WO2015121652A1 - Novel material - Google Patents

Novel material Download PDF

Info

Publication number
WO2015121652A1
WO2015121652A1 PCT/GB2015/050388 GB2015050388W WO2015121652A1 WO 2015121652 A1 WO2015121652 A1 WO 2015121652A1 GB 2015050388 W GB2015050388 W GB 2015050388W WO 2015121652 A1 WO2015121652 A1 WO 2015121652A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite material
mannequin
unsaturated polyester
polyester resin
material according
Prior art date
Application number
PCT/GB2015/050388
Other languages
French (fr)
Inventor
Alan PEGRAM
Original Assignee
Global Display Projects 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 Global Display Projects Limited filed Critical Global Display Projects Limited
Priority to CN201580019348.8A priority Critical patent/CN106164352B/en
Priority to AU2015216789A priority patent/AU2015216789A1/en
Publication of WO2015121652A1 publication Critical patent/WO2015121652A1/en
Priority to ZA2016/06269A priority patent/ZA201606269B/en

Links

Classifications

    • 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
    • D04H1/425—Cellulose series
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/083—Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • 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
    • D04H1/58—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
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47F—SPECIAL FURNITURE, FITTINGS, OR ACCESSORIES FOR SHOPS, STOREHOUSES, BARS, RESTAURANTS OR THE LIKE; PAYING COUNTERS
    • A47F8/00—Dummies, busts or the like, e.g. for displaying garments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
    • B29K2311/10—Natural fibres, e.g. wool or cotton

