WO2020161379A1 - Artificial wood - Google Patents

Artificial wood Download PDF

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Publication number
WO2020161379A1
WO2020161379A1 PCT/FI2019/050077 FI2019050077W WO2020161379A1 WO 2020161379 A1 WO2020161379 A1 WO 2020161379A1 FI 2019050077 W FI2019050077 W FI 2019050077W WO 2020161379 A1 WO2020161379 A1 WO 2020161379A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite material
fibers
fiber reinforced
layers
reinforced composite
Prior art date
Application number
PCT/FI2019/050077
Other languages
French (fr)
Inventor
Heikki Koivurova
Aino Lampio
Armin SEEBASS
Original Assignee
Partones Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Partones Oy filed Critical Partones Oy
Priority to PCT/FI2019/050077 priority Critical patent/WO2020161379A1/en
Priority to EP19914652.3A priority patent/EP3921143A4/en
Publication of WO2020161379A1 publication Critical patent/WO2020161379A1/en

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Classifications

    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow 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
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/12—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 structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10D—STRINGED MUSICAL INSTRUMENTS; WIND MUSICAL INSTRUMENTS; ACCORDIONS OR CONCERTINAS; PERCUSSION MUSICAL INSTRUMENTS; AEOLIAN HARPS; SINGING-FLAME MUSICAL INSTRUMENTS; MUSICAL INSTRUMENTS NOT OTHERWISE PROVIDED FOR
    • G10D1/00—General design of stringed musical instruments
    • G10D1/02—Bowed or rubbed string instruments, e.g. violins or hurdy-gurdies
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10D—STRINGED MUSICAL INSTRUMENTS; WIND MUSICAL INSTRUMENTS; ACCORDIONS OR CONCERTINAS; PERCUSSION MUSICAL INSTRUMENTS; AEOLIAN HARPS; SINGING-FLAME MUSICAL INSTRUMENTS; MUSICAL INSTRUMENTS NOT OTHERWISE PROVIDED FOR
    • G10D3/00—Details of, or accessories for, stringed musical instruments, e.g. slide-bars
    • G10D3/22—Material for manufacturing stringed musical instruments; Treatment of the material
    • 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
    • B32B2250/05—5 or more layers
    • 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
    • B32B2250/20—All layers 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • 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
    • 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
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • 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
    • B32B2419/00—Buildings or parts thereof

