FIBRE COMPOSITE MATERIAL AND METHOD FOR PRODUCING SAME

Abstract

The present invention relates to fiber composite plastic (11, 13) comprising a polymer (40, 41) and at least one textile (50), which has at least one palpably inhomogeneous surface (60, 61) with a textile structure and is entirely surrounded by polymer (40, 41), wherein the fiber composite plastic (11, 13) has at least one palpably inhomogeneous surface (60, 61), wherein inhomogeneities of this fiber composite plastic surface are caused by the textile structure, and a method for producing the fiber composite plastic (11, 13).

Claims

1. A fiber composite plastic (11, 13) comprising a polymer (40, 41) and at least one textile (50) having at least one palpably inhomogeneous textile surface (70, 71) with a textile structure and completely enclosed by the polymer (40, 41), wherein the fiber composite plastic (11, 13) has at least one palpably inhomogeneous fiber composite plastic surface (60, 61), inhomogeneities of said fiber composite plastic surface being caused by the textile structure, wherein the textile structure results from a weave or knit pattern or another type of interconnection of fiber or yarns, and wherein the fiber composite plastic surface (60, 61) has an inhomogeneity with a plurality of height differences of at least 0.01 mm.

2. The fiber composite plastic (11, 13) according to claim 1, wherein the textile (50) is selected from the group consisting of used textile and textile waste, preferably used textile.

3. The fiber composite plastic (11, 13) according to claim 1, wherein the inhomogeneity has an arithmetic average of the roughness profile Ra of at least 3.2 μm.

4. The fiber composite plastic (11, 13) according to claim 1, wherein the textile (50) is selected from the group consisting of woven fabrics, knitted fabrics, braided fabrics and scrims.

5. The fiber composite plastic (11, 13) according to claim 1, wherein the fiber composite plastic (11, 13) comprises a plurality of identical or different textiles (50), which are optionally connected to one another by a binding process selected from the group comprising sewing, gluing, welding and ironing.

6. The fiber composite plastic (11, 13) according to claim 1, wherein the textile (50) comprises natural fibers, and preferably consists thereof.

7. The fiber composite plastic (11, 13) according to claim 1, wherein the fiber composite plastic (11, 13) further comprises reinforcing fibers, preferably natural fibers.

8. The fiber composite plastic (11, 13) according to claim 1, wherein the textile (50) increases the flexural strength of the fiber composite plastic (11, 13), the flexural strength preferably being at least 30 MPa.

9. The fiber composite plastic (11, 13) according to claim 1, wherein the polymer (40, 41) is a thermoset, an elastomer or a thermoplastic, preferably a thermoset.

10. The fiber composite plastic (11, 13) according to claim 1, wherein the fiber volume content is 25-75% Vf, preferably 45% Vf or less.

11. The fiber composite plastic (11, 13) according to claim 1, in which the amount of polymer (40, 41) is 25-75% % Vf, preferably 55% Vf or more.

12. A method of making the fiber composite plastic (11, 13) according to claim 1, comprising steps of: a) providing the textile (50) as a blank (10, 12), b) impregnating the textile (50) with a polymer (40, 41), resulting in an impregnated blank (10, 12), c) optionally, applying a soft overlay layer (30, 31) to the blank (10, 12), wherein the overlay layer (30, 31) is applied to a surface of the blank (10, 12) at which the textile (50) contained in the blank (10, 12) has a palpably inhomogeneous textile surface (70, 71), wherein steps b and c can be carried out in any order, d) when step c) is carried out, subjecting the overlay layer (30, 31) to pressure such that the overlay layer (30, 31) is deformed to produce inhomogeneities of the surface of the impregnated blank (10, 12) caused by the textile structure, e) solidifying the blank, preferably hardening it, and f) if present, detaching the overlay layer (30, 31), wherein, if step c), d) and f) are not present, preference is given to using pultrusion.

13. The method according to claim 12, wherein a plurality of prepregs produced by steps a and b are laminated to produce the fiber composite plastic (11, 13).

