EP1919987A1 - Composite thermodurcissable de fibres naturelles et son procede de fabrication - Google Patents

Composite thermodurcissable de fibres naturelles et son procede de fabrication

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Publication number
EP1919987A1
EP1919987A1 EP06780561A EP06780561A EP1919987A1 EP 1919987 A1 EP1919987 A1 EP 1919987A1 EP 06780561 A EP06780561 A EP 06780561A EP 06780561 A EP06780561 A EP 06780561A EP 1919987 A1 EP1919987 A1 EP 1919987A1
Authority
EP
European Patent Office
Prior art keywords
bamboo
phenol
jute
resin
formaldehyde
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Withdrawn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
EP06780561A
Other languages
German (de)
English (en)
Inventor
Dasarathi Samanta
Anukul Samanta
Mahadeb Samanta
Basudev Samanta
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.)
AB Composites Pvt Ltd
Original Assignee
AB Composites Pvt Ltd
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 AB Composites Pvt Ltd filed Critical AB Composites Pvt Ltd
Publication of EP1919987A1 publication Critical patent/EP1919987A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
    • 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
    • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
    • 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
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • 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
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • 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
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005—Coating boards, e.g. with a finishing or decorating layer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/245—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using natural fibres
    • 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
    • B27N1/00—Pretreatment of moulding material
    • B27N1/02—Mixing the material with binding agent
    • 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
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • 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
    • B27N9/00—Arrangements for fireproofing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/06—Unsaturated polyesters

