WO2008107664A1 - Tapis végétal et procédé pour réaliser un tapis végétal - Google Patents

Tapis végétal et procédé pour réaliser un tapis végétal Download PDF

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Publication number
WO2008107664A1
WO2008107664A1 PCT/GB2008/000730 GB2008000730W WO2008107664A1 WO 2008107664 A1 WO2008107664 A1 WO 2008107664A1 GB 2008000730 W GB2008000730 W GB 2008000730W WO 2008107664 A1 WO2008107664 A1 WO 2008107664A1
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WO
WIPO (PCT)
Prior art keywords
plant
derived
fibre
fibres
mat
Prior art date
Application number
PCT/GB2008/000730
Other languages
English (en)
Inventor
Douglas Spinney
Peter Topham
Original Assignee
Eco Technilin Limited
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 Eco Technilin Limited filed Critical Eco Technilin Limited
Priority to EP08718597A priority Critical patent/EP2118351A1/fr
Publication of WO2008107664A1 publication Critical patent/WO2008107664A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • 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
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/04—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by applying or incorporating chemical or thermo-activatable bonding agents in solid or liquid form
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • E04B1/90—Insulating elements for both heat and sound slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/026—Mattresses, mats, blankets or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/745—Vegetal products, e.g. plant stems, barks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B2001/7687—Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/244—Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires

Definitions

  • the present invention relates to mats made from plant fibres and a method of making such mats and in particular, mats made from two different types of plant.
  • Flax plants can have a stem with a length between 600 and 800 mm.
  • the stem has strong fibre bundles running from root to top. These fibre bundles are disposed outermost in the stem, and in the internal space between the fibre bundles there is a central stalk consisting of wood cells (shives) .
  • hemp plants have stems which are considerably longer than the stem of the flax plants.
  • hemp stem may comprise outer fibre bundles and a inner wood cells (shives) consisting of short fibres with lengths from 0.5 mm to 0.6 mm.
  • shives inner wood cells
  • the flax or hemp fibres are separated from the wood fibres in the stem by a retting process.
  • Retting is a microbiological process which partially decomposes the natural fibre.
  • retting causes hemicellulose and pectin in the natural fibre to bind the fibres together.
  • Harvesting of flax and hemp for textile production consists of pulling up all of the plant. Pulling up the plants is a slow and work intensive process. After the pulling up the plants, the plants are laid aside for retting and the retting process takes place in the field (e.g. dew-retting). The degree of retting is important for determining the properties of the fibres in the making of textile fibres for carding and spinning. The retting process is a biological process and so the retting process is difficult to control.
  • the stems are pressed into bales and transported to a fibre factory.
  • the seeds are torn off in a scutching mill. Scutching is the process of mechanically separating the fibres from the wood part.
  • the straws are processed by placing the stems in parallel and treating them in parallel through processing equipment .
  • Fibre mats are made using the harvested plant fibres such as the above mentioned hemp or flax fibres.
  • Such fibre mats are formed by carding the fibres. Carding the fibres consists of passing the fibres through a card, a comb-like structure, which disentangles them and straightens the fibres. Thereafter, a fur is formed and finally a needling process is performed for making the finished fibre mat.
  • the flax or hemp In order to perform the needling process, the flax or hemp is required to be a certain humidity so that the flax or hemp is pliable. If the flax or hemp is too dry, then the flax or hemp will to dust and short fibres. Short fibres are easily torn out of a formed fibre mat.
  • EP-A-1090176 which is incorporated in its entirety by reference herein, discloses a method of manufacturing a fibre mat. The method incorporates the steps of exposing and using fibres from a completely un-retted to a strongly over-retted quality, depending on the purpose of use .
  • EP-A-1090176 discloses a method of making a vegetable fibre mat including the steps of harvesting the plants by cutting and threshing, retting wholly or partially the plant stems, drying them for providing a desired water content, shortening and separating the fibres for establishing a fibre mass comprising mainly single fibres and for creating their fibrillation, forming the mat by a dry forming process whereby the fibres are randomly oriented and form inter-fibre bonds. Therein, bonds are formed between the single fibres without the need of a binder component.
