• 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:
    This invention is directed to a composite plate which is at least partially made of a non-woven composite material, and wherein this non-woven composite material consists of: - unraveled natural fibers and / or glass fibers, - synthetic fibers, and - between 10 and 75 weight percent liquid thermoset. Moreover, this invention also focuses on the use of such composite boards for all applications where chipboard (PB), medium and high density fiberboard (MDF & HDF), oriented strand board (OSB), laminated veneer lumber (LVL), plywood (PLW) and related materials, and for wall panels, partition walls, insulation panels, laminate flooring, in particular laminate flooring, tiles, furniture, and related applications. In addition, this invention provides a process for producing composite sheets in which unraveled natural fibers and / or glass fibers are mixed with synthetic fibers, thereby creating a fiber layer, and wherein this fiber layer is thermoformed to form a layer of non-woven composite material. This thermoforming consists of impregnating the fiber layer with liquid thermoset and heat under vacuum conditions.
    公开号:BE1024259B1
    申请号:E2016/0115
    申请日:2016-06-30
    公开日:2018-01-15
    发明作者:Rudy Galle；Bernard Lootens；Marnix Moens
    申请人:Rudy Galle；
    IPC主号:
    专利说明:

    Holder:
    GALLE Rudy 9750, ZINGEM Belgium
    Inventor:
    GALLE Rudy 9750 ZINGEM Belgium
    LOOTENS Bernard 9800 DEINZE Belgium
    MOENS Marnix 1910 KAMPENHOUT Belgium
    A COMPOSITE PLATE MADE OF RECYCLED AND RECYCLABLE MATERIAL
    The present invention is directed to a composite sheet which is at least partly made of a non-woven composite material, and wherein this non-woven composite material consists of: - unraveled natural fibers and / or glass fiber, - synthetic fibers, and - between 10 and 75% by weight of liquid thermoset. In addition, this invention also addresses the use of such composite boards for all applications involving chipboard (PB), medium and high density fiberboard (MDF & HDF), oriented strand board (OSB), laminated veneer (LVL), plywood (PLW) and related materials, and for wall panels, partitions, insulation panels, laminate, floor covering, especially laminate flooring, tile, furniture, and related applications. In addition, the present invention provides a process for producing composite sheets in which unraveled natural fibers and / or glass fiber are mixed with synthetic fibers, thereby forming a fiber layer, and this fiber layer is transformed into a layer of non-woven composite material by thermoforming. This thermoforming consists of impregnating the fiber layer with liquid thermoset and heat under vacuum conditions.
    BELGIAN INVENTION PATENT
    FPS Economy, K.M.O., Self-employed & Energy
    Publication number: 1024259 Filing number: BE2016 / 0115
    Intellectual Property Office International classification: B32B 5/02 B32B 5/26 B32B 5/08 B32B 9/02 D04H 1/4209 D04H 1/425 Date of issue: 15/01/2018
    The Minister of Economy,
    Having regard to the Paris Convention of 20 March 1883 for the Protection of Industrial Property;
    Having regard to the Law of March 28, 1984 on inventive patents, Article 22, for patent applications filed before September 22, 2014;
    Having regard to Title 1 Invention Patents of Book XI of the Economic Law Code, Article XI.24, for patent applications filed from September 22, 2014;
    Having regard to the Royal Decree of 2 December 1986 on the filing, granting and maintenance of inventive patents, Article 28;
    Having regard to the application for an invention patent received by the Intellectual Property Office on 30/06/2016.
    Whereas for patent applications that fall within the scope of Title 1, Book XI, of the Code of Economic Law (hereinafter WER), in accordance with Article XI.19, § 4, second paragraph, of the WER, the granted patent will be limited. to the patent claims for which the novelty search report was filed, when the patent application is the subject of a novelty search report indicating a lack of unity of invention as referred to in paragraph 1, and when the applicant does not limit his filing and does not file a divisional filing in accordance with the search report.
