WO2013185819A1 - Procédé de fabrication d'une pièce moulée et pièce moulée - Google Patents

Procédé de fabrication d'une pièce moulée et pièce moulée Download PDF

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Publication number
WO2013185819A1
WO2013185819A1 PCT/EP2012/061269 EP2012061269W WO2013185819A1 WO 2013185819 A1 WO2013185819 A1 WO 2013185819A1 EP 2012061269 W EP2012061269 W EP 2012061269W WO 2013185819 A1 WO2013185819 A1 WO 2013185819A1
Authority
WO
WIPO (PCT)
Prior art keywords
weight
proportion
binder
fibers
matrix
Prior art date
Application number
PCT/EP2012/061269
Other languages
German (de)
English (en)
Inventor
Johann Kiss
Peter Walter
Wolfgang Walter
Konrad Eiweck
Alexander Fuith
Original Assignee
Intier Automotive Eybl Gmbh (Ebergassing) & Co Ohg
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 Intier Automotive Eybl Gmbh (Ebergassing) & Co Ohg filed Critical Intier Automotive Eybl Gmbh (Ebergassing) & Co Ohg
Priority to DE201211006533 priority Critical patent/DE112012006533A5/de
Priority to PCT/EP2012/061269 priority patent/WO2013185819A1/fr
Publication of WO2013185819A1 publication Critical patent/WO2013185819A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B32/00—Artificial stone not provided for in other groups of this subclass
    • C04B32/02—Artificial stone not provided for in other groups of this subclass with reinforcements
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to a process for the production of a molded part using a binder, which as a base formulation water, at least one vegetable
  • the invention further relates to a molding.
  • the molding composition is prepared by mixing a binder with at least one filler.
  • the binder consists of a mixture of milk protein or vegetable protein and lime, especially slaked lime or lime, or a lime substitute selected from the group consisting of NaOH, KOH solution, sodium bicarbonate, ammonium bicarbonate, potash and / or wood ash.
  • the at least one filler is selected from the group consisting of
  • a molded part which is solidified and cured by crosslinking and drying, is produced.
  • the molding compound can also be used for surface finishing of an existing component.
  • Milk protein, cereal flour for example wheat flour, also soybeans, lentils, peas and white beans mentioned.
  • fillers can be expanded mica (vermiculite), glass foam, expanded glass, expanded clay, expanded, volcanic ash, fly ash, bone ash, bone coal, pumice, aerated concrete, sand, crushed stone, clay, glass, stone powder, metal fibers, metal wool, metal shavings, hemp, jute, linen, Abaca, sisal, cotton, kapok, and head Pet hair (sheep wool, cattle and horse hair, etc.), coconut, wood, bamboo, grass, straw, pulp, reed, nettle, silk, viscose fiber, glass and mineral fibers, PET
  • Polypropylene fibers cellulose fibers, polystyrene foam, PU (polyurethane) foam and rubber foams are used.
  • the invention has for its object to provide a method for producing a molded part and a molded part, which is prepared using a binder of the type mentioned, which rigidity, strength,
  • the molded part with respect to the demands placed on this purpose should be the same as the previously used plastic parts or at least largely equal. It should be at the
  • the stated object is achieved according to the invention in that a natural fiber mat of unoriented fibers entangled with one another is provided with the fibers
  • Binder is impregnated, any excess of binder is removed and the impregnated natural fiber mat is cured in a molding tool under pressure and heat and pressed to the molding.
  • the molded part is thus predominantly made of natural raw materials, in particular of those which after use of the moldings are largely biodegradable and decomposable, manufactured.
  • the natural fiber mat gives the molding good mechanical properties, in particular a good rigidity and strength.
  • the moldings also have a lower weight than molded parts, which are made of thermoplastic materials. In the production of low shrinkage in the tool and the low material shrinkage are beneficial.
  • the moldings can be further processed in simple processes, in particular by sawing, cutting, drilling, milling and the like, also by laminating surface materials, by sticking
  • the proportions of these main components are coordinated so that a good impregnation of the natural fiber mat is ensured with the binder.
  • Binder either at least a vegetable protein source with a
  • slaked lime in particular slaked lime
  • Lime lime is available in appropriate quantities and cost-effective and easy to handle in the preparation of the binder.
  • the alkalinity of the binder has several important and crucial roles and functions in biological binder systems. In addition to the alkaline digestion of the protein-containing source of raw materials must be ensured that interfering components such as fat components by alkaline chemical reaction (saponification) lose the disturbing properties of a bond and the improved
  • Dispersing properties of the protein-containing binder can be used to advantage.
  • the alkalinity of the binder system is also important to the premature
  • additives and / or fillers can be added to the binder.
  • Additives are used in a total amount of from 0.01% by weight to 30% by weight, in particular up to 10% by weight, of fillers in a total proportion of from 0.5% by weight to 30% by weight, in particular up to to 20 wt .-%, added to the binder.
  • the molded article produced with such a mat has a density of 0.60 g / cm 3 to 0.95 g / cm 3 .
  • the natural fiber mat can be made of different natural fibers, including fiber blends, preferably flax, jute, hemp, kenaf, sisal, wool, coconut or wood or fibers of grasses, such as reed or cattail.
  • the natural fiber mat is, based on their mat weight, impregnated with 20 wt .-% to 60 wt .-% binder.