  • a vegetable fibre mat may be made using stems that are not retted, which have been dew-retted on the field, or which have been retted by a controlled retting process (e.g. with a chemical process) .
  • the single fibres are used to provide more "airy" products (e.g. less dense) than is the case when making products from fibre bundles.
  • Single cell fibres are not suitable for making fibre mats by the above mentioned needle processes because the single cell fibres are shortened. This makes also makes the single cell fibres unsuitable for carding.
  • a step of the method of EP-A- 1090176 requires that the fibres are fibrillat'ed.
  • the fibrillation of the fibres causes the single fibres to form a sheet wherein the fibre bundles mesh with each other.
  • bonds are formed between the single fibres and the subsequent formed mat does not need to be needled or steam bonded.
  • the formed fibre mat is airy and voluminous and may be compacted to the desired degree, depending on the intended use.
  • the formed fibre mat may also include a binder component.
  • a mat made from plant fibres or other natural fibres does not use synthetic fibres and may be considered environmentally friendly.
  • vehicle manufacturing regulations of certain countries require the vehicle to be made out of a certain percentage of renewable or green products (e.g. made from plants) .
  • fibre mats such as those made according to the method EP-A-1090176 using hemp or flax are very flexible when processed into single cell fibres.
  • the fibre mats In order to stiffen the fibre mats, the fibre mats must be reinforced.
  • fibre mats were stiffened using additives such as synthetic binders or a plastics material. Consequently, the addition of synthetic materials such as those derived from petroleum to the fibre mats mean the fibre mats are considered to be less environmentally friendly.
  • the present invention provides a fibre mat having plant-derived fibres and a plant-derived material, the plant-derived fibres being different from the plant-derived material.
  • the invention provides a fibre mat having: plant-derived fibres arranged in a fibrous network; and a plant-derived material, different from the plant- derived fibres, held within the fibrous network, to provide a mat structure.
  • the plant-derived fibres are bast plant fibres. That is, using parts of plants which are particularly fibrous.
  • the present inventor has observed a surprising effect when a plant-derived material which is different from the plant-derived fibres is mixed with the plant-derived fibres; the plant-derived material is held within a network formed from the plant-derived fibres. Consequently, the characteristics of the plant-derived material may complement the characteristics of the plant- derived fibres and form a fibre mat composite.
  • the physical properties and structure of the fibre mat may be altered.
  • the invention has particular applicability where the plant-derived fibres are derived from a plant of a different species to that from which the plant-derived material is derived.
  • the plant-derived material cannot be used for making a fibre mat alone because the plant-derived material does not form suitable fibres.
  • the plant-derived fibres are high quality and are expensive.
  • a smaller amount of plant-derived fibres is required and hence the resulting fibre mat has a reduced manufacturing cost.
  • the plant-derived fibres have an average length between 0.1mm and 150mm.
  • the structure of the fibrous network may be altered by changing the length of the fibres and the number of links each fibre has in the fibrous network.
  • the addition of a plant-derived material different from the plant-derived fibres may change the overall physical properties of the fibre mat.
  • the plant-derived material comprises material elements having an average stiffness greater than that of the plant-derived fibres.
  • This arrangement provides the fibrous network of plant-derived fibres which is reinforced with material elements of the plant-derived material.
  • the material elements contribute significantly to the overall stiffness of the fibre mat, whilst the plant-derived fibres provide a fibrous network to hold the material elements.
  • the fibre mat requires less reinforcement with synthetic components, i.e. a synthetic binder component, which advantageously reduces the cost of the fibre mat manufacturing process.
  • the plant-derived material elements have an average length between 0.1mm and 150mm.
  • the fibrous network comprises an array or mesh of linked fibres, said fibres each being substantially single fibres.
  • the arrangement of single fibres provide more links / nodes in the fibrous network compared to larger bundles of fibres and this provides a stronger network and mat structure.
