AU2015216789A1 - Novel material - Google Patents
Novel material Download PDFInfo
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- AU2015216789A1 AU2015216789A1 AU2015216789A AU2015216789A AU2015216789A1 AU 2015216789 A1 AU2015216789 A1 AU 2015216789A1 AU 2015216789 A AU2015216789 A AU 2015216789A AU 2015216789 A AU2015216789 A AU 2015216789A AU 2015216789 A1 AU2015216789 A1 AU 2015216789A1
- Authority
- AU
- Australia
- Prior art keywords
- composite material
- mannequin
- unsaturated polyester
- polyester resin
- material according
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title description 7
- 235000011777 Corchorus aestuans Nutrition 0.000 claims abstract description 41
- 235000010862 Corchorus capsularis Nutrition 0.000 claims abstract description 41
- 240000000491 Corchorus aestuans Species 0.000 claims abstract description 40
- 229920006337 unsaturated polyester resin Polymers 0.000 claims abstract description 40
- 239000002131 composite material Substances 0.000 claims abstract description 38
- 241000196324 Embryophyta Species 0.000 claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 claims abstract description 16
- 229920005989 resin Polymers 0.000 claims description 20
- 239000011347 resin Substances 0.000 claims description 20
- 239000003054 catalyst Substances 0.000 claims description 18
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 12
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 claims description 8
- 229940035437 1,3-propanediol Drugs 0.000 claims description 8
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 8
- 229920000166 polytrimethylene carbonate Polymers 0.000 claims description 8
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 7
- LGRFSURHDFAFJT-UHFFFAOYSA-N Phthalic anhydride Natural products C1=CC=C2C(=O)OC(=O)C2=C1 LGRFSURHDFAFJT-UHFFFAOYSA-N 0.000 claims description 6
- JHIWVOJDXOSYLW-UHFFFAOYSA-N butyl 2,2-difluorocyclopropane-1-carboxylate Chemical compound CCCCOC(=O)C1CC1(F)F JHIWVOJDXOSYLW-UHFFFAOYSA-N 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical group CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 claims description 5
- 239000004744 fabric Substances 0.000 claims description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- WQZGKKKJIJFFOK-DVKNGEFBSA-N alpha-D-glucose Chemical compound OC[C@H]1O[C@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-DVKNGEFBSA-N 0.000 claims description 2
- 239000000047 product Substances 0.000 description 15
- 239000011152 fibreglass Substances 0.000 description 6
- 244000198134 Agave sisalana Species 0.000 description 4
- 240000006240 Linum usitatissimum Species 0.000 description 4
- 235000004431 Linum usitatissimum Nutrition 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 244000025254 Cannabis sativa Species 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- ULWHHBHJGPPBCO-UHFFFAOYSA-N propane-1,1-diol Chemical compound CCC(O)O ULWHHBHJGPPBCO-UHFFFAOYSA-N 0.000 description 3
- 244000075850 Avena orientalis Species 0.000 description 2
- 235000007319 Avena orientalis Nutrition 0.000 description 2
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 2
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 240000007154 Coffea arabica Species 0.000 description 2
- NIQCNGHVCWTJSM-UHFFFAOYSA-N Dimethyl phthalate Chemical compound COC(=O)C1=CC=CC=C1C(=O)OC NIQCNGHVCWTJSM-UHFFFAOYSA-N 0.000 description 2
- 240000007594 Oryza sativa Species 0.000 description 2
- 235000007164 Oryza sativa Nutrition 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 235000009120 camo Nutrition 0.000 description 2
- 235000005607 chanvre indien Nutrition 0.000 description 2
- 235000016213 coffee Nutrition 0.000 description 2
- 235000013353 coffee beverage Nutrition 0.000 description 2
- 239000011487 hemp Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 235000009566 rice Nutrition 0.000 description 2
- 239000011863 silicon-based powder Substances 0.000 description 2
- 235000011624 Agave sisalana Nutrition 0.000 description 1
- 240000008564 Boehmeria nivea Species 0.000 description 1
- 235000008697 Cannabis sativa Nutrition 0.000 description 1
- 240000004792 Corchorus capsularis Species 0.000 description 1
- 235000007706 Corchorus sp Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 244000299507 Gossypium hirsutum Species 0.000 description 1
- 240000000797 Hibiscus cannabinus Species 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- FBSAITBEAPNWJG-UHFFFAOYSA-N dimethyl phthalate Natural products CC(=O)OC1=CC=CC=C1OC(C)=O FBSAITBEAPNWJG-UHFFFAOYSA-N 0.000 description 1
- 229960001826 dimethylphthalate Drugs 0.000 description 1
- 238000000855 fermentation Methods 0.000 description 1
- 230000004151 fermentation Effects 0.000 description 1
- 235000004426 flaxseed Nutrition 0.000 description 1
- 229930014626 natural product Natural products 0.000 description 1
- 150000001451 organic peroxides Chemical class 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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
-
- 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
- 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
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Reinforced Plastic Materials (AREA)
- Moulding By Coating Moulds (AREA)
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 "ETERSET 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 GRP).