    Decision:
    Article 1
    GALLE Rudy, Stationsstraat 34, 9750 ZINGEM Belgium;
    represented by
    VAN DAELE Maarten, Uitbreidingstraat 42-46 b5, 2600, BERCHEM;
    a Belgian invention patent with a term of 20 years, subject to payment of the annual fees as referred to in Article XI.48, § 1 of the Economic Law Code, for: ONE
    COMPOSITE SHEET MADE OF RECYCLED AND RECYCLABLE MATERIAL.
    INVENTOR (S):
    GALLE Rudy, Stationsstraat 34, 9750, ZINGEM;
    LOOTENS Bernard, Pontstraat 4, 9800, DEINZE;
    MOENS Marnix, Aarschotsebaan 109, 1910, KAMPENHOUT;
    PRIORITY:
    07/06/2016 EP 16173421.5;
    BREAKDOWN:
    Split from basic application: Filing date of the basic application:
    Article 2. - This patent is granted without prior investigation into the patentability of the invention, without warranty of the Merit of the invention, nor of the accuracy of its description and at the risk of the applicant (s).
    Brussels, 15/01/2018,
    With special authorization:
    BE2016 / 0115
    A COMPOSITE PLATE MADE OF RECYCLED AND
    RECYCLABLE MATERIAL.
    FIELD OF THE INVENTION
    This invention relates to a composite sheet made at least in part from a non-woven composite material.
    In addition, the present invention relates to a process for producing a composite sheet which consists at least in part of a non-woven composite material layer.
    BACKGROUND
    It is well known that wood fiber boards, in particular medium density fiber boards (MDF), are often used as building boards and in the furniture industry. For pieces that will be visible, veneer wood is often glued to a fiberboard to give it the look of conventional wood.
    In addition, fiber boards are also used in industries such as the automotive industry, for example, to create various shapes such as dashboards, parcel shelves and the inside of the doors. These pieces are then usually covered with a skin, foil or fabric.
    Although the environmental impact of, for example, MDF has greatly improved over time through the use of recycled paper, bamboo, carbon fibers and polymers, thinning wood, cutting residues from sawmills, etc., industry is increasingly separating from structural parts and panels based on wood .
    Therefore, numerous attempts have been made to develop composite plates based on alternative materials.
    One of these is voorbeeid US2006111003: a hard fiber board made of nonwoven fibrous layers of material which are used natural and synthetic fibers and fibers of two components, and these are interspersed m ^ E2016 / 0115, for example, layers of woven glass fibers.
    A major drawback of the described technology is that a complex structure of non-woven and woven layers is required to obtain a composite plate with sufficient multidirectional strength.
    In view of the above, the object of this invention is to produce a composite sheet that does not require a complex layer structure to obtain sufficient (bidirectional) strength for conventional use.
    Another object of this invention is to produce a composite sheet with properties suitable for heavy duty applications. Shock resistance, swelling, heat resistance, heat resistance, dimensional stability should be at least comparable to or better than the conventional fiber or composite plates.
    In addition, this invention aims to provide a composite board that has a shock and load resistance comparable to or better than MDF or HDF boards, combined with a much lower weight.
    Another object of this invention is to make a composite sheet from recyclable and / or recycled material.
    In addition, the present invention aims to provide an improved method of producing composite plates so that recycled and recyclable materials can be used.
    In addition, the present invention provides a process for using porous, hydroscopic, viscoelastic raw materials as a base material in the production of durable and dimensionally stable composite plates.
    SUMMARY OF THE INVENTION
    This invention is directed to a composite sheet made at least in part from eeR E2016 / 0115 non-woven composite material, and wherein this non-woven composite material consists of:
    - unraveled natural fibers and / or glass fibers,
    synthetic fibers, and
    - between 10 and 75% by weight of liquid thermoset.
    In addition, this invention also addresses the use of such composite boards for all applications involving chipboard (PB), medium and high density fiberboard (MDF & HDF), oriented strand board (OSB), laminated veneer (LVL), plywood (PLW) and related materials, and for wall panels, partitions, insulation panels, laminate, floor covering, especially laminate flooring, tile, furniture, and related applications.
