EP1436128A1 - Fibre mat, moulded piece produced therefrom and method for production thereof - Google Patents

Fibre mat, moulded piece produced therefrom and method for production thereof

Info

Publication number
EP1436128A1
EP1436128A1 EP02782946A EP02782946A EP1436128A1 EP 1436128 A1 EP1436128 A1 EP 1436128A1 EP 02782946 A EP02782946 A EP 02782946A EP 02782946 A EP02782946 A EP 02782946A EP 1436128 A1 EP1436128 A1 EP 1436128A1
Authority
EP
European Patent Office
Prior art keywords
fiber mat
fibers
cellulose fibers
mat according
cellulose
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
EP02782946A
Other languages
German (de)
French (fr)
Inventor
Jochen Gassan
Ansgar Engel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Faurecia Innenraum Systeme GmbH
Original Assignee
Faurecia Innenraum Systeme GmbH
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 Faurecia Innenraum Systeme GmbH filed Critical Faurecia Innenraum Systeme GmbH
Publication of EP1436128A1 publication Critical patent/EP1436128A1/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
    • 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
    • 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
    • B27N3/08—Moulding or pressing
    • B27N3/10—Moulding of mats
    • B27N3/12—Moulding of mats from 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
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer

Definitions

  • the invention relates to a fiber mat according to the preamble of claim 1, a molded part produced from this fiber mat and a method for its production.
  • DE 2845117 A1 already discloses a process for the production of plate material which can be pressed into molded parts from cellulose-containing material and at least one thermoplastic binder, in which the cellulose-containing material and the thermoplastic binder are mixed and the mixture is formed into plate material in the heated state.
  • the cellulose-containing material is defibrated into fiber and mixed with the thermoplastic binders, a fleece is formed from the mixture and the fleece is compressed to the plate material by the action of heat and pressure.
  • Waste of cellulose materials such as paper, Cardboard, textiles, etc., however, may also be used, possibly even in a predominant proportion of peat, bark and, in a particularly preferred manner, dried plant parts of annual plants such as straw or the like.
  • pulp-containing material such as paper and cardboard waste is broken down into particles with dimensions of approximately 5 ⁇ 5 mm and then fiberized, so that the maximum fiber length is approximately 5 mm.
  • a dry powder of fibrous particle nature made of polyethylene is used as the thermoplastic binder. No lengths are given for these particles.
  • the molded parts made from this sheet material have a limited strength, so that they usually also contain thermosetting binders.
  • the plastic is in the form of fibers with a length in the range of 30-100 mm and the cellulose fibers have a length of 10-100 mm, a relatively dimensionally stable fiber mat can be obtained, in particular after needling, which can be handled without problems until further processing ,
  • the molded part obtained from this is given the great length of the cellulose fibers, great strength and impact resistance, especially at very low temperatures.
  • the fact that no thermosetting binders are required means that the molded parts can be produced inexpensively, are light in weight and are largely free of emissions and odors and are easily recyclable.
  • Preferred cellulose fibers are those which have a length in the range of 50-100 mm, and in particular those whose average length is 70 mm +/- 20%. Their share in the total weight of the fiber mat can be between 10 and 90%.
  • the cellulose fibers advantageously consist of natural fibers from annual plants, such as hemp, flax, sisal or kenaf or technical viscose fibers, and also from cellulose regenerate, that is to say synthetic cellulose, which is preferably obtained from wood but does not contain its lignin components. Mixtures of the aforementioned various cellulose fibers can also be used.
  • the cellulose fibers Before the formation of the fiber mat, the cellulose fibers can have been chemically, chemically-physically or physically pretreated in a known manner, for example bleached, mercerized, alkalized, ace- ethylated or provided with an adhesion promoter, flame retardant or water repellent.
  • Polypropylene is preferably used for the plastic fibers. However, they generally consist of textile fibers, ribbon fibers or fibrous film chips made of polyolyphins, engineering plastics and / or copolymers, as well as mixtures of several polymers (e.g. as bico fibers). In order to obtain a homogeneous fiber mixture, the plastic fibers should have a fineness in the range of 3.3-25 dtex.
  • auxiliaries in particular processing aids such as antistatic agents or adhesion promoters, but also water repellents, flame retardants and additives can be added during the manufacture of the mat. However, their total amount should not exceed 10% of the total weight of the mat.
  • the fiber mat can be covered on at least one side with a light fleece made of e.g. polypropylene / polyester and with a basis weight of up to 300 g / m 2 are covered.
  • the connection between the fiber mat and light fleece is expediently made by needling.