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, (c) 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 (22)
- Claims1. 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).
Applications Claiming Priority (5)
| 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 | ||
| PCT/GB2015/050388 WO2015121652A1 (en) | 2014-02-12 | 2015-02-12 | Novel material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2015216789A1 true AU2015216789A1 (en) | 2016-09-29 |
Family
ID=50390907
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2015216789A Abandoned AU2015216789A1 (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) |
Families Citing this family (1)
| 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 |
Family Cites Families (15)
| 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 |
| 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 |
| WO1983001260A1 (en) * | 1981-10-05 | 1983-04-14 | Wells, Henry | Jute reinforcement of plastics materials |
| DE3150906C2 (en) * | 1981-12-22 | 1984-03-08 | Ernst 8192 Geretsried Pelz | Process for the production of molded parts from coconut, cotton or jute fiber fleece mats containing polyester resin |
| 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 |
| US6974848B2 (en) * | 2002-04-16 | 2005-12-13 | Helena Twardowska | Low-density thermosetting sheet molding compounds |
| WO2004052967A1 (en) * | 2002-12-12 | 2004-06-24 | Caco Chemical Inc. | Plant fiber reinforced plastic formed article |
| WO2005037516A2 (en) * | 2003-10-15 | 2005-04-28 | Michigan State University | Biocomposites sheet molding and methods of making those |
| GB0611884D0 (en) * | 2006-06-15 | 2006-07-26 | South Bank Univ Entpr Ltd | Hair based composite |
| US20110305878A1 (en) * | 2007-01-10 | 2011-12-15 | Gladfelter Harry F | Nonwoven panel and method of construction thereof |
| WO2011100281A1 (en) * | 2010-02-09 | 2011-08-18 | Federal-Mogul Powertrain, Inc. | High loft nonwoven sheet material and method of construction thereof |
-
2014
- 2014-02-12 GB GBGB1402486.3A patent/GB201402486D0/en not_active Ceased
- 2014-02-14 GB GBGB1402652.0A patent/GB201402652D0/en not_active Ceased
-
2015
- 2015-02-12 WO PCT/GB2015/050388 patent/WO2015121652A1/en not_active Ceased
- 2015-02-12 CN CN201580019348.8A patent/CN106164352B/en active Active
- 2015-02-12 AU AU2015216789A patent/AU2015216789A1/en not_active Abandoned
- 2015-02-12 GB GB1502328.6A patent/GB2523472B/en active Active
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2016
- 2016-09-09 ZA ZA2016/06269A patent/ZA201606269B/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| WO2015121652A1 (en) | 2015-08-20 |
| GB201502328D0 (en) | 2015-04-01 |
| GB2523472B (en) | 2016-05-11 |
| CN106164352B (en) | 2019-09-17 |
| GB201402652D0 (en) | 2014-04-02 |
| GB201402486D0 (en) | 2014-03-26 |
| CN106164352A (en) | 2016-11-23 |
| ZA201606269B (en) | 2017-11-29 |
| GB2523472A (en) | 2015-08-26 |
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