DE4226988A1 - Composite shaped pieces with sandwich structure - have centre layer of foamed synthetic resin and outer layers of natural fibres oriented in specified directions. - Google Patents

Composite shaped pieces with sandwich structure - have centre layer of foamed synthetic resin and outer layers of natural fibres oriented in specified directions.

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Publication number
DE4226988A1
DE4226988A1 DE4226988A DE4226988A DE4226988A1 DE 4226988 A1 DE4226988 A1 DE 4226988A1 DE 4226988 A DE4226988 A DE 4226988A DE 4226988 A DE4226988 A DE 4226988A DE 4226988 A1 DE4226988 A1 DE 4226988A1
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Germany
Prior art keywords
natural
outer layers
synthetic resin
resin
foamed synthetic
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.)
Withdrawn
Application number
DE4226988A
Other languages
German (de)
Inventor
Wulfram John Schmucker
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Individual
Original Assignee
Individual
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Application filed by Individual filed Critical Individual
Priority to DE4226988A priority Critical patent/DE4226988A1/en
Publication of DE4226988A1 publication Critical patent/DE4226988A1/en
Withdrawn legal-status Critical Current

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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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/005—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/10—Moulding of mats
    • B27N3/14—Distributing or orienting the particles or fibres
    • B27N3/143—Orienting the particles or fibres
    • 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
    • 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
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0271—Epoxy 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B32B2305/188—Woven fabrics
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/10—Natural fibres, e.g. wool, cotton
    • 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
    • B32B2363/00—Epoxy resins

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Laminated Bodies (AREA)

Abstract

A shaped piece (1) has two outer layers (2,3) of natural fibres which are oriented in one or more predetermined directions and a centre layer (4) consisting at least partially of a foamed synthetic resin. Pref., the centre layer can be foamed epoxy resin, or a non-woven of natural or synthetic fibres saturated with foamed synthetic resin. The centre layer can have a filler of natural material, esp. walnut or hazelnut shells or a synthetic filler, esp. recycled granular waste. The outer layers can be fibre mats, woven fabrics or laid down rovings. During manufacture the outer layers of oriented natural fibres are separated in the mould by the centre material and the closed mould is then heated to the reaction temperature. USE/ADVANTAGE - For shaped components as in automobiles, buildings, furniture and sports equipment. Gives high strength components with environmentally friendly constituents which can be readily recycled.

Description

Die Erfindung betrifft ein Formteil aus mit einem geschäumten Kunstharz durchtränkten Naturfasern sowie ein Verfahren zu dessen Herstellung gemäß dem Oberbegriff des Patentanspruches 9.The invention relates to a molded part with foamed synthetic resin soaked natural fibers as well Process for its production according to the preamble of Claim 9.

Es sind bereits Formteile aus geschäumtem Kunstharz bekannt, in denen nach Art eines Füllmaterials Naturfasern in Form eines Faservlieses angeordnet sind. Diese Formteile können ein geschäumtes Polyesterharz aufweisen (EP-A 83 435) oder die Naturfasern auch in einem geschäumten Epoxidharz enthalten. Auch andere geschäumte Kunstharze wie Melaminharz oder Acrylharz sind denkbar.There are already molded parts made of foamed synthetic resin known in which, like a filler, natural fibers are arranged in the form of a nonwoven fabric. These molded parts can have a foamed polyester resin (EP-A 83 435) or the natural fibers in a foamed one Contain epoxy resin. Other foamed synthetic resins such as Melamine resin or acrylic resin are conceivable.

