• 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 relates to a method of manufacturing a ski core or snowboard core, comprising: stacking foam or wood layers (10) with layers (20, 200, 201) of natural fiber-based composite material; Joining the layers; Obtaining a plurality of structured parts (100) by cutting the obtained stack (1) at right angles to the layer planes, the thickness of the parts being over 1 mm.
    公开号:CH707147B1
    申请号:CH00253/14
    申请日:2012-08-24
    公开日:2016-07-15
    发明作者:Fischer Christian；Rion Julien
    申请人:Bcomp Sa；
    IPC主号:
    专利说明:

    Field of the invention
    The present invention relates to a ski core or snowboard core, and to a method for the production of these.
    Composite materials are often in use, thanks to their highly specific mechanical properties, for the last 40 years, especially in aeronautical and space applications. In recent years, composite materials made of natural fibers have received increased attention due to the growing environmental awareness. Due to their low cost, low environmental impact and relatively high specific mechanical properties, natural fibers constitute a new alternative to glass fibers as reinforcement for composite materials.
    So far, various types of natural fibers have been extracted and characterized, such as flax, hemp, jute, ramie, kenaf, sisal, henequen, bamboo, silk or cotton. Currently, flax and hemp appear among the most promising due to their combination of highly specific properties, availability, low energy production, low plant maintenance during growth, low irrigation and a zero-carbon footprint. In addition to better specific stiffness compared to glass fibers, flax fibers having excellent damping properties have been reported, and the energy needed to produce 1 kg of flax fiber mats is only 1/6 that of glass fibers and only 1/13 that of carbon fibers.
    When a natural fiber-based material can be completely recovered from renewable resources, it is known as a biopolymer. An alternative approach to producing natural fiber-based composite materials is the use of thermoplastic polymers that are used with natural fibers as reinforcement of the polymeric material. Thermoplastic polymers such as PET or polypropylene are well suited for reuse in a recycling step: in combination with natural fibers such as hemp, the mechanical properties remain relatively constant from one recycling step to the next. Biopolymers based on natural fibers have the advantage of being easier to process because the fibers are less abrasive than most synthetic fibers.
    The present invention relates to a ski or snowboard core according to claim 10 and a method for producing a ski or snowboard core according to claim 1. This core combines the low density of a cellular solid (foam, wood, etc.) with high specific, anisotropic and adaptable properties of fiber-plastic composite (FRP). The key advantage of these materials is:<tb> • <SEP> Significantly increased compression and shear moduli in one direction (3-100 times higher) than foam alone;<tb> • <SEP> Significantly increased compression and shear forces in one direction (2-20 times higher);<tb> • <SEP> Significantly increased core-to-site adhesion (+ 50% -150%) over standard foam due to optimized stress transfer from the sides to the core;<tb> • <SEP> Low added weight and low cost because (i) little material is added to the foam and (ii) there is the possibility of a continuous process;<tb> • <SEP> Improved adhesion between the natural fibers and the resin, compared to the best possible adhesions between glass or carbon fibers and the resin.
    The invention will be better understood with the description of the preferred embodiments illustrated by the figures, in which:<Tb> FIG. 1A <SEP> shows a stack of foam and fiber-plastic composite (FKV) using fabric fabrics made from unidirectional (UD) fiber layers oriented at +/- 45 ° as the FKV layer;<Tb> FIG. Figure 1B shows a stack of foam and natural FKVs using plain weave as the FKV layer;<Tb> FIG. Figure 2A shows a joined stack of foam and natural FKV layers;<Tb> FIG. 3A <SEP> shows examples of cutting lines;<Tb> FIG. Figure 3B shows an example of resulting boards;<Tb> FIG. 4A <SEP> shows an example of a milled profile, here a skier.
    Detailed description of the invention
    We will now describe an example of the manufacturing method according to the invention. In this example, the method comprises the main steps I to IV.
