WO2013127733A1

WO2013127733A1 - Method for producing a mat-like semi-finished product from natural fibre and use of a mat-like semi-finished product

Info

Publication number: WO2013127733A1
Application number: PCT/EP2013/053701
Authority: WO
Inventors: Natalie Bogdanov; Roman Rinberg; Torsten BRÜCKNER; Wolfgang Nendel; Franz-Rainer GARDILL; Frank REITMANN
Original assignee: Johnson Controls Interiors Gmbh & Co. Kg
Priority date: 2012-02-29
Filing date: 2013-02-25
Publication date: 2013-09-06

Abstract

The invention relates to a method for producing a mat-like semi-finished product (1) from natural fibres, wherein un-decorticated flax plants are mechanically prepared in untreated form to become a free-flowing whole plant raw material and then processed in a fleece station to form the mat-like semi-finished product (1). The invention further relates to the use of a mat-like semi-finished product (1) thus produced for producing a component (B).

Description

Process for producing a mat-shaped semifinished product from natural fiber and use of a mat-shaped semifinished product

description

The invention relates to a method for producing a mat-shaped semifinished product from natural fibers. Furthermore, the invention relates to

Use of a mat-shaped semi-finished product produced in this way.

From the state of the art natural semi-finished fiber products are known, which are formed as needled natural fiber mats. These are processed into components using thermoplastic or thermosetting binders.

The object of the present invention is to provide an improved method for producing a mat-shaped semifinished product from natural fibers.

The object is achieved by a method for

Production of a mat-shaped semifinished product from natural fibers, wherein not deforested flax plants, especially green flax or

Whole plant raw material, untreated, in particular directly on the field, are mechanically processed to a dosed whole plant raw material. In a subsequent process-compliant processing of this whole plant raw material is processed on a non-woven plant to mat-shaped semifinished product. In the method neither a separation of root and seed capsule areas of the flax plants nor an aftertreatment of the plant material, for example, in a squeezing or shearing mill are necessary. This allows a production of special

inexpensive and competitive semi-finished products with given characteristics. Among undeclared and untreated flax plants are

in particular untreated raw or natural plants, in particular as so-called green flax understood, which to the meterable

Whole plant raw material is mechanically processed and then processed on a nonwoven system to the mat-shaped semi-finished product.

In one possible embodiment, the flax plants are processed directly on the field to the metered whole plant raw material. Alternatively, the flax plants can be recovered from the field and processed to the dosed whole plant raw material. The processing of flax plants directly on the field is particularly simple and inexpensive and requires no further processing facility.

In one embodiment of the invention, the flat plants in the

cut to the unmeshed state and processed to the mat-shaped semi-finished product in the form of a needled semi-finished mat. For this purpose, green flax is used as non-defoliated untreated flax plant, which is tapped by means of a flat harvester and then in a

dried drying time is dried. For example, the green flax is deposited on the field for drying for a predetermined, relatively short time, for example from two to three days. The green flax stored on the field for drying is also called flax straw.

During the drying time, the green flax or straw is turned only once and seeded. If necessary, the green flax can also be turned several times. For example, the green flax is turned once with the help of a turning-rippling machine, at the same time seeded, d. H. decapsulated and riffled, and put back on the field.

After the drying time, the dried, field dried and seeded plant stalks of the green flax or straw by means of a square baler with integrated cutting device

taken up and pressed into square bales of predetermined size and mass. The plant stems, also called plant stems, with root and seed capsule areas preferably directly on the field to a length of 8 cm to 25 cm, in particular from 10 cm to 20 cm, cut, d. H. shortened or cut to length.

Subsequently, the square bales are processed on a non-woven plant to the mat-shaped semi-finished product (also called semi-finished mats) of natural fibers, in particular to a so-called natural fiber fleece.

In addition, the mat-shaped semi-finished with a

thermoplastic binding matrix, d. H. by means of a thermoplastic binding matrix. As a result, the mat-shaped semifinished product is particularly suitable for the production of a component.

The production of components according to known per se

Technologies, for example by pressing and / or injection molding.

For this purpose, the mat-shaped semi-finished product is placed in a pressure-heating element in which the mat-shaped semi-finished product is plasticized under pressure at a temperature of about 210 ° C. This pressure heating element is preferably a high temperature tool.

Subsequently, the plasticized semifinished product in a

Molded low-temperature tool to a component carrier, consolidated and cropped, wherein the manufactured component carrier is introduced into a stamping tool in which the component carrier with a

Surface material, in particular of an olefin-based thermoplastic material (TPO), of polyvinyl chloride (PVC) or of textiles, is coated. The coating takes place under the action of pressure and / or heat with or without an additional adhesive. The final product, ie the finished component is then removed from the press or punch tool.

Reference to the accompanying schematic figures, the invention is explained in detail.

