CA2407880A1 - Process to manufacture high impact natural composites - Google Patents

Process to manufacture high impact natural composites Download PDF

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Publication number
CA2407880A1
CA2407880A1 CA002407880A CA2407880A CA2407880A1 CA 2407880 A1 CA2407880 A1 CA 2407880A1 CA 002407880 A CA002407880 A CA 002407880A CA 2407880 A CA2407880 A CA 2407880A CA 2407880 A1 CA2407880 A1 CA 2407880A1
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Prior art keywords
fibers
matrix
fiber
thermoplastic
loose
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CA002407880A
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French (fr)
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CA2407880C (en
Inventor
Mohini M. Sain
Pervaiz Muhammad
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
    • C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
    • B29K2311/10—Natural fibres, e.g. wool or cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10—Homopolymers or copolymers of propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
    • C08L2205/16—Fibres; Fibrils
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse

Abstract

The use of natural fibers as reinforcing filler in thermoplastics is a relatively new innovation and has great potential to replace glass fiber products in building, consumer goods, furniture and automotive industry. Our published results demonstrated that laying natural fiber mat and polymer film in a definite pattern and orientation can enhance mechanical strength. In this invention, an unique process has been developed to manufacture high impact strength composite that contains loose natural fiber and/or a combination of loose natural fiber and natural fiber mat to develop green composites outstanding impact strength and other mechanical properties. Loose fibers used in this process can be obtained from agro-plant and wood. Mats, if used, can be obtained from similar sources. Polymer those are used include thermoplastic polyolefins (TPOs), acrylic and polyester films. This invention is specially useful for natural composites with natural fiber content above 40% by weight up to 93 wt% fiber. Film stacking and fiber spraying methods were used to construct sheet, laminates and thermoforming and compression molding were used to design a product. A range of impact strength was obtained which varies from 100 J/m to as high as 250 J/m with a significant increase in flexural and tensile strengths. Products having uniform density profiles yield maximum enhancement in impact properties.

Claims (12)

1. A manufacturing process to produce thermoplastic composite in which reinforcement fibers in the form of loose bundle layers are stacked alternately with thermoplastic matrix, whereby each layer of loose fiber is covered by at least one film or foil of matrix material on each side, thereafter hot pressing the alternate film stack/lay-up at high temperature followed by cooling under same consolidation pressure to manufacture desired composite material, characterized in that the loose, random, and un-processed fibers are used and distributed evenly in the said film stacking arrangement where each layer of fiber and matrix material has equal pre-defined quantity by weight.
2. A process according to claim 1, characterized in that fiber mats can be used in similar lay-up method.
3. A process according to claim 1, characterized in that interfacial bonding between cellulose fibers and matrix is introduced by using pre-treated matrix films with maleic-anhydride polymers of polypropylene (MA-PP) or polyethylene (MA-PE).
4. A process according to claim 1 and 2, characterized in that reinforcement fibers fall in one of following categories:
a. Cellulose bast fibers obtained from plants of hemp, flax, kenaf, sisal and jute.
b. Agri-residue fibers, such as rice husk and wheat straw.
c. Virgin or recycled wood fibers.
5. A process according to claim 1 to 3, characterized in that matrix selected is from thermoplastic family of polymers consisting either of homo polypropylene (PP) or co-polymers of polypropylene and polyethylene.
6. The thermoplastic polymer manufactured through the said inventive process consists essentially the following:
1. Alternate stacked layers of loose ligno-cellulose fibers and/or mats in combination with thermoplastic matrix films distributed evenly in stacked lay-up.
2. The matrix films may or may not be treated with coupling agent.
7. The manufacturing process of compression molding consists following steps:
1. Film stacking of fiber layers and matrix films in alternate arrangement in such a way that each layer of natural fibers is covered on both sides by at least one film of matrix.
2. Hot pressing of film stack at elevated temperature and pressure followed by cooling under same consolidation to manufacture desired thermoplastic composite.
8. Thermoforming process can be also used to make three dimensional/intricate products by using same raw materials as mentioned in claim 4 and 5.
9. In the product of claim 6, the reinforcement material belongs to any of plant fibers, agri-residuals or virgin/recycled wood fibers as mentioned in claim 4.
10. The matrix in the product of claim 6 is essentially of thermoplastic family as mentioned in claim 5.
11. The coupling agents in the product of claim 6 can be either impregnated into thermoplastic films or cellulose fibers as mentioned below:
a. The matrix is treated with maleic-anhydrie co-polymers of polypropylene or polyethylene.
b. Reinforcement fibers can be treated with Silane solutions through quick aqous method if required.
12. The commercial use of said product according to any claims 6 to 10 in auto sector, general purpose household, upholstery and semi-structural construction applications as mentioned in potential application section.
CA2407880A 2002-10-26 2002-10-26 Process to manufacture high impact natural composites Expired - Fee Related CA2407880C (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
CA2407880A CA2407880C (en) 2002-10-26 2002-10-26 Process to manufacture high impact natural composites

