WO2002094561A1

WO2002094561A1 - Fiber-reinforced composite material made of pvc molding compound

Info

Publication number: WO2002094561A1
Application number: PCT/CH2002/000260
Authority: WO
Inventors: René Meier; Mathild Vas-Meier
Original assignee: Meier Rene; Mathild Vas-Meier
Priority date: 2001-05-18
Filing date: 2002-05-14
Publication date: 2002-11-28

Abstract

The invention relates to a composite material (20) that is characterized by a platelike base layer (11) made of a curable polymer molding compound ( polymer clay ). After being applied to the face of the base layer (11) while extending over the surface of this base layer (11), a reinforcing material (12, 13) that contains fibers is at least partially embedded in the base layer (11).

Description

DESCRIPTION

FIBER REINFORCED COMPOSITE MATERIAL FROM PVC MODELING MATERIAL

TECHNICAL AREA

The present invention relates to the field of composite materials. It relates to a composite material, a method for producing such a composite material and the use of such a composite material.

STATE OF THE ART

Polymer modeling materials ("polymer clays") have long been known, from which objects, for example jewelry, vases, dolls or the like, can be produced in the uncured state by kneading and molding. After shaping, the manufactured article can then be placed in an oven or otherwise at high temperatures of over 100 ° C can be cured. Polymer modeling clay is available in a wide variety of colors and consistencies (soft or less soft, translucent, opaque) and can be easily combined with various other materials. A well-known polymer modeling clay available on the market is manufactured and sold by the German company Eberhard Faber under the FIMO brand. Special modifications are the FIMO classic and the FIMO soft. Other known polymer modeling compounds are the "Cernit" from T + F-GmbH or the "Sculpey" from the US company Polyform Company. The polymer modeling compounds are all a specific form of polyvinyl chloride (PVC) to which plasticizers have been added. The polymer molecules are arranged in porous grains saturated with plasticizers to keep the mass supple. When these grains are heated, they swell to a gel and begin to bond together. If the temperature is increased further, the bonded grains form a hard, durable plastic. This process of curing is also referred to as PVC fusion.

If thin plates with a thickness in the range of one millimeter are produced from such a polymer modeling compound, such as are used as decorative, colored patterned, translucent lampshades, the shaped and then hardened plates are relatively brittle and can break or tear or otherwise easily damaged.

PRESENTATION OF THE INVENTION

It is therefore an object of the invention to create a material on the basis of a polymer modeling compound which is characterized by a greatly improved mechanical stability and which is characterized by a greatly improved mechanical stability while maintaining the diverse design options which such polymer modeling compounds provide can be processed in a simple manner for a wide variety of purposes, and specify a method for its production and an application.

The object is achieved by the entirety of the features of claims 1, 10 and 16. The essence of the invention consists in providing on the surface of a plate-shaped base layer made of a hardenable polymer modeling compound ("polymer clay") extending over the surface of the base layer a fiber-containing reinforcing material which is at least partially embedded in the base layer. The fibers of the reinforcing material, which are at least partially embedded in the polymer modeling compound, result in a fiber-reinforced composite material on the surface of the base layer, which mechanically stabilizes the surface after curing and in particular largely prevents the plates from breaking and tearing. At the same time, the base layer reinforced in this way can be easily deformed and cut in the uncured state without tearing or breaking.

In principle, it is conceivable to provide the fibrous reinforcing material only on one of the two surfaces of the plate-shaped base layer. Such a procedure is useful, for example, if the composite panel with the non-reinforced surface is to be applied to another surface and possibly connected to this surface. A preferred embodiment of the invention, however, is characterized in that the fiber-containing reinforcing material is provided on both sides or surfaces of the base layer. This results in an optimally stabilized and mechanically protected composite material for all applications.