  • the molded article produced according to the invention after crosslinking and curing of the binder has a proportion of moisture or water of not more than 15%.
  • the molding contains digested proteins in the matrix and possibly also polysaccharides.
  • the proportion of vegetable protein sources in the matrix between 3 wt .-% to 46 wt .-%, the proportion of alkaline substance, in particular lime, in the matrix 1 wt .-% to 39 wt .-%, and the total amount of additives and / or fillers 0.01 wt .-% to 22 wt .-%.
  • Inventive moldings can be used for a variety of applications, above all because of the achievable rigidity and strength.
  • the molding contains digested proteins in the matrix and possibly also polysaccharides.
  • the proportion of vegetable protein sources in the matrix between 3 wt .-% to 46 wt .-%, the proportion of alkaline substance, in particular lime, in the matrix 1 wt .-% to 39
  • interior trim part or interior trim part in vehicles, preferably in motor vehicles, or in airplanes, for example as
  • Headliner trim door trim, decorative trim or divider trim, luggage rack, cover, liner, manhole, duct and the like.
  • the invention relates to a molding of at least one natural fiber mat, which is embedded in a cured matrix, which is based largely on ecologically harmless and biological starting materials, and a method for its preparation.
  • the moldings are made on the basis of starting materials, which after their
  • the base formulation for the binder comprises
  • At least one vegetable protein source in a proportion of 5 to 50% by weight, in particular up to 40% by weight,
  • At least one alkaline reaction component in a proportion of 5 to 50 wt .-%, in particular at least 10 wt .-%.
  • Protein sources which can be used in addition to a certain proportion of protein are polysaccharides (starch) and / or those which have no polysaccharides and a high proportion of protein.
  • protein sources with a polysaccharide content of 50% by weight to 85% by weight and a protein content of between 6% by weight and about 15% by weight are very suitable.
  • This group of vegetable protein sources includes powdered, especially ground, vegetable protein sources, such as cereal flours or potato flour.
  • the vegetable protein sources which do not contain polysaccharides but contain a high proportion of protein, for example of the order of about 50 to 85% by weight, include, for example, purified cereal gluten, in particular wheat gluten.
  • the vegetable protein sources include other impurities such as water, fats, minerals and the like, each in small amounts of a few wt .-%.
  • Protein source are also protein-containing waste products from the
  • the alkaline reaction component is selected from alkali metal and
  • Alkaline earth metal hydroxides, bicarbonates and carbonates selected. Their purpose is the digestion and the conversion of the proteins to corresponding reaction products. It offers protective functions in the finished molded part against external influences, especially against moisture or heat.
  • the alkaline component is neutralized and biodegradable.
  • the alkaline reaction component is NaOH, KOH, Ca (OH) 2 , NaHCO 3 and NH 4 HC0 3 .
  • Ca (OH) 2 , NaOH or KOH or mixtures thereof are used in the context of the present invention.
  • the powdered protein source (s) and the alkaline reaction component (s) are thoroughly mixed with the water.
  • Water content of the binder is adapted to the material of the natural fiber mat, to any additives and fillers added to the binder, which will be discussed in more detail below, and to the technologies used in the processing of the binder-cured natural fiber mats. For the manufacturing process, which will be discussed in more detail below, but still a rather low water content is preferred and useful.
  • the binder may contain as an optional component or components one or more fillers and / or one or more additives.
  • the total amount of additives is, in addition to 100 wt .-% base formulation, 0.01 wt .-% to 30 wt .-%, in particular up to 10 wt .-%, the total amount of fillers, also in addition to 100 wt. % Base formulation, 0.5 wt .-% to 30 wt .-%, in particular to 20 wt .-%.
  • the selection of an additive and / or a filler depends primarily on the desired properties of the end product, the molded part, and its preparation.
  • Preferred additives are: Aluminum powder, aluminum hydroxide powder:
  • Aluminum hydroxide also supports fire resistance.
  • Magnesium carbonate powder, magnesium bicarbonate powder magnesium bicarbonate powder
  • Calcium hydroxide a carbonate and hardness forming agent in the aqueous binder, contributes to an increase in strength and to an improvement of the moisture and the
  • Dry oil for example linseed oil or sunflower oil
  • wax for example
  • Carbon powder for example carbon black or graphite:
  • Dispersing aid and emulsifier in the binder can also be used as a dye.
  • Citric acid Is added in a proportion of 0.1 wt .-% to 5 wt .-%, serves as a plasticizing aid, ensures the solubility of other water-insoluble additives or fillers and serves as a dispersant and emulsifier for fillers.
  • Natural latex milk (as an aqueous dispersion with dry matter - 50%):
  • Is added as a polymer matrix in a proportion of 1 wt .-% to 30 wt .-%, serves to increase the flexibility, elasticity and resistance to fracture of the cured binder and therefore the molded parts produced.
  • fibers of a fiber length between 0.3 mm and 5 mm are added in a proportion of 0.1% by weight to 10% by weight; suitable are both natural fibers and synthetic fibers (for example PES fibers), avoid shrinkage cracks when
  • Amorphous silica / Aerosil® Amorphous silica / Aerosil®:
  • fillers serve primarily to optimize the binder in order to improve the molded part, in particular with regard to water resistance and its mechanical properties.