  • the fibrous network comprises interlinking fibre bundles, each bundle having a plurality of fibres.
  • the plurality of fibres may be a few single fibres up to a maximum of 10 to 30 single fibres.
  • the plant-derived material is one or more selected from the following: wheat straw, oat straw, rye straw, barley straw, grass straw, rice straw, bean straw, oilseed rape straw, cellulose, paper, cardboard, coconut husk or other similar plant-derived material. Such material these plants tends to break down to a dust when mechanically worked.
  • the plant-derived fibres are one or more selected from the following: hemp, jute, flax, ramie, kenaf, rattan, soya bean fibre, okra fibre, vine fibre, peat fibre, kapok fibre, sisal fibre, banana fibre or other similar types of bast fibre material.
  • such plant-derived fibres are fibrous and are flexible .
  • the mat has a binder component.
  • a binder component to provide strong bonds between the plant-derived fibres and the plant- derived material.
  • the binder component is a synthetic binder or a natural binder. Additionally or alternatively, the binder component may be heat activated. More preferably, the binder component is selected from one or more of: polypropylene, polylactic acid, polyethylene, polyester, vinyl, polyvinyl acetate, starch or other similar binding material.
  • the binder component may be heat activated.
  • the binder component is a polymer, for example thermoplastic.
  • relatively large amounts of the binder component may be used.
  • the fibre mat is heated to an activation, or melting, temperature of the plastic, inter-fibre bonds are established.
  • binder component added will thus depend on the intended use of the formed fibre mat.
  • a fibre mat intended for isolation mats may contain very little or no binder.
  • a composite sheet for example, has properties corresponding to those known from fibre and chip-boards will contain a larger amount of binder component.
  • the amount of the binder component present in the fibre mat may alter the physical properties of the overall fibre mat.
  • the percentage weight of the binder component is the range lwt% to 50wt%. All percentage weight values disclose herein refer to the percentage weight (wt%) with respect to the total weight of the fibre mat. (e.g. a mat have 50wt% of a binder component means there are 50 parts by weight binder component in 100 parts by weight fibre mat.) More preferably, the percentage weight of the binder component is in the range 10wt% to 40wt%. Even more preferably, the percentage weight of the binder component is in the range 20wt% to 30wt%.
  • the percentage weight of the binder component may be at least: lwt%, 5wt%, 10wt%, 15wt%, or 20wt%.
  • the percentage weight of the binder component may be at most 25wt%, 30wt%, 35wt%, 40wt%, 45wt% or 50wt%.
  • the percentage weight of the plant-derived fibres is in the range 5wt% to 95wt%. More preferably, the percentage weight of the plant-derived fibres is in the range 20wt% to 80wt%. Even more preferably, the percentage weight of the plant-derived fibres is in the range 30wt% to 70wt%. Most preferably, the percentage weight of the plant-derived fibres is in the range 40wt% to 60wt%. Alternatively, the percentage weight of the plant-derived fibres may be at least lwt%, 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, 35wt%, or 40wt%.
  • the percentage weight of the plant-derived fibres may be at most 45wt%, 50wt%, 55wt%, 60wt%, 65wt%, 70wt%, 75wt%, 80wt%, 85wt%, 90wt% or 95wt% .
  • the percentage weight of the plant-derived material is in the range 5wt% to 95wt% . More preferably, the percentage weight of the plant-derived material is in the range 20wt% to 80wt%. Even more preferably, the percentage weight of the plant-derived material is in the range 30wt% to 70wt%. Most preferably, the percentage weight of the plant-derived material is in the range
  • the percentage weight of the plant-derived material may be at least lwt%, 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, 35wt%, or 40wt%.
  • the percentage weight of the plant-derived material may be at most 45wt%, 50wt%, 55wt%, 60wt%, 65wt%, 70wt%, 75wt%, 80wt%, 85wt%, 90wt% or 95wt%.
  • the fibre mat has additional material elements held in the fibrous network.
  • the additional material elements are non plant-derived organic material .
