown in the table below. All 3 samples were insulative with no discernible difference between the surfaceresistance 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 was created throughout the record to prevent dustsettling 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 producti

[0002] Examples 16 to 19A biocomposite material of the invention were tested. Approximately 2500 recordswere pressed. They were compared with prior art PVC records.The objective of these tests was to observe how the PLA based for record materialreacted to the pressing process and to determine the settings and parameters atwhich this material worked best.A summary of the progress regarding the sound and mechanical characteristics ofthe record materialo It was possible to make a good physical record with the PLA basedmaterial, that reproduced sound accurately in terms of the dynamicfrequency range being a true and uncompromised reflection of the source audio. oWhilst there were no limitations with regard to frequency range; therewas some a low-level background noise.o 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. oThe records produced were flat and hard-wearing, comparable andbetter in this regard to PVC.o 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 oIt required a higher average temperature (than PVC), in the extruder toproduce a flow rate that will enable an evenly formed ‘puck’.o The rate at which the extruded material cooled, was sometimes higher;o However, once the puck was in the press itself; it required significantlyless heat, pressure and energy to form a viable record. On average about a third less heating and cooling than PVC.o 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 andparameters shared across different record pressing machines.o All the record presses utilised a combination of steam and cold waterinjected moulds, under pressure to produce records.o All pressing processes started with the extrusion of a ‘puck’, which wasthen 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). oIn the press, the stampers sat on moulds which were injected withsteam which helped to enable the spread of the material in to thegrooves whilst being compressed, followed by an injection of cold water which helped to firm up the pressed record, so that it could thenbe removed from the press once opened. oThe 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.o The range of temperatures typically used when pressing with PVC wasbetween 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.o 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 between1900 psi (131 bar) to 2400 psi (165 bar). Summary of observed differences in required temperatures and pressure requiredfor PLA material compared to PVC.In general, within the extruder, more heat and screw speed was needed with thePLA material in order to get the material flowing smoothly.PVC averaged a required extruder temperature of 130C and a screw speed of 35rpmThe 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 140Cand 45rpm. In the press, the PLA material required significantly less heat and coolingwhen compared to PVC.Whereas PVC averaged between 10-14 seconds heat cycle (at 10 bar pressure) anda similar 11-15 second cooling cycle (at 20-24c), the PLA material only required 7-8seconds heat and 8-9 seconds cooling.Whilst there were some minor mechanical differences between press machines fromdifferent manufacturers, all cycled steam and cold water. The common processshared by all models and makes of presses are listed below; this allowed the captureof common data when using the PLA material on any press.The common features were: Extruder: o3 heating zones, plus a ‘die-zone’ (nozzle); each with a set pointtemperature.o RPM speed of the screw (inside the extruder barrel); which drives thematerial as it melts. Press: oA minimum of two heating ‘phases’:o 1. Pre-heat cycle – prior to the material being in the press; ando 2. A heat cycle when the material is in the press under pressure.o A cooling cycle that starts whilst the material is in the press and underpressure. ●Some different models of presses may have these heat and cooling cyclessubdivided and may also include ‘dwell’ periods between each cycle.The data given below is based on the observed settings using three different modelsof presses, namely: 1. Phoenix Alpha AD122. Viryl Technologies WarmTone; and3. M-Tech Allegro 2.Summary of parameters for best results when using PLA based material (whencompared to PVC) ●Processing aids (stabilizer; lubricant / dispersant)● Colourant that has no or very low toxicity Process paraments (Pressing / manufacturing) ●Temperature ranges are for different pressing machines, for differentelements in the machine settings ●Pressure settings - materials (screw; press); boiler / steam; etc.● Variable factors e.g. ambient temperature● Curing● Data that shows that we have observed:○ Lower temperature settings - approx 10-15% lower temp settings onpressing machines ○Lower energy use for cooling systems○ Faster cycle times - because less time for heating and cooling○ Lower operational costs / unit○ Faster curing● Advantages○ Reduced materials needs / puck size (estimated 5-10%) - becausematerial spreads more easily in press ○Reduced infrastructure costs - because reduced temperature demand / pressure settings i.e. lower spec needed for infrastructure - lowermanufacturing set up costs (capital costs) ○Reduced risk of operational breakdown because machinery is lesspushed to the upper margins of its performanceCommon elements for all presses tried:● 3 heating zones in extruder● 1 heating zone in the die zone● All above can be controlled● Extruded into the Pre-mould where the puck is formed - the pre-mould can beheated, some were, some were not ●The observation of the temperatures in the extruder, and how it compared toPVC. PVC (depending on the brand) usually had a melt point between 120-150 centigrade. The invention (Evovinyl) melt point in the extruder was in therange of 120-135 centigrade, usually in the range of 125-135 centigrade.● Invention (Evovinyl) formed the puck in a very similar if not identical way toPVC. ●The flow rate was very similar to PVC, albeit with a slightly lower typical meltpoint. ●In the press, PVC regardless of the brand the range of steam cycle and coldcycle ranged between 9 seconds to 15 seconds of steam and a similar timefor cooling with a cold water cycle, as it is typical that a similar amount of time is needed for heating and cooling times. ●In the press, invention (Evovinyl) was typically in the range of 6 seconds to 9seconds in the heating cycle, and a similar time in the cooling cycle, with sometimes a little more cooling time than heating. ●This cycle is essentially the same in all types of record presses, in theextruder and the pressing cycle. In some presses: ●There was a dwell period in the press cycle between the heating and coolingcycles and after the cooling cycle. ●Heating was to allow adequate melt time● Cooling was to all adequate hardening time● The dwell period allowed adequate time for the material to be held in theheated mould, before the steam is flushed out with the cold water.. ●With PVC it is quite common to use the dwell period.● The difference with invention (Evovinyl) was that it did not need any dwellperiod for the material to settle into the stamper grooves, which is a cycle time saving On pressure: ●PVC generally required 120 up to 150 bar of pressure in the press.● Invention (Evovinyl) typically required 110 up to 120 bar of pressure in thepress. This gives an additional energy saving.Cooling and curing time after the record is pressed: ●PVC typically required 8 hours to 12 hours of cooling and curing for the recordto fully settle to be ready to package and / or ship. ●Invention (Evovinyl) PVC typically and consistently required 4 hours of coolingand curing for the record to fully settle to be ready to ship. So invention gives a workflow process and efficiency gain. Other beneficial properties in the record pressing process: ●The biopolymer compound material and the invention (evovinyl) records werenaturally anti-static, which is a beneficial characteristic for the end user with the playing and care of the record, and in the manufacturing process. The manufacturing benefit arises in the production process is that PVC creates static as it is processed, which can draw in dust particles to the pressing of the record and can create distortions in the quality of the sound reproduction. ●Invention (Evovinyl) records did not create static while the material was beingpressed or have static in the final product, so it is less prone to drawing dustparticles to the pressing process. ●Two most common problems with PVC when making the records in the pressare non-fill and stitching. Non-fill is where material has not adequately filled the groove, and therefore there is sound distortion. Stitching is where material gets stuck in the grooves when the record is removed from the pressing leaving PVC particles in the press, which then impacts the record being removed, and the next record to be pressed.● With the invention (Evovinyl) material non-fill and stitching was less likely tohappen because the material melts more easily to fill the grooves and more easily releases from the grooves. Ambient temperature and humidity: ●Best practice was to use all the material, and if it was not all used, to vacuumseal the material, as material takes on moisture from the air .Material production differences with different types of presses - lifting the record offsome presses:● With Toolex style automatic presses (Pheenix Alpha and Newbilt Classic) thepressed record was picked up by the flashing before it is cut off, and the material is softer ●The non-Toolex automatic presses such as WarmTone and Emtech Allegro II,and all manual presses including Newbilt manual (Duplix, Simplex) the pick up for the record uses a different system that works normally for the invention(evovinyl) records, and pick-up of Evovinyl was normal on a manual press.● Particle sizes above 15 micron - material presses well, but lesser soundqualityPlastChem sourced material1. Stabiliser2. Lubricants3. Mould release4. CPE (chlorinated polyethylene) - if or when needed to influence performancesuch as brittleness Plus Colouring Around 40 different variations of ingredients Can effect the % of each category of each elementThis influenced the mechanical process to blend the materials together, using a highspeed rotation that allowed the chemical bonding of the ingredients (the material isnot melted to achieve blending). The blending process combines spinning and heating (but not melting) can be tuned to influence the effectiveness of the bonding process.Starts at 70 degrees - beyond 200 degrees the bonding was reduced.