Definitions

  • the present invention relates to a novel material.
  • the present invention relates to a novel composite material comprising plant fibres and an unsaturated polyester resin.
  • the unsaturated polyester resin is biodegradable.
  • Plant fibres are natural products that have many uses; for example, they are used to make fabric for clothing or carpets, or are used to make rope. Examples of such plant fibres are flax (Linum usitatissimum), hemp (Cannabis sativa), sisal (Agave sisalana) and jute (Corchorus sp.). These plant fibres are readily available. They are also easy to produce agriculturally and are relatively cheap as a raw material. Plant fibres come in many forms and may be the main product of a crop, or a by-product.
  • a composite material is a complex product in which two or more distinct substances combine to produce structural or functional properties not present in any individual component.
  • An example of a composite material is fibreglass which comprises a polymer, reinforced by glass fibres. However, if fibreglass is damaged or broken, glass fibres may be released into the atmosphere and these are harmful if breathed in. The present invention seeks to provide a more eco-friendly alternative to fibreglass.
  • the present invention seeks to provide an eco-mannequin manufactured using closed loop recycling of plant fibres, such as those sourced from jute sacks.
  • a composite material comprising an unsaturated polyester resin and plant fibres.
  • the unsaturated polyester resin is biodegradable.
  • the plant fibres comprise jute fibres, and more preferably comprise recycled jute fibres.
  • all of the plant fibres in the composite material may be jute fibres; in other embodiments, jute fibres are mixed with other types of plant fibres.
  • the jute fibres may originate from recycled jute sacks, typically used for transporting coffee, rice and oats, which in turn offers the opportunity for closed loop recyclability.
  • the jute fibres may instead originate from virgin material.
  • the plant fibres may originate from cloth, recycled clothing, sacks, thread or twine. A combination of all these materials, including jute sacks, may be used as a source of the plant fibres.
  • the composite material comprises unsaturated polyester resin and plant fibres (for example jute fibres) in a weight: weight ratio of about 2:1 to 3:1.
  • the resin to plant fibre weight: weight ratio is about 2.25:1.
  • a jute mat has a mass of 450g per m 2 then, in a preferred embodiment, 2.25 kg of resin may be applied to adequately saturate the mat.
  • enough unsaturated polyester resin must be applied for it to adequately saturate the jute or other plants fibres. The exact amount of resin used, therefore, depends on what form the jute (or other plant fibres) is in.
  • the jute fibres may be provided in the form of a jute mat (i.e. a sheet of jute).
  • the Jute fibres may also be provided in the form of jute sacks (also being a sheet of jute), such as those typically used to transport coffee, oats and rice.
  • the composite material may comprise other plant fibres, for example, hemp, sisal, kenaf, cotton, ramie or flax fibres instead of or in addition to the jute fibres.
  • the composite material could comprise a mixture of jute and sisal or jute and flax.
  • These alternative fibres may also be in the form of a mat.
  • the plant fibre mat may be a compressed mat.
  • the plant fibre mat may also be a woven mat.
  • the plant fibre mat may be a combination of a compressed and a woven mat.
  • the unsaturated polyester resin comprises 1,3 - Propanediol.
  • this is SusterraTM Propanediol.
  • SusterraTM Propanediol
  • Propanediol is available from DuPont Tate & Lyle Bio Products Company, USA.
  • SusterraTM Propanediol is sourced from corn sugar using a fermentation process and enables the manufacture of renewable, natural and sustainable products.
  • the unsaturated polyester resin is biodegradable.
  • Unsaturated polyesters resins are commercially available.
  • One example of an unsaturated polyester resin for use in the present invention comprises:
  • the unsaturated polyester resin comprises:
  • ETE SET 2522PT One such resin is available from Eternal Chemical Company Limited under the product name "ETE SET 2522PT”.
  • the unsaturated polyester resin comprises:
  • the unsaturated polyester resin comprises: (a) 20 to 35%, more preferably 25 to 29%, by weight of 1,3 - Propanediol
  • the unsaturated polyester resin further comprises a catalyst for activating the curing process.
  • the catalyst may be, for example, a methyl ethyl ketone peroxide.
  • the catalyst may be an "organic peroxide type D".
  • Suitable catalysts include Butanox ® methyl ethyl ketone peroxide catalysts, for example Butanox ® M-50, Butanox ® HBO-50 or Butanox ® 28. Butanox ® M-50, HBO-50 and 28 comprise methyl ethyl ketone peroxide in solution in dimethyl phthalate.