  • the non plant-derived organic material may be wool.
  • the additional material elements may be one or more selected from the following: peat, rice waste, foam, acoustic insulation, absorbent granules, sawdust, vermiculite
  • the additional material elements may include a fire retardant such as borax, boric acid, aluminium hydroxide or other similar material or materials.
  • the fibre mat may have at least two layers, the at least two layers having different percentage weights of the plant-derived material and / or different percentage weights of the plant-derived fibres.
  • a composite fibre mat structure may be formed having multiple layers with different physical properties. More preferably, a layer of the at least two layers has a different plant-derived material and/or different plant- derived fibre to another layer of the at least two layers .
  • the relative physical properties of the layers of the fibre mat can be further altered. For example a stiff layer can be combined with a thermally insulating layer.
  • the plant-derived material and the plant-derived fibres have different physical properties.
  • a physical property of the plant-derived material has a different value with respect to the same physical property of the plant-derived fibre.
  • the physical property may be any one of the following: thermal conductivity, density, elastic modulus or tensile strength.
  • the elastic modulus of the plant-derived material is greater than the elastic modulus of the plant-derived fibres.
  • Other properties of relevance here include absorbency (e.g. water absorbency), acoustic properties, fire retarding properties, odour properties, plant root penetration properties, hydrophobic/hydrophilic properties .
  • the plant-derived material may have a different acoustic insulation properties, liquid absorbency, hardness, thermal insulation properties, smell, density, insect repelling properties, fire retarding properties, odour properties, plant root penetration properties, and/or hydrophobic/hydrophilic properties, etc. from those properties of the plant- derived fibres .
  • the fibre mat has a thickness between 2mm and 300mm.
  • fibre mat has an area density in the range of 30 and 8000g/m 2 .
  • the fibrous network of plant-derived fibres is a web and net formation.
  • the present invention provides a method of making a fibre mat having the steps: mixing plant-derived fibres arranged in a fibrous network with a plant-derived material, the plant-derived material being different from the plant-derived fibres; and forming a mat structure from a mixture of the fibrous network and the plant-derived material. In this way, the mat according to the first aspect is manufactured.
  • the step of forming a mat structure comprises the step of applying suction to draw the mixture of the fibrous network and the plant-derived material onto a template for a mat.
  • the fibrous network holds material elements of the plant-derived material and the mixture of the fibrous network and the plant-derived material are drawn towards a template by a differential pressure created by a suction means.
  • Multiple layers of fibrous network may be drawn towards the template, each layer of fibrous network integrating and interlocking with adjacent layers of the fibrous network.
  • the method may further have the step of separating a fibrous plant material into the fibrous network of plant- derived fibres.
  • the bast fibres typically break down into a fibrous network when the fibrous plant material is beaten, bashed, milled, hammered or worked by a similar method.
  • the method may further have the step of working the plant-derived material to break down the plant-derived material.
  • the plant-derived material may be used in a raw state and processed.
  • the plant-derived material may be processed until the material elements of the plant-derived material are of a suitable length and / or shape.
  • the step of working the plant- derived material and the step of mixing are carried out together.
  • the method of making the fibre mat is made more efficient if the plant-derived material is broken down into material elements at the same time as mixing the plant-derived material with the fibrous network. This reduces the manufacturing time and increases the amount the fibrous network and material elements are mixed together.
  • the step of working the plant-derived material and the step of mixing may occur at different times. Different plant materials will require different amounts of processing, depending on their raw state
  • the step of separating the plant-derived fibres occurs at the same time as the step of working the plant-derived material.
  • the method of making the fibre mat may be sped up.
  • the step of separating the plant-derived fibres and the step of working the plant-derived material are the same process step.
  • the same machinery for working the plant-derived material is used to separate the plant-derived fibres at the same time.
  • the steps of working and separating are carried out with a mill. More preferably, the mill is a hammer-mill.
  • the step of separating the plant-derived fibres occurs at a different time from the step of working the plant-derived material.