Claims

CLAIMS1. A phonograph record comprising one or more of the following:-a. polylactic acid (PLA), suitably at an amount of from 55% to 95% byweight (or 70 to 95 mole %);b. a poly alkylene (e.g. adipate) terephthalate polymer, such aspolybutylene adipate terephthalate (PBAT); c. PLA and PBAT; and / ord. Calcium carbonate (CaCO3), such as a filler.

2. A record according to claim 1 which is a “vinyl” record, an LP, an analoguesound storage medium or a flat or planar disc inscribed with a modulated spiral groove.

3. A record according to claim 1 or 2 which comprises polylactic acid (PLA) at from60, 65, 70 or 75% and / or up to .70, 75, 89 or 85% (by weight), optimally from 50 or55% to 665 or 70% and / or from 70, 80 or 85 to 85, 90 or 95 mole %;and / or comprises PBAT at from 15, 18 or 20% up to 18, 20 or 25%; suitably where the ratio of PLA:PBAT is 2:1 to 4:1, such as 2.5:1 to 3.5:1 optimally about 3:1.

4. A record according to any preceding claim which comprises a biodegradablebioplastic or compostable polymer and / or resin composition.

5. A phonograph record which does not contain any PVC (polyvinyl chloride)and / or PVA (polyvinyl acetate); and / or which meets EU compostable standard EN13432.

6. A phonograph record according to any of claims 1 to 5 wherein the calciumcarbonate may be present at from 10 to 30%, such as from 15 to 20 or 25%, optimally from 18 to 23%; or the calcium carbonate is present at from 2 to 16%, such as from 5 to 11%, optimally from 7 to 10%; optionally which comprises talc or hydratedmagnesium silicate, suitably wherein the particles of Mg silicate are (on average) lessthan 12µm, preferably less than 5µm or 3µm, for example in diameter.

