• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The present invention is directed to a composite sheet made at least in part of a non-woven composite material, said non-woven composite material comprising: between 40 and 90 wt.% Unraveled natural fibers and / or glass fibers, between 40 and 5 wt. % synthetic fibers, and between 40 and 5 wt. % thermoset. Furthermore, the present invention is also directed to the use of such a composite board in all applications in which chipboard (Particle Board - PB), medium and hardboard (Medium and Density Fibreboard - MDF & HDF), Oriented Strand Board. OSB), laminated veneer lumber (LVL), laminated wood (Plywood - PLW) and related materials are used, and in wall panels, partition panels, insulation panels, laminates, flooring materials, more specifically laminate flooring, tiles, furniture, and related applications. In addition, the present invention is directed to a process for producing a composite sheet comprising mixing between 40 and 90 wt. % unraveled natural fibers and / or glass fibers, between 40 and 5 wt. % synthetic fibers, and between 40 and 5 wt. % thermoset, and thermoforming of said blend in a non-woven composite material layer.
    公开号:BE1023275B1
    申请号:E2015/0265
    申请日:2015-12-03
    公开日:2017-01-19
    发明作者:Rudy Galle
    申请人:Rudy Galle；Lootens Bernard；Moens Marnix；
    IPC主号:
    专利说明:

    Composite sheet made from recycled and recyclable materials
    FIELD OF THE INVENTION
    The present invention relates to a composite plate that is at least partially made from a non-woven composite material.
    In addition, the present invention relates to a process for producing a composite plate that is at least partially made from a non-woven composite material layer. Background
    As is well known, fiberboard, more specifically medium-hardboard (MDF), is very often used as building panels and in the furniture industry. For snares that will be visible, a wood veneer is often glued to the fiberboard to achieve the appearance of conventional wood. Furthermore, fiberboard is also used in, for example, industries such as automotive industry to create free shapes such as dashboards, rear hatboards and interior door finishes. These pieces are then covered with a film, foil or fabric.
    Although the environmental impact of, for example, MDF has greatly improved over the years through the use of recycled paper, bamboo, carbon fibers and polymers, sawing residues from the forest exploitation industry etc. are consistently less used for building elements and panels based on made of wood.
    That is why many attempts have been made to develop composite sheets based on alternative materials. One example is US 2006 111 003, which describes a wood fiber board made from non-woven fibrous material layers using natural fibers, plastic fibers and bi-component fibers, alternating with woven fiber layers, for example from glass fiber.
    A clear disadvantage of the technology described is that, in order to obtain a composite sheet with sufficient multidirectional force, a complex structure of non-woven and woven layers is required.
    Taking into account the above, it is an object of the present invention to provide a composite sheet that does not require a complex layer structure to obtain sufficient (bi-directional) strength for conventional use.
    Another object of the present invention is to provide a composite sheet with properties suitable for use in intensive use applications. Impact strength, swelling, heat resistance, heat retardation, dimensional stability can be at least comparable to or improved versus conventional fiber plates or composite plates.
    In another object of the present invention, a composite plate is provided with an impact strength and load resistance that is comparable to or higher than that of MDF or HDF plates, as such combined with a significantly lower weight.
    Another object of the present invention is to provide a composite sheet made from recyclable and / or recycled materials.
    Furthermore, it is an object of the present invention to provide an improved method for producing composite sheets that allows the use of recycled and recyclable materials.
    Furthermore, the present invention provides a process that allows the use of porous, hydroscopic, visco-elastic raw materials as a base material in the production of durable and dimensionally stable composite sheets.
    Summary of the invention
    The present invention is directed to a composite plate that is at least partially made from a non-woven composite material, said non-woven composite material comprising: between 40 and 90% by weight unraveled natural fibers and / or glass fibers, between 40 and 5% by weight plastic fibers, and between 40 and 5 wt.% thermoset.
    Furthermore, the present invention is also directed to the use of such composite board in all applications in which chipboard (Partial Board-PB), medium hard and hard board (Medium and Density)
    Fiberboard - MDF & HDF), facing wood chips (Oriented Strand Board - OSB), laminated veneer lumber (Laminated Veneer Lumber - LVL), laminated wood (Plywood - PLW) and related materials are used, and in wall panels, separation panels, insulation panels, laminates, floor materials, more specifically laminate flooring, tiles, furniture, and related applications.
    In addition, the present invention is directed to a process for producing a composite sheet comprising mixing between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, between 40 and 5% by weight of plastic fibers, and between 40 and 5% by weight. % thermoset, and thermoforming said mixture in a non-woven composite material layer.
    Detailed description
    In an embodiment according to the present invention, a composite plate is provided which is at least partially made from non-woven composite material, said non-woven composite material comprising: - unraveled natural fibers and / or glass fibers, and - plastic fibers, and - with between 0 and 50 wt% thermoset.
