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WO2008116466A2 - Matériau biocomposite comprimé, procédé de fabrication d'un tel matériau et produits à l'aide dudit matériau - Google Patents

Matériau biocomposite comprimé, procédé de fabrication d'un tel matériau et produits à l'aide dudit matériau Download PDF

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Publication number
WO2008116466A2
WO2008116466A2 PCT/DK2008/000116 DK2008000116W WO2008116466A2 WO 2008116466 A2 WO2008116466 A2 WO 2008116466A2 DK 2008000116 W DK2008000116 W DK 2008000116W WO 2008116466 A2 WO2008116466 A2 WO 2008116466A2
Authority
WO
WIPO (PCT)
Prior art keywords
layers
layer
biocomposite
fibres
production
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.)
Ceased
Application number
PCT/DK2008/000116
Other languages
English (en)
Other versions
WO2008116466A3 (fr
Inventor
Michael Lindgren STRØM
Lasse Svensson
Tom Løgstrup ANDERSEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BIOBIQ AS
Original Assignee
BIOBIQ AS
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 BIOBIQ AS filed Critical BIOBIQ AS
Publication of WO2008116466A2 publication Critical patent/WO2008116466A2/fr
Publication of WO2008116466A3 publication Critical patent/WO2008116466A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C5/00—Chairs of special materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the present invention relates to a compressed layered biocomposite material consisting of a core material, which on each side is covered by a structural layer and optionally a surface coating. Furthermore, the invention relates to a method for the production of such material as well as the use of the material for the production of materials or ob- jects within several industries such as furniture industry, automobile industry and construction industry.
  • biocomposites based on natural fibres and biopolymers are potentially CO 2 neutral and therefore easier to dispose of; - most biocomposites are fully compostible;
  • a specific characteristic of the present invention is that the production process counts fewer stages compared to the conventional production methods for furniture veneer, the cycle time can be reduced substantially, the amount of waste can be reduced and an attractive working environment can be established.
  • JP 2001-335710 A discloses a biodegradable, fibre-reinforced composite material and a method for the production hereof.
  • Thermoplastic resin and vegetable cellulose fibre, such as Manila hemp or henequen, are hot-pressed at 100-300 0 C.
  • JP 2005-280361 A a biodegradable composite material is disclosed.
  • the composite material consists of at least three layers, of which the two outer layers are made of a mixture of a polylactic acid base polymer and a crystalline-nucleating agent and of which one or more intermediate layers are made of a biodegradable aliphatic polyester.
  • the material is produced using vacuum pressing.
  • WO 2005/042222 A discloses a moulding product consisting of a plant material that has been soaked and a thermoplastic resin. The product is shaped by means of hot- pressing.
  • WO 2004/094509 A discloses a sheet with excellent biodegradability and satisfactory characteristics in terms of formability and mechanical strength. The material is moulded into a sheet at a temperature of 120-180 0 C. Furthermore, JP 2004-255833 A discloses a biodegradable fibre laminate which is produced by pressing. The material appears to be a cotton-like material on the basis of bamboo fibre and polylactic acid fibre, which in a specific weight proportion is pressed into its shape at a temperature, which does not affect the features of the bamboo fibres and which is higher than the melting point of polylactic acid fibres.
  • EP 1600288 A1 describes a method for the production of a fibre-reinforced decorative laminate, in which the stacked layers having been resin-impregnated are pressed and cured under heat and pressure.
  • WO 2005/105435 A1 discloses a thermoplastic composite sheet with excellent features not only when it comes to mechanical features, such as bending strength, modulus of elasticity, impact strength and linear thermal expansion coefficient, but also in terms of further processability suitable for moulding into various structures, for example for building materials and automobile parts.
  • the material produced by melt-extruding a thermoplastic resin and providing a reinforcing fibre layer, after which the layers are compressed, is not based on a material with biopolymers.
  • US 5.635.123 A describes a fibre-reinforced protein-based material in the form of particles including a thermosetting resin obtained from legumes which together with cellulose fibre are pressed for the production of rigid biocomposite materials.
  • a secondary thermosetting adhesive such as an isocyanate is used.
  • WO 03/047955 A1 discloses a composite material for a skateboard deck, preferably comprising two structural layers bonded to either side of a light flexible core, largely made of renewable biomaterials.
  • the core is not made of a thermoplastic polymer - which would allow yielding - but rather of a thermosetting polymer.
  • EP 0687711 A2 discloses a composite material, which is biodegradable.
  • the possibility of using natural fibres is mentioned and so is the possibility of using a matrix material based on a biopolymer.
  • a sandwich stacking with a flexible core, which may undergo yielding during consolidation is, however, neither claimed nor suggested.
  • the closest prior art within the field of composites may thus be characterised in that it does not include a sandwich stacking of biomaterials, that it only to a limited extent makes use of real biomaterials and that the production of furniture veneer is usually done by hot pressing, where the retention time in the press is conditional on the time necessary for the glue, e.g. urea-formaldehyde, to cross-link and cure.
  • the present invention includes a pressing process, in which a sandwich stacking is heated separately, shaped and cooled down in the press. Therefore, the retention time in the press may typically be reduced to about one third and the biologic raw materials used for the method according to the invention give enormous advantages in terms of raw material consumption (widely available raw materials), working environment and last but not least elimination of waste disposal issues since the material is compostible and potentially CO 2 neutral.
  • the invention relates to the production of a layered compressed biocomposite material and products obtained when using the material. More specifically, the invention relates to a compressed layered biocomposite material character- ised in (a) that it is made from a sandwich stacking consisting of a structural layer (2) in the form of one or more layers with oriented fi-bres or veneer and a thermoplastic core material (3) possibly reinforced with short fibres and/or fillers, which allow for yielding, both consisting of materials based on renewable resources, and optionally a surface coating (1), the layers (1) and (2) optionally being replaced with a pre-consolidated skin layer (4), and (b) that the matrix material in (2) and (3) is a biopolymer.
  • the biocomposite material referred to consists of a core material, which on each side is covered by one or more structural layers and optionally a surface coating.