7. A record according to any preceding claim comprising a resin, or resincomposition, or polymer or polymer composition which is:plant based or derived; comprises sucrose and / or plant cellulose; and / or is derived from alfalfa, corn, cotton, sugar cane, flax, cane and / or bamboo.

8. A record according to any preceding claim which comprises a resin, or resincomposition or polymer that is (e.g., injection) mouldable, extrudable (subject toextrusion) and / or is thermoplastic.

9. A phonograph record comprising a mould release agent or a record havingantistatic properties.

10. A phonograph record according to any preceding claim which comprises a heatstabilizer, such as a metal salt of a fatty acid and / or comprises a plasticizer, such asa phthalate ester and / or which comprises a colourant, for example carbon black,11. A phonograph record according to any preceding claim which comprises alubricant, such as a (e.g. hard) waxes, for example either natural (montan) or synthetic (for example stearamide) type wax.

12. A phonograph record according to any preceding claim which comprises:stabilizers an amount up to 1.5%, such as from 1-2%; Lubricants at below 1%, for example between 0.5-1.5%; Plasticizer at less than 1%, for example from 0.5-1.5%; Colorants up to 0.5%, for example from 0.25-0.75%.

13. A method of producing a record, the process comprising admixing a firstbiodegradable, bioplastic or compostable resin or polymer composition with a secondpolymer and / or resin composition (such as a master batch).

14. A method according to claim further comprising creating a biscuit or puck whichis then heated and / or compressed.

15. A method according to claim 13 or 14 wherein the first component comprises80-99%, such as from 85-96%, such as from 90-95% of the record and / or wherein thesecond (e,g, master batch) component is present at from 10-2%, such as from 7-3%, preferably around 5%.

16. A method according to any of claims 13 to 15 wherein the temperature of thepuck either before, or during, compression is from 150-160°C.

17. A record produced by a method according to any of claims 13 to 16.

18. A phonograph record that has (substantially) no static or is static free, wherethe static level is:less than 100, preferably less than 70, and optimally less than 50 nanocoulombs (nC); and / or less than 1.0, such as 0.5, optimally less than 0.2 kV.

19. A phonograph record which does not warp, distort, or does not bend, suitablyhaving; a flexural stiffness (Mpa) of at least 100, preferably at least 400, optimally at least 800; and / or a tensile strength (Mpa) of at least 24, such as least 30, preferably at least 35, and optimally at least 40.

20. A phonograph record that can be packaged (such as placed in a sleeve) withinat least 2, such at least 3, preferably at least 4 hours after pressing or manufacture.

21. A method of packaging a (e.g. newly pressed) phonograph record, the methodcomprising 3. pressing a record in a mould; and4. packaging the record within 2, 3, or 4 hours (such as within 10, 15 or 20hours) of pressing the record (resulting from step a).

22. A process or method for producing (or making or manufacturing) a phonographrecord, suitably comprising pressing (or compressing) a material in a mould, comprising:o heating the material (such as to form a “puck” or “biscuit”) so that it (atleast partially) melts; ooptionally, pre-heating the mould;o heating (such as from 120 or 125C to 135C) and pressing the (e.g.molten) material in the mould under pressure (such as from 110-120Bar); ocooling the material and / or mould;o releasing the (pressed) material, such as from the mould, to thereby forma record; 1. optionally, repeating stage (a), such as with fresh or newmaterial (to form another record).

23. A process according to claim 22 wherein c) may comprise two pressing steps:.a first pressing step (c1) under low (or lower) pressure; a second pressing step (c2) may be under high (or higher) pressure; or where step 2 is omitted and there may be only one heating step, usually under low pressure.

24. A process according to claim 22 or 23 wherein:the length of pre-heating in b) (bt) is one or about one second long, suitablybetween 0.5 and 1.5 seconds; the length of time of heating the mould and / or material during pressing (forexample, while the puck is in the press or mould, suitably under low pressure, c1t, is6-11 seconds, such as 7-10 seconds, optimally 7 or 8 to 9 seconds;the length of time for heating the mould and / or material (usually with the puckin the press or mould, suitably under high pressure, c2t, is less than 1.0 or 0.5 seconds,and optimally zero (0);the length of time spent cooling the mould and / or material (usually the materialwill already have been pressed in the mould, dt, is 6-11 seconds, such as 7-10seconds, optimally 6 or 8 to 9 seconds;the time between heating the mould and / or the material in the press, suitablyunder pressure (thus in between steps c) and d) is less than 1.0 or 0.5 seconds, or zero (0). (thus, there may be no gap or wait time); and / or the time between e) and a), usually a cooling cycle, for example allowing waterto remain or sit in the mould, before being ejected, or pushed out, such as with steam (to heat in step b), eat, is less than 1.0 or 0.5 seconds, or there is no gap, or wait time).

25. A process according to any of claims 22 to 24 wherein;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; 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; and / or steps c and d last from 14, 15 or 16 seconds to 17, 18 or 19 seconds.

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