Nachteilig an den bekannten Kunstharz-Formteilen ist, daß es bisher bei Verwendung von Naturfasern als Füllmaterial oder als Bewehrung nicht gelungen ist, Formteile mit einer hinreichend hohen Biege-Festigkeit herzustellen, die ihre Verwendung für statisch höher belastete Bauteile erlauben. Eine solche Verwendung ist jedoch aufgrund des relativ niedrigen Eigengewichts und der durch die Herstellungsmethode bedingten hohen Maßhaltigkeit bei Epoxidharz-Formteilen gerade für den Automobilbau (Kotflügel, Motorhauben, Türen und dgl.), für das Bauwesen (Fassadenteile, Dachkonstruktionen), für die Möbelindustrle (Sitze, Stühle, Tische und Bänke) und für den Sport­ gerätebau (Boote, Surfbretter, Ski und dgl.) sehr erwünscht. Man hat deshalb als Füllmaterial oder Bewehrung von Formteilen mit erwünscht höherer Festigkeit bisher stets Glasfasern oder Hochmodulfasern, wie Kohlefaser, Kevlar oder dgl., eingesetzt. Diese Fasermaterialien schränken jedoch die Recycling-Fähigkeit sehr ein und sind im Vergleich zu Naturfasern weniger umweltfreundlich.A disadvantage of the known synthetic resin molded parts is that so far when using natural fibers as filler or as reinforcement failed, molded parts with a to produce sufficiently high bending strength that their Allow use for components subject to higher static loads. However, such use is relative because of the low weight and by the Manufacturing method due to high dimensional accuracy Epoxy resin molded parts especially for the automotive industry (Fenders, bonnets, doors and the like), for construction (Facade parts, roof structures), for the furniture industry  (Seats, chairs, tables and benches) and for sports equipment construction (boats, surfboards, skis and the like) very much he wishes. One therefore has filler or reinforcement of molded parts with desired higher strength so far always glass fibers or high-modulus fibers, such as carbon fiber, Kevlar or the like, used. These fiber materials However, the recycling ability is very limited and are less environmentally friendly compared to natural fibers.

Aufgabe der Erfindung ist es daher, ein Formteil aus geschäumtem Kunstharz vorzuschlagen, für das eine Füllung oder Bewehrung aus Naturfasern beibehalten werden kann, das jedoch trotzdem statisch höher belastbar und daher für Verwendungen der vorstehend aufgezählten Art einsetzbar ist. Darüber hinaus soll ein Verfahren zur Herstellung eines solchen Formteils geschaffen werden.The object of the invention is therefore to make a molded part propose foamed resin for which a filling or reinforcement made of natural fibers can be maintained however still statically more resilient and therefore for Uses of the type listed above can be used is. In addition, a manufacturing process is said to of such a molded part can be created.

Erfindungsgemäß wird diese Aufgabe gelöst durch die Ausgestaltung gemäß dem Kennzeichen der Patentansprüche 1 bzw. 9.According to the invention, this object is achieved by Design according to the characterizing part of patent claims 1 or 9.