  • Adding a catalyst to the unsaturated polyester resin is advantageous as it accelerates the curing process.
  • a mixture of unsaturated polyester resin and catalyst should contain 1 to 3% catalyst by weight, most preferably, around 2% catalyst by weight. Additions outside these ranges are not advisable for proper curing of the resin. For example, a mixture with more than 4% catalyst by weight may fail to cure. Similarly, mixtures with less than 1% catalyst by weight may cure too slowly.
  • the composite material of the present invention may be employed in a number of applications including various applications of fibreglass. In one particular application, the composite material of the present invention may be used in the production of mannequins.
  • the present invention therefore also provides a mannequin formed from the composite material of the present invention.
  • a mannequin formed from a composite material comprising an unsaturated polyester resin and plant fibres which preferably comprise jute fibres and are preferably in the form of a jute mat or a jute sack.
  • the unsaturated polyester resin is biodegradable.
  • the total gross weight of a mannequin made from jute fibres and/or other plant fibres and unsaturated polyester resin typically is less than a mannequin produced from conventional glass fibre (eg G P).
  • a mannequin manufactured in accordance with the present invention provides a significant reduction in carbon dioxide emissions compared with conventional fibreglass mannequins.
  • a gel coat In products made from fibreglass, a gel coat must be applied to the surface of the product before the product can be painted.
  • the composite material of the present invention allows paint to be applied directly to any product, for example, a mannequin, formed from the material: a gel coat is not required.
  • a product such as a mannequin produced using a composite material of the present invention may be painted with a water based paint.
  • joints and/ or arms of the mannequin may be filled with a combination of an unsaturated polyester resin, jute fibres (as an example of plant fibres) and silicon powder.
  • the resin, jute (for example) and silicon powder mixture is a paste-like substance that can be used to fill gaps and help bond areas of the mannequin together.
  • a method of making a mannequin from the composite material of the present invention is provided.
  • the method of making a mannequin comprises:
  • the method of making a mannequin preferably comprises:
  • step (e) releasing the cured product from the mannequin mould.
  • the resin is applied to the mould first and may be allowed to begin to cure, thereby forming a slight skin on the surface of the mould.
  • step (b) the sheet is laid in the mould, preferably ensuring minimum overlapping of adjacent sheets, with a maximum overlap being 25mm.
  • a brush or roller may be used to apply the resin to the sheet, and the resulting composite material may be compressed using a metal roller and/or using hand pressure to remove air from the material.
  • any joints around metal fittings may be filled using a combination of the unsaturated polyester resin and chopped strands of plant fibre to create a paste.
  • the sheet is preferably a sheet of jute with the jute fibres in the form of a jute mat or a jute sack.
  • the sheet may comprise jute fibres or other plant fibres originating from cloth, thread, twine, recycled sacks and recycled clothing, meaning that closed loop recycling is possible.
  • a mannequin may be formed using a single mannequin mould.
  • different parts of the same mannequin can be formed using different mannequin moulds (for example, the body of the mannequin may be formed separately to the arms and legs). If multiple moulds are used, the cured products must be assembled to form a complete mannequin.
  • a release agent for example, a wax, may be applied to the mould before the sheet or unsaturated polyester resin is placed in the mould. The release agent may be applied to the mould when producing the first item, then is typically re-applied after the release of every second mannequin produced.
  • the unsaturated polyester resin is applied to the sheet using a brush or roller, which may be woollen and/or polyester.
  • additional sheets and additional unsaturated polyester resin may be applied after step (b) of the method.
  • pressure is applied to help the resin saturate the sheet.
  • pressure may be applied by hand or by using a vacuum or a roller. The application of pressure also helps to remove any air pockets.
  • the mannequin may be released from the mould and finished, for example, by trimming. Then, if required, the mannequin can be painted. No gel coat has to be applied to the surface of the mannequin before the product can be painted.