Definitions

  • the present invention relates to building material for musi cal instruments and specially replacing tonewood species in instrument manufacturing.
  • Many music instruments are tradi tionally constructed of wood, but also have been fabricated from plastics, composite materials, metals and combinations of such materials. Listeners are used to the sound of tradi tional materials.
  • the quality of the wood is essential in building a good acoustic musical instrument.
  • a tree grown in nature is affected by many external variables and therefore the harvested lumber can vary very much in quality.
  • an instrument builder e.g. a luthier
  • the present invention relates to a replace material for wood and other exotic materials especially in music instrument manufacturing.
  • the invention in question relates particularly to save and reduce the use of endangered species of wood like ebony by replacing them in music instruments.
  • String instruments like violins, have been manufactured from very specific species of wood until nowadays. Different parts in the instrument require different features and therefore a variety of wood species has been used in string instrument manufacturing. Some of these traditional tonewoods are aller genic and the instrument builders may risk their health deal ing with them.
  • Import and export of endangered species are strongly moni tored and controlled according to the CITES treaty.
  • the CITES treaty has caused problems to musicians travelling abroad.
  • a music instrument made from endangered wood can draw harmful and unnecessary attention at the customs because the origin of the piece of endangered wood in the instrument is expected to be proven and may cause a lot of paperwork.
  • One objective of the present invention is to eliminate the need to use endangered wood or other rare materials in music instrument manufacturing by introducing a fiber reinforced composite material with similar features of wood or other in strument building materials.
  • Another objective of the present invention is to achieve a wood look-alike material which can be easily proven as arti ficial material at the customs inspection. This is made by adding some UV marking substance in the composite matrix ma terial and fibers. When illuminating the material with UV light it will show up and confirm its non-wooden nature.
  • every layer can be printed with a wood looking pattern to imitate the visual appearance of wood throughout the composite. This allows a 3D wood look ing texture to be visible also after processing the material.
  • the present invention provides a layered fiber reinforced composite material to replace expensive and scarce woods in music instrument manufacturing.
  • the material according to the invention comprises layered fibers bound together with help of a binding substance.
  • matrix is used for the binding substance.
  • Some of the fi bers can be hollow.
  • density of the composite material can be varied by changing the ratio of hollow fibers, other fibers and the matrix.
  • hollow fibers can be used to manipulate the density of the fiber reinforced composite material. Adding hollow fibers in the composite material affects therefore the Q factor of the composite material. By varying the proportion of hollow fibers to other fibers and matrix material, a method to imi tate features of different species of wood is achieved.
  • Another advantage is that the visual appearance for every layer can be designed individually and therefore hidden 3D patterns can be visible even after processing the material. This is achieved by printing individual sheets of layers and stacking them to desired thickness to planks and plates.
  • the compo site material can be distinguished from natural wood by add ing some UV-marking material in the composite material.
  • compo site material is not sensitive to temperature or humidity changes .
  • thermoset plastic in the matrix can be done with the same tools as with real wood and no special tools or special safe ty arrangements are needed. Some trees have toxic biocides which can be allergenic to instrument builders and also even to musicians .
  • Yet a further advantage of the invention is that the yield of artificial wood according to the invention is close to 100% while yield of known tonewoods is only some percent from a real tree.
  • FIG. 1 presents in an oblique side view a layered compo site material according to the invention
  • FIG. 2 presents a magnification of layered composite mate rial of one embodiment of the invention
  • FIG. 3 presents a magnification of layered composite mate rial of another embodiment of the invention.
  • FIG. 4 presents the interaction of the three variables in manipulating the density of artificial tonewood.
  • the pre sent invention provides layered fiber reinforced composite materials with features of tonewood and looking like wood but not being wood.
  • This novel layered fiber reinforced composite material comprises a thermoset plastic matrix, oriented and unoriented fibers which can be hollow fibers.
  • Fig. 1 presents a layer 2 and a block 10 of laminated layered fiber reinforced composite material according to the inven tion where the layer 2 is printed with a texture 3 and the surface of the block 10 is printed with a different texture 6, looking like wood and the side 4 shows the laminated mul tilayer structure 5. Every layer can be attached with its own printed texture to imitate the natural 3D character of wood.
  • Fig. 2 presents a magnification of layered fiber reinforced composite material of one embodiment of the invention where the oriented fibers 9 are shown visible for explanatory rea sons.
  • the layered structure comprises first layers 7 of ori ented fibers 9 and second layers 8 of unoriented fibers.
  • the first layers 7 of oriented fibers 9 and the second layers 8 are stacked by turns.
  • the oriented fibers 9 are arranged sub stantially parallel to each other.
  • the oriented fibers 9 can have for example S twist or Z twist structure. All layers comprise a binding substance or matrix.
  • Unoriented fibers can be added also to the first layers 7 comprising oriented fi bers 9.
  • the laminated layered structure is made by arranging oriented fibers 9 and unoriented fibers on top of each other to form sheets comprising layers 7 and 8.
  • a tex ture is printed to the sheets before or after the binding substance or matrix is added.
  • the matrix is for example ther moset plastic such as melamine, polyester, epoxy, phenol- formaldehyde, lignin derivatives, polyfuran, casein and/or polyurethane.
  • the matrix is formed of powdery substance and the layered structure is formed as a result of heating and pressing the fibers and matrix together.
  • the first layers 7 comprise oriented fibers 9 which can be hollow and/or not hollow fibers.
  • the fibers of the first lay ers 7 are e.g. cellulose based fibers such as linen, hemp, sisal, viscose and/or some other fibers suitable for the pur pose.
  • the first layers 7 can comprise also e.g. kapok, coir, hollow viscose and/or some other fibers suitable for the pur pose.
  • the second layers 8 comprise unoriented fibers which can be hollow fibers e.g. kapok, coir, hollow viscose and/or some other fibers suitable for the purpose.
  • the hollow fibers decrease the density of the layered structure. Adjusting the density with help of hollow fibers in a manufacturing phase a feasible Q factor of the layered structure is achieved. A feasible Q factor for different music instrument parts varies depending on the music instrument part.
  • Fig. 3 presents a magnification of layered fiber reinforced composite material of another embodiment of the invention where the oriented fibers 9 are shown visible for explanatory reasons.
  • this embodiment there are only first layers 7 of oriented fibers 9 which are stacked on top of each other. Al so, in this embodiment unoriented fibers can be added to the first layers 7 comprising oriented fibers 9.
  • Fig. 4 presents the interaction of the three variables in ma nipulating the density of artificial tonewood according to the invention in the manufacturing phase.
  • the density of most commonly used reinforcement fibers is varying between 1,4 g/cm3 - 1,5 g/cm3 and the feasible thermoset plastics or ma trix 1,1 g/cm3 - 1,5 g/cm3. Adding remarkably lighter hollow 0,15 - 1,0 g/cm3 fibers in the composite the density can be altered closer to common tonewoods' density of 0,75 g/cm3 - 1,35 g/cm3.
  • UV-marking material can be added in the composite material according to the invention. In that way the material can be distinguished from natural wood. It is obvious to the person skilled in the art that the in vention is not restricted to the examples described above but that it may be varied within the scope of the claims present ed below. Thus, for instance the structure of the layered ma- terial can be different from what is disclosed above.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