Es hat sich gezeigt, daß eine erhebliche Festigkeits­ steigerung des Formteils auch unter Verwendung von Naturfasern dann erzielbar ist, wenn grundsätzlich eine Sandwich-Bauweise eingehalten wird und die Naturfasern nicht - wie bisher - als Faservliese, sondern als gerich­ tete Fasergebilde zum Einsatz kommen. Unter "gerichteten Fasergebilden" in diesem Sinn sind Anordnungen der Naturfasern zu verstehen, in welchen diese in einer oder mehreren, vorzugsweise zwei, vorbestimmten Richtungen verlaufen. Die Verlaufsrichtung der Naturfasern wird man dabei so wählen, daß am fertigen Formteil dadurch eine den zu erwartenden Haupt-Beanspruchungen entsprechende Biege- Festigkeit erzielt wird. In der Sandwich-Konstruktion sind die Naturfasern als die beiden äußeren, das heißt oberflächennahen Schichten angeordnet und durch eine Mittelschicht auf gegenseitigem Abstand und einem bestimmten Abstand von der "neutralen Faser" in bezug auf Biegung gehalten. Die vorbestimmten Richtungen, in denen die Naturfasern angeordnet sind, können beliebiger Art sein und werden zweckmäßig auf die Art der Belastung und der Gestaltung des Formteils abgestimmt. Am häufigsten wird man, wenn Biegungen in zueinander senkrechten Richtungen auftreten, eine 0°-90°-Ausrichtung wählen. Wenn zusätz­ lich oder allein Torsionsmomente in dem Formteil auftreten, ist eine den Torsionsmomenten angepaßte andere Winkel­ ausrichtung, z . B. eine -45°/+45 °-Ausrichtung zweckmäßig.It has been shown that considerable strength increase of the molded part also using Natural fibers can be achieved when there is basically one Sandwich construction is followed and the natural fibers not - as before - as a non-woven fabric, but as a dish fiber structures are used. Under "directed In this sense, fiber structures are arrangements of the To understand natural fibers, in which these in one or several, preferably two, predetermined directions run. The direction of the natural fibers becomes one choose so that the finished molded part corresponding bending stresses to be expected Strength is achieved. In the sandwich construction are the natural fibers than the two outer ones, that is  arranged near the surface and by a Middle class at a mutual distance and one certain distance from the "neutral fiber" with respect Bend held. The predetermined directions in which the natural fibers are arranged, can be of any type and are appropriate to the type of load and the Design of the molded part coordinated. Most often one when bends in mutually perpendicular directions occur, choose a 0 ° -90 ° orientation. If additional torsional moments occur in the molded part or only is another angle adapted to the torsional moments alignment, e.g. B. a -45 ° / + 45 ° orientation useful.

Obwohl im Rahmen der Erfindung geschäumte Kunstharze jeder Art denkbar sind, die sich schäumen läßt und zur Durchdringung und Benetzung von Naturfasern geeignet ist, schlägt die Erfindung vorzugsweise die Verwendung von Epoxidharz vor.Although foamed synthetic resins in the context of the invention everyone Kind are conceivable, which can be foamed and Penetration and wetting of natural fibers is suitable, the invention preferably suggests the use of Epoxy resin before.

Die Verwendung von Epoxidharz erweist sich aus produktionstechnischen Gründen sowie aus Gründen des Umweltschutzes und besserer Arbeitsbedingungen als vorteilhaft. Der Vorteil in produktionstechnischer Hinsicht beruht darauf, daß die aus dem geschäumten Epoxidharz bestehenden Formteile zur Herstellung nicht unter äußeren Druck in der Form gesetzt werden müssen, sondern lediglich auf die Reaktionstemperatur (z. B. 60°C) der Epoxid/Härter- Kombination erwärmt werden. Arbeits- und umwelttechnisch liegt der Vorteil darin, daß das Epoxidharz lösungsmittelfrei ist. Darüber hinaus lassen sich sowohl das Epoxidharz als auch die darin enthaltenen Naturfasern umweltfreundlich recyclen.The use of epoxy resin proves itself production-technical reasons as well as for reasons of Environmental protection and better working conditions than advantageous. The advantage in terms of production technology is based on the fact that the foamed epoxy resin existing molded parts for manufacturing not under external Pressure must be put in the form, just to the reaction temperature (e.g. 60 ° C) of the epoxy / hardener Combination are warmed. Labor and environmental technology The advantage is that the epoxy resin is solvent free. In addition, both the epoxy resin and the natural fibers it contains recycle in an environmentally friendly manner.