  • the method further comprises the step of mixing a binder component with the mixture of the fibrous network and the plant-derived material.
  • the binder component is a heat activated and the method further includes the step of heating the mixture of the fibrous network, the plant-derived material and the binder component to an activation temperature such that bonds are established between the fibrous network and the plant-derived material.
  • the method further comprises the steps of mixing hot water and / or steam with the mixture of the fibrous network and the plant-derived material and drying the mixture of the fibrous network and the plant-derived material.
  • the mixture dries such that the fibrous network has more nodes.
  • the fibrous network has an increased number of interlocking fibres.
  • this method does not require a binder component and the percentage of natural, renewable type products in the fibre mat may be increased.
  • the invention provides a fibre panel having a fibre mat according to the first aspect; wherein the fibre mat is compressed and heated at a panel-forming pressure and temperature.
  • the fibre mat as mentioned previously may be used to form a stiff, panel type structure.
  • Such a panel may have improved structural properties over the fibre mat that make it particularly suitable for interior walls of buildings and / or vehicles.
  • fibre panel may be reinforced with a thermosetting plastic material or a thermoplastic material. This means that when the fibre mat is pressed and heated, bonds will form between the plant-derived fibres and plant-derived material, further strengthening the fibre panel.
  • the present invention provides a method of making a plant fibre panel comprising the method of making a fibre mat according the second aspect; wherein the method further comprises the steps of compressing the fibre mat to a panel-forming pressure; and / or heating the fibre mat to a panel-forming temperature.
  • the panel-forming pressure is between 6 tonnes/m 2 to 120 tonnes/m 2 .
  • the panel-forming temperature is between 100 0 C and 250 0 C. More preferably, the panel-forming temperature is between 150°C and 250°C, e.g. about 200°C.
  • the method further includes the step of moulding the plant fibre panel.
  • a thermosetting plastic material or a thermoplastic material is added to the fibre mat.
  • the fibre panel is particularly suitable for moulding into desired shapes.
  • an interior panel of a vehicle may be produced using a fibre panel when pressed and heated on a respective interior vehicle panel mould.
  • any of the preferred and/or optional features may be applied separately or in conjunction with any of the aspects of the invention, unless the context demands otherwise.
  • the present invention includes a combination of each aspect with one or more other aspects.
  • the invention provides another aspect which includes the combination of any aspect with one or more aspect (s) .
  • FIG. 1 shows a schematic magnified view of a fibre mat according to a first embodiment of the present invention .
  • Fig. 1 shows a schematic magnified view of a fibre mat according to first embodiment of the present invention.
  • the fibre mat has plant-derived fibres 2 arranged in a fibrous network 1 and a plant-derived material 3 held within the fibrous network 1.
  • the fibrous network 1 is formed from the plant-derived fibres 2 which interlock at nodes 4.
  • the plant-derived fibres are typically single fibres.
  • the nodes 4 connect the separate plant-derived fibres 2 together and are locations where the separate plant-derived fibres are tangled together or are bonded together by a binder component or other suitable binding mechanism.
  • the plant-derived material 3 comprises material elements which have been cut to a desired length. The material elements are held within the fibrous network 1 by bonds to the plant-derived fibres 2 or being entangled within the fibrous network 1. The material elements are sufficiently entangled / bonded within the fibrous network 1 such that movement of the material elements is limited.
  • flax is the plant-derived fibres 2 and the straw is the plant-derived material 3.
  • polyethylene is used as a binder component.
  • the polyethylene forms bonds between the separate plant-derived fibres 2 in the fibrous network 1 and bonds between the plant-derived fibres 2 and the material elements of the plant-derived material 3.
  • cellulose is used with hemp.
  • the hemp is the plant-derived fibres 2 and the cellulose is the plant-derived material 3.
  • Cellulose material elements have good water absorption properties .
  • the fibre mat made from hemp and cellulose has good water absorption properties and is suitable for absorbing liquids and mopping up spillages (e.g. spilt water or oil) .
  • wheat straw is used with hemp.
