PT107092B - COMPOSITE MATERIAL, PROCESS OF OBTAINMENT AND ITS APPLICATIONS - Google Patents

Abstract

THE PRESENT REQUEST CONCERNS A COMPOSITE MATERIAL, WHICH INCLUDES A MATRIX, RESIN AND TEXTILE MATERIAL, WHICH PRESENTS EXTERNAL, STRUCTURAL AND FUNCTIONAL FEATURES THAT ALLOW FOR ITS USE AS FUNCTIONAL AND / OR DECORATIVE FURNITURE. The composite material disclosed herein comprises a textile material incorporated in an EPOXY RESIN MIX AND A HARDENER, wherein said textile material is coated with a waterproof polymer film to the said EPOXY RESIN AND HARDENER MIX. WITH THE TECHNOLOGY HERE PRESENTED, THE COMPOSITE MATERIAL POTENTIATES THE INTRODUCTION OF GRAPHIC IMAGES AND / OR PLAN / THREE-DIMENSIONAL OBJECTS, SINCE THE TEXTILE MATERIAL IS SUBJECT TO A PROCESS OF LAMINATION / ENCAPSULATION IN ORDER TO NOT DAMAGE THE SAME.

Description

DESCRIPTION

COMPOSITE MATERIAL, OBTAINING PROCESS AND ITS

APPLICATIONS

Technical field This application relates to a composite material comprising a matrix, resin and textile material having external, structural and functional characteristics which allow its use as functional and / or decorative furniture.

Background Art

Innovations in textiles multiply to keep up with the decoration and furniture market. Fashion in textiles changes every season, but in furniture trends are very variable and are related to various factors such as consumer behavior, technological innovations, industry production and real estate pressure. As a result, furniture companies are looking to textiles for important support in conveying new concepts and styles through decoration rather than just price.

It is in this context that the need arises to complement furniture with textiles. Nowadays, the textile is combined with the furniture in the interior decoration and as protection against dirt, stains, scratches, etc.

Currently, the application of resins in decorative elements of furniture is used for coatings, table tops, paintings, floors, among others. However, their conjugation with textile materials is not yet known, due to difficulties in preserving the characteristics of textile materials, the application processes and the compatibility of resins.

It is in this sense that it is important to innovate by researching and developing new methods and processes of application of resins that allow the maximum compatibility of the characteristics inherent to wood, or other materials / dies / molds commonly used for furniture, such as glass, rubber, silicone, aluminum, among others, and textiles, which react quickly in contact with air and thus dispense with the need to use energy-efficient polymerization systems that are easily adjustable to the desired dimensions with application and finishing method. that comply with all applicable health and environmental requirements. The integration of decorative and / or functional elements such as LED (Light Emitting Diode) wires, stamping effects, glitter, optical fibers, chromatic elements, digital prints, phosphorescent pigments, etc., in the matrix / textile / resin composite is another aspect. Noteworthy, as the functionalization is increasingly striking in all segments of furniture, from complements to kitchens. Besides being functional, it is intended to create new styles, as well as facilitate customization by incorporating various decorative elements in the composite.

The innovation concerned deals with a matrix / textile / resin composite, and in order to enhance the introduction of graphic images and / or flat / three-dimensional objects, the textile material is subjected to a laminating / encapsulation process so as not to damage the material. same.

Although there is no such application in matrix / textile / resin composites, its partial use is referred to in the following documents:

US5849124 describes a colored gravel floor system incorporated in epoxy resin to be poured and spread to form the floor.

US7670022 discloses a commercial entrance mat with a built-in light source and a polycarbonate resin coating so that the light emitted is visible, creating a decorative effect.

DE102009023737 describes a composite material comprising a matrix, which may be made of paper, ceramic plates, wood, cork and others, laminated with another material, of an aesthetic or functional character, which in the case of fabric may be digitally printed.

General Description The present application relates to a matrix / textile / resin composite material comprising a textile material incorporated in an epoxy resin and a hardener preferably

75-85% w / w epoxy resin and

25-15% w / w hardener, preferably products derived from amines, polyamines, polyamides and anhydrides.

In another embodiment, the composite material described in the present application comprises 35-50 g of hardener component and 90-110 g of resin component.