14. Use of waste textiles and/or textile waste for production of the fiber composite plastic (11, 13) according to claim 1.

15. Use of a soft overlay layer (30, 31) for production of the fiber composite plastic (11, 13) according to claim 1.

16. A furniture, flooring, or interior design element comprising the fiber composite plastic according to claim 1.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0147] FIG. 1 shows a textile layer 50, a polymer 40, 41 and a soft support layer 30 in a tool 100 before the application of pressure p.sub.01,

[0148] FIG. 2 shows a textile layer 50, a polymer 40, 41 and a soft support layer 30 in a tool 100 after pressure p.sub.01i has been applied,

[0149] FIG. 3 shows the finished fiber composite plastic 11 with a palpably inhomogeneous surface 60,

[0150] FIG. 4 shows a textile layer 50, a polymer 40, 41 and two soft support layers 30, 31 in a tool 100 before the application of pressure p.sub.01, p.sub.02,

[0151] FIG. 5 shows a textile layer 50, a polymer 40, 41 and two soft overlay layers 30, 31 in a mold 100 after applying pressure p.sub.01, p.sub.02,

[0152] FIG. 6 shows the finished fiber composite plastic 13 with a palpably inhomogeneous surface 60, 61,

[0153] FIG. 7 shows a schematic overview of a process according to the invention for the production of a fiber composite plastic.

[0154] FIG. 8 shows an image of a fiber composite plastic produced according to embodiment 7.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0155] Preferred exemplary embodiments are described below, for example with reference to the figures.

[0156] Elements that are the same, similar or have the same effect are provided with identical reference symbols in the different figures, and a repeated description of these elements is partially omitted in order to avoid redundancies.

[0157] FIG. 1 shows a textile layer 50, a polymer 40, 41 and a soft overlay layer 30 in a mold 100 before applying pressure p.sub.01, In this case, the blank 10 corresponds to a textile layer 50 and a polymer 40, 41.

[0158] The textile 50 has two palpably inhomogeneous surfaces 70, 71. The blank 10 is placed between the top surface 40 and the bottom surface 41 of a tool 100. A soft covering layer 30 is placed on the upper side of the blank 10.

[0159] FIG. 2 shows a textile layer 50, a polymer 40, 41 and a soft support layer 30 in a tool 100 after pressure p.sub.01 has been applied. Here, the overlay layer 30 is subjected to a pressure p.sub.01 by pressure on the upper surface 20 of the mold 100. Alternatively, the pressure may be applied to the lower surface 21 of the tool 100. This presses the overlay layer against the blank in such a way that the part of the polymer 40 which covers the textile 50 or the palpably inhomogeneous surface 70 of the textile 50 is formed in such a way that an inhomogeneous surface 60 is produced, wherein inhomogeneities of this fiber composite surface are caused by the textile structure, i.e. by the palpably inhomogeneous surface 70 of the textile 50. The part of the polymer 41 that covers the lower, palpably inhomogeneous surface 71 of the textile 50 is shaped according to the tool 100 used or the lower surface 21 of the tool 100.

[0160] FIG. 3 shows the finished fiber composite plastic 11 with two surfaces 60, 62 after cooling and removal of the overlay layer 30. In this case, the palpably inhomogeneous surface 60 has inhomogeneities 60 which are caused by the palpably inhomogeneous surface 70 of the textile 50. The surface 62 does not have any inhomogeneities which are caused by the palpably inhomogeneous surface 71 of the textile 50, but has a surface 62 which results from the surface properties of the lower surface 21 of the tool 100. In this case, it is homogeneous, or smooth.

[0161] Within the scope of the invention, it is possible to produce fiber composite plastics in which the surface 62 of the fiber composite plastic 11 has inhomogeneities which are not caused by the inhomogeneous surface 71 of the textile 50.