Abstract

A novel composite material comprising an unsaturated polyester resin and plant fibres, a mannequin made from this composite material, and a method of making a mannequin from the composite material. Preferably, the plant fibres are jute fibres which may be recycled from jute sacks to enable closed loop recyclability. Preferably,the unsaturated polyester resin is biodegradable.

Description

Novel Material
The present invention relates to a novel material. In particular, the present invention relates to a novel composite material comprising plant fibres and an unsaturated polyester resin. Preferably the unsaturated polyester resin is biodegradable.
Plant fibres are natural products that have many uses; for example, they are used to make fabric for clothing or carpets, or are used to make rope. Examples of such plant fibres are flax (Linum usitatissimum), hemp (Cannabis sativa), sisal (Agave sisalana) and jute (Corchorus sp.). These plant fibres are readily available. They are also easy to produce agriculturally and are relatively cheap as a raw material. Plant fibres come in many forms and may be the main product of a crop, or a by-product.
A composite material is a complex product in which two or more distinct substances combine to produce structural or functional properties not present in any individual component. An example of a composite material is fibreglass which comprises a polymer, reinforced by glass fibres. However, if fibreglass is damaged or broken, glass fibres may be released into the atmosphere and these are harmful if breathed in. The present invention seeks to provide a more eco-friendly alternative to fibreglass.
In particular, the present invention seeks to provide an eco-mannequin manufactured using closed loop recycling of plant fibres, such as those sourced from jute sacks.
According to a first aspect of the present invention, there is provided a composite material comprising an unsaturated polyester resin and plant fibres. In a preferred embodiment of the invention, the unsaturated polyester resin is biodegradable.
Preferably the plant fibres comprise jute fibres, and more preferably comprise recycled jute fibres. In some embodiments, all of the plant fibres in the composite material may be jute fibres; in other embodiments, jute fibres are mixed with other types of plant fibres.
The jute fibres may originate from recycled jute sacks, typically used for transporting coffee, rice and oats, which in turn offers the opportunity for closed loop recyclability. The jute fibres may instead originate from virgin material.
The plant fibres, whether or not including jute, may originate from cloth, recycled clothing, sacks, thread or twine. A combination of all these materials, including jute sacks, may be used as a source of the plant fibres.
In one example, 2.25kg of resin is applied to 1 m2 of plant fibres, which may be in the form of cloth, thread, twine, recycled sacks or recycled clothing.
Preferably, the composite material comprises unsaturated polyester resin and plant fibres (for example jute fibres) in a weight: weight ratio of about 2:1 to 3:1. For example, the resin to plant fibre weight: weight ratio is about 2.25:1.
If a jute mat has a mass of 450g per m2 then, in a preferred embodiment, 2.25 kg of resin may be applied to adequately saturate the mat. In general, during the method of making the composite material, enough unsaturated polyester resin must be applied for it to adequately saturate the jute or other plants fibres. The exact amount of resin used, therefore, depends on what form the jute (or other plant fibres) is in.
The jute fibres may be provided in the form of a jute mat (i.e. a sheet of jute). The Jute fibres may also be provided in the form of jute sacks (also being a sheet of jute), such as those typically used to transport coffee, oats and rice. In alternative embodiments of the invention, the composite material may comprise other plant fibres, for example, hemp, sisal, kenaf, cotton, ramie or flax fibres instead of or in addition to the jute fibres. For example, the composite material could comprise a mixture of jute and sisal or jute and flax. These alternative fibres may also be in the form of a mat. The plant fibre mat may be a compressed mat. However, the plant fibre mat may also be a woven mat. Furthermore, the plant fibre mat may be a combination of a compressed and a woven mat.
Preferably, in embodiments of the invention, the unsaturated polyester resin comprises 1,3 - Propanediol. Preferably, this is Susterra™ Propanediol. Susterra™
Propanediol is available from DuPont Tate & Lyle Bio Products Company, USA. Susterra™ Propanediol is sourced from corn sugar using a fermentation process and enables the manufacture of renewable, natural and sustainable products. Preferably the unsaturated polyester resin is biodegradable. Unsaturated polyesters resins are commercially available. One example of an unsaturated polyester resin for use in the present invention comprises:
(a) 1,3 - Propanediol
(b) Phthalic anhydride
(c) Maleic anhydride, and
(d) Styrene
In one embodiment of the invention, the unsaturated polyester resin comprises:
(a) 29% by weight of 1,3 - Propanediol
(b) 24.5% by weight of Phthalic anhydride
(c) 14% by weight of Maleic anhydride, and
(d) 32.5% by weight of Styrene
One such resin is available from Eternal Chemical Company Limited under the product name "ETE SET 2522PT".
In another embodiment of the invention, the unsaturated polyester resin comprises:
(a) 25% by weight of 1,3 - Propanediol
(b) 20% by weight of Phthalic anhydride
(c) 15% by weight of Maleic anhydride
(d) 40% by weight of Styrene
One such resin is available from Yong Shun Chemical Co Ltd under the product name type 157 BQT-BS (BioGala-100).
Preferably, the unsaturated polyester resin comprises: (a) 20 to 35%, more preferably 25 to 29%, by weight of 1,3 - Propanediol
(b) 15 to 30%, more preferably 20 to 24.5%, by weight of Phthalic anhydride
(c) 10 to 20%, more preferably 14 to 15%, by weight of Maleic anhydride, and
(d) 30 to 45%, more preferably 32.5 to 40%, by weight of Styrene