In another embodiment, the textile material of the composite material is coated with a polymeric film impermeable to said epoxy resin and hardener mixture, namely polyurethane, among others having similar properties, preventing deterioration of the textile material and allowing its correct visualization.

In another embodiment, the textile material may have in its composition synthetic or natural fibers, preferably said textile material may be selected from the following list: cotton, wool, silk, polyamide, polyester.

In another embodiment, the described composite material may further comprise decorative and / or functional elements in particular LED wires, stamping effects, glitter, optical fibers, chromatic elements, digital prints, phosphorescent pigments, etc.

In another embodiment, the described composite material may comprise a coating or die / mold in at least one of the following materials: wood, metal, glass, acrylic, cork, rubber, among others.

Another embodiment describes an article comprising the composite material described above.

In one embodiment, the article may be a frame, panel, board, table, door, cladding or other decorative / functional furniture element.

Another embodiment describes a process for obtaining composite material comprising the following steps:

laminating / encapsulating the textile material, preferably said laminating / encapsulating the fabric is performed with two samples of impermeable film, preferably polyurethane;

- preparation of the hardener epoxy resin;

- introduction of the textile material in the epoxy resin and hardener mixture;

- composite finish.

In another embodiment of the described process the lamination / encapsulation of the textile material may take place at a temperature between 100 and 140 ° C and / or at a pressure between 0.2 and 0.4 MPa and / or have a duration of between 15 and 150 ° C. 25 seconds

In another embodiment of the processes described above, the preparation of the epoxy resin and hardener mixture and the introduction of the textile material into the epoxy resin and hardener mixture may further comprise the following steps:

Adding a hardener - preferably products derived from amines, polyamines, polyamides and anhydrides - to the resin;

Partially pouring the above mixture into a mold / matrix to cover it evenly;

• place the sample of laminated textile material;

• first cure the mixture with a minimum of 24 hours;

Adding a new layer of the above mixture over the cured material, preferably and depending on the matrix and / or molds used, the entire surface should be filled with resin to create a uniform layer;

• Second cure the mixture.

In a preferred embodiment of the described process the finishing of the composite may comprise the following steps:

• apply localized heat, preferably using a blowtorch;

• After allowing the resin to cure completely, apply low grit sandpaper to the sample surface;

• clean the surface to remove resin, dust and dirt;

• apply water varnish on the entire surface;

• allow to dry for at least 45 min;

• apply water varnish on the entire surface;

• allow to dry for at least 3 hours;

• Repeat the previous steps as many times as necessary until a smooth and even surface is obtained.

In a preferred embodiment, said mold / die may be wood, metal, silicone, glass, acrylic, cork, or rubber.

The present invention describes a matrix / textile / resin composite material having external, structural, principally stability, durability and strength, and functional characteristics that allow its use in furniture, flooring or decoration without deterioration of the textile material inserted in the matrix. The present invention allows for the flexibility of the final result allowing the customization of the final product without deterioration of the textile material. In preferred embodiments of the present invention, to the composite material described with incorporation of the textile material, decorative materials by incorporating functional or decorative elements such as LED wires, stamping effects, glitter, optical fibers, chromatic elements, embossing are added. digital, phosphorescent pigments, etc. The product obtained, besides allowing a perfect presentation of the incorporated textile material, is resistant to cleaning and maintenance.

Description of the Figures

For easier understanding of the invention, attached are the figures which represent preferred embodiments of the invention which, however, are not intended to limit the present application.

Figure 1 represents a process diagram.

Figure 2 illustrates a composite structure view in which the following reference numerals represent:

- represents the matrix / mold;

- represents the first layer of epoxy resin and hardener mixture;

- represents the laminated textile material;

- represents a second layer of epoxy resin and hardener mixture.

Figure 3 illustrates a schematic representation of one of the samples where the following reference numbers represent:

- represents the matrix / mold;

- represents the textile material / epoxy resin + hardener assembly;

- represents LED wires integrated in the textile material.