  • fibrous fillers such as glass fiber.
  • Carbon fiber Natural fiber and the like: These can be both short and long fibers, they can be mixtures of different fiber lengths and fiber materials. Natural fibers and also synthetic fibers can be in any mixing ratios and
  • Powdery fillers such as stone meal. Diatomaceous earth. Chalk. Wood flour cork powder and the like:
  • Cost optimization of the molded part are in particular added in proportions of 0.5 wt .-% to 30 wt .-% of the binder.
  • Table 1 below contains examples of binder formulation formulations using various vegetable protein sources and the addition of some additives and / or fillers:
  • the individual proportions are given in% by weight.
  • the protein sources I to III according to Table 2 have the following compositions: Protein source I about 70% polysaccharides / about 12% proteins / about 14% moisture
  • Protein Source II about 64% polysaccharides / about 8.5% proteins / about 12% moisture
  • Protein source III about 80% protein / about 8% moisture / about 2% minerals
  • the natural fiber mats which are impregnated with the binder, consist of unoriented fibers entangled with one another and are produced in a manner known per se.
  • the starting material for the natural fiber mats are preferably natural fibers, for example wool, flax, hemp, jute or kenaf, sisal, coconut or
  • Wood fibers such as spruce fibers or pine fibers, also fibers of grasses, such as hay, reeds or cattails.
  • Particularly preferred fiber materials are flax, kenaf or hemp.
  • Carding produces an oriented batt which is converted as a transverse, multilayered directional batt in a needle felting machine to felt or nonwoven, that is, a fabric of disordered fibrous material that is difficult to be separated, which forms the batt.
  • the natural fiber mat used for producing a molded part is at least roughly adapted to the size of the molded part to be produced.
  • the impregnation of the natural fiber mat with the binder can be done in different ways, for example by immersing the mat in the binder, spraying the binder or rolling the
  • Binder wherein penetration or impregnation of the mat is to ensure with the binder. Any excess binder is removed to adjust a defined amount of binder for the subsequent pressing operation. This can
  • the impregnated fiber mat is optionally pre-dried and in the produced on the Molded adapted, heated mold inserted, this is closed and heated in a known manner, so that the shaping by the mold and the
  • Reacting the binder takes place.
  • the fiber mats are deformed and pressed with removal of water vapor from the binder. This process takes place in a temperature range of about 120 ° C to 200 ° C over a corresponding period of time, in particular on the time required for reacting the binder.
  • the impregnated and predried fiber mats it is also possible for the impregnated and predried fiber mats to be temporarily stored before the final shaping and to be shaped, pressed and hardened later in the mold.
  • the proportion of water in the finished molding is at most 15% by weight.
  • the molding contains, depending on the composition of the binder, at least one vegetable protein source, which optionally also contains polysaccharides, in a proportion of 3 wt .-% to 46 wt .-%. It can therefore in the matrix at least one vegetable protein source with a
  • lime in the matrix is 1 wt .-% to 39 wt .-%.
  • additives and / or fillers may also be present in the matrix.
  • the finished molded part can be provided by lamination with a decorative material or a decorative surface or a coating. Subsequent lamination may also have the purpose of surface protective equipment or
  • Fasteners and / or stiffening elements can be subsequently glued, sprayed, screwed or welded onto the molded part if necessary, for example. It can moldings with a multi-layered structure - made of several layers of impregnated fiber mats - are produced. In this case, various fiber mat materials in Combination can be used together.
  • the impregnated with the binder fiber mats are placed on each other in the tool and connected with the tool closed with the supply of pressure and heat by reacting the binder.
  • Also possible are embodiments of a combination of one or more cured fiber mat (s) with layers (intermediate layers) of other materials, for example films.
  • the molded parts produced have a thickness of 1 mm to 7 mm in the case of a single-layer structure, and in the case of multi-layered construction also have a greater thickness corresponding to the layer thicknesses.
  • a thickness of 1 mm to 7 mm in the case of a single-layer structure, and in the case of multi-layered construction also have a greater thickness corresponding to the layer thicknesses.
  • composition of the binder results in a variety of
  • Moldings according to the invention can therefore form, for example, a luggage compartment lining, a shelf, a seat pan, a seat back wall, a headliner lining, a door trim, a trim strip, a partition wall lining, a cover, a cover element and the like.
  • Natural fiber mats whose mat weight is between 700 g / m 2 and 1500 g / m 2 are predominantly used for these molded parts.
  • the molded article produced has a density of 0.60 g / cm 3 to 0.95 g / cm 3 .
  • a binder amount between 20% and 50%, in particular between 30% and 40%, of the mat weight is used for soaking.
  • the molded parts according to the invention also convince with regard to their mechanical properties, so that they are preferred for use as
  • Interior fittings are suitable in the automotive industry. Above all, they have a high rigidity and strength. During production, the impregnated mats have a small, negligible shrinkage in the tool. In addition, the moldings have a lower weight than those usually made of thermoplastic