    In the context of the present invention, the natural raw materials such as jute, hemp, coconut, are treated by a bast fiber opening device or tear device to be unraveled into fiber phase. The unraveled natural fibers are also called bast fibers and can be up to a few centimeters in length. The unraveled natural fibers can include any natural fiber such as, for example, jute, flax, hemp, sisal, coconut, or bamboo, or animal fibers.
    Alternatively, or in combination with unraveled natural fibers, glass fibers can also be used.
    The major types of natural fibers used in composite sheets of the present invention are flax, hemp, jute, kenaf, coconut and sisal due to their properties and availability. Use of jute fiber has many advantages. First, it has woody properties because it is a bast fiber. Jute has very specific properties, low density, less abrasive behavior for the processing equipment, good dimensional stability and harmlessness. The fiber has a high aspect ratio, high strength to weight ratio, and has good insulation properties. Jute is a cost-effective ecofriendly product and is abundantly available and easy to transport.
    In the context of the present invention, the plastic fibers can be freshly produced fibers or can come from any type of scrap or recycled plastic fiber sheet material, such as textile, fabric, carpet, clothing, or large bags (i.e., flexible intermediate bulk containers (FIBC)). In the case of recycled plastic fibers, they can be obtained by unraveling or tearing, and optionally subsequently combining, recycled plastic fiber material, woven and non-woven. The plastic fiber material can be of any type of plastic used in the production of plastic fiber materials, woven or non-woven, such as, for example, polypropylene fibers, polyvinyl fibers, polyethylene fibers, polyester fibers, etc.
    In an embodiment of the present invention, a composite sheet is provided comprising at least 40% by weight, at least 50% by weight, or at least 60% by weight, or at least 80% by weight, or at least 90% by weight unraveled natural fibers and / or glass fibers.
    In another embodiment of the present invention, a composite sheet is provided comprising less than 60% by weight, or less than 50% by weight, or less than 40% by weight, or less than 20% by weight, or less than 10% by weight. %, or less than 5% plastic fibers.
    Without wishing to be bound by theory, it is believed that use of unraveled fibers as described above results in non-woven composite material with a 3-dimensional network structure embedded in a plastic thermoset matrix, thereby providing a composite plate according to the present invention for use in heavy duty "applications. Impact strength, swelling, heat resistance, heat retardation, dimensional stability can be at least comparable to or improved versus conventional fiber plates or composite plates.
    Furthermore, impact strength and load resistance can be comparable to or higher than the characteristics of conventionally used MDF or HD boards, combined with significantly lower weight. For example, a typical 650 kg / m3 medium hardboard as required in many furniture applications can be replaced by a composite plate according to the present invention with a density of less than 550, or less than 450, or even less than 400 kg / m3, itself approximately 350 kg / m3.
    Another advantage is that this composite plate is made from recyclable and / or recycled materials.
    A thermoset as used in the present invention can be any type of thermoset material that allows mixing with a mixture of unraveled natural fibers and / or glass fibers, and plastic fibers. Such a thermoset may exist in powder form or in liquid form, for example a polyester-based powder, or an epoxy-based powder or liquid, or a formaldehyde-based powder or liquid, or polyurethane liquid resin, or a water-glass-based binder as described. in WO 2013 079 635 which is incorporated herein by reference, or a biological binding agent comprising natural and / or synthetic biological substances, substances conjugated thereto, or polymer-containing derivatives thereof. An example may be a polysaccharide-based binding agent.
    Use of a thermoset can result in reinforcement of the plastic fiber matrix and can improve the formation of an even more durable and rigid non-woven composite material structure.
    A composite plate according to the present invention may comprise less than 50% by weight, or less than 25% by weight, or less than 20% by weight, or less than 10% by weight, or less than 5% of said thermoset.
    In a specific embodiment of the present invention, a composite plate may comprise between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, between 40 and 5% by weight of synthetic fibers, and between 40 and 5% by weight of thermoset.
    In another specific embodiment of the present invention, a composite plate can comprise between 50 and 75% by weight of unraveled natural fibers and / or glass fibers, between 10 and 40% by weight of synthetic fibers and between 10 and 40% by weight of thermoset.
    In another specific embodiment of the present invention, a composite plate may comprise between 50 and 75% by weight of unraveled natural fibers and / or glass fibers, between 15 and 40% by weight of synthetic fibers, and between 10 and 30% by weight of thermoset.
    In addition, a composite sheet of the present invention may further comprise bi-component fibers, preferably less than 25% by weight, or less than 20% by weight, or less than 10% by weight, or less than 5% by weight.
    Bi-component fibers are produced from two different polymers by spinning and joining them in a simultaneous process from a spinneret, which, for example, results in a fiber with a polyethylene terephthalate core and an outer polypropylene layer.