Description of Embodiments matrix / textile / resin composite material described in the present application comprises:

• wood matrix, textiles and epoxy resin + hardener;

• aluminum matrix, textiles and epoxy resin + hardener; • glass matrix, textiles and resin epoxy + hardener; • rubber matrix, textiles and epoxy resin + hardener; • metal matrix, textiles and resin epoxy + hardener;

• matrix of cork, textiles and epoxy resin + hardener;

• one of the foregoing matrices, textiles with decorative and functional motifs incorporated via LED wires, stamping effects, glitter, optical fibers, chromatic elements, digital prints, phosphorescent pigments, etc., and hardening epoxy resin;

• Textile and epoxy resin + hardener blend.

This application also presents various differentiating processes, such as:

• Method of curing epoxy resins with respect to concentrations, temperature and cure time;

• Encapsulation of the textile into polymeric film preferably polyurethane (PU), or other similar properties, through the lamination process. This process makes it impossible for the epoxy resin to absorb the textile material, thus preventing the degradation of the textile and other decorative and functional motifs, such as LED wires,

stamping, glitter, optical fibers, elements chromatic, patterned digital, pigments phosphorescent, etc. ;

• Incorporation of textile material based on natural or synthetic fibers in epoxy + hardener composites without degradation of the aesthetic appearance and mechanical properties of the textile material;

• Incorporation of decorative and functional effects such as LED wires, stamping effects, glitter, optical fibers, chromatic elements, etc.

GENERAL PROCESS

1. Textile lamination / encapsulation process: The textile material is laminated with two samples of waterproof film, preferably polyurethane (PU), with a thickness between 30 and 50 gm, a temperature between 100 and 140 ° C. pressure between 0.2 and 0.4 MPa and process duration between 15 and 25 seconds;

2. Preparation of the mixture epoxy resin and hardener: between 35 and 50 g of hardener component is preferably added to 90 to 110 g of resin component;

3. Introduction of textile material in the epoxy resin + hardener mixture comprising:

a) Spread the matrix base with epoxy resin and hardener mixture;

b) Place the laminated textile material on the base of the matrix and proceed with the preliminary curing process until the mixture is sufficiently consistent;

c) Apply new layer of epoxy resin + hardener, depending on the desired thickness;

d) Proceed with the final curing process at room temperature.

4. Composite Finishing

In order for the composite surface to be smooth, the following steps must be performed:

a) Apply localized heat, for example with a blow dryer or blowtorch.

b) Apply a low grit sandpaper between each coat;

c) Apply water varnish as many times as necessary to obtain a smooth and even surface.

ROLLING

(a) switch on the laminating machine and adjust the process conditions, including temperature, pressure and time parameters;

(b) prepare 2 samples of PU film slightly larger than those of the textile sample in such a way as to create a margin around the textile sample;

c) With the laminating machine at the set parameters, place the textile sample between the film samples;

(d) start the rolling process;

e) Take a sample of laminated textile material.

RESIN AND SAMPLE

1) Add the hardener component to the resin component;

2) Spread the resin and hardener mixture into the mold to be used as a matrix;

3) Place the sample of laminated textile material;

4) Performing the preliminary curing process, preferably at a temperature of from 20 to 25 ° C, for 24 h, more preferably without said mixture curing completely;

5) After 24h, add a new layer of said mixture over ^the layer, preferably and depending on the matrix, and the mold used, the entire surface should be filled with the mixture to create a uniform layer;

6) Perform the final curing process at room temperature, ie at a temperature of from 20 to 25 ° C for more than 24 h, preferably.

SURFACE FINISHES

In order for the composite surface to be smooth, the following steps must be performed:

(a) apply localized heat, for example with a blow dryer or blowtorch;

b) After allowing the resin to cure completely after more than 24 hours, apply low grit sandpaper to the sample surface;

(c) wiping surface to remove remnants of the mixture and hardener, dust and dirt;

d) Apply water varnish on the entire surface;

e) Allow to dry for 45 min;

f) Apply water varnish on the entire surface;

g) Allow to dry for 3h;

h) Repeat the previous steps as many times as necessary until a smooth and uniform surface is obtained.

Application Examples

Preferably, the wood matrix is constructed from crimped frames to support the incorporation of resin and textile materials with decorative elements, for example a jacquard fabric, with LED threads, stamping effects, glitter, optical fibers, chromatic elements, digital prints, phosphorescent pigments, etc. The frame typology and dimensions are important to obtain the defined resin layer and thickness.

