WO2021115636A1

WO2021115636A1 - Carbon as filler for a carrier matrix

Info

Publication number: WO2021115636A1
Application number: PCT/EP2020/053132
Authority: WO
Inventors: Thorsten Becker
Original assignee: carbonauten GmbH
Priority date: 2019-12-13
Filing date: 2020-02-07
Publication date: 2021-06-17

Abstract

The invention relates to a composite material comprising: a first material as the matrix material, wherein the first material comprises in particular plastic and/or building materials or more particularly consists of plastic and/or building materials, and a second material as a filler, wherein the filler is at least in part carbon, and wherein the composite material is produced by extrusion, extrusion moulding compression moulding, blow moulding, rotation forming, casting, injection moulding, deep-drawing or vacuum forming.

Description

Carbon as a filler for a carrier matrix

DESCRIPTION

FIELD OF THE INVENTION

The present invention relates to a composite material made of a matrix material which has carbon as a filler, and a method for producing the composite material.

BACKGROUND OF THE INVENTION

It is known in the prior art that a raw material can consist of a material that represents a matrix material that can be filled with a filler. Here, the matrix fulfills the task of giving the filler the necessary hold and the filler leads, for example, to a desired stiffness or resistance of the material.

The documents DE 102015 223238 A1 and WO 2017 089500 A2 describe a sintering laser printing method in which a thin layer of carbon powder is applied, onto which resin is applied drop by drop. The green body is then impregnated with liquid synthetic resin. The green body is then “carbonized”, ie the components of the matrix are converted to carbon. SUMMARY OF THE INVENTION

A material in composite materials in which other components are embedded is referred to as a matrix material. In this sense, the matrix material can be referred to as a binder. A composite material or composite material or composite or composite or compound is a material which comprises at least two materials, the mixture resulting in new, advantageous properties. The term compound is mainly used for composite materials with a plastic component. The advantageous properties result from the material properties and the geometry of the components, for example a first material with its material properties can bring about a high level of resistance and a second material ensures that the composite material holds together and does not disintegrate into its individual parts.

In addition to the matrix material, the composite material includes the filler. Different materials are known as fillers. However, it has not yet been possible to provide a suitable material that has both good electrical conductivity, good thermal and acoustic insulation properties and, at the same time, good damping properties against vibrations or vibrations.

Has vibrations.

Nowadays, profiles, for example profiles for the production of windows, are made from aluminum, plastic or wood. Aluminum is increasingly being rejected as a material because of its energy-intensive production. In addition, aluminum is a very good conductor of heat and therefore generally unsuitable for insulating a building. Alternatively, plastic can be used as a profile material, which has very good insulation.

However, plastics have the disadvantage that they are not disposed of in an environmentally friendly manner. In particular, plastics such as PVC (polyvinyl chloride) are environmentally critical in their manufacture and disposal. Another disadvantage is their lack of UV stability. The material wood is resistant to distortion only in the case of small dimensions. In addition, wood must be kept weatherproof in regular succession by means of chemical paints, which can be environmentally harmful. Despite regular maintenance measures, the lifespan of wood is limited.

The object of the invention is to create a material belonging to the technical field mentioned at the beginning which, compared to a material from the prior art, has both good electrical conductivity, good thermal and acoustic insulation properties and at the same time good damping properties against oscillations or vibrations.

As a first embodiment of the invention, a composite material is provided, comprising: a first material as a matrix material, the first material in particular comprising plastic and / or building materials or in particular consisting of plastic and / or building materials, and a second material as a filler, the The filler is at least partially carbon and wherein the composite material is produced by extrusion, extrusion, compression molding, blow molding, rotational molding, casting, injection molding, deep drawing or vacuum molding.

The advantage of a profile made of carbon, in particular biocarbon, is that environmentally problematic materials can be replaced, that the energy contained in the biomass can be used as raw material in the case of biomass residues, that no pyrolytic processing is required for fossil carbons Injection molding / extrusion ensures that the building material is UV and weather resistant, and that a high level of thermal insulation is also achieved. In addition, a cascade use of the biomass residues is made possible, which results in multiple economic added value. The compound according to the invention can also be produced using conventional mechanical processes. The waste resulting from processing and disposal during dismantling can be disposed of in an environmentally friendly manner.

In particular, the composite material has a proportion of 10% to 95%

Carbon, in particular a proportion of 30% to 70% carbon.

As a second embodiment of the invention, a method for producing the composite material according to one of claims 1 to 8 is provided, comprising the steps: extrusion, extrusion, compression molding, blow molding, rotational molding, casting, injection molding, deep drawing or vacuum molding of a first material, the first Material in particular plastic and / or building materials, in particular cement, comprises or in particular consists of plastic and / or building materials, in particular cement, wherein the first material acts as a matrix material, with a second material which acts as a filler, wherein the filler comprises carbon.