    The procedure I / IV: stacking of the layers
    During the first step, as shown in Figs. 1A and 1B, the structured solid layers 10 (preferably a foam board or a wood board such as balsa or other light weight wood) are stacked with natural fiber reinforced polymer layers 20, 200, 201 :The foam or wood layer 10 may have a variable thickness t, preferably in the range 0.5 cm <t <10 cmThe foam or wood layer 10 can be made from any commonly known polymeric foam, such as PVC, PP, PET or other thermoplastic polyester, PU, PS, SAN, or any natural cellular solid such as wood or cork, and so on. In a preferred embodiment, the solid is made from a recyclable material, such as PET or PP. In a preferred embodiment, the solid is made of a thermoplastic material that can be easily bonded by the application of heat and pressure to the adjacent layers of the same material.Different types of wood or foam layers 10 may be used within the same stack 1, e.g. a mixture between foam layers, wood layers or different layers of wood / foam with different densities.<tb> • <SEP> The number of natural fiber layers 20, 200, 201 between each foam or wood layer may vary; preferably one layer is used as in Fig. 1B, but two or more layers can be used as in Fig. 1A.<tb> • <SEP> The natural fiber layers 20, 200, 201 may be made of a textile, e.g. a sewn or a woven textile, a scrim, a multiaxial scrim, etc.The fibers constituting the natural fiber layers are preferably natural fibers (kenaf, bamboo, flax, hemp, jute, ramie, sisal, henequen, silk, wool or cotton, etc.), but may additionally contain any polymer fibers contain.
    According to various embodiments of the invention, at least one of the natural fiber layers 20, 200, 201 has:<tb> (i) <SEP> 45 ° plain weave woven fabric, i. a textile with natural fibers oriented + 45 ° relative to the longitudinal direction of the layers (0 ° parallel to the longitudinal direction, 90 ° perpendicular to the longitudinal direction of the foam or wooden plate 10);<tb> (ii) <SEP> a 45 ° plain weave woven fabric, i. a textile with natural fibers oriented at -45 ° and with other natural fibers oriented at + 45 ° relative to the longitudinal direction of the layers;<tb> (iii) </ RTI> a textile with natural fibers oriented at -45 °, with other natural fibers oriented at + 45 °, and other other natural fibers oriented 90 ° relative to the longitudinal direction of the layers.
    The use of textiles 20 having a single layer without a backsheet reduces the overall weight of the product.
    As will be described later, at least some of the natural fiber layers 20, 200, 201 may comprise a textile in which thermoplastic fibers are embedded and mixed with natural fibers. In one embodiment, the producing filaments may be blended with filaments containing both natural and polymeric fibers.
    The method W / N: connect
    As illustrated in Fig. 2A, the various layers 10, 20, 200, 201 are adhesively bonded together so as to form a board 1 from a stack 1 of layers 10, 20 which are generally parallel to the upper side and / or to the lower side of the plate.
    Various methods may be used for bonding the natural fibers to the foam or wood layers: If the natural fiber layers 20, 200, 201 already contain a thermoplastic material, e.g. additional threads in addition to the natural fiber threads, or as mixed threads, bonding can be achieved by heating and compressing the stack 1 so that the thermoplastic material melts and is welded to the foam or wood 10. Alternatively, the natural fiber layers 20, 200, 201 may be impregnated prior to or during stacking with a thermoplastic powder that is welded to the foam or wood layers 10. In a preferred embodiment, the material for the thermoplastic fibers / filaments or thermoplastic powder is the same as the material for the foam; this improves the quality of the connection and facilitates the recycling of the final product. This material can be PET, polypropylene, PA, PE, PVC, TPU, PS, EVA, SAN, PLA or thermoplastic polyester such as e.g. Be PET.
    In an alternative embodiment, the natural fiber textile layers 20 may be impregnated during the stacking process, or may be previously completely or partially impregnated with an adhesive material, such as e.g. Thermoset resin, e.g. an epoxy resin, to be impregnated. Alternatively, a thermoplastic or an adhesive layer may be interposed between the layers 20, 200, 201 of the natural fiber composites and a foam or wood layer 10 and used to join these layers. The use of additional adhesives has the advantage of improving heat resistance, e.g. if the product is further processed using further heat-involved steps; however recycling makes it much more difficult.
    The procedure III / IV: cutting
    As shown in Fig. 3A, the obtained composite material 1 is cut perpendicular to the plate and to the layer planes. This results in plates 100 shown in FIG. 3B having the upper sides 103 and lower sides 102 corresponding to the cutting planes, i. perpendicular to the layer planes. The cut may be straight or curved (not shown) as shown in Figs. 3A and 3B, the latter resulting in a board having a lower and / or upper side 102, 103 which is not flat.<tb> • <SEP> The thickness of the plate 100 (i.e., the distance between adjacent cutting planes) may vary between 1 mm and several dm<tb> • <SEP> The cut lines may or may not be parallel to each other so that plates 100 having upper and lower sides that are parallel or not parallel to each other are manufactured. Different plates may have different thicknesses and / or different vertical sections.<tb> • <SEP> When a thermosetting resin is used in the natural FRP layers, a post-curing step may be added to increase the glass transition temperature (Tg) of the polymer or the resin.
