FIBER COMPOSITE PRODUCT AND A METHOD FOR PRODUCING THEREOF

Abstract

A fiber composite product for an automotive interior or exterior component. The fiber composite product includes a first layer including a structured natural fiber fabric embedded within a solidified matrix of thermoplastic resin; a second layer including natural fibers in form of a non-woven mat within a solidified matrix of thermoplastic resin, which is attached at the first layer, and injections of thermoplastic resin onto the second layer.

Claims

1. A fiber composite product for an automotive interior or exterior component, comprising: a first layer comprising a structured natural fiber fabric embedded within a solidified matrix of thermoplastic resin; a second layer comprising natural fibers in form of a non-woven mat within a solidified matrix of thermoplastic resin, which is attached at the first layer; and injections of thermoplastic resin onto the second layer.

2. The fiber composite product according to claim 1, the structured natural fiber fabric comprising aligned, braided, woven or knitted natural fibers.

3. The fiber composite product according to claim 1, the structured natural fiber fabric comprising commingled yarns comprising natural fibers and thermoplastic resin fibers.

4. The fiber composite product according to claim 1, the structured natural fiber fabric comprising a pre-impregnated preform with a laminated thermoplastic film, powder thermoplastic resin, thermoplastic binder or thermoplastic foil.

5. The fiber composite product according to claim 1, the structured natural fiber fabric comprising at least a natural fiber unidirectional tape.

6. The fiber composite product according to claim 1, the non-woven mat comprising low-grade and/or recycled natural fiber.

7. The fiber composite product according to claim 1, a ratio of natural fibers to synthetic material is between 20:80 by weight and 80:20 by weight, respectively.

8. The fiber composite product according to claim 1, the injections of thermoplastic resin forming a fastening means such as a fasting point or a fasting clip or a reinforcing rib.

9. The fiber composite product according to claim 1, the first layer and/or the second layer being colored, textured and/or grained.

10. The fiber composite product according to claim 1, the first and/or the second layer being covered with a colored foil or fabric.

11. The fiber composite product according to claim 1, the natural fibers and/or the thermoplastic resin comprising a stabilizing agent selected from a group comprising at least a UV absorber, light stabilizer, heat stabilizer, moisture scavenger and a combination thereof.

12. The fiber composite product according to claim 1, the first layer having a density in a range of 50-3000 g/m.sup.2 and/or the second layer having a density in a range of 300-3000 g/m.sup.2.

13. The fiber composite product according to claim 1, the structured first layer comprising a woven structure, the injections of thermoplastic resin being provided on the first layer.

14. A method for producing a fiber composite product for an automotive interior or exterior component, comprising: providing a first layer comprising a structured natural fiber fabric within a solidified matrix of thermoplastic resin; attaching a second layer at the first layer, the second layer comprising natural fibers in form of a non-woven mat within a solidified matrix of thermoplastic resin; and providing injections of thermoplastic resin onto the second layer.

15. The method according to claim 14, attaching the second layer to the first layer comprising an in-situ impregnation comprising heating the second layer and/or the first layer above a pre-determined temperature.

16. The method according to claim 14, further comprising pressing of the attached first and second layers.

17. The method according to claim 14, further comprising shredding and/or grinding of the fiber composite product after use as an automotive interior or exterior component, and adding of the cut, shredded and/or ground fiber composite product in a forming of a non-woven mat or in injections onto a second layer of a new fiber composite product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Examples of the disclosure will be described in the following with reference to the following drawings.

[0042] FIG. 1 shows an illustration of a life cycle of a fiber composite product according to the disclosure,

[0043] FIG. 2 shows an embodiment of a fiber composite product according to the disclosure,

[0044] FIGS. 3a-3f show illustrations of an example method for producing a fiber composite product according to the disclosure,

[0045] FIGS. 4a-4e show illustrations of another example method for producing a fiber composite product according to the disclosure.

[0046] The figures are merely schematic representations and serve only to illustrate examples of the disclosure. Identical or equivalent elements are in principle provided with the same reference signs.