    In addition, the present invention provides a process for producing composite plates in which unraveled natural fibers and / or glass fibers are mixed with synthetic fibers, thereby forming a fiber layer, and in which this fiber layer is converted into a layer of non-woven composite material by thermoforming. This thermoforming consists of impregnating the fiber layer with liquid thermoset and heat under vacuum conditions.
    DETAILED DESCRIPTION
    A composite sheet in accordance with this invention is made at least in part from a non-woven composite material. This non-woven composite material consists of:
    - unraveled natural fibers and / or glass fibers,
    synthetic fibers, and
    - between 10 and 75% by weight of liquid thermoset.
    In the context of this invention, natural raw materials such as jute, hemp, coconut, etc. are unraveled into fibers by an open or tearing machine for bast fibers. Unraveled natural fibers are also called bast fibers and can be several centimeters long. The unraveled natural fibers can consist of any type of natural fiber, such as jute, flax, hemp, sisal, coconut, bamboo or animal fibers.
    Alternatively, or in combination with unraveled natural fibers, glass fibers can also be used.
    The main types of natural fibers used in composite boards in accordance with this invention are flax, hemp, jute, kenaf, coconut and sisal, due to their properties and availability. The use of jute fibers has many advantages. First, it has woody properties as it is a bast fiber. Jute has high specific properties, low density, good dimensional stability, is harmless and less abrasive to the processing equipment. The fiber has a high aspect ratio, a high strength / weight ratio and good insulating properties. Jute is an inexpensive, environmentally friendly product, abundant and easy to transport.
    In the context of this invention, the synthetic fibers may have just been produced or from any kind of waste or recycled synthetic fiber sheet material, such as textiles, fabric, carpet, clothing or big bags (i.e. flexible intermediate bulk containers (FIBC)). Recycled synthetic fibers can be obtained by unraveling or tearing recycled synthetic material, woven and non-woven, and then possibly combing it. The synthetic fiber material can be any type of plastic used to produce synthetic fiber material, woven or non-woven, such as polypropylene fibers, polyvinyl fibers, polyethylene fibers, polyester fibers, etc.
    A composite sheet in accordance with this invention contains at least 40, at least 50, or at least 60, or at least 80, or at least 90 weight percent unraveled natural fibers and / or glass fibers.
    Another composite sheet in accordance with this invention contains less than 60, or less than 50, or less than 40, or less than 20, or less than 10 or less than 5 weight percent synthetic fibers.
    Without being bound by theory, we assume that by using unraveled fibers as described above, a non-woven composite material having a three-dimensional net structure embedded in a synthetic or liquid thermoset matrix is obtained, thereby obtaining a composite sheet according to this invention which suitable for heavy applications. Shock resistance, swelling, heat resistance, heat resistance, dimensional stability should be at least comparable to or better than the conventional fiber or composite plates.
    In addition, the shock and load resistance can be similar to or higher than the properties of conventional MDF or HDF boards.
    Another advantage is that this composite sheet is made of recyclable and / or recycled material.
    A liquid thermoset according to this invention can be any type of liquid thermoset with which a mix of unraveled natural fibers and / or glass fibers and synthetic fibers can be mixed. Such a liquid thermoset may be, for example, a liquid based on polyester, epoxy, formaldehyde or polymethyl methacrylate or liquid polyurethane resin or a water glass based binder as described in WO2013079635, to which reference is made, or a biological binder, including natural and / or synthetic biological substances, conjugates or derivatives thereof, including polymers. An example of this is a binder based on polysaccharide.
    A liquid thermoset used in this invention preferably has a viscosity and surface tension suitable for filling the void in the nonwoven material without being taken up by the fibers themselves.
    Surface tension may, for example, be between 100 and 300 mN / m or better between 150 and 300 mN / m, or preferably between 200 and 300 mN / m.
    Viscosity may be between 70 and 1000 mPa.s or better between 70 and 700 mPa.s, or preferably between 70 and 350 mPa.s at 20 ° C.
    BE2016 / 0115
    For example, a water glass-based binder can have a surface tension of about 250 mN / m and a viscosity of 250-300 mPa.s. at 20 ° C.