  • the biocomposite material is made from raw materials, which are abundantly available and the method for production hereof includes a pressing process in the form of cold pressing, where the material is shaped and cooled down in the pressuring unit.
  • the biocomposite material referred to and the method for production hereof distinguishes itself by enabling the production of materials with both sharp edges and double curved surfaces, while the thickness of the material may vary.
  • the invention makes it pos- sible to manufacture materials in a considerably more rational way, since the production process counts fewer stages compared to conventional production methods for moulded furniture veneer.
  • the cycle time of the material can be reduced substantially compared to known production methods, which means higher productivity of the pressing machine.
  • a preferred embodiment of the present invention is the production of shell seats.
  • veneer shell seats are produced by a method including hot pressing. Then, the edges of the seat are trimmed, polished and varnished before the chair is assembled. Typically, the polishing varnishing will have to be repeated at least two times in order to obtain a satisfying result.
  • the traditional hot pressing of furniture veneer is replaced with a pressing, in which the material cools down during the shaping process.
  • Another advantage is that composite materials tend to open up more opportunities in terms of design compared to furniture veneer as far as double curved surfaces and sharp edges and corners are concerned.
  • the pressed layered biocomposite material according to the invention may be covered with a surface coating, which may be relevant for example when the material has to be used for the production of chairs.
  • the surface coating will typically be in the form of a foil, which eliminates the need for environment-unfriendly and costly surface treatments such as varnishing.
  • the surface foil may vary in shine, colour and pattern.
  • the method according to the invention may be carried out in a number of embodiments based on a sandwich stacking as described below and shown in Fig. 1.
  • the stacking is as follows:
  • the outermost structural layer 2 can also be one single layer of furniture veneer, even a 3-D furniture veneer, if the requirements for the double curved surfaces and sharp edges of the material allow for it.
  • a stacking as shown in Fig. 1 is established and heated, for example by means of a belt press or by means of infrared radiation. Afterwards, the ma- terial is shaped and consolidated in a press mould while cooling down.
  • Another embodiment particularly suited for the production of chairs, includes placing preformed and pre-consolidated skin layers in a pressing machine.
  • the pre- consolidated layers 1 and 2 together constitute layer 4 as shown in Fig. 1.
  • the skin layers it is possible to mount threaded bushings and inserts or similar devices for subsequent embedment.
  • a melted core layer 3 is then placed between the pre-consolidated skin layers 4 in the pressing machine.
  • the core layer may be subject to yield- ing and constitute a core with varying thickness.
  • the material is consolidated in a press mould while cooling down. Here, the layers get their final shape while being joined.
  • Yielding in the sandwich stacking means a condition in which the heated biopolymer is more or less molten.
  • the polymer assumes a viscous or elastic state, in which especially the core material is allowed to be shaped under pressure.
  • the stacking is heated in a plane state with uniform material thickness.
  • the heated stacking is shaped under pressure in a mould allowing yielding to proceed until the plastic material solidifies and the composite material has been consolidated.
  • the thickness of the composite material may vary along the surface which is an advantageous feature, because it gives a higher degree of design freedom and makes it easier to adapt the individual parts to each .other.
  • the biocomposite material produced distinguishes itself by consisting exclusively of biological, i.e. vegetable, material and by having surprising and unexpected characteristics in terms of strength, tenability and flexibility.
  • the biocomposite mate- rial is a plastic material produced on the basis of for example maize, which is reinforced with for example flax fibre.
  • the vegetable material for biopolymers may be chosen from a wide range of materials like maize, potatoes, wheat or biowaste.
  • Natural fibres for the structural layers will typically be plant fibres of the bast type with a high cellulose con- tent, such as flax and hemp, in order to obtain good mechanical characteristics. However, sisal, jute, straw and wood fibre may also be used.
  • the biocomposite material according to the invention has turned out to be particularly well-suited for the production of formable sheets and semi-finished products, which may be used separately, but are also appropriate for further processing.
  • the material is particularly suited for the production of chairs and other furniture in a potentially cost- effective way, because the method for the manufacture of the products is considerably simplified compared to the methods used so far.
  • FIG. 2 One example of a chair made out of the biocomposite material according to the invention is shown in Fig. 2.
  • the seat shell is produced in two stages: the stacking is pressed as described above and then the edges are trimmed. As soon as the seat shell leaves the press mould, the surface is ready since it does not need varnishing, painting or any other surface treatment. Consequently, the environment-unfriendly surface treatments necessary when dealing with traditional veneer chairs are avoided.
  • the chair depicted in Fig. 2 has a surface, which is both water and dirt repelling and can be obtained with a high-lustre finish in all kinds of colours and patterns.
  • the method according to the invention distinguishes itself by a significant reduction of the cycle time as described above. This means that more objects can be produced per unit of time with a set of pressing machines resulting in an increase in productivity. Surface treatments like for example varnishing are replaced with a surface foil. In short, apart from potentially financial advantages, substantial environmental advantages are obtained in terms of raw material consumption, reduced or even no waste at all and a better physical working environment. For disposal of the product, for example a seat shell, composting may be used since the material is entirely vegetable-based and therefore CO 2 -neutral. This is a clear advantage in countries, such as Denmark, in which waste is not burned.
  • the method of the invention and the biocomposite material produced according to this method may not only be used for the manufacture of chairs, but also more generally for the production of shell components, for example bodywork parts and other components for the automobile industry, plywood-like construction materials and similar materials.
  • the biocomposite material according to the invention can be made of natural fibres in the broadest sense, for example maize, and reinforced with fibre made of for example flax, which gives good rigidity.
  • the invention is not limited to the use of these plant materials. It is thus possible to use many other plant materials with an appropriately high content of starch.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