Die Mittelschicht kann prinzipiell nur durch das geschäumte Kunstharz gebildet sein. Vorteilhafterweise wird jedoch ein Füllmaterial eingesetzt, das beim Herstellungsprozeß die beiden Außenschichten in dem gewünschten gegenseitigen Abstand hält. Als Füllmaterial kann Fasermaterial jeder Art verwendet werden. Im Sinne des Umweltschutzes und der Recycling-Fähigkeit ist jedoch ein aus Naturstoffen bestehendes Füllmaterial bevorzugt. Dafür kann beispiels­ weise ein Faservlies oder ein granulatförmiges Füll­ material, zum Beispiel Mehl aus Walnuß- oder Haselnuß­ schalen eingesetzt werden. Das Mehl oder Granulat kann auch in Kombination mit einem Faservlies in der Mittelschicht vorliegen. Geeignet sind auch Popcorn, getrocknete Bananen­ schalen (hoher Faseranteil), Holzspreißel und -schnitzel, Kork, Wolle, Rinde, Hanf, Bast, Zuckerrohr, Filz, Nadeln von Koniferen, Raps, Reis, Torf, zerkleinertes welkes Laub und dgl.The middle class can in principle only through the foamed Be made of synthetic resin. Advantageously, however, a  Filling material used, which in the manufacturing process two outer layers in the desired mutual Keep your distance. Fiber material of any kind can be used as filling material be used. In terms of environmental protection and However, recyclability is a natural product existing filler preferred. For example as a nonwoven or a granular filling material, for example flour made from walnut or hazelnut shells are used. The flour or granules can also in combination with a non-woven fabric in the middle layer available. Popcorn and dried bananas are also suitable shells (high fiber content), wood chippings and chips, Cork, wool, bark, hemp, bast, sugar cane, felt, needles of conifers, rapeseed, rice, peat, shredded withered leaves and the like

Als Naturfasern eignen sich zum Beispiel Flachs, Hanf, Sisal, Kokos-, Baumwoll-, Seide- und Jutefasern. Die Naturfasern können in Form von Matten, Geweben oder Gelegen vorliegen. Dabei können die Naturfasern in Form von Garnen enthalten sein, die - gegebenenfalls leicht miteinander verbunden - in ihrer Längsrichtung parallel zueinander angeordnet sind. Die Matten, Gewebe und Gelege können mehrere Schichten mit unterschiedlicher Verlaufsrichtung der Garne enthalten.For example, flax, hemp, Sisal, coconut, cotton, silk and jute fibers. The Natural fibers can be in the form of mats, fabrics or scrims available. The natural fibers can be in the form of yarn be included, which - if necessary, easily with each other connected - parallel to each other in their longitudinal direction are arranged. The mats, fabrics and scrims can several layers with different directions of yarn included.

Zur Herstellung der erfindungsgemäßen Formteile eignen sich grundsätzlich die schon bisher zur Herstellung von Form­ teilen aus geschäumtem Kunstharz mit Naturfaserbewehrung verwendeten Verfahren. Das erfindungsgemäße Verfahren unterscheidet sich von dem bekannten Verfahren dadurch, daß in Folge der Sandwich-Bauweise für das erfindungsgemäße Formteil durch Abstandhalter die oberflächennahe Anordnung der in bestimmter Orientierung ausgerichteten äußeren Naturfaserschichten gewährleistet sein muß. Als Abstandhalter dienen zweckmäßigerweise die später teilweise die Mittelschicht bildenden Füllmaterialien.Are suitable for producing the molded parts according to the invention basically the one previously used to make mold parts made of foamed synthetic resin with natural fiber reinforcement method used. The method according to the invention differs from the known method in that that as a result of the sandwich construction for the invention Molded part by spacers the arrangement close to the surface the outer oriented in a certain orientation Natural fiber layers must be guaranteed. When  Spacers suitably serve the later part filling materials forming the middle layer.