    Another example is an epoxy-based resin with a surface tension of about 250 mN / m and a viscosity of about 100 mPa.s. at 20 ° C.
    The use of a liquid thermoset can strengthen the synthetic fiber matrix and promote the formation of an even more durable and firmer non-woven composite material.
    A composite sheet in accordance with this invention may consist of at least 20, at least 30, at least 40, at least 50, at least 60, or at least 70 weight percent of this liquid thermoset, depending on the desired properties of the composite sheet, such as density, swelling, tensile strength, load resistance etc.
    A composite sheet according to this invention may contain between 30 and 85 weight percent unraveled natural fibers and / or glass fibers, between 40 and 5 weight percent synthetic fibers, and between 10 and 65 weight percent liquid thermosets.
    Another composite sheet according to this invention may contain between 30 and 70 weight percent unraveled natural fibers and / or glass fibers, between 10 and 40 weight percent synthetic fibers, and between 20 and 60 weight percent liquid thermosets.
    Another composite sheet according to this invention may contain between 35 and 55 weight percent unraveled natural fibers and / or glass fibers, between 5 and 15 weight percent synthetic fibers, and between 30 and 60 weight percent liquid thermosets.
    In addition, a composite sheet according to this invention can be made at least in part from non-woven composite material. This nonwoven composite material may consist of a single layer of vacuum impregnated and thermoformed nonwoven composite material or of multilayer impregnated thermoformed nonwoven composite material layers.
    Alternatively, multiple non-woven composite material layers can be alternated with layers of other materials.
    A composite sheet in accordance with this invention may have an outer layer on one or more sides that has been treated so that it can be painted or printed.
    In addition, a composite sheet in accordance with this invention may contain one or more finishing layers on one or more sides, such as a preprint layer that can be printed on, and / or a printed decorative layer, and / or one or more lacquer or cover layers.
    A composite board in accordance with this invention can be used for all applications involving chipboards (PB), medium and high density fiber boards (MDF & HDF), oriented strand board (OSB), laminated veneer lumber (LVL), plywood (PLW) and related materials are used, and for wall panels, partitions, insulation panels, laminate, carpet, especially laminate floors, tiles, furniture, and related applications.
    In addition, the present invention provides a process for producing composite plates in which unraveled natural fibers and / or glass fibers are mixed with synthetic fibers, thereby forming a fiber layer, and in which this fiber layer is converted into a layer of non-woven composite material by thermoforming. This thermoforming consists of impregnating the fiber layer with liquid thermoset and heat under vacuum conditions.
    In the context of this invention, vacuum impregnation is understood to mean: placing the blend of unraveled natural fibers / glass fibers and synthetic fibers, for example, a needle punch or spunlace fiber layer, in a vacuum envelope or bag and sealing and then extracting the air from the envelope or bag with a vacuum pump so that ^ E2016 / 0115 fully penetrates the liquid thermoset into the fiber layer.
    The impregnated fiber layer can be heated simultaneously with or after exhausting the air, whereby the layer of composite material is formed under the influence of the temperature and air pressure.
    The layer can be heated by any type of heating that has the capacity to sufficiently raise the temperature in the core of the fiber layer during thermoforming under vacuum conditions.
    In a particular composite sheet, a fiber layer partially impregnated with the liquid thermoset so that part of the fiber layer does not initially come into contact with the liquid thermoset will be fully impregnated by the liquid thermoset after the viscosity at core temperature higher than room temperature has decreased so that when the layer is heated in a vacuum envelope or bag without an autoclave, the liquid thermoset flows and completely penetrates into the fiber layer.
    An advantage of vacuum impregnation is that the impregnation agent, e.g. the liquid thermoset, can improve the heat transfer to the core of the fiber layer.
    Another advantage of vacuum impregnation is that the excess liquid thermoset can easily be drained from the vacuum bag.
    The core temperature of the composite material mix during thermoforming may be at least 60 ° C, or at least 80 ° C, or at least 100 ° C, or at least 120 ° C, often at least 140 ° C.