L'invention porte sur un matériau biocomposite stratifié comprimé consistant en une couche structurale (2) sous la forme d'une ou plusieurs couches avec des fibres orientées ou un placage, et un matériau de noyau (3) le cas échéant renforcé par de courtes fibres et/ou charges, qui permet l'élasticité, tous deux consistant en des matériaux à base de ressources renouvelables, et le cas échéant un revêtement de surface (1). Les couches (1) et (2) sont facultativement remplacées par une couche active préconsolidée (4). Le matériau biocomposite est particulièrement bien approprié pour la fabrication de chaises et autres meubles d'une manière rentable et écophile, étant donné que le procédé approprié pour la fabrication des produits est considérablement simplifié comparativement aux procédés utilisés jusqu'ici. De plus, le matériau est neutre vis-à-vis de CO2 et, par conséquent, plus facile à éliminer.
PCT/DK2008/000116 2007-03-27 2008-03-19 Matériau biocomposite comprimé, procédé de fabrication d'un tel matériau et produits à l'aide dudit matériau Ceased WO2008116466A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DK200700469A DK200700469A (da) 2007-03-27 2007-03-27 Pressekonsolideret biokompositmateriale, fremgangsmåde til fremstilling af et sådant materiale og produkter opnået ved anvendelse af materialet
DKPA200700469 2007-03-27