Preferably, the unsaturated polyester resin further comprises a catalyst for activating the curing process. The catalyst may be, for example, a methyl ethyl ketone peroxide. For example, the catalyst may be an "organic peroxide type D". Suitable catalysts include Butanox® methyl ethyl ketone peroxide catalysts, for example Butanox® M-50, Butanox® HBO-50 or Butanox® 28. Butanox® M-50, HBO-50 and 28 comprise methyl ethyl ketone peroxide in solution in dimethyl phthalate.
Adding a catalyst to the unsaturated polyester resin is advantageous as it accelerates the curing process.
It is important to ensure that the catalyst is thoroughly mixed into the resin before the resin is applied to the plant fibres.
Preferably, a mixture of unsaturated polyester resin and catalyst should contain 1 to 3% catalyst by weight, most preferably, around 2% catalyst by weight. Additions outside these ranges are not advisable for proper curing of the resin. For example, a mixture with more than 4% catalyst by weight may fail to cure. Similarly, mixtures with less than 1% catalyst by weight may cure too slowly. The composite material of the present invention may be employed in a number of applications including various applications of fibreglass. In one particular application, the composite material of the present invention may be used in the production of mannequins.
The present invention therefore also provides a mannequin formed from the composite material of the present invention.
According to the present invention, there is provided a mannequin formed from a composite material comprising an unsaturated polyester resin and plant fibres which preferably comprise jute fibres and are preferably in the form of a jute mat or a jute sack. Preferably the unsaturated polyester resin is biodegradable.
The total gross weight of a mannequin made from jute fibres and/or other plant fibres and unsaturated polyester resin typically is less than a mannequin produced from conventional glass fibre (eg G P).
Also, independent tests have demonstrated that a mannequin manufactured in accordance with the present invention provides a significant reduction in carbon dioxide emissions compared with conventional fibreglass mannequins.
In products made from fibreglass, a gel coat must be applied to the surface of the product before the product can be painted. However, the composite material of the present invention allows paint to be applied directly to any product, for example, a mannequin, formed from the material: a gel coat is not required. A product such as a mannequin produced using a composite material of the present invention may be painted with a water based paint.
In mannequins formed from the composite material of the present invention, joints and/ or arms of the mannequin may be filled with a combination of an unsaturated polyester resin, jute fibres (as an example of plant fibres) and silicon powder. The resin, jute (for example) and silicon powder mixture is a paste-like substance that can be used to fill gaps and help bond areas of the mannequin together. According to a further aspect of the present invention, there is provided a method of making a mannequin from the composite material of the present invention.
The method of making a mannequin comprises:
(a) laying a sheet of jute and/or other plant fibre in a mannequin mould,
(b) applying an unsaturated polyester resin as described herein to the sheet,
(c) allowing the resin to cure, and
(d) releasing the cured product from the mannequin mould.
The method of making a mannequin preferably comprises:
(a) applying an unsaturated polyester resin as described herein to a mannequin mould,
(b) laying a sheet of jute and/or other plant fibre in the mannequin mould,
applying the unsaturated polyester resin to the sheet,
(d) allowing the resin to cure, and
(e) releasing the cured product from the mannequin mould. In step (a) the resin is applied to the mould first and may be allowed to begin to cure, thereby forming a slight skin on the surface of the mould.
In step (b) the sheet is laid in the mould, preferably ensuring minimum overlapping of adjacent sheets, with a maximum overlap being 25mm.
In step (c) a brush or roller may be used to apply the resin to the sheet, and the resulting composite material may be compressed using a metal roller and/or using hand pressure to remove air from the material.
Between steps (c) and (d), any joints around metal fittings may be filled using a combination of the unsaturated polyester resin and chopped strands of plant fibre to create a paste.
The sheet is preferably a sheet of jute with the jute fibres in the form of a jute mat or a jute sack. The sheet may comprise jute fibres or other plant fibres originating from cloth, thread, twine, recycled sacks and recycled clothing, meaning that closed loop recycling is possible.
In embodiments of the invention a mannequin may be formed using a single mannequin mould. Alternatively, different parts of the same mannequin can be formed using different mannequin moulds (for example, the body of the mannequin may be formed separately to the arms and legs). If multiple moulds are used, the cured products must be assembled to form a complete mannequin. A release agent, for example, a wax, may be applied to the mould before the sheet or unsaturated polyester resin is placed in the mould. The release agent may be applied to the mould when producing the first item, then is typically re-applied after the release of every second mannequin produced.
Preferably, the unsaturated polyester resin is applied to the sheet using a brush or roller, which may be woollen and/or polyester.
To ensure a good finish, air should preferably not be trapped between the sheet and the mould.
Depending on the desired thickness of the mannequin, additional sheets and additional unsaturated polyester resin may be applied after step (b) of the method. Preferably, after the resin has been applied to the sheet, pressure is applied to help the resin saturate the sheet. For example, pressure may be applied by hand or by using a vacuum or a roller. The application of pressure also helps to remove any air pockets.
Once the resin has cured, the mannequin may be released from the mould and finished, for example, by trimming. Then, if required, the mannequin can be painted. No gel coat has to be applied to the surface of the mannequin before the product can be painted.