However, it is also conceivable to arrange a fiber-containing reinforcing material alone or in addition to the near-surface reinforcement in the interior of the base layer. This can be particularly useful if a greater thickness of the composite panels is required. Although felt- or paper-like fiber materials are basically suitable for reinforcement, it has proven to be particularly advantageous in practice to use a fabric as the fiber-containing reinforcement material, because with a fabric there are defined mesh sizes that embed the reinforcement material in the base layer significantly facilitate. The type and material of the fabric can be varied within a wide range and depend not only on the mechanical reinforcement effect to be achieved, but also on the area of application of the finished composite material. For example, if the composite material is to be translucent because it is used in the lighting area (lampshade, etc.), it is advantageous to use a fabric made of a translucent material, preferably polyester. A polyester fabric also has the advantage that it combines well with the polymer modeling clay and thus increases the reinforcing effect.

In order that the fabric can be embedded well into the base layer on the one hand and on the other hand has as little effect as possible on the visual appearance of the mostly colored and patterned base layer, it is particularly advantageous to use a very thin and fine fabric. This is particularly true if the fabric is an organdy or organza fabric.

The essence of the method according to the invention is to produce a plate from the uncured polymer modeling compound and to compress a stack of the plate and an applied or applied reinforcement material perpendicular to the plane of the plate in such a way that the fibrous reinforcement material is at least partially embedded in the material of the plate. wherein the fiber-containing reinforcing material is preferably applied or placed on both surfaces of the plate.

Basically, the pressing can take place between two flat parallel punches. However, it is simpler in terms of production if, according to a preferred embodiment of the method according to the invention, pressing takes place in the third step between two parallel rollers, preferably in a calendering machine.

In order to produce (colored) pattern areas in the composite material, it is advantageous to reduce the thickness of a first pre-plate made of polymer modeling compound from a first composition; in particular by calendering, producing a first intermediate plate of a first thickness, sample pieces of polymer modeling compound of a second composition, e.g. Grains or flakes, to be distributed on at least one surface of the first intermediate plate, and to produce the plate from the first intermediate plate with the pattern pieces placed thereon by a further reduction in thickness, in particular by calendering.

However, it is also conceivable to produce a second intermediate plate of a second thickness from a second preliminary plate made of polymer modeling compound of the second composition by thickness reduction, in particular by calendering, and to cut out the sample pieces from the second intermediate plate.

A preferred application of the composite material according to the invention is characterized in that the object formed is an element that can be used for lighting purposes, in particular a lampshade.

Further embodiments result from the dependent claims.

BRIEF EXPLANATION OF THE FIGURES

The invention will be explained in more detail below on the basis of exemplary embodiments in connection with the drawing. Show it

Fig. 1 shows the section through a composite material according to a first

Embodiment of the invention with a reinforcement on a plate surface; 2 shows the section through a composite material according to a particularly preferred second exemplary embodiment of the invention with a reinforcement on both surfaces;

Fig. 3 shows the section through a composite material according to a third

Embodiment of the invention with reinforcements on the surfaces and inside of the plate;

Fig. 4-7 in a schematic representation of various steps

Production of a composite material according to FIG. 2 with an incorporated pattern;

8 shows a preferred application of the composite material according to the invention in the form of a lampshade.

WAYS OF CARRYING OUT THE INVENTION

1 to 3, three different exemplary embodiments of a composite material according to the invention are shown in a sectional view. The first exemplary embodiment according to FIG. 1 shows a composite material 10, which comprises a plate-shaped base layer 11 made of (initially uncured) polymer modeling material (FIMO or others). A fabric 12 is embedded in one surface (upper in the figure), the cut through the warp or weft threads being indicated by small circles. The fabric 12 is completely embedded in the polymer modeling compound of the base layer 11 in FIG. 1; however, it can also be only partially embedded if the connection between the fabric 12 and the material of the base layer 11 is sufficiently good to ensure the desired mechanical stabilization. A complete embedding of the fabric 12 ensures that the basic color of the base layer 11 can be perceived from the outside largely undisturbed by the fabric 12. But it is also conceivable to consciously include the structure of the fabric 12 as a design element. The thickness of the composite material 10 is of the order of 1 mm and is, for example, 0.6 mm. The fabric 12 is preferably a very fine, transparent fabric, in particular an organza or organdy fabric. Particularly good results are achieved with a polyester organdy fabric that optimally combines with the polymer modeling material of the base layer 11.