  • the hemp is the plant-derived fibres 2 and the wheat straw is the plant-derived material 3.
  • the wheat straw is stiff and is resistant to abrasive forces.
  • the fibre mat made from hemp and straw is suitable for preventing soil erosion. Typically, such a fibre mat is placed, partially buried or completely buried on a soil bank or an area of ground with exposed soil.
  • the fibre mat of the fourth embodiment prevents the soil from being eroded.
  • coconut husk fibres are used with hemp.
  • the hemp is the plant-derived fibres 2 and the coconut husk fibre is the plant-derived material 3.
  • coconut husk fibre is stiff (but flexible) compared to hemp fibre.
  • coconut husk fibre is resiliently deformable.
  • the fibre mat made from hemp and coconut husk fibre provides a springy mat, which returns to its original shape after being deformed.
  • such a fibre mat is used for thermal and / or acoustic insulation because the resiliently deformable nature of the fibre mat traps air within the mat. This means the mat is lightweight and has good thermal and acoustic insulating properties.
  • the fibre mat is compressed and heated and the polypropylene melts and forms bonds between the separate plant-derived fibres 2 in the fibrous network 1 and bonds between the plant- derived fibres 2 and the material elements of the plant- derived material 3.
  • the polypropylene reinforces the fibre mat and after the heating and pressing of the fibre mat, a fibre panel is produced.
  • the fibre panel is a highly reinforced composite material .
  • the flax stems are laid in swaths and after about ten days on the field are combine harvested with a typical combine harvester machine.
  • the flax lies in a straw run/swath on the field and is retted.
  • the retting process may be observed by noting a change in colour on the straw.
  • the desired degree of retting has been achieved when the colour on the straw/fibres changes to light grey. It may be necessary to turn the swath in order to ensure a uniform retting.
  • the retting process is monitored and samples are taken daily in order to ascertain how far the retting process has advanced.
  • the straw is gathered by pressing into bales, for example round bales. Normally baling of the flax takes place when there is a 15wt% water content in the flax.
  • bales are transported to the factory where they are dried to a 12wt% water content. After drying, the bale is unrolled/cut up. The flax straw is fed into a hammer mill where the scutching takes place. This separates the flax straw into a fibrous network 1.
  • the plant-derived material in this case, wheat straw
  • the hammer mill works the wheat straw and breaks the wheat straw down into smaller components, referred to herein as material elements. Typically the material elements are 15 mm long, but the size range may be 10-15 mm.
  • the hammer mill also mixes the material elements of the wheat straw into the fibrous network.
  • the mixture of the flax straw fibrous network and wheat straw material elements is then transported to the fibre mat manufacturing plant where a dry-forming process takes place .
  • the dry-forming process uses a former head placed above a vacuum box. Between the former head and the vacuum box, there is a template or former wire on which the mixture is deposited. The vacuum box creates a differential pressure between the former head and the former wires. The mixture is held on the former wires by virtue of the differential pressure.
  • the fibre mat manufacturing plant is adjusted to forming a fibre mat of a desired thickness. This is regulated by means of the speed at which the fibrous network and plant-derived material mixture is fed from the former head. At the same time the advancing speed on the wire is regulated. During the dry-forming process, where the fibres are drawn onto the former wires, 2-3wt% of polyethylene is added.
  • the fibre mat is then placed in an oven at 145°C. After heating the fibre mat, it is packed and cut into shape.
  • the fibre mat is made according to the method of manufacturing the fibre mat of the first embodiment as mentioned above, except that a different binder component and amount of binder component are used.
  • a fibre panel is made using a fibre mat having a weight of 300 g/m 2 .
  • a plant-fibre compatilizer is sprayed on. That is, a chemical component which modifies the surface of the plant-derived fibres.
  • the plant-compatilizer is isocyanate (about 1- 2wt%) in order to ensure the hydrophobic fibres obtain a surface which is compatible with the binder component such as the above mentioned binder components in the fibre panel. It is possible at this stage also (or alternatively) to add a hydrophilic agent, a hydrophobic agent and/or a fire retarding agent.