Show

FIG. 1 schematically shows a sequence of a method for producing a mat-shaped semi-finished product from natural fibers,

FIG. 2 schematically shows a first method sequence for producing a component using a mat-shaped semifinished product made of natural fibers, and

FIG. 3 schematically shows a second method sequence for producing a component using a mat-shaped semifinished product made of natural fibers.

Corresponding parts are provided in all figures with the same reference numerals.

FIG. 1 schematically shows a sequence of a method for producing a mat-shaped semifinished product 1 from natural fibers. Known from the prior art method for producing such semi-finished products 1 are dependent on a single fiber extraction. There are high

Material losses on bast fiber plants amount to at least 60% of the initial mass and in the form of shives and fiber dust attack. Furthermore, an economy of technical natural fibers, which are produced by methods known from the prior art, depending on the respective fiber pulping process, a supra-regional competitive situation in the natural fiber market and fashion trends in the textile industry. This and the absence of

Tailored system solutions made the locals

Natural fibers unattractive for manufacturing companies.

The inventive method for producing a mat-shaped semifinished product 1 of natural fibers, which in the following with reference to a

Embodiment is described, allows the production of a so-called stems direct semi-finished product, bypassing a

upstream material processing. Unprocessed or unfedged whole plant crops are fed directly to a fleece laying process and processed into mat-shaped semifinished product 1 of natural fibers in the form of a needled semi-finished mat. This allows a production of particularly inexpensive and competitive semi-finished products with predetermined properties. In general, plant components are present as a composite. That is, plant fibers are not separated or separated from shives. Fiber pulping is understood to mean the separation of the fibers from the rest of the plant and the singling or refinement of the fiber pulp into individual fiber bundles or their collectives.

The basis of the process is a new raw material template on the basis of non-deforested flax plants, which are mechanically processed in an unroasted state directly on the field to a meterable whole plant raw material. Alternatively, the flax plants can be salvaged from the field and mechanically processed to a dosed whole plant raw material. At the time of harvest, the occurrence of a yellow-green ripening phase of the flax plants should be chosen, as fibers of the flax plants then reach their maximum strength and stem properties are optimal for subsequent semi-finished product.

In a first method step VS1, the flax plants are preferably in an unroasted state, ie. H. as greenflax, by means of

Standard flax harvesters are harvested and stored for a relatively short time, for example two to three days, for drying in the field. During this drying time, the deposited flax straw is turned once in a second method step VS2 with the aid of a turning corrugating machine, while at the same time desiccating, d. H. decapsulated and riffled, and put back on the field. After the drying time has elapsed, the field-dried and seeded plant stems in a third method step VS3, for example by means of a

Square baler with integrated cutting device recorded and pressed into square bales of predetermined size and mass. The plant stems, also called plant stems, with root and

Seed capsule areas preferably directly on the field to a length of 8 cm to 25 cm, in particular from 10 cm to 20 cm, cut in such a way, d. H. shortened or cut to length, that subsequently in a fourth

Process step VS4 a process-compliant processing on a non-woven plant to mat semi-finished natural fibers, d. H. to a

Natural fiber fleece can be done. A post-processing of the plant material is preferably no longer necessary.

In this way, neither a loss-rich separation of the root and seed capsule areas of the flax plants nor the aftertreatment of the plant material, for example, in a squeezing or shearing mill are necessary. The resulting dosed plant material in

Square bale shape is in the fourth step VS4 on a

Standard fleece plant processed into a homogeneous nonwoven fabric, wherein a defined proportion of thermoplastic fibers, preferably Polypropylene fibers, polyester fibers and / or BICo fibers between 10 weight percent and 60 weight percent, in particular between 15 weight percent and 55 weight percent fed and processed together with the flax material prepared in the manner described to mat-shaped semifinished product 1.

A mat-shaped semifinished product 1, which has a thermoplastic-bonded matrix, is in this way, for example, from flax fibers in a proportion of 40 percent by weight to 70 percent by weight and synthetic fibers, for example of polypropylene (PP) and / or polyester (PEs), in a proportion of formed according to 60 weight percent to 30 weight percent.

A mat-shaped semifinished product 1 embodied as a fiber fleece can be provided on one side or both sides with polypropylene (PP) or with PP, PEs or PP-PE nonwovens, in particular coated, wherein the latter

Grammage in the range of 30 to 300 g / m ² and preferably in the range of 100 to 200 g / m ² . In this case, the coating may be formed as a non-woven fabric, which is also needled and present as a component. The grammage here refers only to the nonwoven fabric.

A mat-shaped semifinished product 1, which has a thermoset-bonded matrix, in this way, for example, from flax fibers in a proportion of 65 weight percent to 75 weight percent and a bio resin and / or epoxy resin in a proportion of corresponding

35 weight percent to 25 weight percent formed.

On a bottom and / or on an upper side of this mat-shaped semifinished product 1 can be used in a simple way Kunstfaser Abdeckvliesstoffe which according to the standard technology of Surface finishing of natural fiber nonwovens in one

Semifinished, for example, by needling to be processed. However, these synthetic fiber cover fabrics are not essential to the mat making process.