Je nach der Art der verwendeten Kunstharze kann das eigentliche Herstellungsverfahren unterschiedlich ausgeführt werden, wobei bekannte Praktiken einsetzbar sind. Z.B. bei der bevorzugten Verwendung von geschäumtem Epoxidharz besteht die Möglichkeit, schon außerhalb der Form eine mit dem geschäumten Kunstharz versehene Einheit, die aus Mittelschicht und den beiden Außenschichten besteht, vorzubereiten und diese dann in die vorgeheizte Form einzubringen, so daß sich nach dem Schließen der Form das Formteil ausbildet. Dabei braucht die geschäumte Epoxidharzschicht nur auf einer Fläche (oben oder unten) der aus den Naturfasern + Füllmittel bestehenden Einheit aufgebracht zu werden, weil infolge des Reaktionsvorganges die Einheit von dem Epoxidharz ganz durchdrungen wird. Dies schließt eine Aufbringung mehrfacher Schichten des Epoxidharzes, insbesondere bei besonders dicken Formteilen, nicht aus. Das Epoxidharz kann dabei selbst bereits vorerwärmt sein, so daß seine Temperatur nur wenig unter der Reaktionstemperatur liegt oder es sogar schon zu reagieren beginnt.Depending on the type of synthetic resin used, this can actual manufacturing process different be carried out using known practices are. E.g. with the preferred use of foamed Epoxy resin is already available outside of the Form a unit provided with the foamed synthetic resin, the middle layer and the two outer layers exists to prepare and then put it in the preheated Form to bring in so that after closing the mold forms the molding. The foamed one needs Epoxy resin layer only on one surface (top or bottom) the unit consisting of natural fibers + fillers to be applied because of the reaction process the unit is completely penetrated by the epoxy resin. This includes applying multiple layers of the Epoxy resin, especially in the case of particularly thick molded parts, not from. The epoxy resin itself can already do so be preheated so that its temperature is just below the reaction temperature is or it is already too start reacting.

Denkbar ist aber auch eine Durchführungsweise des Verfahrens, bei der die genannte Einheit aus den Naturfasern einschließlich ggf. vorhandener Füllmittel in der Form angeordnet wird und auf dem Grund der Form oder anschließend nach dem Einlegen der Einheit die Epoxidharzschicht aufgebracht wird. Schließlich ist auch ein stufenweises Vorgehen, wiederum bevorzugt bei dicken Formteilen, denkbar, wobei die einzelnen Schichten nacheinander in die Form eingelegt werden und zwischen dem Einlegen einzelner Schichten die Epoxidharz/Härter- Kombination aufgebracht wird. Dadurch ist in jedem Fall gewährleistet, daß das Epoxidharz in sämtliche Zwischenräume zwischen den Fasern und dem Füllmaterial hineinexpandiert und eine zusammenhängende Matrix bildet, die den Verbund der einzelnen Schichten gewährleistet und wesentlich zur Festigkeit des Formteils beiträgt.It is also conceivable that the Procedure in which the named unit from the Natural fibers including any fillers in the shape is arranged and on the bottom of the shape or then after inserting the unit Epoxy resin layer is applied. Finally, too a step-by-step approach, again preferred for thick ones Molded parts, conceivable, the individual layers one after the other in the mold and between the Insert individual layers of epoxy resin / hardener Combination is applied. This is in any case  ensures that the epoxy resin in all Gaps between the fibers and the filler expanded into a coherent matrix, which ensures the bond between the individual layers and contributes significantly to the strength of the molded part.

Schließlich ist es auch möglich, die Formteile vor der eigentlichen Formgebung als Halbfabrikate (prepregs) vorzubereiten, wobei durch eine Kühlhaltung dafür gesorgt ist, daß die Temperatur der Reaktionsharzmasse genügend weit unter der Reaktionstemperatur liegt. Die Reaktionsharzmasse kann dabei, wie schon beschrieben, als einzelne oder mehrere Schichten vorliegen, aber auch schon die Naturfasern und das Füllmittel weitgehend einhüllende oder durchdringende Masse enthalten sein. In diesem Fall genügt es, die prepregs in die Form einzubringen und lediglich durch Temperatursteigerung den Reaktionsvorgang und damit die eigentliche Formgebung auszulösen und zu Ende zu führen.Finally, it is also possible to preform the molded parts actual shaping as semi-finished products (prepregs) prepare, taking care by keeping it cool is that the temperature of the reaction resin mass is sufficient is far below the reaction temperature. The Reaction resin mass can, as already described, as single or multiple layers are present, but also already the natural fibers and the filler largely enveloping or penetrating mass. In this case it is sufficient to insert the prepregs into the mold and the reaction process only by increasing the temperature and thus trigger the actual shaping and finish respectively.