In a first step the textile is preferably encapsulated in a waterproof polyurethane film of thickness between 30 and 50pm or other with similar properties by the lamination technique, using the following process parameters: Temperature between 100 and 140 ° C; Pressure between 0.3 and 0.5 MPa; Process duration 15 to 25 seconds.

Resin recipe preparation: mixing the resin component with the hardener component in a ratio 70/30 to 85/15.

Prototype construction: The support, which may be a wooden frame, is deposited with a very thin layer of hardening epoxy resin, barring only the surface of the wood on which the previously encapsulated textile material is placed and allowed to cure. until a pre-composite of sufficient consistency is obtained for 12 to 24h at room temperature of 20 ° C. After this phase more epoxy + hardener is applied to the desired thickness and allowed to cure - for 24 to 48h at an average room temperature of 20 ° C.

Polishing the surface of the composite: In order to completely smooth the surface of the composite, it is polished with a suitable abrasive material.

The present invention is, of course, not in any way restricted to the embodiments described herein and a person of ordinary skill in the art may foresee many possibilities for modification thereof without departing from the general idea of the invention as defined in the claims.

The preferred embodiments described above are obviously combinable with each other. The following claims further define preferred embodiments of the invention.

Claims (19)

A matrix / textile / resin composite material comprising a textile material incorporated in a mixture of epoxy resin and a hardener, wherein said textile material is coated with polyurethane. Composite material according to the preceding claim, further comprising: • 75-85% w / w epoxy resin; • 25-15% w / w hardener. Composite material according to any one of the preceding claims, characterized in that the hardener is selected from the following list: amines, polyamines, polyamides, anhydrides. Composite material according to any one of the preceding claims, characterized in that the textile material is synthetic or natural. Composite material according to the preceding claim, characterized in that the textile material is selected from the following list: cotton, wool, silk, polyamide, polyester. Composite material according to any one of the preceding claims, characterized in that it comprises functional elements, in particular LED wires, stamping effects, glitter, optical fibers, chromatic elements, phosphorescent prints. digital pigments Composite material according to any one of the preceding claims, characterized in that it comprises a coating on fur any less one of the following materials: wood, metal, glass, acrylic, eraser, cork. Featured Article per understand the material composite described in any preceding claim. Article according to the preceding claim, characterized in that it is a frame, panel, plate, table, door, cladding or other decorative / functional furniture element. Process for obtaining composite material as described in any one of claims 1 to 7, comprising the following steps: • laminating / encapsulating the textile material with polyurethane; • preparation of the hardener epoxy resin mixture; Introducing said textile encapsulated / laminated material into the epoxy + hardener resin; • cure process of composite material; • composite finish. Method according to the preceding claim, characterized in that said laminating / encapsulating the textile material is carried out with an impermeable polymeric film, preferably polyurethane. Process according to any one of claims 10-11, characterized in that the lamination / encapsulation of the textile material takes place at a temperature between 100 and 140 ° C. Method according to any one of claims 10-12, characterized in that the lamination / encapsulation of the textile material takes place at a pressure of between 0.2 and 0.4 MPa. Method according to any one of claims 10-13, characterized in that the laminating / encapsulation of the textile material lasts between 15 and 25 seconds. A process according to any one of claims 10-14 comprising specifically the following steps: • add a hardener to the resin; Partially pouring the epoxy resin + hardener mixture into a mold to cover said mold; • place the sample of laminated textile material; • first cure the mixture for at least 24 hours; • Adding a new layer of resin and hardener mixture over the cured layer, preferably depending on the matrix, and the mold used, fill the entire surface with the mixture to create a uniform layer; proceed to a second cure of the mixture. Process according to the preceding claim, characterized in that said mold / die is made of wood, metal, glass, acrylic, rubber, cork. Process according to any one of claims 10-16, characterized in that said mixture comprises 75-85% w / w epoxy resin and 25-15% w / w hardener. Process according to any one of claims 15-17, characterized in that said first curing takes place at 20-25 ° C for 24 h. Process according to any one of claims 15-18, characterized in that said second curing takes place at a temperature of 20-25 ° C for more than 24 h. Process according to any one of claims 10-19, characterized in that the finishing step is carried out by applying localized heat, preferably using a blowtorch, and further surface finishes such as varnishing.