  • the manufacture of the fiber mat basically takes place in a known manner, as is known for example from DE 2845117 AI.
  • the main steps in mat formation are as follows:
  • the corresponding fiber components are delivered in bale form to a processing plant and fed via a bale opener with metering devices, pre-opener, fine opener, fiber finisher, mixing chamber and box storage as a fiber mixture to the fleece system.
  • the bale opener releases the cellulose and plastic fibers from the respective bales.
  • a weighing device doses the desired mixing ratio of the fibers on a collecting belt.
  • the material is transported from the collecting belt to a mixer opener (pre-opener) in which the fiber components are roughly mixed.
  • a mixer opener pre-opener
  • the following fine opener is used to shorten, refine and clean bast fibers.
  • This device is equipped with a trough feed and a sawtooth barrel. Cockroaches and other contaminants are separated by means of expanded metal gratings arranged on the circumference of the tambour.
  • the fibers are treated with a spray system with liquid additives such as water repellents, lubricants, flame retardants, antistatic agents, adhesion promoters and the like.
  • a stationary rotary separator in the bunker ceiling ensures an even layering of the fibers and the formation of a fiber sandwich.
  • This fiber sandwich is milled vertically by an emptying machine.
  • the box feeder doses the fiber mixture into a volumetric filler shaft using a flat cloth belt. This doses the fiber cake into the fleece system via a dosing scale.
  • the fleece system consists of a pre-fleece and an end fleece.
  • a pre-web is produced in the pre-web former either by a carding system or an aerodynamic system.
  • the fibers are placed in an oriented manner.
  • the homogeneously premixed fiber components in the form of the preliminary nonwoven are broken down from a high-speed sawtooth turret to individual fibers. Due to the centrifugal force, the fibers detach themselves from the tambour and are blown onto the screen surface by the pleasure flow of a cross-flow fan. The simultaneous suction by vacuum fans causes the formation of tangled fleece on the screen surface.
  • the subsequent needling of the fiber mats is a mechanical consolidation, which is based on a weaving of the fibers and the increase in friction between the fibers caused by the compaction of the fleece.
  • the fleece is first pre-compacted by rolling or a press belt and then fed to the needle machine.
  • the endlessly produced needle felt is then cut to mat dimensions for pallet stacking or rolled goods by means of a cross-cut and a longitudinal cut device.
  • the mats will stored on pallets via an automatic stacking device.
  • the needle fleece is wound onto carrier sleeves.
  • the production of the molded parts can take place spatially and temporally separately from the fiber mat production. It is possible to produce the molded part together with a lamination from a fabric, a decorative film or the like in the so-called one-shot process. This can significantly reduce production costs.
  • the fiber mat is first fed to a preheating station, in which it is heated to approximately 180 degrees Celsius. At the same time, pre-compression takes place. At this temperature, the plastic fibers melt so that they lose their fiber structure.
  • the heated fiber mat is then introduced together with the lamination into a molding press, in which the molding receives its shape and at the same time the lamination is connected to the molding by the molten plastic.
  • the molding press has a temperature of less than 80 degrees Celsius, so that the molded part is cooled and the molten plastic solidifies, as a result of which a dimensionally stable molded part can be removed from the molding press.
  • Such a molded part which was made from 50 percent by weight of cellulose fibers and 50 percent by weight of polypropylene fibers, has, for example, a density of 1.0 g / cm 3 , a water absorption of 4.5 percent by weight, a flexural modulus of 3500 N / mm 2 and a bending strength of 65-70 N / mm 2 .

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Nonwoven Fabrics (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

A fibre mat as intermediate in the production of moulded pieces with preferably the same wall thickness is disclosed, comprising fibres made overwhelmingly of cellulose which are pressed together with a plastic in a homogeneous mixture. The plastic is in the form of fibres with a length in the range of 30-100 mm and the cellulose fibres have a length of 10-100 mm. The cellulose fibres preferably comprise natural fibres, formed from, flax, sisal, hemp, kenaf, technical viscose fibres or mixtures thereof, or from regenerated cellulose, particularly synthetic cellulose obtained from wood.

Description

Fasermatte, daraus hergestelltes Formteil und Verfahren zu dessen HerstellungFiber mat, molded part made therefrom and process for its production
Die Erfindung betrifft eine Fasermatte nach dem Ober- begriff des Anspruchs 1, ein aus dieser Fasermatte hergestelltes Formteil sowie ein Verfahren zu dessen Herstellung.The invention relates to a fiber mat according to the preamble of claim 1, a molded part produced from this fiber mat and a method for its production.