  • the sixth embodiment incorporates polypropylene as a binder component. Approximately 50wt% of polypropylene is added to the mixture of the plant- derived fibres and plant-derived material immediately before the fibre mat is formed on the template former wires. Additionally, a coconut husk component may be added, in order to promote stiffness and resilience to the finished product.
  • the mixture of plant-derived fibres, plant- derived material and polypropylene is heated to an activation temperature of 200 0 C and compressed at a panel-forming pressure of 150 Tonnes/m 2 .
  • the fibre panels are be cut and formed in to mouldable fibre panel blanks. These are typically flat panels which may be conveniently transported.
  • the fibre panel blanks can be heated and moulded into a suitable shape after the manufacturing process the fibre panel.
  • the fibre panel blanks may be moulded for interior panels of vehicles or buildings.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Wood Science & Technology (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Forests & Forestry (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

Le tapis végétal objet de la présente invention contient des fibres dérivées de plantes disposées selon un réseau fibreux ainsi qu'un matériau d'origine végétale différent des fibres dérivées de plantes et maintenu dans le réseau fibreux. Ce réseau fibreux comprend un ensemble de fibres liées, ces fibres étant essentiellement des fibres isolées. Le tapis est également constitué d'un composant de liant activé thermiquement. La présente invention concerne également les procédés de fabrication du tapis végétal et des panneaux végétaux réalisés à partir des tapis végétaux.
PCT/GB2008/000730 2007-03-05 2008-03-04 Tapis végétal et procédé pour réaliser un tapis végétal WO2008107664A1 (fr)

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GB0704236.9 2007-03-05
GB0704236A GB2452235A (en) 2007-03-05 2007-03-05 Plant fibre mat and method of making a plant fibre mat

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ITPA20080023A1 (it) * 2008-10-16 2010-04-17 Filippo Albamonte Realizzazione di pannelli isolanti termico-acustici per l'edilizia a base di legno di opunzia.
WO2010146355A1 (fr) * 2009-06-16 2010-12-23 Ecotechnilin Limited Composites stratifiés
FR2953132A1 (fr) * 2009-11-30 2011-06-03 Oreal Dispositif d'application de produit cosmetique comprenant des fibres de soja et procede de fabrication associe.
WO2011133755A1 (fr) * 2010-04-23 2011-10-27 Castagra Products, Inc. Composition de gypse fibreuse plastifiée
WO2011141644A1 (fr) * 2010-05-11 2011-11-17 Fabrice Carpanzano Materiau isolant a base de microfibres issues de fibres de hampes de bananiers fruitiers
WO2012059713A1 (fr) * 2010-11-03 2012-05-10 Ecotechnilin Limited Panneaux composites acoustiques et procédés pour leur fabrication
LT5903B (lt) 2011-02-03 2013-02-25 Lana Care Neaustinės medžiagos iš kapoko pluošto ir sintetinio pluošto gamybos būdas ir jos panaudojimas
EP2881249A1 (fr) * 2013-12-05 2015-06-10 Hanil E-Hwa Co., Ltd. Composite de polymère de fibres naturelles et matériau de base léger et écologique pour habitacles d'automobiles
EP2963197B1 (fr) * 2014-06-30 2017-11-22 NAPORO Klima Dämmstoff GmbH Procédé de préparation de broyage de matières premières renouvelables en fibre végétale, pour la transformation, notamment en nattes isolantes, et les matières premières renouvelables broyées obtenues selon ce procédé.