[0162] FIG. 4 shows a textile layer 50, a polymer 40, 41 and two soft overlay layers 30, 31 in a mold 100 before applying pressure p.sub.01, p.sub.02. The textile 50 has two palpably inhomogeneous surfaces 70, 71. The blank 12 corresponds to a textile layer 50 and a polymer 40, 41. Here, the blank 12 is positioned between the upper surface 20 and the lower surface 21 of a tool 100. A first soft overlay layer 40 is placed on the upper side of the blank 12, and a second soft overlay layer 41 is placed on the lower side of the blank 12.

[0163] FIG. 5 shows a textile layer 50, a polymer 40, 41 and two soft overlay layers 30, 31 in a mold 100 after applying pressure p.sub.01, p.sub.02. Here, the overlay layer 30 is subjected to a pressure p.sub.01 by the upper surface 20 of the mold 100. Alternatively (or additionally), the pressure p.sub.02 can also be applied to the lower surface 21 of the tool 100. As a result, the overlay layers 30, 31 are pressed against the blank 12 in such a way that the polymer 40, 41 covering the two palpably inhomogeneous surfaces 70, 71 of the textile 50 is shaped in such a way that inhomogeneous surfaces 60, 61 are formed, wherein inhomogeneities are caused by the palpably inhomogeneous surfaces 70, 71 of the textile 50.

[0164] In FIG. 6, the finished fiber composite 13 is shown with two palpably inhomogeneous surfaces 60, 61 after cooling and removal of the overlay layers 30, 31. The palpably inhomogeneous surfaces 60, 62 exhibit inhomogeneities caused by the palpably inhomogeneous surfaces 70, 71 of the textile 50.

[0165] FIG. 7 shows a schematic overview of a process according to the invention for the production of a fiber composite plastic. Here, in a first step of impregnation 200, the textile 50 is impregnated with the polymer 40, 41, i.e., brought into contact with each other, resulting in an impregnated blank 10. In a second step, a soft overlay layer 30 is placed on a surface of the blank 10. In the next step, the support layer 30 is subjected to a pressure μm, by the upper surface of the tool 100. This presses the overlay layer against the blank in such a way that the part of the polymer 40 covering the palpably inhomogeneous surface 70 of the textile 50 is formed in such a way that an inhomogeneous surface 60 is produced, wherein inhomogeneities of this blank surface are caused by the palpably inhomogeneous surface 70 of the textile 50. The next step is to harden 201 the blank 10 into a fiber composite plastic.

[0166] In this process, crosslinking of the polymer 40, 41 takes place, resulting in a fiber composite plastic 11.

[0167] Finally, the fiber composite plastic is cooled 202 and the overlay layer 30 is removed. The process described in FIG. 7 produces a fiber composite plastic 11 that has a palpably inhomogeneous surface 60, which has inhomogeneities 60 caused by the palpably inhomogeneous surface 70 of the textile 50.

[0168] In this case, the surface 62 does not have any inhomogeneities which are caused by the palpably inhomogeneous surface 71 of the textile 50, but it is homogeneous, or smooth, i.e. it has a surface 62 which is caused by the surface properties of the lower surface 21 of the tool 100. However, it is also possible that the surface 62 of the fiber composite plastic 11 has inhomogeneities that are not caused by the textile structure 50.

[0169] FIG. 8 is the finished fiber composite plastic with palpably inhomogeneous surfaces 60 after pultrusion and cooling. The palpably inhomogeneous surfaces 60 exhibit inhomogeneities caused by the palpably inhomogeneous surfaces of the textile.

[0170] Further preferred exemplary embodiments are described below.