Aus der DE 2845117 AI ist bereits ein Verfahren zur Herstellung von zu Formteilen verpressbarem Plattenmaterial aus zellstoffhaltigem Material und mindestem einem thermoplastischem Bindemittel bekannt, bei dem das zellstoffhaltige Material und die thermoplastischen Bindemittel gemischt und die Mischung in er- wärmtem Zustand zu Plattenmaterial geformt werden. Um ein Plattenmaterial, das sich durch gute Homogenität und mechanische Eigenschaften auszeichnet sowie sich in einfacher Weise zu Formteilen hoher Qualität fertig pressen läßt, kostengünstig herzustellen, wird das zellstoffhaltige Material zu Faserstoff zerfasert und mit den thermoplastischen Bindemitteln gemischt, aus der Mischung ein Vlies gebildet und das Vlies durch Einwirkung von Wärme und Druck zu dem Plattenmaterial verdichtet. Als zellstoffhaltiges Material können Abfälle von Zellfaserwerkstoffen wie Papier, Pappe, Textilien usw. jedoch aber auch zusätzlich, unter Umständen sogar in überwiegendem Anteil Torf, Rinde und in besonders zu bevorzugender Weise getrocknete Pflanzenteile von einjährigen Pflanzen wie Stroh oder dergleichen eingesetzt werden. In einem Ausführungsbeispiel wird zellstoffhaltiges Material wie Papier- und Pappeabfälle in Partikel mit Abmessungen von ca. 5x5 mm zerkleinert und dann zerfasert, so daß die maximale Faserlänge etwa 5 mm beträgt. Als thermoplastisches Bindemittel wird ein trockenes Pulver von faserartiger Teilchenbeschaffenheit aus Polyäthylen verwendet. Hinsichtlich dieser Teilchen werden keine Längenangaben gemacht. Die aus diesem Plattenmaterial hergestellten Formteile haben jedoch eine begrenzte Festigkeit, so daß sie üblicherweise auch duroplastische Bindemittel enthalten.DE 2845117 A1 already discloses a process for the production of plate material which can be pressed into molded parts from cellulose-containing material and at least one thermoplastic binder, in which the cellulose-containing material and the thermoplastic binder are mixed and the mixture is formed into plate material in the heated state. In order to inexpensively manufacture a sheet material that is characterized by good homogeneity and mechanical properties and that can be easily pressed into high-quality molded parts, the cellulose-containing material is defibrated into fiber and mixed with the thermoplastic binders, a fleece is formed from the mixture and the fleece is compressed to the plate material by the action of heat and pressure. Waste of cellulose materials such as paper, Cardboard, textiles, etc., however, may also be used, possibly even in a predominant proportion of peat, bark and, in a particularly preferred manner, dried plant parts of annual plants such as straw or the like. In one embodiment, pulp-containing material such as paper and cardboard waste is broken down into particles with dimensions of approximately 5 × 5 mm and then fiberized, so that the maximum fiber length is approximately 5 mm. A dry powder of fibrous particle nature made of polyethylene is used as the thermoplastic binder. No lengths are given for these particles. However, the molded parts made from this sheet material have a limited strength, so that they usually also contain thermosetting binders.
Es ist auch bekannt, Glasfasern zur Verstärkung von Formteilen zu verwenden, welche eine Länge von mehr als 10 mm haben. Diese Formteile sind jedoch insbesondere bei tiefen Temperaturen relativ spröde und bruchanfällig.It is also known to use glass fibers to reinforce molded parts which have a length of more than 10 mm. However, these moldings are relatively brittle and prone to breakage, especially at low temperatures.
Es ist daher die Aufgabe der vorliegenden Erfindung, eine Fasermatte als Zwischenprodukt zur Herstellung von Formteilen vorzugsweise gleicher Wanddicke aus mit Kunststoff in homogener Mischung verpressten, überwiegend aus Zellulose bestehenden Fasern zu schaffen, aus der sich ein festes, weitgehend stoßre- sistentes, leichtes, emissions- und geruchsarmes sowie recycelfähiges Formteil herstellen läßt. Es ist auch die Aufgabe der vorliegenden Erfindung, ein derartiges Formteil zu schaffen sowie ein Verfahren zu dessen Herstellung anzugeben.It is therefore the object of the present invention to create a fiber mat as an intermediate product for the production of molded parts, preferably of the same wall thickness, from fibers pressed with plastic in a homogeneous mixture, consisting predominantly of cellulose, from which a solid, largely impact-resistant, light, emission is produced - Can produce low-odor and recyclable molded part. It is also the object of the present invention to create such a molded part and to specify a method for its production.