DETAILED DESCRIPTION

[0047] FIG. 1 shows a life cycle of a fiber composite product 10. A natural material 100, here illustrated as flax plant, is processed into fine-grade natural fibers 101. The natural material 100 is also processed into low-grade natural fibers 102. The fine-grade natural fibers 101 are integrated with thermoplastic resin (not shown in FIG. 1) to form the first layer 11. The low-grade natural fibers 102 are also integrated with thermoplastic resin (not shown in FIG. 1) to form the second layer 12. The second layer 12 is attached to the first layer 11 and injections of thermoplastic resin 13 are provided onto the second layer 12 (not shown), forming the fiber composite product 10. After use as an automotive interior or exterior component, the fiber composite product 10 is shredded and/or ground to form low-grade natural fibers 102. The low-grade natural fibers 102 are used in the forming of the second layer 12 and/or in injections of thermoplastic resin onto the second layer 12 of a new fiber composite product (recycled product 103).

[0048] FIG. 2 shows a finished fiber composite product 10 for an automotive interior or exterior component. The fiber composite product 10 includes the first layer 11, the second layer 12 and the injections of thermoplastic resin 13 on the second layer 12. The first layer 11 includes a natural fiber fabric within a solidified matrix of thermoplastic resin (not shown in the figures). The second layer 12 includes natural fibers 22 in form of a non-woven mat within a solidified matrix of thermoplastic resin (not shown), which is attached to the first layer 11. Further, the fiber composite product 10 includes injected resin on the second layer 12 extending out of the second layer 12 to form protrusions in different shapes.

[0049] FIGS. 3a-3f and 4a-4e show illustrations of example methods for producing a fiber composite product 10. The method shown in FIGS. 3a-3f differs from the method shown in FIG. 4a-4e in heating the first and the second layers 11, 12 while compression.

[0050] In FIG. 3a, the first layer 11 and the second layer 12 are placed in a flat press 30, which is heated around e.g. 200? C. In FIG. 3b, the heated layers 11, 12 are pressed to make the first and the second layers 11, 12 thinner. Accordingly, an in-situ impregnation of the fiber composite product 10 is achieved. In FIG. 3c, the combined first and the second layers 11, 12 are placed on a shaped press 31, which is cooled down to e.g. 20-120? C. As shown in FIGS. 3c and 3d, the edges of the fiber composite product 10 is cut by an accessory 32 of the shaped press 31 by joining the shaped press 31 while the fiber composite product 10 is inside. The accessory is depicted as cutters in FIGS. 3c and 4a. Nevertheless they can be any kind of accessory fulfilling any other function for shaping the fiber composite product 10. In FIG. 3e, injections of thermoplastic resin 13 are added to the second layer 12, while the shaped press 31 is in the joined position. In FIG. 3f, the fiber composite product 10 is produced.

[0051] In FIG. 4a, the first layer 11 and the second layer 12 are placed in a shaped press 31 without heating the shaped press 31. Here, flattening of the combined first and second layers 11, 12 is skipped. The shaped press 31 includes the accessory 32. In FIG. 4b, the first and the second layers 11, 12 are compressed, still without application of any heat and edges of the first and the second layers 11, 12 are cut. In the step shown in FIG. 4c, the shaped press 31 is heated (for instance to around 200? C., possibly in cycles) while the first and the second layers 11, 12 are inside the shaped press 31. In FIG. 4d, injections of thermoplastic resin 13 are added to the second layer 12, while the shaped press 31 is in the joined position. In FIG. 4e, finished fiber composite product 10 is produced.

[0052] Other variations to the disclosed examples can be understood and effected by those skilled in the art in practicing the claimed disclosure, from the study of the drawings, the disclosure, and the appended claims. In the claims the word comprising does not exclude other elements or steps and the indefinite article a or an does not exclude a plurality. A single processor or other unit may fulfill the functions of several items or steps recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. A computer program may be stored/distributed on a suitable medium such as an optical storage medium or a solid-state medium supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems. Any reference signs in the claims should not be construed as limiting the scope of the claims.