As a third embodiment of the invention, a computer program product is provided which has a software program for realizing a composite material, the computer program product comprising a set of instructions which cause a method according to claim 9 to be carried out.

As a fourth embodiment of the invention, a computer program is provided, distributable by electronic data transmission, with computer program code means which are adapted so that when the program is loaded onto a computer, the latter can carry out the procedure according to claim 9.

Exemplary embodiments are described in the dependent claims.

According to a further exemplary embodiment of the present invention, a composite material is provided, the first material being selected from the following Materials consists of or at least includes: cement, plaster of paris, mortar, plaster mortar, lime mortar, gypsum mortar, clay plaster, loam, clay-containing loams, clays, ceramics, glass, metal, synthetic resin, natural resin, silicone, elastomers, agarose, mono- and / or polysaccharides .

Agarose is a polysaccharide made from algae.

According to a further exemplary embodiment of the invention, a composite material is made available, the proportion by weight of the filler of carbon being between 5% and 95%, in particular between 20% and 80%, particularly between 30% and 70%.

According to an exemplary embodiment of the invention, a composite material is provided, the first material being an elastomer, a silicone, a rubber, a thermosetting plastic, a thermoplastic, starch or starch blends, a polylactic acid (PLA), a polyhydroxybutyric acid (PHB), cellulose acetates, made from pressed leaves of the betel palm, resins, saccharide, polybutylene succinate (PBS), celluloses or lignin.

In a further embodiment according to the invention, a composite material is provided, the composite material comprising a third material as an additive, the additive being a plasticizer and / or an extender and / or a stabilizer and / or a light stabilizer and / or a flame retardant and / or is a colorant.

According to a further exemplary embodiment of the present invention, a composite material is provided, the proportion by weight of the additives in the composite material being between 0.1% and 10%, in particular between 2% and 8%, particularly between 3% and 7%.

In a further embodiment of the invention, a composite material is provided, wherein the second material is a biocarbon. According to a further exemplary embodiment of the present invention, a composite material is provided, the composite material being a profile, in particular for the production of windows, an extruded / pressed plate for furniture, walls, floors, an injection-molded facade element / a roof tile, an injection-molded brick or a Plant pot is, the plant pot has a hexagonal shape.

In a further embodiment according to the invention, a method is made available, the extrusion taking place at a temperature between 30 ° Celsius and 400 ° Celsius and a pressure between 0 bar and 500 bar.

The material according to the invention can advantageously be used to manufacture extruded / pressed panels for furniture, walls, floors, injection-molded or foamed facade elements / roof tiles, which replace environmentally critical, glazed tile pans and metal panels, etc., if necessary with integrated PV modules and / or Solar thermal elements for generating renewable energy, injection-molded bricks that are mechanically connected via a tongue-and-groove system without mortar, or plant pots that replace those made of environmentally critical plastics and are planted with the seedling.

The building material according to the invention is advantageously broken down in the soil by microorganisms, in particular if the matrix material is bioplastic. This releases the biocarbon and forms the basis for "Terra Preta".

In a particular embodiment, building materials, in particular cement, are used as the matrix material.

One idea of the invention can be seen to produce a raw material which consists to a considerable extent of carbon. That would make one Get raw material, which is characterized by good electrical conductivity, high UV stability, high insulation properties, especially in thermal and acoustic terms. In addition, oscillations and vibrations are well dampened by carbon. In an alternative embodiment, the carbon can be in the form of nanoparticles, the size of the nanoparticles being 12 μm or smaller.

According to the invention, the raw material comprises thermosetting plastics, thermoplastics, elastomers, starch or starch blends, polylactic acid (PLA), polyhydroxybutyric acid (PHB), cellulose acetates, catering articles, for example made from pressed leaves of the betel palm, resins, saccharide or lignin. The matrix components can have a weight fraction of 5% to 95% in the finished raw material. According to the invention, carbon, in particular biocarbon, is used as filler, the filler being able to occupy a proportion of 95% to 5%.

In addition, the raw material according to the invention can have additives which improve its properties. These additives can be plasticizers, extenders, stabilizers, light stabilizers, flame retardants, fiber materials (natural and artificial), laminates and / or colorants. The additives can have a weight proportion of 0.1% to 10% weight proportion of the finished raw material.

The raw material according to the invention can be produced by primary molding processes such as injection molding, extrusion, calendering, rotational molding, foaming, injection blow molding, deep drawing and 3D printing. In addition, the raw material according to the invention can be processed and / or processed by reshaping, welding and gluing.