EP3461609A1 (fr) * 2017-09-29 2019-04-03 Daw Se Procédé de fabrication de matériaux fibreux, matériaux fibreux obtenus selon ledit procédé et utilisation des tels matériaux fibreux
EP3461940A1 (fr) * 2017-09-29 2019-04-03 Daw Se Procédé de fabrication de matières fibreuses ainsi que matières fibreuses obtenues selon un tel procédé et leur utilisation
EP4212680A1 (fr) * 2022-01-14 2023-07-19 Muance Couche en materiau isolant, procédé de fabrication de la couche en materiau isolant et panneau de construction comprenant une telle couche en materiau isolant

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GB2484545A (en) * 2010-10-15 2012-04-18 Glenn Williams Panel comprising sustainable material
CN109397460A (zh) * 2018-09-22 2019-03-01 书香门地（上海）美学家居股份有限公司 一种无醛阻燃地板及其制备方法

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Cited By (18)

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Publication number Priority date Publication date Assignee Title
ITPA20080023A1 (it) * 2008-10-16 2010-04-17 Filippo Albamonte Realizzazione di pannelli isolanti termico-acustici per l'edilizia a base di legno di opunzia.
WO2010146355A1 (fr) * 2009-06-16 2010-12-23 Ecotechnilin Limited Composites stratifiés
FR2953132A1 (fr) * 2009-11-30 2011-06-03 Oreal Dispositif d'application de produit cosmetique comprenant des fibres de soja et procede de fabrication associe.
RU2600947C2 (ru) * 2010-04-23 2016-10-27 Кастагра Продактс, Инк. Волокнистая пластифицированная гипсовая композиция
JP2013525248A (ja) * 2010-04-23 2013-06-20 キャスタグラ・プロダクツ，インコーポレイテッド 繊維性可塑化石膏組成物
US20110262733A1 (en) * 2010-04-23 2011-10-27 Peter Paul Roosen Fibrous plasticized gypsum composition
WO2011133755A1 (fr) * 2010-04-23 2011-10-27 Castagra Products, Inc. Composition de gypse fibreuse plastifiée
CN102947241A (zh) * 2010-04-23 2013-02-27 卡斯塔戈拉产品公司 纤维增塑石膏混合物
WO2011141644A1 (fr) * 2010-05-11 2011-11-17 Fabrice Carpanzano Materiau isolant a base de microfibres issues de fibres de hampes de bananiers fruitiers
FR2960010A1 (fr) * 2010-05-11 2011-11-18 Fabrice Carpanzano Materiau isolant a base de microfibres issues de fibres de hampes de bananiers fruitiers.
WO2012059713A1 (fr) * 2010-11-03 2012-05-10 Ecotechnilin Limited Panneaux composites acoustiques et procédés pour leur fabrication
LT5903B (lt) 2011-02-03 2013-02-25 Lana Care Neaustinės medžiagos iš kapoko pluošto ir sintetinio pluošto gamybos būdas ir jos panaudojimas
EP2881249A1 (fr) * 2013-12-05 2015-06-10 Hanil E-Hwa Co., Ltd. Composite de polymère de fibres naturelles et matériau de base léger et écologique pour habitacles d'automobiles
EP2963197B1 (fr) * 2014-06-30 2017-11-22 NAPORO Klima Dämmstoff GmbH Procédé de préparation de broyage de matières premières renouvelables en fibre végétale, pour la transformation, notamment en nattes isolantes, et les matières premières renouvelables broyées obtenues selon ce procédé.
EP3461609A1 (fr) * 2017-09-29 2019-04-03 Daw Se Procédé de fabrication de matériaux fibreux, matériaux fibreux obtenus selon ledit procédé et utilisation des tels matériaux fibreux
EP3461940A1 (fr) * 2017-09-29 2019-04-03 Daw Se Procédé de fabrication de matières fibreuses ainsi que matières fibreuses obtenues selon un tel procédé et leur utilisation
EP4212680A1 (fr) * 2022-01-14 2023-07-19 Muance Couche en materiau isolant, procédé de fabrication de la couche en materiau isolant et panneau de construction comprenant une telle couche en materiau isolant
FR3131928A3 (fr) * 2022-01-14 2023-07-21 Muance Couche en matériau isolant, procédé de fabrication de la couche en matériau isolant et panneau de construction comprenant une telle couche en matériau isolant

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GB2452235A (en) 2009-03-04
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