Zur Veranschaulichung des Erfindungsgedankens ist nach­ folgend anhand der beiliegenden Zeichnungen die Struktur eines Ausführungsbeispiels für ein erfindungsgemäßes Form­ teil besprochen. In den Zeichnungen zeigen:To illustrate the inventive concept is after the structure follows with the aid of the accompanying drawings an embodiment of a shape according to the invention partially discussed. The drawings show:

Fig. 1 Eine rein schematische Draufsicht auf einen Abschnitt eines ebenen Formteils, und Fig. 1 is a purely schematic plan view of a portion of a flat molding, and

Fig. 2 einen Querschnitt durch das Formteil. Fig. 2 shows a cross section through the molded part.

Gemäß Fig. 2 weist das im ganzen mit 1 gezeichnete Formteil einen Sandwich-Aufbau aus drei Schichten 2, 3 und 4 auf, wobei die Außenschichten 2, 3 Naturfasern in Form von gezielt orientierten Fasergebilden enthalten und die von den beiden Außenschichten 2, 3 eingefaßte Mittelschicht 4 ein Naturfaservlies aufweist, in welchem die Naturfasern wirr angeordnet sind. Alle drei Schichten 2, 3 und 4 sind von einem - hier bevorzugt verwendeten - geschäumten Epoxidharz durchtränkt oder durchsetzt, das die Faseranteile in Form einer Matrix umgibt und einschließt und eine durch die Gießform bestimmte glatte Außenfläche der Außenschichten 2, 3 bildet.According to FIG. 2, the molded part shown overall with 1 has a sandwich structure made up of three layers 2 , 3 and 4 , the outer layers 2 , 3 containing natural fibers in the form of specifically oriented fiber structures and the one bordered by the two outer layers 2 , 3 Middle layer 4 has a natural fiber fleece in which the natural fibers are arranged in a tangled manner. All three layers 2 , 3 and 4 are impregnated or penetrated by a foamed epoxy resin - which is preferably used here - which surrounds and encloses the fiber parts in the form of a matrix and forms a smooth outer surface of the outer layers 2 , 3 determined by the casting mold.

In Fig. 1 ist schematisch der Richtungsverlauf der Naturfasern in den für die Außenschichten 2, 3 enthaltenen Fasergebilden dargestellt. Demgemäß verläuft die weit überwiegende Anzahl von aus Naturfasern hergestellten Garnen 5 in einer bestimmten Richtung (Pfeil x) und eine geringere Anzahl von in größeren Abständen voneinander angeordneten Garnen 6 quer dazu, also 90° versetzt, (Pfeil y). Die Garne 5, 6 können miteinander nach Art eines Gewebes verbunden, als Roving angeordnet oder als Gelege vorgesehen sein. Das auf die gezeigte Weise bewehrte Formteil hat eine ausgeprägte Biege-Festigkeit in der Richtung x.In Fig. 1, the direction of the course of the natural fibers is shown in for the outer layers 2, 3 fiber structures contained schematically. Accordingly, the vast majority of yarns 5 made from natural fibers run in a certain direction (arrow x) and a smaller number of yarns 6 arranged at greater distances from one another transversely thereto, ie offset by 90 ° (arrow y). The yarns 5 , 6 can be connected to one another in the manner of a fabric, arranged as a roving or provided as a scrim. The molded part reinforced in the manner shown has a pronounced flexural strength in the direction x.