A layered fiber reinforced composite mate- rial comprising layers (7,8) of fibers and binding substance or matrix which is arranged to bind the layers together. The layers (7,8) comprise oriented fibers (9) and unoriented fibers which are arranged on top of each other by turns, and at least some of the fibers are hollow, and the density of the composite material is arranged to be adjusted by quality and quantity of the hollow fibers.

Description

ARTIFICIAL WOOD
Field of the invention
The present invention relates to building material for musi cal instruments and specially replacing tonewood species in instrument manufacturing. Many music instruments are tradi tionally constructed of wood, but also have been fabricated from plastics, composite materials, metals and combinations of such materials. Listeners are used to the sound of tradi tional materials. The quality of the wood is essential in building a good acoustic musical instrument. A tree grown in nature is affected by many external variables and therefore the harvested lumber can vary very much in quality. For an instrument builder (e.g. a luthier) it has been challenging to find suitable and best pieces of wood for his instrument. An artificial produced material of even quality, workability and with the similar features of wood would give to an in strument builder possibilities to build and manufacture in struments constantly of the same desired quality and tonal qualities. After centuries of experimentation some species of wood have become ideal for instrument manufacturing because of their mechanical and acoustic properties, like high stiff- ness-to-weight ratio, speed of the sound, low mass and densi ty. Producing music instruments from wood brings some disad vantages like sensitivity to humidity changes, fragility, scarcity in supply and quality differences in structure. Al so, many species of wood have become endangered.
Background of the invention
The present invention relates to a replace material for wood and other exotic materials especially in music instrument manufacturing. The invention in question relates particularly to save and reduce the use of endangered species of wood like ebony by replacing them in music instruments.
String instruments, like violins, have been manufactured from very specific species of wood until nowadays. Different parts in the instrument require different features and therefore a variety of wood species has been used in string instrument manufacturing. Some of these traditional tonewoods are aller genic and the instrument builders may risk their health deal ing with them.
Music instruments have been designed to have certain fea tures, like sound and visual appearance. These features are achieved by using the right kind of material in specific parts of the instrument. For that reason, it will be diffi cult to replace wood with composite material unless the com posite material has similar features than the replaced wood.
Import and export of endangered species are strongly moni tored and controlled according to the CITES treaty. The CITES treaty has caused problems to musicians travelling abroad. A music instrument made from endangered wood can draw harmful and unnecessary attention at the customs because the origin of the piece of endangered wood in the instrument is expected to be proven and may cause a lot of paperwork. Object of the invention
One objective of the present invention is to eliminate the need to use endangered wood or other rare materials in music instrument manufacturing by introducing a fiber reinforced composite material with similar features of wood or other in strument building materials.
Another objective of the present invention is to achieve a wood look-alike material which can be easily proven as arti ficial material at the customs inspection. This is made by adding some UV marking substance in the composite matrix ma terial and fibers. When illuminating the material with UV light it will show up and confirm its non-wooden nature.
It is another object of the present invention to provide non toxic, non-allergenic, consistent material and stable availa bility of composite raw material for music instrument manu facturing .
It is still another object of the present invention to pro vide a wood imitating layered material with similar features as wood. In this present invention every layer can be printed with a wood looking pattern to imitate the visual appearance of wood throughout the composite. This allows a 3D wood look ing texture to be visible also after processing the material.
The material according to the invention is characterized by what is disclosed in the characterization part of claim 1. Other embodiments of the invention are characterized by what is disclosed in the other claims.
Brief Description of the Invention
The present invention provides a layered fiber reinforced composite material to replace expensive and scarce woods in music instrument manufacturing. The material according to the invention comprises layered fibers bound together with help of a binding substance. In this application, also the term "matrix" is used for the binding substance. Some of the fi bers can be hollow. To achieve similar acoustical features of a specific wood in fiber reinforced composite the density of the composite material can be varied by changing the ratio of hollow fibers, other fibers and the matrix.
Advantages of the Invention
One advantage of the solution according to the invention is that hollow fibers can be used to manipulate the density of the fiber reinforced composite material. Adding hollow fibers in the composite material affects therefore the Q factor of the composite material. By varying the proportion of hollow fibers to other fibers and matrix material, a method to imi tate features of different species of wood is achieved.