    In the context of the present invention, the bi-component fibers can be made from two components with a melting point of at least 80 ° C, or at least 110 ° C for the outer layer, and at least 140 ° C or at least 160 ° C for the core.
    Without wishing to be bound by theory, it is assumed that due to its high melting point the core fiber is kept intact during processing and blended with the unraveled natural fibers and / or glass fibers, while the outer layer becomes part of the plastic matrix, and even stronger and more rigid structure can be obtained.
    In addition, a composite plate according to the present invention can be at least partially made from non-woven composite material board, said non-woven composite material board being made from a monolayer of thermally formed compressed non-woven composite material, or made from a multi-layer of thermally formed non-woven composite material layers pressed together.
    Alternatively, in a multi-layer of non-woven composite material layers, various monolayers can be alternated with layers of alternative materials.
    A composite sheet according to the present invention may comprise an outer layer on one or more sides that has been treated for direct painting or decor printing.
    Furthermore, the composite plate according to the present invention may comprise one or more finishing layers on one or more sides, such as, for example, a preprint layer suitable for direct printing, and or a printed decor layer, and / or one or more lacquer or coating layers.
    Composite board according to the present invention can be used in all applications in which chipboard (PB), medium hardboard and hardboard (MDF & HDF), oriented structure board (OSB), laminated veneer lumber (LVL), plywood (PLW) and related materials are used , and in wall panels, partition panels, insulation panels, laminates, floors, specifically measures laminate floors, tiles, furniture, and related applications.
    In addition, the present method provided a process for producing a composite sheet comprising blending unraveled natural fibers and / or glass fibers, with plastic fibers, and with between 0 and 50% by weight thermoset, and thermoforming said blend into a non-woven composite material layer .
    In the context of the present invention, thermoforming can be any type of thermoforming that is suitable for forming composite sheets (e.g., thermobonding, heat pressing, casting, vacuum casting, etc.), and can include any type of heating with the capacity to control the temperature. increase sufficiently in the core of the composite material mixture during thermoforming, such as, for example, steam heating or steam injection heating or microwave heating.
    The temperature in the core of the composite material mixture during thermoforming can be at least 100 ° C, or at least 120 ° C, or at least 140 ° C.
    A process according to the present invention may comprise mixing between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, and between 10 and 60% by weight of plastic fibers.
    Although natural fibers such as jute, etc., are porous, hydroscopic, visco-elastic materials, a process of the present invention allows their use as a base material in the production of durable and reusable composite sheets.
    The plastic fibers can have a melting point of at least 100 ° C, or at least 120 ° C, or even at least 140 ° C, so that during thermoforming the unraveled natural fibers (or the glass fibers) are sufficiently embedded in a plastic thermoset melt.
    In a specific embodiment of the present invention, between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, between 40 and 5% by weight of synthetic fibers, and between 40 and 5% by weight of thermoset can be mixed.
    In another specific embodiment of the present invention, 50 and 75% by weight of unraveled natural fibers and / or glass fibers, between 10 and 40% by weight of synthetic fibers and between 10 and 40% by weight of thermoset can be mixed.
    The natural fibers or glass fibers and the plastic fibers can be blended by any conventional technique suitable for blending fibers such as airlaying, needle punching, carding, wet-laying, spunlacing, or a combination thereof.
    For example, needle punching can be used, i.e. a technique in which mechanical interweaving or entanglement of the fibers is obtained by means of thousands of retracted felting needles that are repeatedly fed into and out of the fiber blend.
    The unraveled natural fibers and / or glass fibers and / or the plastic fibers cannot be shredded, cut, ground or treated by any other technique with the aim of reducing the fiber length compared to the unraveled natural fiber length or the original plastic fiber length.
    The unraveled natural fiber length can be at least 0.5 cm, or at least 0.7 cm, at least 50% of which is at least 1 cm, or at least 2 cm, to obtain a desired 3-dimensional mesh structure. The fiber length is preferably at least 1.2 cm, or more preferably at least 1.5 cm, or even more preferably at least 4 cm.
    The thermoset can be mixed with the unraveled natural fibers and / or glass fibers and the plastic fibers by any type of conventional technique for Mixing a powder in a mixture of fibers, for example by air blowing or spreading on the fiber layer. Alternatively, in the case of a liquid thermoset, spraying or immersion may be used, for example, a layer of material punched with a needle may be immersed in a bath fluid thermoset.
    After thermoforming, the non-woven composite material layer can be cold pressed, thereby forming a single-layer non-woven composite material plate. Cold pressing can have the advantage that the non-woven composite material plate is relaxed in order to reduce the risk of breaking.
    Alternatively, the thermoforming step may include immediate heat pressing of the non-woven composite material layer in a single-layer non-woven composite material plate.