Die Herstellung eines Formteils gemäß den Fig. 1, 2 vollzieht sich zweckmäßigerweise in einer der vorstehend bereits beschriebenen Arten, wobei im vorliegenden das in der Mittelschicht 4 enthaltene Faservlies mit den aus den Garnen 5, 6 bestehenden Fasergebilden zu einer Einheit zusammengefaßt, mit einer Schicht einer Epoxidharz/Härter- Kombination versehen in eine nicht gezeigte Form eingelegt wird. Nach dem Schließen der beheizten Form wird die Temperatur der Reaktionsharzmasse auf beispielsweise 60°C gebracht, wodurch sie aufschäumt und dabei die Faserschichten durchsetzt.The preparation of a molded part according to FIGS. 1, 2 takes place conveniently in one of the types already described above, and summarized in the present the nonwoven fabric contained in the middle layer 4 with the group consisting of the yarns 5, 6 fiber structures to form a unit, with a layer an epoxy resin / hardener combination is inserted into a mold, not shown. After the heated mold has been closed, the temperature of the reaction resin composition is brought to, for example, 60 ° C., causing it to foam and thereby penetrate the fiber layers.

Die Faserschichten können zur besseren Handhabung der genannten Einheit miteinander leicht verbunden, zum Beispiel vernadelt werden oder einen rasterartigen Klebstoffauftrag erhalten. Die Formflächen können auch eine Strukturierung aufweisen, so daß das fertige Formteil eine Strukturoberfläche besitzt. Auch ist eine sogenannte in-mould-Lackierung möglich, bei der die die spätere Lack- Außenseite bildende Lackschicht vor dem eigentlichen Formvorgang in die Form eingebracht wird.The fiber layers can be used for better handling mentioned unit easily connected to each other  Example needled or a grid-like Receive glue application. The mold surfaces can also have a structure so that the finished molded part has a textured surface. Also is a so-called in-mold painting possible, in which the later paint Outside paint layer before the actual one Molding process is introduced into the mold.

Die Zusammensetzung der Epoxidharz/Härter-Kombination und die bei der Aufschäumung davon einzuhaltenden Verfahrens­ bedingungen sind einschlägig bereits bekannt und brauchen deshalb hier nicht näher erläutert zu werden. Das gilt auch für die Verwendung anderer bekannter Kunstharzmassen.The composition of the epoxy resin / hardener combination and the procedures to be followed when foaming Relevant conditions are already known and need therefore not to be explained in more detail here. This is also true for the use of other known synthetic resin compounds.

Claims (11)