Claims

Claims
1. A composite material comprising an unsaturated polyester resin and plant fibres.
2. A composite material according to Claim 1 wherein the unsaturated polyester resin is biodegradable.
3. A composite material according to Claim 1 or 2 wherein the plant fibres comprise or consist of recycled fibres.
4. A composite material according to any preceding claim wherein the plant fibres are jute fibres.
5. A composite material according to any preceding claim wherein the plant fibres are in the form of a mat, a sack, cloth, thread, twine or clothing.
6. A composite material according to any preceding claim wherein the composite material comprises unsaturated polyester resin and plant fibres in a weight: weight ratio of 2:1 to 3:1, preferably in a weight: weight ratio of about 2.25:1.
7. A composite material according to any preceding claim wherein the unsaturated polyester resin comprises 1,3 - Propanediol, preferably sourced from corn sugar.
8. A composite material according to any preceding claim wherein the unsaturated polyester resin further comprises a catalyst.
9. A composite material according to Claim 8 wherein the catalyst is a methyl ethyl ketone peroxide.
10. A composite material according to Claim 8 or 9 wherein the catalyst is a Butanox® methyl ethyl ketone peroxide catalyst.
11. A composite material according to any one of Claims 8 to 10 wherein a mixture of unsaturated polyester resin and catalyst contains 1 to 3% catalyst by weight.
12. A composite material according to any preceding claim wherein the unsaturated polyester resin comprises:
(a) 1,3 - Propanediol
(b) Phthalic anhydride
(c) Maleic anhydride, and
(d) Styrene
13. A composite material according to Claim 12 wherein the unsaturated polyester resin comprises:
(a) 20 to 35%, more preferably 25 to 29%, by weight of 1,3 - Propanediol
(b) 15 to 30%, more preferably 20 to 24.5%, by weight of Phthalic anhydride
(c) 10 to 20%, more preferably 14 to 15%, by weight of Maleic anhydride, and
(d) 30 to 45%, more preferably 32.5 to 40%, by weight of Styrene
14. A mannequin formed from a composite material according to any preceding claim.
15. A method of making a mannequin from a composite material according to any preceding claim, wherein the method of making a mannequin comprises:
(a) laying a sheet of jute or other plant fibre in a mannequin mould,
(b) applying an unsaturated polyester resin to the sheet,
(c) allowing the resin to cure, and
(d) releasing the cured product from the mannequin mould.
16. A method of making a mannequin according to Claim 15 wherein a layer of
unsaturated polyester resin is applied to the mould before step (a).
17. A method of making a mannequin according to Claim 15 or Claim 16 wherein a release agent is applied to the mould before the sheet is placed in the mould.
18. A method of making a mannequin according to any one of Claims 15 to 17 wherein the unsaturated polyester resin is applied to the sheet using a brush or roller.
19. A method of making a mannequin according to any one of Claims 15 to 18 wherein additional sheets and additional unsaturated polyester resin are applied after step (b).
20. A method of making a mannequin according to any one of Claims 15 to 19 wherein after the resin has been applied, pressure is applied to the composite material.
21. A method of making a mannequin according to Claim 20 wherein pressure is applied by hand or by using a vacuum or a roller.
22. A method of making a mannequin according to any one of Claims 15 to 21 wherein the mannequin is trimmed, sanded, filed and/or painted after step (d).
PCT/GB2015/050388 2014-02-12 2015-02-12 Novel material WO2015121652A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201580019348.8A CN106164352B (en) 2014-02-12 2015-02-12 New material
AU2015216789A AU2015216789A1 (en) 2014-02-12 2015-02-12 Novel material
ZA2016/06269A ZA201606269B (en) 2014-02-12 2016-09-09 Novel material