Another advantage is that the visual appearance for every layer can be designed individually and therefore hidden 3D patterns can be visible even after processing the material. This is achieved by printing individual sheets of layers and stacking them to desired thickness to planks and plates.
Yet a further advantage of the invention is that the compo site material can be distinguished from natural wood by add ing some UV-marking material in the composite material.
Yet a further advantage of the invention is that the compo site material is not sensitive to temperature or humidity changes .
Yet a further advantage of the invention is that processing the thermoset plastic in the matrix can be done with the same tools as with real wood and no special tools or special safe ty arrangements are needed. Some trees have toxic biocides which can be allergenic to instrument builders and also even to musicians .
Yet a further advantage of the invention is that the yield of artificial wood according to the invention is close to 100% while yield of known tonewoods is only some percent from a real tree.
List of figures
In the following, the invention will be described in detail by the aid of example embodiments by referring to the at tached simplified and diagrammatic drawings, wherein FIG. 1 presents in an oblique side view a layered compo site material according to the invention,
FIG. 2 presents a magnification of layered composite mate rial of one embodiment of the invention,
FIG. 3 presents a magnification of layered composite mate rial of another embodiment of the invention and
FIG. 4 presents the interaction of the three variables in manipulating the density of artificial tonewood.
Detailed Description of the invention
In order to achieve the objectives mentioned above, the pre sent invention provides layered fiber reinforced composite materials with features of tonewood and looking like wood but not being wood. This novel layered fiber reinforced composite material comprises a thermoset plastic matrix, oriented and unoriented fibers which can be hollow fibers.
Fig. 1 presents a layer 2 and a block 10 of laminated layered fiber reinforced composite material according to the inven tion where the layer 2 is printed with a texture 3 and the surface of the block 10 is printed with a different texture 6, looking like wood and the side 4 shows the laminated mul tilayer structure 5. Every layer can be attached with its own printed texture to imitate the natural 3D character of wood.
Fig. 2 presents a magnification of layered fiber reinforced composite material of one embodiment of the invention where the oriented fibers 9 are shown visible for explanatory rea sons. The layered structure comprises first layers 7 of ori ented fibers 9 and second layers 8 of unoriented fibers. The first layers 7 of oriented fibers 9 and the second layers 8 are stacked by turns. The oriented fibers 9 are arranged sub stantially parallel to each other. The oriented fibers 9 can have for example S twist or Z twist structure. All layers comprise a binding substance or matrix. Unoriented fibers can be added also to the first layers 7 comprising oriented fi bers 9.
In this embodiment the laminated layered structure is made by arranging oriented fibers 9 and unoriented fibers on top of each other to form sheets comprising layers 7 and 8. A tex ture is printed to the sheets before or after the binding substance or matrix is added. The matrix is for example ther moset plastic such as melamine, polyester, epoxy, phenol- formaldehyde, lignin derivatives, polyfuran, casein and/or polyurethane. Advantageously, the matrix is formed of powdery substance and the layered structure is formed as a result of heating and pressing the fibers and matrix together.
The first layers 7 comprise oriented fibers 9 which can be hollow and/or not hollow fibers. The fibers of the first lay ers 7 are e.g. cellulose based fibers such as linen, hemp, sisal, viscose and/or some other fibers suitable for the pur pose. The first layers 7 can comprise also e.g. kapok, coir, hollow viscose and/or some other fibers suitable for the pur pose. The second layers 8 comprise unoriented fibers which can be hollow fibers e.g. kapok, coir, hollow viscose and/or some other fibers suitable for the purpose. The hollow fibers decrease the density of the layered structure. Adjusting the density with help of hollow fibers in a manufacturing phase a feasible Q factor of the layered structure is achieved. A feasible Q factor for different music instrument parts varies depending on the music instrument part.
Fig. 3 presents a magnification of layered fiber reinforced composite material of another embodiment of the invention where the oriented fibers 9 are shown visible for explanatory reasons. In this embodiment there are only first layers 7 of oriented fibers 9 which are stacked on top of each other. Al so, in this embodiment unoriented fibers can be added to the first layers 7 comprising oriented fibers 9.
Fig. 4 presents the interaction of the three variables in ma nipulating the density of artificial tonewood according to the invention in the manufacturing phase. The density of most commonly used reinforcement fibers is varying between 1,4 g/cm3 - 1,5 g/cm3 and the feasible thermoset plastics or ma trix 1,1 g/cm3 - 1,5 g/cm3. Adding remarkably lighter hollow 0,15 - 1,0 g/cm3 fibers in the composite the density can be altered closer to common tonewoods' density of 0,75 g/cm3 - 1,35 g/cm3.
Additionally, some UV-marking material can be added in the composite material according to the invention. In that way the material can be distinguished from natural wood. It is obvious to the person skilled in the art that the in vention is not restricted to the examples described above but that it may be varied within the scope of the claims present ed below. Thus, for instance the structure of the layered ma- terial can be different from what is disclosed above.
It is also obvious to the person skilled in the art that also other fibers than mentioned above can be used in the rein forced composite material.