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CA2407880A1 true CA2407880A1 (en) 2004-04-26
CA2407880C CA2407880C (en) 2011-02-01

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2923179A1 (en) * 2007-11-02 2009-05-08 Carbone Forge Sarl PROCESS FOR THE MANUFACTURE BY MOLDING A THERMOPLASTIC COMPOSITE PIECE
EP2269789A1 (en) * 2008-03-27 2011-01-05 Toyota Boshoku Kabushiki Kaisha Method of producing composite plant fiber material
EP2455421A1 (en) * 2009-07-15 2012-05-23 Lion Idemitsu Composites Co., Ltd. Composite resin composition
CN102643557A (en) * 2012-04-23 2012-08-22 安徽红树林新材料科技有限公司 Novel wood flour and rice hull powder mixed type thermoplastic wood-plastic composite material and preparation method thereof
EP2555913A1 (en) * 2010-04-08 2013-02-13 Juha Varis Method and device for fabricating a composite product
WO2015005854A1 (en) * 2013-07-01 2015-01-15 Sik - Institutet För Livsmedel Och Bioteknik Ab A formable composite material and a method for manufacturing a formable composite material
CN105040275A (en) * 2015-08-31 2015-11-11 常州市康捷特种无纺布有限公司 Wet-process substrate non-woven fabric used for reverse osmosis membrane and preparation method thereof
CN105199232A (en) * 2015-10-28 2015-12-30 辽宁石油化工大学 Polyolefin resin composition
US11447920B2 (en) * 2020-08-01 2022-09-20 Luke G. Millam System and method for hemp reinforced ice bridge

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101058675B (en) * 2007-05-23 2011-05-04 泉州云麻新资源高分子材料研究中心有限公司 Modified hemp stalk core powder composition
EP3124192B1 (en) 2015-07-27 2018-08-22 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Method for manufacturing an injection moulding or extrudable granulate
DE102015116185B3 (en) * 2015-07-27 2017-01-26 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Process for producing a plate-shaped material, an injection-moldable or extrudable granulate therefrom and granules

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2923179A1 (en) * 2007-11-02 2009-05-08 Carbone Forge Sarl PROCESS FOR THE MANUFACTURE BY MOLDING A THERMOPLASTIC COMPOSITE PIECE
EP2269789A1 (en) * 2008-03-27 2011-01-05 Toyota Boshoku Kabushiki Kaisha Method of producing composite plant fiber material
EP2269789A4 (en) * 2008-03-27 2011-05-18 Toyota Boshoku Kk Method of producing composite plant fiber material
US8309006B2 (en) 2008-03-27 2012-11-13 Toyota Boshoku Kabushiki Kaisha Method of producing composite plant fiber material
EP2455421A1 (en) * 2009-07-15 2012-05-23 Lion Idemitsu Composites Co., Ltd. Composite resin composition
EP2455421A4 (en) * 2009-07-15 2013-04-17 Lion Idemitsu Composites Co Ltd Composite resin composition
EP2555913A1 (en) * 2010-04-08 2013-02-13 Juha Varis Method and device for fabricating a composite product
EP2555913A4 (en) * 2010-04-08 2014-07-02 Juha Varis Method and device for fabricating a composite product
CN102643557A (en) * 2012-04-23 2012-08-22 安徽红树林新材料科技有限公司 Novel wood flour and rice hull powder mixed type thermoplastic wood-plastic composite material and preparation method thereof
WO2015005854A1 (en) * 2013-07-01 2015-01-15 Sik - Institutet För Livsmedel Och Bioteknik Ab A formable composite material and a method for manufacturing a formable composite material
CN105040275A (en) * 2015-08-31 2015-11-11 常州市康捷特种无纺布有限公司 Wet-process substrate non-woven fabric used for reverse osmosis membrane and preparation method thereof
CN105040275B (en) * 2015-08-31 2017-03-29 常州市康捷特种无纺布有限公司 Wet method base material non-woven fabrics for reverse osmosis membrane and preparation method thereof
CN105199232A (en) * 2015-10-28 2015-12-30 辽宁石油化工大学 Polyolefin resin composition
US11447920B2 (en) * 2020-08-01 2022-09-20 Luke G. Millam System and method for hemp reinforced ice bridge

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