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB1402486.3 2014-02-12
GBGB1402486.3A GB201402486D0 (en) 2014-02-12 2014-02-12 Novel Material
GBGB1402652.0A GB201402652D0 (en) 2014-02-12 2014-02-14 Novel material
GB1402652.0 2014-02-14

Publications (1)

Publication Number Publication Date
WO2015121652A1 true WO2015121652A1 (en) 2015-08-20

Family

ID=50390907

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2015/050388 WO2015121652A1 (en) 2014-02-12 2015-02-12 Novel material

Country Status (5)

Country Link
CN (1) CN106164352B (en)
AU (1) AU2015216789A1 (en)
GB (3) GB201402486D0 (en)
WO (1) WO2015121652A1 (en)
ZA (1) ZA201606269B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106894161A (en) * 2017-03-16 2017-06-27 福建省天连化纤织造有限公司 The modified green beautiful core cloth formula of twill of one kind and preparation method

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2614955A (en) * 1950-01-13 1952-10-21 L A Darling Company Pressure molding laminates
GB706096A (en) * 1950-08-04 1954-03-24 Ernest Bader Manufacture of laminated articles using unsaturated polyester resins
WO1983001260A1 (en) * 1981-10-05 1983-04-14 Wells, Henry Jute reinforcement of plastics materials
EP0083435A2 (en) * 1981-12-22 1983-07-13 ERPE - Ernst Pelz - Vertriebs GmbH + Co. - Verwaltungs KG Moulded body with a pressure-moulded polyester-impregnated fibrous sheet of coconut, cotton or jute and method for its production
US20030199625A1 (en) * 2002-04-16 2003-10-23 Helena Twardowska Low-density thermosetting sheet molding compounds
WO2005037516A2 (en) * 2003-10-15 2005-04-28 Michigan State University Biocomposites sheet molding and methods of making those
WO2007144653A1 (en) * 2006-06-15 2007-12-21 South Bank University Enterprises Limited Hair based composite

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB804497A (en) * 1954-12-09 1958-11-19 Rohm & Haas Improvements in bonded and molded products and preparation thereof
GB1437081A (en) * 1972-02-11 1976-05-26 Kichlu K Resin-fibre sheets nitro-imidazole derivatives
GB1396189A (en) * 1972-12-15 1975-06-04 Ici Ltd Fibre-reinforced thermosetting polyester resins
SE503272C2 (en) * 1994-08-22 1996-04-29 Moelnlycke Ab Nonwoven material prepared by hydroentangling a fiber web and method for making such nonwoven material
TW369408B (en) * 1998-08-05 1999-09-11 ming-jie Li Method of producing mannequin and its strsucture
AU2003289302A1 (en) * 2002-12-12 2004-06-30 Caco Chemical Inc. Plant fiber reinforced plastic formed article
US20110305878A1 (en) * 2007-01-10 2011-12-15 Gladfelter Harry F Nonwoven panel and method of construction thereof
JP5951507B2 (en) * 2010-02-09 2016-07-13 フェデラル−モーグル パワートレイン インコーポレイテッドＦｅｄｅｒａｌ−Ｍｏｇｕｌ Ｐｏｗｅｒｔｒａｉｎ， Ｉｎｃ． High loft nonwoven sheet material and method for producing the same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2614955A (en) * 1950-01-13 1952-10-21 L A Darling Company Pressure molding laminates
GB706096A (en) * 1950-08-04 1954-03-24 Ernest Bader Manufacture of laminated articles using unsaturated polyester resins
WO1983001260A1 (en) * 1981-10-05 1983-04-14 Wells, Henry Jute reinforcement of plastics materials
EP0083435A2 (en) * 1981-12-22 1983-07-13 ERPE - Ernst Pelz - Vertriebs GmbH + Co. - Verwaltungs KG Moulded body with a pressure-moulded polyester-impregnated fibrous sheet of coconut, cotton or jute and method for its production
US20030199625A1 (en) * 2002-04-16 2003-10-23 Helena Twardowska Low-density thermosetting sheet molding compounds
WO2005037516A2 (en) * 2003-10-15 2005-04-28 Michigan State University Biocomposites sheet molding and methods of making those
WO2007144653A1 (en) * 2006-06-15 2007-12-21 South Bank University Enterprises Limited Hair based composite