Claims

1. A layered fiber reinforced composite material comprising layers and binding substance or matrix which is arranged to bind the layers together, characterized in that the layers comprise oriented fibers (9) and unoriented fibers, and at least some of the fibers are hollow, and the density of the composite material is based on the type and quantity of the hollow fibers.
2. A layered fiber reinforced composite material according to claim 1, characterized in that the material comprise first layers (7) and second layers (8) and the first layers (7) comprise oriented fibers (9) and the second layers (8) com prise unoriented fibers and the layers (7,8) are arranged on top of each other by turns.
3. A layered fiber reinforced composite material according to claim 1 and 2, characterized in that unoriented fibers are added also to the first layers (7) comprising oriented fibers (9) .
4. A layered fiber reinforced composite material according to claim 1, 2 or 3, characterized in that the Q factor of the composite material is based on the type and quantity of the hollow fibers.
5. A layered fiber reinforced composite material according to any of the claims above, characterized in that the matrix is formed of powdery substance.
6. A layered fiber reinforced composite material according to any of the claims above, characterized in that the layered structure is formed as a result of heating and pressing the fibers and matrix together.
7. A layered fiber reinforced composite material according to any of the claims above, characterized in that the matrix is thermoset plastic such as melamine, polyester, epoxy, phenol- formaldehyde, lignin derivatives, polyfuran, casein and/or polyurethane .
8. A layered fiber reinforced composite material according to any of the claims above, characterized in that all layers (7, 8) comprise binding substance or matrix.
9. A layered fiber reinforced composite material according to any of the claims above, characterized in that the layers (7, 8) are arranged to be printing surfaces for textures.
10. A layered fiber reinforced composite material according to any of the claims above, characterized that the composite material is equipped with a UV marking.
11. A layered fiber reinforced composite material according to any of the claims above, characterized in that the first layers (7) comprising oriented fibers (9) comprise hollow fi bers .
12. A layered fiber reinforced composite material according to any of the claims above, characterized in that the second layers (8) comprising unoriented fibers comprise hollow fi bers .
13. A layered fiber reinforced composite material according to any of the claims above, characterized in that hollow fi bers are added to the oriented fibers (9) .
14. A layered fiber reinforced composite material according to any of the claims above, characterized in that hollow fi bers are coir, kapok and/or viscose.
15. A layered fiber reinforced composite material according to any of the claims above, characterized in that the orient ed fibers (9) are cellulose based fibers such as linen, hemp, sisal viscose, kapok, coir and/or hollow viscose.
16. A layered fiber reinforced composite material according to any of the claims above, characterized in that the unor iented fibers are paper, felt, filaments, threads and/or fab rics.
PCT/FI2019/050077 2019-02-04 2019-02-04 Artificial wood WO2020161379A1 (en)

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PCT/FI2019/050077 WO2020161379A1 (en) 2019-02-04 2019-02-04 Artificial wood
EP19914652.3A EP3921143A4 (en) 2019-02-04 2019-02-04 Artificial wood

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RU2196680C1 (en) * 2001-05-24 2003-01-20 Суханов Александр Викторович Structural member of composite material (modifications)
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EP0170215A2 (en) * 1984-08-02 1986-02-05 Ppg Industries, Inc. Novel cartridge and reactor
JPH05299978A (en) * 1992-04-20 1993-11-12 Toshiba Corp Comparator
EP0697963B1 (en) * 1993-04-28 1998-01-21 HARTMANN, Harry Musical instrument with a sounding board
RU2196680C1 (en) * 2001-05-24 2003-01-20 Суханов Александр Викторович Structural member of composite material (modifications)
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