Diese Aufgabe wird erfindungsgemäß gelöst durch eine Fasermatte mit den Merkmalen des Anspruchs 1. Vorteilhafte Weiterbildungen ergeben sich aus den Unteransprüchen.This object is achieved by a Fiber mat with the features of claim 1. Advantageous further developments result from the subclaims.
Dadurch, daß der Kunststoff in Form von Fasern mit einer Länge im Bereich von 30-100 mm vorliegt und die Zellulosefasern eine Länge von 10-100 mm aufweisen, kann insbesondere nach Vernadelung eine relativ formstabile Fasermatte erhalten werden, die problemlos bis zur Weiterverarbeitung handhabbar ist. Das hieraus gepresste Formteil erhält durch die große Länge der Zellulosefasern eine große Festigkeit und Schlagzähigkeit insbesondere bei sehr tiefen Temperaturen. Dadurch, daß keine duroplastischen Bindemittel benö- tigt werden, sind die Formteile kostengünstig herzustellen, besitzen geringes Gewicht und sind weitgehend emissions- und geruchsfrei sowie leicht recycel- bar. Bevorzugt sind solche Zellulosefasern, die eine Länge im Bereich von 50-100 mm aufweisen, und insbe- sondere solche, deren mittlere Länge 70 mm +/- 20 % beträgt. Ihr Anteil am Gesamtgewicht der Fasermatte kann zwischen 10 und 90 % liegen.Because the plastic is in the form of fibers with a length in the range of 30-100 mm and the cellulose fibers have a length of 10-100 mm, a relatively dimensionally stable fiber mat can be obtained, in particular after needling, which can be handled without problems until further processing , The molded part obtained from this is given the great length of the cellulose fibers, great strength and impact resistance, especially at very low temperatures. The fact that no thermosetting binders are required means that the molded parts can be produced inexpensively, are light in weight and are largely free of emissions and odors and are easily recyclable. Preferred cellulose fibers are those which have a length in the range of 50-100 mm, and in particular those whose average length is 70 mm +/- 20%. Their share in the total weight of the fiber mat can be between 10 and 90%.
Die Zellulosefasern bestehen vorteilhaft aus Naturfa- sern aus einjährigen Pflanzen, wie Hanf, Flachs, Sisal oder Kenaf oder technischen Viskosefasern, sowie auch aus Zelluloseregenerat, das heißt synthetischer Zellulose, welche vorzugsweise aus Holz gewonnen wird, aber nicht dessen Ligninanteile enthält. Auch Mischungen der vorgenannten verschiedenen Zellulosefasern sind einsetzbar.The cellulose fibers advantageously consist of natural fibers from annual plants, such as hemp, flax, sisal or kenaf or technical viscose fibers, and also from cellulose regenerate, that is to say synthetic cellulose, which is preferably obtained from wood but does not contain its lignin components. Mixtures of the aforementioned various cellulose fibers can also be used.
Die Zellulosefasern können vor der Bildung der Fasermatte in bekannter Weise chemisch, chemisch- physikalisch oder physikalisch vorbehandelt worden sein, z.B. gebleicht, merzerisiert, alkalisiert, ace- thyliert oder mit einem Haftvermittler, Flammschutz- mittel oder Hydrophobierungsmitteln versehen.Before the formation of the fiber mat, the cellulose fibers can have been chemically, chemically-physically or physically pretreated in a known manner, for example bleached, mercerized, alkalized, ace- ethylated or provided with an adhesion promoter, flame retardant or water repellent.
Für die Kunststofffasern wird vorzugsweise Polypropy- len verwendet. Sie bestehen jedoch generell als tex- tile Fasern, Bändchenfasern oder faserförmige Folienschnitzel aus Polyolyphinen, technischen Kunststoffen und/oder Copolymeren sowie Mischungen aus mehreren Polymeren (z.B. als Bico-Fasern) . Um eine homogene Fasermischung zu erhalten, sollten die Kunststofffasern eine Feinheit im Bereich von 3,3-25 dtex besitzen.Polypropylene is preferably used for the plastic fibers. However, they generally consist of textile fibers, ribbon fibers or fibrous film chips made of polyolyphins, engineering plastics and / or copolymers, as well as mixtures of several polymers (e.g. as bico fibers). In order to obtain a homogeneous fiber mixture, the plastic fibers should have a fineness in the range of 3.3-25 dtex.