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une pièce moulée au moyen d'un liant, contenant en tant qu'ingrédients de base de l'eau, au moins une source de protéines végétale et au moins un composant de réaction alcalin choisi parmi des hydroxydes, des hydrogénocarbonates et des carbonates de métaux alcalins et de métaux alcalino-terreux. Une nappe de fibres naturelles composée de fibres non orientées feutrées les unes avec les autres est imprégnée du liant, un éventuel excès de liant est retiré et la nappe de fibres durcie est durcie et moulée sous forme de pièce moulée dans un outil de moulage avec application de pression et de chaleur.
PCT/EP2012/061269 2012-06-14 2012-06-14 Procédé de fabrication d'une pièce moulée et pièce moulée WO2013185819A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE201211006533 DE112012006533A5 (de) 2012-06-14 2012-06-14 Verfahren zur Herstellung eines Formteiles und Formteil
PCT/EP2012/061269 WO2013185819A1 (fr) 2012-06-14 2012-06-14 Procédé de fabrication d'une pièce moulée et pièce moulée

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2012/061269 WO2013185819A1 (fr) 2012-06-14 2012-06-14 Procédé de fabrication d'une pièce moulée et pièce moulée

Publications (1)

Publication Number Publication Date
WO2013185819A1 true WO2013185819A1 (fr) 2013-12-19

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PCT/EP2012/061269 WO2013185819A1 (fr) 2012-06-14 2012-06-14 Procédé de fabrication d'une pièce moulée et pièce moulée

Country Status (2)

Country Link
DE (1) DE112012006533A5 (fr)
WO (1) WO2013185819A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19704383A1 (de) * 1997-02-06 1998-08-13 Moeller Plast Gmbh Formteil und Verfahren zu seiner Herstellung
WO2011006660A1 (fr) 2009-07-16 2011-01-20 Austria Wirtschaftsservice Gesellschaft Mbh Matière moulable pour la fabrication de pièces moulées
WO2012006651A1 (fr) * 2010-07-15 2012-01-19 Austria Wirtschaftsservice Gesellschaft Mbh Composition destinée à la fabrication de surfaces antidérapantes

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19704383A1 (de) * 1997-02-06 1998-08-13 Moeller Plast Gmbh Formteil und Verfahren zu seiner Herstellung
WO2011006660A1 (fr) 2009-07-16 2011-01-20 Austria Wirtschaftsservice Gesellschaft Mbh Matière moulable pour la fabrication de pièces moulées
WO2012006651A1 (fr) * 2010-07-15 2012-01-19 Austria Wirtschaftsservice Gesellschaft Mbh Composition destinée à la fabrication de surfaces antidérapantes

Also Published As

Publication number Publication date
DE112012006533A5 (de) 2015-03-05

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