    In an embodiment of the present invention, a process for producing a composite sheet may further include blending bi-component fibers in the fiber blend.
    In a preferred embodiment of the present invention, a process is provided for producing a composite plate comprising thermoforming a plurality of non-woven composite material layers and joining them by pressing, vacuum forming, gluing, or welding, thereby forming a multi-layered non-woven composite material plate formed.
    A process for producing a composite plate according to the present invention may further comprise a finishing treatment on one or more sides of the non-woven composite plate material, for example a pre-printing treatment (ie preparing the plate surface for direct (digital) printing), and / or a decor print step (ie imitation wood print), or coating, painting, washing, etc.
    Alternatively, such a process may further comprise providing one or more finishing layers and pressing said one or more finishing layers on one or more sides of the non-woven composite sheet material. Such a finishing layer can, for example, be a pre-printing layer suitable for direct (digital) printing, and or a printed decorative layer, and / or one or more lacquer or coating layers.
    A composite plate according to the present invention can be further processed in all types of sawing, cutting, nailing, gluing, grinding, polishing or painting operations.
    In an embodiment of the present invention, a specific process is provided for producing a composite sheet comprising: - mixing unraveled natural fibers and / or glass fibers, plastic fibers, and thermoset powder - preheating the mixture in a preheated mold - transferring the preheated fiber layer to a steam injection oven, thereby forming a non-woven composite material layer - cold pressing the non-woven composite material layer - pressing various non-woven composite material layers together to form a multi-layered non-woven composite plate.
    In another embodiment of the present invention, an alternative process is provided for producing a composite sheet comprising: - mixing unraveled natural fibers and / or glass fibers, and plastic fibers by airlaying, needle punching, carding, wet-laying, spunlacing, or a combination thereof that results in a provisional non-woven composite fiber mat. - sprinkling thermoset fluid on this composite fiber mat, or immersing the mat in a thermoset fluid bath - the heat-pressing heat of the submerged mat into a non-woven composite material layer - pressing various non-woven composite material layers together, whereby a multilayer non-woven composite sheet is formed.
    权利要求:
    Claims (12)
    [1]
    CONCLUSIONS
    1. - Composite plate made at least partially from non-woven composite material, said non-woven composite material comprising: between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, between 40 and 5% by weight of plastic fibers, and between 40 and 5% by weight thermoset.
    [2]
    Composite plate according to claim 1, comprising between 50 and 75% by weight of unraveled natural fibers and / or glass fibers, between 10 and 40% by weight of synthetic fibers and between 10 and 40% by weight of thermoset.
    [3]
    The composite plate of claims 1 to 2, wherein the non-woven composite material further comprises bi-component fibers.
    [4]
    Composite plate according to claims 1 to 3, comprising one or more finishing layers, optionally comprising a pre-printing layer and / or a printed decorative layer on one or more sides.
    [5]
    5. - Process for producing a composite plate comprising mixing between 40 and 90% by weight of unraveled natural fibers and / or glass fibers, between 40 and 5% by weight of synthetic fibers, and between 40 and 5% by weight of thermoset, and thermoforming of said mixture in a non-woven composite material layer.
    [6]
    The process for producing a composite plate according to claim 5, wherein thermoforming comprises steam heating or steam injection heating or microwave heating.
    [7]
    Method for producing a composite plate according to claims 5 to 6, wherein the mixing step comprises airlaying, needle punching, carding, wet-laying, spunlacing, or a combination thereof.
    [8]
    Method for producing a composite plate according to claims 5 to 6, wherein after thermoforming, the non-woven composite material is cold pressed, thereby forming a single-layer non-woven composite material plate.
    [9]
    A method for producing a composite plate according to claims 5 to 6, comprising thermoforming a plurality of non-woven composite material layers and joining them by pressing, vacuum forming, gluing or welding, thereby forming a multi-layered non-woven composite material plate formed.
    [10]
    Method for producing a composite plate according to claims 5 to 6, further comprising a finishing treatment, optionally a pre-printing treatment, on one or more sides of the non-woven composite plate material.
    [11]
    A method for producing a composite sheet according to claims 5 to 6, further comprising providing one or more finishing layers, optionally comprising a printed decor layer, and pressing said one or more finishing layers on one or more sides of the non-woven composite sheet material.
    [12]
    12. - Use of a composite board according to claims 1-4 in all applications in which chipboard (Partial Board - PB), medium-hard and hardboard (Medium and Density Fiberboard - MDF & HDF), plate of directional wood chips (Oriented Strand Board - OSB) ), laminated veneer lumber (Laminated Veneer Lumber - LVL), laminated wood (Plywood - PLW) and related materials are used, and in wall panels, separation panels, insulation panels, laminates, floor materials, more specifically laminate flooring, tiles, furniture, and related applications.
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    法律状态:
    优先权:
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