1. Formteil aus mit einem geschäumten Kunstharz durchtränkten Naturfasern, dadurch gekennzeichnet, daß das Formteil (1) aus zwei Außenschichten (2, 3) aus Naturfasern (5, 6), die in einer oder mehreren vorbestimmten Richtungen (x, y) angeordnet sind, und aus einer von den Außenschichten eingefaßten Mittelschicht (4) besteht, die zumindest teilweise von dem geschäumten Kunstharz gebildet ist.1. Molding made of natural fibers impregnated with a foamed synthetic resin, characterized in that the molding ( 1 ) consists of two outer layers ( 2 , 3 ) made of natural fibers ( 5 , 6 ) which are arranged in one or more predetermined directions (x, y) , and consists of a middle layer ( 4 ) bordered by the outer layers, which is at least partially formed by the foamed synthetic resin. 2. Formteil nach Anspruch 1, dadurch gekennzeichnet, daß das geschäumte Kunstharz ein Epoxidharz ist.2. Molding according to claim 1, characterized in that the foamed synthetic resin is an epoxy resin. 3. Formteil nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß die Mittelschicht aus einem Natur- oder Kunststoff-Faservlies gebildet ist, das von dem geschäumten Kunstharz durchtränkt ist.3. Molding according to claim 1 or 2, characterized characterized that the middle class from a natural or plastic fiber fleece is formed by the foamed resin is soaked. 4. Formteil nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Mittelschicht ein Füllmaterial aus Naturstoffen enthält.4. Molding according to one of claims 1 to 3, characterized characterized in that the middle layer is a filling material contains natural substances. 5. Formteil nach Anspruch 4, dadurch gekennzeichnet, daß als Füllmaterial in der Mittelschicht Mehl oder Granulat aus Walnuß- oder Haselnußschalen enthalten ist.5. Molding according to claim 4, characterized in that as filling material in the middle layer flour or Contains granules from walnut or hazelnut shells is. 6. Formteil nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Mittelschicht ein Füllmaterial aus Kunststoff enthält. 6. Molding according to one of claims 1 to 3, characterized characterized in that the middle layer is a filling material contains plastic.   7. Formteil nach Anspruch 6, dadurch gekennzeichnet, daß das Füllmaterial ein Regranulat aus Kunststoff- Abfällen der Formteilherstellung ist.7. Molding according to claim 6, characterized in that the filling material is a regranulate made of plastic Waste of the molding production. 8. Formteil nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß die Naturfasern der Außenschichten in Form einer Fasermatte, eines Gewebes, eines Geleges oder als gezielt gelegte Garne (Roving) vorliegen.8. Molding according to one of claims 1 to 7, characterized characterized in that the natural fibers of the outer layers in the form of a fiber mat, a fabric, a scrim or as specifically laid yarns (roving). 9. Verfahren zur Herstellung eines Formteils nach Anspruch 1, bei dem Naturfasermaterial mit einer Reaktionsharzmasse versehen und in einer geschlossenen Form zur Reaktion gebracht wird, dadurch gekennzeichnet, daß zwei voneinander durch ein Füllmaterial im Abstand gehaltene Naturfasergebilde, in denen die Naturfasern in einer oder mehreren vorbestimmten Richtungen verlaufen, mit der Reaktionsharzmasse versehen zur Reaktion gebracht werden.9. Process for the production of a molded part Claim 1, in the natural fiber material with a Reaction resin compound provided and in a closed Form is reacted, thereby characterized in that two are separated by one Filling material spaced natural fiber structures, in which the natural fibers in one or more predetermined directions with which Reaction resin mass provided to react become. 10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, daß das Füllmaterial und die im Abstand voneinander gehaltenen Naturfasergebilde, zu einer Einheit zusammengefaßt, mit einer Schicht von Epoxidharz als Reaktionsharzmasse versehen und in der Form auf die Reaktionstemperatur der Reaktionsharzmasse gebracht werden.10. The method according to claim 9, characterized in that the filler and the spaced apart held natural fiber structures, to a unit summarized with a layer of epoxy as Reaction resin compound provided and in the form on the Brought reaction temperature of the reaction resin mass become. 11. Verfahren nach Anspruch 9 oder 10, dadurch gekennzeichnet, daß die Reaktionsharzmasse schon vor ihrem Aufbringen auf oder nahe an ihre Reaktionstemperatur vorgewärmt wird.11. The method according to claim 9 or 10, characterized characterized that the reaction resin mass before their application on or close to hers Reaction temperature is preheated.
DE4226988A 1992-08-14 1992-08-14 Composite shaped pieces with sandwich structure - have centre layer of foamed synthetic resin and outer layers of natural fibres oriented in specified directions. Withdrawn DE4226988A1 (en)

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WO2014063672A1 (en) 2012-10-15 2014-05-01 Gerald Neubauer Continuous method for producing a lightweight sandwich panel and lightweight sandwich panels producible according to this method
WO2014131801A1 (en) * 2013-02-27 2014-09-04 Georg-August-Universität Göttingen Stiftung Öffentlichen Rechts Wood and composite-material plate and method for production
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DE102013101937A1 (en) * 2013-02-27 2014-08-28 Georg-August-Universität Göttingen Stiftung Öffentlichen Rechts Wood and composite panel
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