Während der Mattenherstellung können zusätzlich zu den Zellulosefasern und den Kunststofffasern auch Hilfsstoffe, insbesondere Verarbeitungshilfsmittel wie Antistatika oder Haftvermittler aber auch Hydrophobierungsmittel, Flammschutzmittel und Avivagen zugegeben werden. Deren Gesamtmenge sollte jedoch 10 % des Gesamtgewichts der Matte nicht überschreiten.In addition to the cellulose fibers and the plastic fibers, auxiliaries, in particular processing aids such as antistatic agents or adhesion promoters, but also water repellents, flame retardants and additives can be added during the manufacture of the mat. However, their total amount should not exceed 10% of the total weight of the mat.
Um die Vernadelungseigenschaften der Matte zu verbessern, zur Minimierung von etwaigen durch die Naturfasern bewirkten Geruchsemissionen des fertigen Form- teils sowie zum definierten Ausgleich von Verzug kann die Fasermatte mindestens einseitig mit einem Leichtvlies aus z.B. Polypropylen / Polyester und mit einem Flächengewicht bis zu 300 g/m2 bedeckt werden. Die Verbindung zwischen Fasermatte und Leichtvlies erfolgt zweckmäßig durch Vernadeln.In order to improve the needling properties of the mat, to minimize any odor emissions from the finished molded part caused by the natural fibers and to compensate for warpage, the fiber mat can be covered on at least one side with a light fleece made of e.g. polypropylene / polyester and with a basis weight of up to 300 g / m 2 are covered. The connection between the fiber mat and light fleece is expediently made by needling.
Die Herstellung der Fasermatte findet grundsätzlich in bekannter Weise, wie sie z.B. aus der DE 2845117 AI bekannt ist, statt. Die wesentlichen Schritte der Mattenbildung sind wie folgt: So werden in einer Aufbereitungsanlage die entsprechenden Faserkomponenten in Ballenform angeliefert und über einen Ballenöffner mit Dosiereinrichtungen, Voröffner, Feinöffner, Faserausrüster, Mischkammer und Kastenspeicher als Fasergemisch der Vliesanlage zugeführt.The manufacture of the fiber mat basically takes place in a known manner, as is known for example from DE 2845117 AI. The main steps in mat formation are as follows: The corresponding fiber components are delivered in bale form to a processing plant and fed via a bale opener with metering devices, pre-opener, fine opener, fiber finisher, mixing chamber and box storage as a fiber mixture to the fleece system.
Durch den Ballenöffner werden die Zellulose- und Kunststofffasern aus den jeweiligen Ballen gelöst. eine Wiegeeinrichtung dosiert das jeweils gewünschte Mischungsverhältnis der Fasern auf einem Sammelband.The bale opener releases the cellulose and plastic fibers from the respective bales. a weighing device doses the desired mixing ratio of the fibers on a collecting belt.
Vom Sammelband wird das Material zu einem Mischöffner (Voröffner) befördert, in welchem die Faserkomponen- ten grob gemischt werden.The material is transported from the collecting belt to a mixer opener (pre-opener) in which the fiber components are roughly mixed.
Der nachfolgende Feinöffner dient zur Einkürzung, Verfeinerung und Ausreinigung von Bastfasern. Diese Vorrichtung ist mit einem Muldeneinzug und einem Sä- gezahntambur versehen. Mittels am Umfang des Tamburs angeordneter Streckgitterroste erfolgt eine Absonderung von Schaben und anderen Verunreinigungen.The following fine opener is used to shorten, refine and clean bast fibers. This device is equipped with a trough feed and a sawtooth barrel. Cockroaches and other contaminants are separated by means of expanded metal gratings arranged on the circumference of the tambour.
Im Faserausrüster werden die Fasern durch eine Be- sprühungsanlage mit flüssigen Zusatzstoffen wie Hydrophobierungsmitteln, Gleitmitteln, Flammschutz it- teln, Antistatika, Haftvermittlern und dergleichen behandelt.In the fiber finisher, the fibers are treated with a spray system with liquid additives such as water repellents, lubricants, flame retardants, antistatic agents, adhesion promoters and the like.
Im nachfolgenden Mischbunker (Mischkammer) wird dieIn the subsequent mixing bunker (mixing chamber) the
Fasermischung homogenisiert und vorübergehend gespeichert. Ein stationärer Drehabscheider in der Bunkerdecke sorgt für eine gleichmäßige Aufschichtung der Fasern und zur Bildung eines Fasersandwiches. Dieser Fasersandwich wird von einer Entleerungsfräse vertikal abgefräst. Der Kastenspeiser schließlich dosiert die Fasermischung über ein Steillattentuchband in einen volume- trischen Füllschacht. Dieser dosiert den Faserkuchen über eine Dosierwaage in die Vliesanlage.Fiber mixture homogenized and temporarily stored. A stationary rotary separator in the bunker ceiling ensures an even layering of the fibers and the formation of a fiber sandwich. This fiber sandwich is milled vertically by an emptying machine. Finally, the box feeder doses the fiber mixture into a volumetric filler shaft using a flat cloth belt. This doses the fiber cake into the fleece system via a dosing scale.