By means of the mat-shaped semi-finished products 1 made of natural fibers produced in this way, it is then possible to produce components B according to known technologies, for example by pressing and / or injection molding. Two embodiments for

Processes for producing such components B using the mat-shaped semifinished product 1 made of natural fibers are shown by way of example in FIGS. 2 and 3.

In the embodiment shown in Figure 2, the component B by means of a mat-shaped semifinished product 1 with a thermoplastic bonded matrix, d. H. produced by means of a thermoplastic binding matrix. In this case, the mat-shaped semifinished product 1 is inserted into a pressure heating element 2 in a first production step HS1. This pressure heating element 2 is preferably a high-temperature tool in which the mat-shaped semifinished product 1 is plasticized under pressure at a temperature of for example 210 ° C. In a second production step HS2, the now plasticized semifinished product 1 is deformed in a low-temperature tool 2.1 to the component carrier BT, consolidated and trimmed. Thereafter, the thus manufactured component carrier BT in a third

Manufacturing step HS3 introduced into a stamping tool 3, in which the component carrier BT in a fourth manufacturing step HS4 with a surface material 4, for example, from a thermoplastic

Olefin-based material (TPO), polyvinyl chloride (PVC) or

Textiles is coated. This can be done for example under the action of pressure and / or heat, with or without an additional

Adhesive. The final product, ie the finished component B is then in a fifth production step HS5 removed from the stamping tool 3.

In the alternative embodiment shown in Figure 3, the component B by means of a mat-shaped semifinished product 1 with a thermoset bonded matrix, d. H. produced by means of a thermosetting binding matrix. In this case, in a first production step HS1, a thermosetting resin is applied to the mat-shaped semifinished product 1 designed as a natural fiber mat of flax and / or hemp and dried.

This resinated semi-finished product 1 is cut in a second production step HS2 and inserted in a third production step HS3 in a heated tool 5, in which the component B is formed in a pressing operation and then removed from the heated tool 5. The component B is formed, for example, as a door inner support of a vehicle door.

LIST OF REFERENCE NUMBERS

1 mat-shaped semi-finished product

2 pressure heating element

2.1 low temperature tool

3 punch tool

4 surface material

5 heated tools

B component

BT component carrier

HS1 first production step

HS2 second production step

HS3 third production step

HS4 fourth production step

HS5 fifth production step

VS1 first process step

VS2 second process step

VS3 third process step

VS4 fourth process step

Claims

claims

1 . Process for the production of a mat-shaped semifinished product (1) from natural fibers, wherein non-defoliatory flax plants are mechanically processed into a meterable whole plant raw material and subsequently to a mat-shaped plant on a non-woven plant

Semi-finished products (1) are processed.

2. The method according to claim 1,

characterized in that the flax plants are recovered directly on the field or from the field and treated untreated to the meterable whole plant raw material.

3. The method according to claim 1 or 2,

characterized in that the flat plants are cut in the unroasted state and the mat-shaped

Semi-finished products (1) are processed in the form of a needled semi-finished mat.

4. The method according to any one of the preceding claims,

characterized in that is used as non-decorticated untreated flax plants Grünflachs, which by means of a

Flax harvester harvested, grated and then dried in a predetermined drying time.

5. The method according to claim 4,

characterized in that the green flax is turned over during the drying time and thereby seeded.

6. The method according to claim 4 or 5,

characterized in that after the drying time, the dried, field-dried and seeded plant stalks of the green flax by means of a square baler with integrated

Recorded cutting device and pressed into square bales of predetermined size and mass.

7. The method according to claim 6,

characterized in that the square bales are then processed on a nonwoven system to the mat-shaped semi-finished product (1) made of natural fibers.

8. The method according to any one of the preceding claims,

characterized in that the mat-shaped semi-finished product (1) is produced with a thermoplastic bonded matrix.

9. Use of a produced according to claims 1 to 8

mat-shaped semi-finished product (1) for producing a component (B).

10. Use according to claim 9, wherein the mat-shaped semi-finished product (1) in a pressure-heating element (2) is inserted, in which the

mat-shaped semi-finished product (1) is plasticized at a temperature of about 210 ° C under pressure.

1 1. Use according to claim 10, wherein the plasticized semifinished product (1) is subsequently deformed, consolidated and trimmed in a low-temperature mold (2.1) to form a component carrier (BT).

12. Use according to claim 1 1, wherein the manufactured component carrier (BT) introduced into a punching tool (3), in which the component carrier (BT) with a surface material (4), in particular from a Olefin-based (TPO) thermoplastic material, of polyvinyl chloride (PVC) or of textiles, coated wi

13. Use according to claim 12, wherein the coating takes place under the action of pressure and / or heat with or without an additional adhesive.