In the embodiment of FIG. 1, one (lower) surface is not reinforced. The sensitivity to mechanical influences is correspondingly higher there. This then does not matter who the composite material 10 is applied with the unreinforced side on another surface. If, on the other hand, the composite material is shaped and used on its own, it is advantageous if it is mechanically reinforced on both surfaces (sides). An embodiment of such a composite material 20 reinforced on both sides is shown in FIG. 2. Material selection and thickness are preferably the same as in the embodiment of FIG. 1 with the difference that a fabric 13 is also embedded in the lower surface of the base layer 11 for reinforcement. In the simplest case, the fabrics 12 and 13 are of the same type. However, it is also conceivable to select different fabrics in order to achieve a different surface quality on the two surfaces. The composite material 20 reinforced on both sides according to FIG. 2 is best suited for most applications because it covers a wide range of applications with the best mechanical properties.

Another embodiment of the composite material according to the invention is shown in FIG. 3. In this composite material 30, a reinforcing fabric 15,... 17 is embedded in a somewhat thicker base layer 14 made of polymer modeling compound not only on the two surfaces but also on the inside. Such a composite material 30 can be produced, for example, by connecting the composite materials 10 from FIGS. 1 and 20 from FIG. 2 over a wide area. Here, too, the materials can be the same as in FIG. 1 or 2. The production of the composite material according to the invention can be explained on the basis of the production steps shown in FIGS. 4 to 7. The manufacturing steps shown relate to a composite material reinforced on both sides according to FIG. 2 with (colored) patterns introduced on one side. For the production, initially uncured polymer modeling compound (FIMO or the like) in the desired consistency and color (basic color) is kneaded well and processed into a comparatively thick first front plate 21 (FIG. 4). The first pre-plate 21 is then rolled out in a calendering machine 31 between two counter-rotating rollers 18, 19 to form a first intermediate plate 21 'of thickness d1 (FIG. 4). The thickness d1 is, for example, 1.5 mm.

A corresponding second pre-plate 22 made of polymer modeling compound of a different color is rolled out according to FIG. 5 in the calender 31 to a second intermediate plate 22 'of thickness d2 (e.g. d2 = 0.7 m). Individual sample pieces 24 are cut out of the intermediate plate 22 'by means of a knife 23 (only indicated in FIG. 5) or scissors or the like, the size and shape of which are matched to the desired pattern. But it is also conceivable to produce a finely distributed pattern (e.g. for floor slabs or the like) instead of the rolled, flat pattern pieces 24 irregularly shaped pattern pieces of a different color, e.g. Flakes, grains or cutlets.

The sample pieces 24 (or flakes, grains or schnitzel) are then placed (or scattered) on one side (or both sides) of the first intermediate plate 21 'in the desired arrangement and again together with the underlying first intermediate plate 21' in the Calender 31 to a plate 25 with a thickness of, for example 1.5 mm Kalai .driert (Fig. 6). The pattern pieces 24 placed on top are widened, differently colored pattern areas 24 'integrated into the plate 25.

The patterned plate 25 thus prepared with the pattern areas 24 'is then (FIG. 7) between two fabric webs 26, 27 made of polyester organdy or one comparable fabric in the calender 31 to the composite material 28 with a thickness of, for example, 0.6 mm, the fabric sheets 26, 27 being pressed together with the polymer modeling compound in such a way that the modeling compound completely bonds to the fabric. The composite material 28 then has the structure shown in FIG. 2.

Plates of a certain shape can then be punched out of the finished rolled composite material 28 or cut out with scissors. These plates are then modeled or pressed onto molds while still moist, for example to form a lampshade 29 according to FIG. 8. The fully formed parts are then cured together with the tool in the oven at approx. 130 ° C for approx. 30 minutes.

Overall, the invention makes it possible to produce mechanically stable, almost arbitrarily moldable objects in a simple and quick manner, which can have the most varied of colored patterns. If, in particular, a translucent polymer modeling compound is used as the base material, parts for lighting technology such as e.g. Lampshades are made.