Die Vliesanlage besteht aus einem Vorvliesbildner und einem Endvliesbildner. Im Vorvliesbildner wird entweder durch ein Krempelsystem oder ein aerodynamisches System ein Vorvlies erzeugt. Die Fasern werden hierbei orientiert abgelegt.The fleece system consists of a pre-fleece and an end fleece. A pre-web is produced in the pre-web former either by a carding system or an aerodynamic system. The fibers are placed in an oriented manner.
Im Endvliesbildner werden die homogen vorgemischten Faserkomponenten in Form des Vorvlieses von einem hochtourigen Sägezahntambur bis zur Einzelfaser aufgelöst. Aufgrund der Zentrifugalkraft lösen sich die Fasern vom Tambur und werden vom Luststrom eines Querstromgebläses auf die Siebfläche geblasen. Durch gleichzeitiges Ansaugen durch Unterdruckventilatoren erfolgt auf der Siebfläche die Wirrvliesbildung.In the final nonwoven, the homogeneously premixed fiber components in the form of the preliminary nonwoven are broken down from a high-speed sawtooth turret to individual fibers. Due to the centrifugal force, the fibers detach themselves from the tambour and are blown onto the screen surface by the pleasure flow of a cross-flow fan. The simultaneous suction by vacuum fans causes the formation of tangled fleece on the screen surface.
Durch entsprechende Einstellung der Materialabzugsgeschwindigkeit können gewünschte Flächengewichte für die Fasermatten erhalten werden.By setting the material take-off speed accordingly, desired grammages for the fiber mats can be obtained.
Die anschließende Vernadelung der Fasermatten ist eine mechanische Verfestigung, die auf einer Verschlingung der Fasern und der durch die Verdichtung des Vlieses verursachten Erhöhung der Reibung der Fasern untereinander beruht. Das Vlies wird zunächst durch Walzen oder ein Pressband vorverdichtet und dann der Nadelmaschine zugeführt.The subsequent needling of the fiber mats is a mechanical consolidation, which is based on a weaving of the fibers and the increase in friction between the fibers caused by the compaction of the fleece. The fleece is first pre-compacted by rolling or a press belt and then fed to the needle machine.
Das endlos hergestellte Nadelvlies wird abschließend durch eine Querzuschnitt- und eine Längszuschnittvor- richtung auf Mattenmaße für eine Pallettenstapelung oder zu Rollenware zugeschnitten. Die Matten werden über eine automatische Abstapelvorrichtung auf Palletten abgelegt. Bei Rollenware wird das Nadelvlies auf Trägerhülsen aufgewickelt.The endlessly produced needle felt is then cut to mat dimensions for pallet stacking or rolled goods by means of a cross-cut and a longitudinal cut device. The mats will stored on pallets via an automatic stacking device. In the case of rolls, the needle fleece is wound onto carrier sleeves.
Die Produktion der Formteile kann räumlich und zeitlich getrennt von der Fasermattenherstellung erfolgen. Dabei besteht die Möglichkeit, das Formteil zusammen mit einer Kaschierung aus einem Gewebe, einer Dekorfolie oder dergleichen im sogenannten One-Shot- Verfahren herzustellen. Hierdurch können die Produktionskosten erheblich gesenkt werden.The production of the molded parts can take place spatially and temporally separately from the fiber mat production. It is possible to produce the molded part together with a lamination from a fabric, a decorative film or the like in the so-called one-shot process. This can significantly reduce production costs.
Hierzu wird die Fasermatte zunächst einer Vorwärmstation zugeführt, in welcher sie auf etwa 180 Grad Cel- sius erwärmt wird. Gleichzeitig findet eine Vorverdichtung statt. Bei dieser Temperatur schmelzen die Kunststofffasern, so daß sie ihre Faserstruktur verlieren. Anschließend wird die erwärmte Fasermatte zusammen mit der Kaschierung in eine Formpresse einge- bracht, in der das Formteil seine Form erhält und gleichzeitig die Kaschierung durch den geschmolzenen Kunststoff mit dem Formteil verbunden wird. Die Formpresse weist eine Temperatur von weniger als 80 Grad Celsius auf, so daß das Formteil abgekühlt wird und der geschmolzene Kunststoff sich verfestigt, wodurch der Formpresse ein formstabiles Formteil entnommen werden kann.For this purpose, the fiber mat is first fed to a preheating station, in which it is heated to approximately 180 degrees Celsius. At the same time, pre-compression takes place. At this temperature, the plastic fibers melt so that they lose their fiber structure. The heated fiber mat is then introduced together with the lamination into a molding press, in which the molding receives its shape and at the same time the lamination is connected to the molding by the molten plastic. The molding press has a temperature of less than 80 degrees Celsius, so that the molded part is cooled and the molten plastic solidifies, as a result of which a dimensionally stable molded part can be removed from the molding press.