Example 1 (Decor Panel, 2 mm Thick)

[0171] A used coffee sack comprising a jute fiber fabric with a basis weight of 417 g/m.sup.2 was stripped of the seams all around. It was then cut into squares with a width of 50 cm. These layers were impregnated by hand with a furan resin consisting of 95% Furolite 120514 RF DAC MV (resin) and 4.8% PAT 6399 (hardener) such that the amount of resin based on the weight of the textile is 1.26. The prepreg was then dried in an oven at 80° C. to constant weight. The same was done with a used old towel comprising cotton fabric. Since the towel layers are only 25 cm wide, they were sewn together end to end. The basis weight of the textile is 218 g/m.sup.2 and the amount of resin is also 1.26 times the weight of the textile. After drying, 1 layer of coffee sack prepreg, then 2 layers of towel prepreg and finally 1 layer of coffee sack prepreg were stacked on top of each other. This layer structure was placed between 2 steel plates in a hot press at 150° C. and pressed at 2 mm distances for 10 minutes. The plate was then quickly removed from the press and cooled to room temperature under pressure. The plate has a flexural strength of 90 MPa at 0° and 85 MPa at 90°.

Example 2 (Visible Plate, Thick)

[0172] A patchwork quilt consisting of selvedges with a basis weight of 1.5 kg/m.sup.2 is placed on a glass plate.

[0173] The glass plate is separated beforehand with a release agent, Jost Chemicals Mold Sealer S-31. A tear-off fabric is placed on the patchwork quilt and a flow aid is placed over it. The entire structure is sealed with Tacky Tape running around the glass plate and a vacuum foil bag placed over it. A vacuum is then drawn and then infused with the RIM resin from Lange+Ritter. The resin consists of RIMR 935 (resin) and the hardener RIMH 936 in a mixing ratio of 100:29. After the part is completely infused, it is hardened in an oven at 80° C. for 14 hrs. The component is then demolded and the peel ply removed.

Example 3 (Profile)

[0174] For a round profile with a diameter of 8 mm, selvedges consisting of cotton and polyester were trimmed so that they have a titer of 3650 tex. 6 of these edges were processed into the profile by pultrusion. An unsaturated itaconic acid resin consisting of 86.2% itaconic acid ester (resin), 8.6% dibutylitaconate (reactive diluent), 1.7% PAT 654 ME (release agent) and 3.5% tert-butyl perbenzoate was used as matrix resin. The impregnation was carried out in an immersion bath. Hardening was performed in the mold at 175° C.

[0175] The bars have a flexural strength of 200 MPa at 0°.

Example 4 (Molded Part, Here Shaft Plate)

[0176] A used cotton curtain with a basis weight of 238 g/m.sup.2 was cut into rectangular areas, with a width of 50 cm. These layers were impregnated with the furan resin, consisting of 97.7% Furolite 120514 RF DAC MV (resin) and 2.3% PTSA (hardening agent) with padding such that the amount of resin based on textile weight was 1.26. The prepreg was then dried in an oven at 80° C. to constant weight. The same was done with a used old towel comprising cotton fabric. Since the towel layers are only 25 cm wide, they were sewn together end to end. The basis weight of the textile is 218 g/m.sup.2 and the amount of resin is also 1.26 times the textile weight. After drying, 1 layer of cotton curtain, 1 layer of prepreg towel, 1 layer of cotton curtain, 1 layer of prepreg towel and finally 1 layer of cotton curtain again were stacked. This layer structure was placed between 2 shaft tools made of aluminum and pressed in a hot press at 150° C. for 10 min at 2 mm distances. The corrugated plate was then cooled to room temperature under pressure.

[0177] The material has a bending strength of 110 MPa at 0° and 130 MPa at 90°.

Example 5 (Decor Panel, 2 mm Thick)

[0178] A discarded bed sheet from a hospital with a basis weight of 240 g/m.sup.2 was cut into rectangular panels with a width of 50 cm after the seam had been removed. These layers were impregnated with the furan resin, consisting of 95% Furolite 120514 RF DAC MV (resin) and 4.8% PAT 6399 (hardener) by means of a doctor blade in such a way that the amount of resin based on the textile weight is 1.26. The prepreg was then dried in an oven at 80° C. to constant weight. The same was done with a used old towel comprising cotton fabric. Since the towel layers are only 25 cm wide, they were sewn together end to end. The basis weight of the textile is 218 g/m.sup.2 and the amount of resin is also 1.26 times the textile weight. After drying, 1 layer of cotton curtain, 1 layer of prepreg towel, 1 layer of cotton curtain, 1 layer of prepreg towel and finally 1 layer of cotton curtain again were stacked. On the outermost layer was laid a dry auger of cotton and flax yarn. This layer structure was placed between 2 steel plates in a hot press at 150° C. and pressed at 2 mm distances for 10 minutes. The plate was then quickly removed from the press and cooled to room temperature under pressure.