    A process according to this invention can mix between 40 and 90 weight percent unraveled natural fibers and / or glass fiber and between 10 and 60 weight percent synthetic fibers, with this weight percentage relative to the fiber layer (which does not yet contain a liquid thermoset).
    BE2016 / 0115
    Although natural fibers such as jute, etc., are porous, hydroscopic, viscoelastic materials, a process in accordance with this invention allows them to be used as a base material to produce durable and reusable composite sheets.
    The synthetic fibers can have a melting point of at least 60 ° C, or at least 80 ° C, or at least 100 ° C, or at least 120 ° C, or even at least 140 ° C, so that during the thermoforming the unraveled natural fibers (or the glass fibers) ) be sufficiently embedded in the synthetic and liquid thermoset.
    The natural fibers or glass fibers and the synthetic fibers can be mixed by any conventional technique suitable for mixing fibers, such as airlaid, needle punching, carding, wetlaid, spunlace or a combination thereof. For example, needle punching, a technique in which a mechanical bond or entanglement of the fibers is achieved through the passage of thousands of toothed felting needles through the layer of fiber, can be used.
    The unraveled natural fibers and / or glass fibers and / or synthetic fibers must not be shredded, cut, ground or treated by any other technique with the intention of reducing the fiber length compared to the length of the unraveled natural fiber or the original length of the synthetic fiber.
    The length of the unraveled natural fiber can be at least 0.5 cm or at least 0.7 cm, of which at least 50% is at least 1 cm or at least 2 cm to obtain the desired three-dimensional mesh structure. The fiber length is at least
    1.2 cm or better 1.5 cm, or preferably at least 4 cm.
    The fiber layer of unraveled natural fibers and / or glass fibers and synthetic fibers can be exposed to the liquid thermoset by spraying, immersion or lubrication.
    30 to 300 g of liquid thermoset per 100 g of fiber layer, or more preferably 60 to 200 g of liquid thermoset per 100 g of fiber layer, or preferably, to the fiber layer with mixed unraveled natural fibers and / or glass fibers and / or E20i6 / 0H5 synthetic fibers. 80 to 120 g of liquid thermoset per 100 g of fiber layer.
    A process for manufacturing a composite sheet in accordance with this invention involves thermoforming several layers of nonwoven composite material and joining them by pressing, vacuum forming, gluing or welding to form a multilayer nonwoven composite sheet.
    Alternatively and preferably, several non-impregnated fiber layers are placed in a vacuum bag and simultaneously impregnated and thermoformed under vacuum conditions to form a multilayer nonwoven composite sheet. The various non-impregnated fiber layers can be individually treated with liquid thermoset before being placed in the bag, for example by spraying or lubricating, or can be treated at the same time, for example by immersing them.
    In addition, a process for making a composite sheet in accordance with this invention may include post-treatment on one or more sides of the non-woven composite sheet, for example a preprint treatment (ie prepare the surface for direct printing) and / or a decor print (ie imitation wood print) or coating, paint, wax etc.
    Alternatively, such a process may also provide one or more finishing layers or press these finishing layers onto one or more sides of the composite sheet. Such a finishing layer can for instance be a preprint layer on which can be printed directly and / or a printed decor layer and / or one or more lacquer or cover layers.
    In addition, a composite sheet in accordance with this invention can be processed by sawing, cutting, nailing, gluing, grinding, polishing or painting.
    For example, a non-woven composite plate having a thickness of 6 mm jH E2016 / 0115 accordance with the present invention, 100 g of liquid thermoset by adding the basis of epoxy per 100 g of the fibrous layer too, may have the following properties:
    - weight: 2-4 kg / m 2
    - swelling: 1.5%
    - tensile strength: 4.5 kg / cm 2
    - maximum load: 10 kg / m 2
    Another example: a 6 mm thick non-woven composite sheet obtained in accordance with this invention by adding 50 g of water glass liquid thermoset per 100 g of fiber layer may have the following properties:
    - swelling: 10%
    - tensile strength: 0.8 kg / cm 2
    - maximum load: 2.5 kg / m 2
    权利要求:
    Claims (10)
    [1]
    CONCLUSIONS:
    BE2016 / 0115
    1. A composite sheet that is at least partially made of a non-woven composite material, and wherein this non-woven composite material contains:
    - unraveled natural fibers and / or glass fibers,
    synthetic fibers, and
    - between 10 and 75% by weight of liquid thermoset.