LIST OF REFERENCE NUMBERS

10,20,30 composite material

11, 14 base layer (polymer clay)

12, 13, 15, .., 17 fabrics (e.g. polyester organdy)

18.19 roller

21, 22 front plate (polymer clay)

21 ', 22' intermediate plate (polymer clay)

23 knives

24 sample 24 ', 24 "sample area

25 plate (polymer clay) 26.27 fabric web (e.g. polyester organdy)

28 composite material

29 lampshade

31 calendering machine

Claims

1. Composite material (10, 20, 28, 30), characterized by a plate-shaped base layer (11, 14) made of a curable polymer modeling compound ("polymer clay"), with the surface of the base layer (11, 14) itself A fiber-containing reinforcing material (12, 13, 15, .., 17) is at least partially embedded in the base layer (11, 14) and extends over the surface of the base layer (11, 14).

2. Composite material according to claim 1, characterized in that the fiber-containing reinforcing material (12, 13, 15, 17) is provided on both sides of the base layer (11, 14).

3. Composite material according to one of claims 1 or 2, characterized in that a fiber-containing reinforcing material (16) is additionally arranged inside the base layer (14).

4. Composite material according to one of claims 1 to 3, characterized in that the fiber-containing reinforcing material is a fabric (12, 13, 15, .., 17).

5. Composite material according to claim 4, characterized in that the fabric (12, 13, 15, .., 17) consists of a translucent material, preferably polyester.

6. Composite material according to one of claims 4 or 5, characterized in that the fabric (12, 13, 15, .., 17) is an organdy or organza fabric.

7. Composite material according to one of claims 1 to 6, characterized in that polymer modeling material of the base layer (11, 14) is translucent.

8. Composite material according to one of claims 1 to 7, characterized in that the base layer (11, 14) consists of a uniform material and in the base layer (11, 14) pattern areas (24 ', 24 ") are made of another material ,

9. Composite material according to one of claims 1 to 8, characterized in that the composite material (10, 20, 30) has a thickness of less than or equal to 1 mm, preferably about 0.6 mm.

10. A method for producing a composite material according to one of claims 1 to 8, characterized in that in a first step a plate (25) is produced from the uncured polymer modeling compound, that in a second step on at least one surface of the first plate ( 25) fiber-containing reinforcing material (26, 27) is applied or placed flat, and that in a third step the stack of the plate (25) and the applied or placed reinforcing material (26, 27) is pressed together perpendicular to the plate plane such that the fiber-containing reinforcing material (26, 27) is at least partially embedded in the material of the plate (25).

11. The method according to claim 10, characterized in that in the second step the fiber-containing reinforcing material (26, 27) is applied or placed on both surfaces of the plate (25).

12. The method according to any one of claims 10 or 11, characterized in that the compression in the third step between two parallel rollers (18, 19), preferably in a calendering machine (31).

13. The method according to any one of claims 10 to 12, characterized in that for generating pattern areas (24 ') in the composite material (28) from a first front plate (21) made of polymer modeling compound of a first composition by reducing the thickness; especially by calendering, a first intermediate plate (21 ') of a first thickness (d1) is produced, that pattern pieces (24) made of polymer modeling compound of a second composition are placed on at least one surface of the first intermediate plate (21') and that the first intermediate plate (21 ' ) with the placed sample pieces (24) by a further reduction in thickness, in particular by calendering, the plate (25) is produced.

14. The method according to claim 13, characterized in that a second intermediate plate (22 ') of a second thickness (d2) is produced from a second front plate (22) made of polymer modeling compound of the second composition by thickness reduction, in particular by calendering, and that the sample pieces (24) are cut out of the second intermediate plate (22 ').

15. The method according to any one of claims 10 to 14, characterized in that a fine-mesh fabric (26, 27), preferably made of polyester, in particular an organdy or organza fabric, is used as the fiber-containing reinforcing material.

16. Use of the composite material according to one of claims 1 to 9 for forming objects with a predetermined spatial shape, characterized in that the composite material (10, 20, 30) in the uncured state, if necessary after a previous cut, brought into the desired shape and is cured in this form.

17. Application according to claim 16, characterized in that the object formed is an element which can be used for lighting purposes, in particular a lampshade (29).