The individual features can of course also be combined with one another, which in some cases can also have advantageous effects that go beyond the sum of the individual effects. BRIEF DESCRIPTION OF THE DRAWINGS

Further details and advantages of the invention will become clear on the basis of the exemplary embodiments shown in the drawings. Show it

1 shows a perspective sectional view of a window,

2 shows a representation of structural elements 3 that can hold planters 4 in such a way that “vertical planting” can be obtained,

Fig. 3 a wall 5,

Fig. 4 shows a stool 6 and

5 shows a plant pot 7.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

1 shows a representation of a window which consists of a profile according to the invention, the profile having a material with a matrix material made of plastic and a carbon as filler.

FIG. 2 shows a representation of structural elements 3 that can hold planters 4 in such a way that “vertical planting” can be obtained. The structural elements 3 and the planters 4 can be made from a material according to the invention, since the material according to the invention has a very high load-bearing capacity and mechanical strength due to the carbon particles in the plastic matrix.

3 shows a wall 5 which can be made from a substance according to the invention. 4 shows a stool 6 which can be made from a fabric according to the invention. The wall 5 and the stool 6 are exposed to high mechanical loads during use. The fabric according to the invention has a high mechanical load-bearing capacity and can therefore be used as a wall element 5 and a stool 6.

5 shows a plant pot 7 which is made from a substance according to the invention with a plastic matrix in which carbon is embedded.

In a particular embodiment, plant pots 7 are made available for growing, transporting, storing and selling plants. In contrast to the prior art, the plant pots 7 according to the invention do not consist of conventional, mineral oil-based, thermoplastic plastics that are injection-molded, deep-drawn or blow-molded. The prior art plant pots are removed by the user after purchase, since the plant must be placed in a larger container for growth.

With the prior art plant pots, there are further problems because of the consumption of resources and energy. In addition, environmentally harmful greenhouse gases are generated through development, transport, production and disposal / recycling. Because of the adherence of organic substances such as soil and substrates, recycling is time-consuming. The cleaning leads to a further consumption of water, chemicals and energy. For this reason, recycling often does not make sense and the plant pots of the prior art are disposed of with normal household waste and in landfills or in waste incineration plants.

The plant pots 7 according to the invention advantageously have a matrix made of plastic and a filler made of carbon, in particular biocarbon, the biocarbon being produced from woody plant residues. Advantageously, renewable energy is generated as a by-product in the production of the biocarbons. Thermoplastic or other biogenic and biodegradable binders are added, whereby a production by conventional methods such as injection molding, deep drawing or blow molding is possible.

A plant can be placed in the ground or in a larger vessel together with the plant pot 7 according to the invention. The addition of water, heat and the activity of microorganisms and soil fungi break down the biogenic binder. The biocarbon released as a result is the basis for the "super fertilizer Terra Preta" and a moisture storage or storage for microorganisms, moisture / water and nutrients, which can bind up to four times its own volume of water. This advantageously results in a more effective supply of the plant, as a result of which water can be saved or can be used more effectively than previously for supplying the plant.

The released biocarbon permanently binds CO2 because it is not metabolized in the soil and remains stable for an unlimited period of time. Advantageously, natural and long-term humus soils are formed.

The plant pot 7 is hexagonal in shape, so that the space available for production, storage and transport is better used in comparison to round pots. The pots also “interlock”, which improves stability during storage and transport.

The advantages of the composite material according to the invention are that the composite material is characterized by better electrical conductivity, better thermal conductivity, higher vibration damping, better UV resistance, better mechanical properties, in particular higher stability and compressive strength, better processability and food safety.

In a special embodiment of the composite material according to the invention, fibers are incorporated to increase the compressive, tensile and shear strength, A material in composite materials in which other components are embedded is referred to as a matrix material. In this sense, the matrix material can be referred to as a binder. A composite material or composite material or composite or composite or compound is a material which comprises at least two materials, the mixture resulting in new, advantageous properties. The term compound is mainly used for composite materials with a plastic component. The advantageous properties result from the material properties and the geometry of the components, for example a first material with its material properties can bring about a high level of resistance and a second material ensures that the composite material holds together and does not disintegrate into its individual parts. In addition to the matrix material, the composite material includes the filler. Different materials are known as fillers. However, it has not yet been possible to provide a corresponding material that has both good electrical conductivity, good thermal and acoustic insulation properties and, at the same time, good damping properties against oscillations or vibrations, as well as high UV resistance.

According to the invention, the material comprises from 10 to 60 percent by weight of a matrix material. In addition, an additive component can be present in the material in an amount of 0 to 50 percent by weight.

Plastic matrix material within the meaning of the application is understood to mean both petroleum-based and bio-based, bioresistant and biodegradable materials. The proportion of plastic matrix is between 20 and 90 percent by weight of the compound according to the invention.