Publications (2)

Publication Number Publication Date
WO2008116466A2 true WO2008116466A2 (fr) 2008-10-02
WO2008116466A3 WO2008116466A3 (fr) 2009-03-26

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PCT/DK2008/000116 Ceased WO2008116466A2 (fr) 2007-03-27 2008-03-19 Matériau biocomposite comprimé, procédé de fabrication d'un tel matériau et produits à l'aide dudit matériau

Country Status (2)

Country Link
DK (1) DK200700469A (fr)
WO (1) WO2008116466A2 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2223786A1 (fr) * 2009-02-26 2010-09-01 Kronotec AG Plaque en matériau dérivé du bois et procédé de fabrication d'une plaque en matériau dérivé du bois
CN102615870A (zh) * 2012-04-10 2012-08-01 天津工业大学 一种轻质三明治结构复合材料及其制备方法
US8389107B2 (en) 2008-03-24 2013-03-05 Biovation, Llc Cellulosic biolaminate composite assembly and related methods
US8652617B2 (en) 2008-03-24 2014-02-18 Biovation, Llc Biolaminate composite assembly including polylactic acid and natural wax laminate layer, and related methods
CN106808747A (zh) * 2015-12-01 2017-06-09 曾贵华 复合型轻质板材

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE504226C2 (sv) * 1995-04-24 1996-12-09 Tetra Laval Holdings & Finance Förpackningslaminat jämte förpackning framställd därav
DE19608947A1 (de) * 1996-03-08 1996-10-31 Weserland Textilchemie Gmbh Verrottbares Formteil und Verfahren zur Herstellung eines derartigen Formteils
JP2000052306A (ja) * 1998-08-05 2000-02-22 Miki Riken Kogyo Kk 木製容器の製造方法
JP2001300906A (ja) * 2000-04-24 2001-10-30 Akihiro Hidaka 単板及び集成単板の製造方法及びその得られた単板の成型方法並びに重合板の成型方法。

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8389107B2 (en) 2008-03-24 2013-03-05 Biovation, Llc Cellulosic biolaminate composite assembly and related methods
US8652617B2 (en) 2008-03-24 2014-02-18 Biovation, Llc Biolaminate composite assembly including polylactic acid and natural wax laminate layer, and related methods
EP2223786A1 (fr) * 2009-02-26 2010-09-01 Kronotec AG Plaque en matériau dérivé du bois et procédé de fabrication d'une plaque en matériau dérivé du bois
WO2010097209A1 (fr) * 2009-02-26 2010-09-02 Kronotec Ag Plaque de matériau en bois et procédé de fabrication d'une plaque de matériau en bois
CN102292197A (zh) * 2009-02-26 2011-12-21 克罗诺泰克股份公司 木基板材和制备木基板材的方法
JP2012518563A (ja) * 2009-02-26 2012-08-16 クロノテック・アーゲー 誘導木材板及び誘導木材板の製造方法
RU2524819C2 (ru) * 2009-02-26 2014-08-10 Кронотек Аг Древесная плита и способ изготовления древесной плиты
CN102615870A (zh) * 2012-04-10 2012-08-01 天津工业大学 一种轻质三明治结构复合材料及其制备方法
CN102615870B (zh) * 2012-04-10 2015-05-06 天津工业大学 一种轻质三明治结构复合材料及其制备方法
CN106808747A (zh) * 2015-12-01 2017-06-09 曾贵华 复合型轻质板材

Also Published As

Publication number Publication date
WO2008116466A3 (fr) 2009-03-26
DK200700469A (da) 2008-09-28

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