Ein derartiges Formteil, das zu 50 Gewichtsprozent aus Zellulosefasern und 50 Gewichtsprozent aus Polypropylenfasern hergestellt wurde, hat beispielsweise eine Dichte von 1,0 g/cm3, eine Wasseraufnahme von 4,5 Gewichtsprozent, ein Biege-E-Modul von 3500 N/mm2 sowie eine Biegefestigkeit von 65-70 N/mm2. Such a molded part, which was made from 50 percent by weight of cellulose fibers and 50 percent by weight of polypropylene fibers, has, for example, a density of 1.0 g / cm 3 , a water absorption of 4.5 percent by weight, a flexural modulus of 3500 N / mm 2 and a bending strength of 65-70 N / mm 2 .

Claims

Patentansprüche claims
1. Fasermatte als Zwischenprodukt zur Herstellung von Formteilen vorzugsweise gleicher Wanddicke aus mit Kunststoff in homogener Mischung ver- pressten, überwiegend aus Zellulose bestehenden Fasern, dadurch gekennzeichnet, daß der Kunst- stoff in Form von Fasern mit einer Länge im Bereich von 30-100 mm vorliegt und die Zellulosefasern eine Länge von 10-100 mm aufweisen.1. Fiber mat as an intermediate product for the production of moldings, preferably of the same wall thickness, made from plastics pressed in a homogeneous mixture, predominantly consisting of cellulose fibers, characterized in that the plastic is in the form of fibers with a length in the range from 30-100 mm is present and the cellulose fibers have a length of 10-100 mm.
2. Fasermatte nach Anspruch 1, dadurch gekennzeichnet, daß die Zellulosefasern aus Naturfasern aus Hanf, Flachs, Sisal, Kenaf, technischen Viskosfasern oder Mischungen hiervon bestehen.2. Fiber mat according to claim 1, characterized in that the cellulose fibers consist of natural fibers made from hemp, flax, sisal, kenaf, technical viscose fibers or mixtures thereof.
3. Fasermatte nach Anspruch 1, dadurch gekennzeichnet, daß die Zellulosefasern aus Zellulosregeneratfasern bestehen.3. Fiber mat according to claim 1, characterized in that the cellulose fibers consist of regenerated cellulose fibers.
4. Fasermatte nach einem der Ansprüche 1-3, dadurch gekennzeichnet, daß die Zellulosefasern eine Länge im Bereich von 50-100 mm aufweisen.4. Fiber mat according to one of claims 1-3, characterized in that the cellulose fibers have a length in the range of 50-100 mm.
5. Fasermatte nach Anspruch 4, dadurch gekennzeichnet, daß die mittlere Länge der Zellulosefasern 70 mm +/- 20 % beträgt.5. Fiber mat according to claim 4, characterized in that the average length of the cellulose fibers is 70 mm +/- 20%.
6. Fasermatte nach einem der Ansprüche 1-5, dadurch gekennzeichnet, daß der Anteil der Zellulosefasern am Gesamtgewicht der Fasermatte zwischen 10 und 90 % liegt.6. Fiber mat according to one of claims 1-5, characterized in that the proportion of cellulose fibers in the total weight of the fiber mat is between 10 and 90%.
7. Fasermatte nach einem der Ansprüche 1-6, dadurch gekennzeichnet, daß die Zellulosefasern ehe- misch, thermisch oder chemisch-physikalisch vorbehandelt sind.7. fiber mat according to any one of claims 1-6, characterized in that the cellulose fibers marriage- are pretreated mix, thermally or chemico-physically.
8. Fasermatte nach einem der Ansprüche 1-7, dadurch gekennzeichnet, daß die Kunststofffasern aus Po- lypropylen bestehen.8. Fiber mat according to one of claims 1-7, characterized in that the plastic fibers consist of polypropylene.