The compound according to the invention can also be provided with natural, glass or synthetic fibers of 2 to 50 percent by weight, preferably 5 to 35 percent by weight, particularly preferably 7 to 20 percent by weight. In addition, the material can comprise an additive component in an amount from 0 to 50 percent by weight, preferably from 10 to 40 percent by weight, particularly preferably from 20 to 30 percent by weight. An additive component does not necessarily have to be present in the material.

The high carbon content permanently binds the carbon in long-lasting products. In the case of short-lived products with a biodegradable matrix, the material according to the invention can also be used as compost after use. This applies in particular to packaging materials, plant pots, etc. The carbon content remains in the soil for several hundred years and leads to a significant improvement in the soil (terra preta).

Due to the components used, the degradable material according to the invention is liquid or at least flowable at temperatures from 120 ° C.

This allows the material to be shaped into any desired shape. “Curing” in the context of the present application is understood to be the process in which the material solidifies after the production of the molded part by chemical processes or by setting processes. Curing begins immediately after the injection molding process, extrusion, pressing, molding or printing of the molded part and continues until the molded part made from the material is inherently dimensionally stable.

In a particular embodiment of the invention, the composite material has a first material as matrix material, which consists of or at least comprises the following substances: cement, gypsum, mortar, plastering mortar, lime mortar, gypsum mortar, clay plaster, loam, clay-containing loams, clays, ceramics, Glass, metal, synthetic resin, natural resin, silicone, elastomers, agarose, mono- and / or polysaccharides.

Agarose is a polysaccharide made from algae. In particular, the agarose is a polysaccharide composed of D-galactose and 3,6-anhydro-L-galactose, which are glycosidically linked to one another. It should be noted that the term “comprise” does not exclude further elements or method steps, just as the term “a” and “an” does not exclude several elements and steps. The reference symbols used only serve to increase the understanding and are in no way to be regarded as restrictive, the scope of protection of the invention being reproduced by the claims.

LIST OF REFERENCES

1 pane of glass from a window

2 profile as the frame of the window 3 grids

4 planters

5 wall

6 stools

7 plant pot

Claims

EXPECTATIONS

1. Composite material comprising: a first material as matrix material, the first material in particular comprising plastic and / or building materials or in particular consisting of plastic and / or building materials, and a second material as filler, characterized in that the filler is at least partially carbon and wherein the composite material is produced by extrusion, extrusion, compression molding, blow molding, rotational molding, casting, injection molding, deep drawing or vacuum molding.

2. Composite material according to claim 1, wherein the first material consists of the following substances or at least comprises these: cement, gypsum, mortar, plaster mortar, lime mortar, gypsum mortar, clay plaster, loam, clay-containing loams, clays, ceramics, glass, metal, synthetic resin, natural resin , Silicone, elastomers, agarose, mono- and / or polysaccharides.

3. Composite material according to one of claims 1 or 2, wherein the proportion by weight of the filler of the carbon is between 5% and 95%, in particular between 20% and 80%, particularly between 30% and 70%.

4. Composite material according to one of the preceding claims, wherein the first material is an elastomer, a silicone, a rubber, a thermosetting plastic, a thermoplastic, starch or starch blends, a polylactic acid (PLA), a polyhydroxybutyric acid (PHB), cellulose acetates, from pressed sheets of the Betel palm is made from resins, saccharide, polybutylene succinate (PBS), celluloses or lignin.

5. Composite material according to one of the preceding claims, wherein the composite material comprises a third material as an additive, the additive being a plasticizer and / or an extender and / or a stabilizer and / or a light stabilizer and / or a flame retardant and / or a colorant .

6. The composite material according to claim 5, wherein the proportion by weight of the additives in the composite material is between 0.1% and 10%, in particular between 2% and 8%, particularly between 3% and 7%.

The composite of any preceding claim, wherein the second material is a biocarbon.

8. Composite material according to one of the preceding claims, wherein the composite material is a profile, in particular for the production of windows, an extruded / pressed plate for furniture, walls, floors, an injection-molded facade element / a roof tile, an injection-molded brick or a plant pot, wherein the Plant pot has a hexagonal shape.

9. A method for producing the composite material according to any one of the preceding claims comprising the steps:

Extrusion, extrusion, compression molding, blow molding, rotational molding, casting, injection molding, deep drawing or vacuum molding of a first material, the first material in particular comprising plastic and / or building materials, in particular cement, or in particular consisting of plastic and / or building materials, in particular cement, where the first material acts as a matrix material, with a second material that acts as a filler, the filler comprising carbon and / or the extrusion taking place at a temperature between 30 ° Celsius and 400 ° Celsius and a pressure between 0 bar and 500 bar.

10. A computer program product having a software program for realizing a composite material, the computer program product comprising a set of instructions which cause a method according to claim 9 to be carried out.