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106894161A (en) * 2017-03-16 2017-06-27 福建省天连化纤织造有限公司 The modified green beautiful core cloth formula of twill of one kind and preparation method

Also Published As

Publication number Publication date
GB201502328D0 (en) 2015-04-01
GB2523472B (en) 2016-05-11
CN106164352A (en) 2016-11-23
GB201402652D0 (en) 2014-04-02
GB2523472A (en) 2015-08-26
GB201402486D0 (en) 2014-03-26
AU2015216789A1 (en) 2016-09-29
CN106164352B (en) 2019-09-17
ZA201606269B (en) 2017-11-29

Similar Documents

Publication Publication Date Title
Sapuan et al. Mechanical properties of woven banana fibre reinforced epoxy composites
Sathishkumar et al. Characterization of natural fiber and composites–A review
Jiang et al. Bioresin infused then cured mycelium-based sandwich-structure biocomposites: Resin transfer molding (RTM) process, flexural properties, and simulation
CN103302864B (en) A kind of natural fiber and acid fiber by polylactic Blend fiber plate and preparation method thereof
Jiang et al. Manufacturing of mycelium-based biocomposites
EP2229421B1 (en) Textile semifinished product with at least one surface provided with an adhesive
Dieckmann et al. New sustainable materials from waste feathers: Properties of hot-pressed feather/cotton/bi-component fibre boards
Sapuan et al. Design and fabrication of kenaf fibre reinforced polymer composites for portable laptop table
WO2015121652A1 (en) Novel material
WO2009079583A1 (en) Odor improved soy resins and composites
US20100178842A1 (en) Hair Based Composite
JP2020512947A (en) Method for manufacturing recycled plastic composites
Prabhuram et al. Hybrid composite materials
Davindrabrabu et al. Effect of fibre loading on the flexural properties of natural fibre reinforced polymer composites
Azzouz Development and characterisation of novel biocomposites fabricated using natural fibres and rapid prototyping Technology
Ashok et al. An experimental investigation of new hybrid composite material using ramie-flax and its mechanical properties through finite element method
Jahagirdar et al. Biodegradable composites: vinyl ester reinforced with coconut fibers and vinyl ester reinforced with coconut fibers and rubber particles
JP2012158733A (en) Composite comprising urusi (or japanese lacquer) mixture and natural fiber
Kesarwani et al. Composites: Classification and its manufacturing process
Thangamuthu et al. Jute composites
Surid et al. A Review on Fabrication and Physico-Mechanical Characterizations of Fiber Reinforced Biocomposites
Annapoorani et al. Development of green composites
JP2015504932A (en) Fiber reinforced resin molding compound and method for producing the fiber reinforced resin molded product
Abdul et al. BPC Prosthetic Leg
AU2008364935A1 (en) High-strength, environmentally friendly contoured articles

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 15705063

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 2015216789

Country of ref document: AU

Date of ref document: 20150212

Kind code of ref document: A

122 Ep: pct application non-entry in european phase

Ref document number: 15705063

Country of ref document: EP

Kind code of ref document: A1