9. Fasermatte nach einem der Ansprüche 1-8, dadurch gekennzeichnet, daß die Kunststofffasern eine Feinheit von 3,3-25 dtex und eine beliebige Querschnittsform aufweisen.9. Fiber mat according to one of claims 1-8, characterized in that the plastic fibers have a fineness of 3.3-25 dtex and any cross-sectional shape.
10. Fasermatte nach einem der Ansprüche 1-9, dadurch gekennzeichnet, daß sie durch Vernadeln der Fasern verfestigt ist.10. Fiber mat according to one of claims 1-9, characterized in that it is solidified by needling the fibers.
11. Fasermatte nach einem der Ansprüche 1-10, dadurch gekennzeichnet, daß sie zusätzlich Hydro- fobierungsmittel, Avivagen, Flammschutzmittel und/oder Haftvermittler enthält.11. Fiber mat according to one of claims 1-10, characterized in that it additionally contains water repellents, finishing agents, flame retardants and / or adhesion promoters.
12. Fasermatte nach einem der Ansprüche 1-11, dadurch gekennzeichnet, daß sie mindestens einseitig eine aufgenadelte Faserdeckschicht aus Poly- propylen / Polyester mit einem Flächengewicht bis 300 g/m2 aufweist.12. Fiber mat according to one of claims 1-11, characterized in that it has at least on one side a needled fiber cover layer made of polypropylene / polyester with a basis weight of up to 300 g / m 2 .
13. Aus einer Fasermatte nach einem der Ansprüche 1- 12 durch Verpressen hergestelltes Formteil, dadurch gekennzeichnet, daß es in einer homogenen Kunststoffschicht gleichmäßig verteilte Naturfasern mit einer Länge im Bereich von 10-100 mm enthält.13. A molded part produced by pressing from a fiber mat according to one of claims 1- 12, characterized in that it contains evenly distributed natural fibers with a length in the range of 10-100 mm in a homogeneous plastic layer.
14. Formteil nach Anspruch 13, dadurch gekennzeichnet, daß es eine Dichte von ca. 0,9 g/cm3 auf- weist. 14. Molding according to claim 13, characterized in that it has a density of about 0.9 g / cm 3 .
15. Formteil nach Anspruch 13 oder 14, dadurch gekennzeichnet, daß es eine Wasseraufnahme im Bereich von 4-6 Gewichtsprozent aufweist.15. Molding according to claim 13 or 14, characterized in that it has a water absorption in the range of 4-6 percent by weight.
16. Formteil nach einem der Ansprüche 13-15, dadurch gekennzeichnet, daß es mit einer unmittelbar mit der verpressten Fasermatte verbundenen Dekorschicht versehen ist.16. Molding according to one of claims 13-15, characterized in that it is provided with a decorative layer directly connected to the pressed fiber mat.
17. Verfahren zur Herstellung eines Formteils nach einem der Ansprüche 13-16, dadurch gekennzeich- net, daß die Fasermatte vor dem Verpressen auf eine Temperatur von etwa 180 - 200 Grad Celsius erwärmt wird.17. A method for producing a molded part according to any one of claims 13-16, characterized in that the fiber mat is heated to a temperature of about 180-200 degrees Celsius before pressing.
18. Verfahren nach Anspruch 17, dadurch gekennzeichnet, daß bei der Erwärmung eine Vorverdichtung durchgeführt wird.18. The method according to claim 17, characterized in that a pre-compression is carried out during the heating.
19. Verfahren nach Anspruch 17 oder 18, dadurch gekennzeichnet, daß gleichzeitig mit dem Verpressen der Fasermatte auf diese eine Dekorschicht im One-Shot-Verfahren aufgebracht wird.19. The method according to claim 17 or 18, characterized in that at the same time with the pressing of the fiber mat, a decorative layer is applied to this in a one-shot process.
20. Verfahren nach einem der Ansprüche 17-19, dadurch gekennzeichnet, daß das Formwerkzeug beim Verpressen eine Temperatur von weniger als 80 Grad Celsius hat. 20. The method according to any one of claims 17-19, characterized in that the molding tool has a temperature of less than 80 degrees Celsius during pressing.
EP02782946A 2001-10-17 2002-10-17 Fibre mat, moulded piece produced therefrom and method for production thereof Withdrawn EP1436128A1 (en)

Applications Claiming Priority (3)

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DE10151368 2001-10-17
DE2001151368 DE10151368A1 (en) 2001-10-17 2001-10-17 Fiber mat, molded part made therefrom and process for its production
PCT/EP2002/011653 WO2003033226A1 (en) 2001-10-17 2002-10-17 Fibre mat, moulded piece produced therefrom and method for production thereof

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