[0179] The material has a bending strength of 110 MPa at 0° and 130 MPa at 90°.

Example 6 (Thick Plate)

[0180] A light-colored fleece, consisting of pressed fibers with a high cotton content from used textiles, with a basis weight of 165 g/m.sup.2 is cut into rectangular areas with a width of 50 cm. These layers are impregnated with the furan resin, consisting of 95% Furolite 120514 RF DAC MV (resin) and 4.8% PAT 6399 (hardener) by means of padding in such a way that the amount of resin relative to the weight of the textile is 1.26. The prepreg is then dried in an oven at 80° C. until its weight is constant. The same happens with used coffee sacks consisting of a jute fiber fabric with a basis weight of 417 g/m.sup.2. This is cleaned from the seams all around. In addition, a used old towel roll, consisting of cotton fabric is used. Since the towel layers are only 25 cm wide, they are sewn together end to end. The basis weight of the textile is 218 g/m.sup.2 and the amount of resin is also 1.26 times the textile weight. After drying, 1 coffee sack prepreg, 1 layer of towel prepreg, 1 layer of coffee sack prepreg, 1 layer of towel prepreg, 68 layers of fleece prepreg, 1 layer of towel prepreg, 1 layer of coffee sack prepreg, 1 layer of towel prepreg and finally 1 layer of coffee sack prepreg are layered on top of each other. This layer structure is placed between 2 steel plates in a hot press at 150° C. and pressed at a distance of 20 mm for 100 minutes.

[0181] The plate is then cooled to room temperature under pressure.

Example 7 (Thick Profile)

[0182] A total of 40 flax yarns with a titer of 1000 tex each, 48 jute yarns with a titer of 830 tex each, 22 black cotton recycled yarns with a titer of 800 tex each, 28 white cotton recycled yarns with a titer of 800 tex each, 6 coconut colored cotton recycled yarns with a titer of 800 tex each, 2 selvedges of cotton with a titer of 4300 tex each, white textile strips from different waste textiles with a titer 10,500 tex and black dyed textile strips made of various waste textiles with a titer of 10,500 tex, prepared for a square profile with an edge length of 16 mm. An unsaturated itaconic acid resin consisting of 86.2% itaconic acid ester (resin), 8.6% dibutylitaconate (reactive diluent), 1.7% PAT 654 ME (release agent) and 3.5% tert-butyl perbenzoate was used as matrix resin. The impregnation was carried out in an immersion bath. Hardening was performed in the mold at 170° C.

[0183] The bars have a flexural strength of 250 MPa at 0°.

[0184] To the extent applicable, any of the individual features shown in the description and/or embodiments may be combined and/or interchanged without departing from the scope of the invention.

REFERENCE LIST

[0185] 10, 12 Blank [0186] 11 Fiber composite plastic with a palpably inhomogeneous surface [0187] 13 Fiber composite plastic with two palpably inhomogeneous surfaces [0188] Upper surface of a tool [0189] 21 Lower surface of a tool [0190] 30, 31 Overlay layer [0191] 40, 41 Polymer [0192] 50 Textile layer [0193] 60, 61 palpably inhomogeneous surface of the fiber composite plastic [0194] 62 Smooth surface of the fiber composite plastic [0195] 70, 71 palpably inhomogeneous surface of the textile [0196] 100 Tool [0197] 200 Laminate [0198] 201 Hardening [0199] 202 Cooling [0200] p.sub.01, p.sub.02Pressure