    [2]
    A composite sheet according to claim 1, wherein the non-woven composite material contains between 30 and 85 percent by weight unraveled natural fibers and / or glass fibers, between 40 and 5 percent by weight synthetic fibers, and between 10 and 65 percent by weight liquid thermosets.
    [3]
    A composite sheet according to claim 1, wherein the non-woven composite material contains between 30 and 70 weight percent unraveled natural fibers and / or glass fibers, between 10 and 40 weight percent synthetic fibers, and between 20 and 60 weight percent liquid thermosets.
    [4]
    A composite sheet according to claim 1, wherein the non-woven composite material contains between 35 and 55 weight percent unraveled natural fibers and / or glass fibers, between 5 and 15 weight percent synthetic fibers, and between 30 and 60 weight percent liquid thermosets.
    [5]
    5. A process for producing composite plates in which unraveled natural fibers and / or glass fibers are mixed with synthetic fibers, whereby a fiber layer is formed, and this fiber layer is transformed into a layer of non-woven composite material by thermoforming. This thermoforming consists of impregnating the fiber layer with liquid thermoset and heat under vacuum conditions.
    [6]
    6. Process according to claim 5, wherein 30 to 300 g of liquid thermoset is added per 100 g of fiber layer.
    [7]
    7. Process according to claim 5, wherein 60 to 200 g of flowable E2016 / 0115 thermoset is added per 100 g of fiber layer.
    [8]
    8. Process in accordance with buckskin 5, where 80 to 120 g are liquid
    5 thermoset is added per 100 g fiber layer.
    [9]
    9. A process in accordance with buckskin 5, wherein several non-impregnated fiber layers are placed in a vacuum bag and simultaneously impregnated and thermoformed under
    [10]
    10 vacuum conditions to form a multilayer non-woven composite sheet.
    A COMPOSITE PLATE MADE OF RECYCLED AND
    RECYCLABLE MATERIAL.
    类似技术:
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    NL9101687A|1993-05-03|APPLICATION OF NON-WOVEN, NEEDLE-PICKED FIBER MATERIAL.
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    同族专利:
    公开号 | 公开日
    US20190308392A1|2019-10-10|
    EP3478492A1|2019-05-08|
    WO2017211453A8|2019-01-10|
    BR112018075209A2|2019-03-19|
    EP3254841A1|2017-12-13|
    WO2017211453A1|2017-12-14|
    BE1024259A1|2018-01-09|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    JP4289721B2|1999-05-19|2009-07-01|名古屋油化株式会社|Molding material, interior material using the same, and method for producing molding material|
    US8158539B2|2001-11-07|2012-04-17|Flexform Technologies, Llc|Heat deflection/high strength panel compositions|
    CA2656369A1|2006-07-03|2008-01-10|Nagoya Oilchemical Co., Ltd.|Fiber sheet|
    DE102009039534A1|2009-07-23|2011-02-03|Hydroflex Technologies Gmbh|Composite body|
    WO2013079635A1|2011-12-01|2013-06-06|Global Telecom Organisation S.A.|Substrate binding process|
    WO2014177941A2|2013-03-14|2014-11-06|Basf Se|Automotive panels|
    EP3028846A1|2014-12-03|2016-06-08|Galle, Rudy|A composite board made from recycled and recyclable materials|US20200101656A1|2018-10-02|2020-04-02|Johns Manville|Molds for making insulation products|
    法律状态:
    2018-02-22| FG| Patent granted|Effective date: 20180115 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP16173421.5|2016-06-07|
    EP16173421.5A|EP3254841A1|2016-06-07|2016-06-07|A composite board made from recycled and recyclable materials|
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