    The procedure IV / IV: milling / sands
    As shown in Fig. 4A, the obtained plate 100 can be used as a structural core material which can be milled / sanded / shaved:<tb> • <SEP> to change the shape in the plane (for example, to get a ski or snowboard shape),<tb> • <SEP> to change the thickness along the plate (in any direction, e.g., according to the thickness of the skid).<tb> • <SEP> Preferably, computer numerically controlled (CNC) machine tools are used for milling.
    applications
    The structured core materials disclosed in this invention find application in:<Tb> • <September> Skikernen<Tb> • <September> snowboard cores
    The product can be generated in a batch; however, an economically most efficient option is a continuous production line that combines extrusion foaming of the foam layers between impregnated FRP layers followed by consolidation and cutting to the correct shape.
    权利要求:
    Claims (11)
    [1]
    A method of making a ski core or a snowboard core, comprising:Impregnating at least one layer of natural fiber-based composite material (20, 200, 201) with an adhesive material,Stacking further layers of foam or wood (10) with the at least one impregnated layer (20, 200, 201) of the natural fiber-based composite material;Joining the layers;Obtaining a plurality of structured parts (100) by cutting the obtained stack (1) at right angles to the layer planes, the thickness of the parts being greater than 1 mm, each of the structured parts being a board (100) comprising an upper side (100) 103) and a lower side (102), the layers being perpendicular to the upper or lower side plane;Forming the board as a ski core or snowboard core (100) by milling, sanding and / or machining the upper side (103) and / or the lower side (102).
    [2]
    2. The method of claim 1, wherein the stack is cut perpendicular to the layer planes along a curved path.
    [3]
    3. The method of claim 1 or 2, wherein the natural fibers are made of flax.
    [4]
    4. The method of claim 3, wherein the further layers consist of balsa.
    [5]
    5. The method of claim 3 wherein the further layers are foam.
    [6]
    A method according to any one of claims 1 to 5, wherein at least one of the layers of the natural fiber-based composite material has a plurality of layers (200, 201) of natural fibers in different orientations.
    [7]
    The method of claim 6, wherein at least one of the layers of the natural fiber-based composite (20, 200, 201) is oriented to a textile having natural fibers oriented at + 45 ° and other natural fibers oriented at -45 ° relative to the longitudinal direction of the layers are, has.
    [8]
    The method of claim 6, wherein at least one of the layers of the natural fiber-based composite material (20, 200, 201) is a textile having natural fibers oriented at + 45 ° with other natural fibers oriented at -45 ° and with other natural fibers. which are oriented 90 ° relative to the longitudinal direction of the layers.
    [9]
    A method according to any one of claims 1 to 8, wherein the steps of stacking, bonding and cutting are performed in a continuous manufacturing process.
    [10]
    10. Skikern or snowboard core, comprising a composite material;an upper side (103) and a lower side (102);a stack of foam or wood (10) adhesively bonded to layers of natural fiber based composite material, the layers extending in a direction perpendicular to at least one of the upper side (103) and the lower side (102), the upper side (FIG. 103) and / or the lower side (102) is formed by milling, sanding and / or machining.
    [11]
    11. The ski core or snowboard core according to claim 16, wherein the height of the stack (1) is greater than the width of the layers between the upper side and the lower side.
    类似技术:
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    同族专利:
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    WO2013026925A1|2013-02-28|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US5834082A|1992-05-04|1998-11-10|Webcore Technologies, Inc.|Reinforced foam cores and method and apparatus of production|
    WO2001026899A1|1999-10-08|2001-04-19|Milwaukee Composites, Inc.|Panels utilizing a precured reinforced core and method of manufacturing the same|
    US7851048B2|2008-02-12|2010-12-14|Milliken & Co.|Fiber reinforced core panel|
    DE102008010869A1|2008-02-23|2009-09-10|Thermoplast Composite Gmbh|Support structure and method for producing and using such a support structure|DK2784106T3|2013-03-28|2018-12-17|Siemens Ag|Composite Structure|
    FR3086883B1|2018-10-05|2021-02-26|Bcomp Sa|DEVICE FOR REINFORCING THE STRUCTURE OF A SNOWBOARD|
    WO2021185632A1|2020-03-19|2021-09-23|Mubea Carbo Tech Gmbh|Protecting member for a battery structure of an electric vehicle|
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    CH13902011|2011-08-25|
    PCT/EP2012/066516|WO2013026925A1|2011-08-25|2012-08-24|A method for manufacturing a composite material, and a sheet made of this composite material|
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