Definitions

  • the present invention relates to natural fibre thermoset composite products and a method for producing the same. More particularly the invention relates to natural fibre thermoset composite products made mainly from bamboo and jute. The products are adapted to be used as floor board, panelling sheet, roofing material and the like.
  • bamboo is one of the fastest renewable plant with a maturity cycle of 3-4 years, thus making it a highly attractive natural resource compared to forest hardwoods.
  • bamboo offers good potential for processing it into composites as a wood substitute.
  • bamboo laminates could replace timber in many applications such as furniture, doors & windows and their frames, partitions, wardrobes, cabinets, flooring etc. Accordingly bamboo laminates are being developed from slivers milled out from the bamboo culm. After primary processing comprising cross cutting, splitting and 2-side planing, the slivers are treated for starch removal and prevention of termite/borer attack. The slivers are then subjected to hot air drying followed by 4-side planing for attaining uniform thickness.
  • slivers are coated with glue on the surface and are arranged systematically. They are subjected to a curing in a hot press (6'X4' 2-day light) at temp.f ⁇ 70 0 C using steam & pressure ⁇ 17 Kg/cm 2 . The pressed laminate (panels/tiles) is then put through trimming, sanding & grooving machines to give a pre-finish shape.
  • mats are woven from bamboo slivers. From split bamboo epidermal layer is removed and slivers of thickness ranging from 0.6mm to 1.0 mm are made and dried in air to moisture content of around 15%. The dried slivers are manually / machine woven into mats of different sizes and patterns. Herring bone weaving pattern is most common throughout the world.
  • bamboo mats are dipped in modified phenol formaldehyde resin mixed with a preservative to increase resistance to termite and. decay. Resin coated mats are dried to a moisture content of around 10% either in drying chambers or industrial dryers. Dried resin coated mats are assembled in 2, 3 or 5 plies and hot pressed to produce bamboo mat boards of desired thickness. For thickness greater than 6mm, bamboo mats are interleaved with wood veneers to make bamboo mat veneer composites.
  • BMCS roofing sheets confirms to the requirements prescribed for asbestos cement roofing sheets with enhanced characteristics like toughness, resilience and ductility. Apart from this BMCS is environment friendly, energy efficient and possesses good fire resistance. The BMCS developed is first of its kind in the country.
  • mats and sheets of varying width and thickness can also be made by interweaving strips of cichu culms.
  • mats used For house construction and for drying agricultural crops, mats used should be big and strong and hence wider and thicker strips are needed. Strips used for making sleeping mats and packing sheets should be smaller and thinner.
  • weaving fancy articles such as pictorial curtains and screens, ladyfans, vase or cup slipcovers, etc., only the outer part of cichu culms is selected and then split into wire like strips of amazing uniformity and fineness.
  • World War II the Chinese Bureau of Aeronautical Research studied bamboomat boards and made bamboo mat oil tanks.
  • bamboo mat board In India, although several products have been developed, bamboo mat board is the only one that has attracted entrepreneurs and gained user acceptance. In Thailand, bamboo mat board glued with urea-formaldehyde (UF) resin is being manufactured, mainly for export. In countries such as Laos, the Philippines and Vietnam, interest on bamboo board is recent and still experimental or at the level of pilot production.
  • UF urea-formaldehyde
  • Plybamboo A highly decorative product, in which rotary-cut bamboo veneers are used as face and wood veneers or blocks as core, is produced at present in small quantities in China.
  • bamboo particleboard Largely following technology employed for wood particleboard, bamboo particleboard has been developed in Canada (in collaboration with Costa Rica), China, India and Vietnam. Although the product is comparable to wood particleboard in properties and performance, production is limited as the technology is yet to overcome some inherent problems of bamboo.
  • bamboo curtain plywood bamboo curtain board is used as face and wood veneers as core. Small quantity produced in China.
  • bamboo mat and wood particleboard bamboo mat is used as face and wood particleboard as core. Produced in limited quantity in China.
  • bamboo mat and rice husk board bamboo mat is used as face and rice husk particleboard as core. Produced in small quantity in India.
  • bamboo strip, wood veneer and particleboard forms the face. Wood veneer and particleboard are used as core.
  • bamboo mat board a bamboo panel that has shown maximum promise
  • bamboo strip board have been exploited on an industrial scale and products marketed for various end-uses.
  • Other technologies are either in various stages of development or only at the initial stages of experimentation. Further research is foreseen in these cases.
  • bamboo mat corrugated roofing sheets are produced in China (known as bamboo mat corrugated plywood) and, to a limited extent, in Vietnam. Exploratory studies have recently been initiated in India and the Philippines.
  • This specialty panel is produced in China as bamboo sliver laminated board.
  • the technology is as follows: Conversion of culms into slivers. 15-20 mm wide and 0.8-I 2 mm thick;
  • this panel is for truck floors, gang planks and, less commonly, in building construction. While it is a material of great strength, its weight is a disadvantage. Moreover, it requires large quantity of resin, thereby pushing up the cost and pressing time.
  • This specialty panel (locally known as 'lamboo') is produced in Taiwan-China and used in furniture making.
  • the aesthetically designed curvature and attractive color imparted by dyeing produce highly valued panels for manufacturing furniture.
  • the three-layered boards generally manufactured are locally known as bamboo curtain plywood. It is found that several species of bamboo are suitable for this, and the process of making curtains is simpler and less time-consuming than weaving mats. In view of the simple processing technology and high quality of the product, this panel has high potential.
  • the technology is outlined below:
  • Adhesive application (generally by dipping in PF glue);
  • Paper-laminated bamboo curtain plywood is produced more commonly.
  • the paper normally used is resin-impregnated Kraft paper.
  • PF at 80-120 g/m 2
  • modified melamine is used as resin adhesive.
  • Impregnation of resin is accomplished by dipping. Before dipping, small amounts of a diluent and release agent are added to the resin. After resin impregnation, the paper is dried. One or two layers of dried paper are placed on either faces of a layer of bamboo curtain board, and hot-pressed into shape by preheating (50-135 0 C), curing and shaping (1 1/2 to 2 minutes/mm thickness), and cooling to 50 0 C.
  • Laminated bamboo curtain plywood is used in concrete formwork, and has gained wide acceptance as compared with steel and plywood formworks, because it is: lighter; cheaper; easier and quicker to assemble; more heat-resistant; and ideal to get smooth formwork surface. These advantages have earned it official endorsement, and steel frame bamboo curtain plywood has been declared as the ideal formwork material.
  • bamboo strip board A panel of high strength, stiffness and rigidity, the board is also called bamboo strip plywood and bamboo plywood. Resistance to deformation, abrasion and weathering characterizes it. Its bending strength, torsion and impact resistance are superior to wood panel and therefore its application potential particularly as platform boards, vehicle platforms, rail carriages, ship floors, etc. is very high. It is produced in China, and to a small extent in Costa Rica, Malaysia and Vietnam.
  • the Costa Rica Building Research Center (CIVCO), with the cooperation of the Queen's University of Canada, has developed a bamboo strip board called 'piybambu'. It is still in the experimental stage and a small quantity is produced on a laboratory scale. Guadua spp. is employed and PVA is used as binder. This product is expected to find interior applications like doors, windows, partitions, ceilings, etc. Further work is in progress to achieve consistent physical and mechanical properties.
  • the board is used in interior applications like ceiling, parquet flooring, etc. Although the board is strong and application potential is wide, its manufacture has not expanded on account of problems such as high energy requirement for flattening, suitability of only species with thick-walled culms, and requirement of sophisticated machinery.
  • Adhesive (PVA) application Assembly in layers (laths of each layer at right angles to the other);
  • Laminated lumber has excellent water resistance, durability, dimensional stability and strength properties, and is used in building construction and carriage platforms.
  • This bamboo counterpart of "zephyr” wood has been developed in Indonesia and is locally called 'semi-fiber bamboo board'. It is also a variant of strip board, but here the culm is crushed into strands of fiber. A small quantity of this board has been produced and the technology is undergoing further trials.
  • the process is as follows: Splitting of fresh culms; Crushing of split culms under pressure; Drying to 10-12% moisture content; Soaking in resin (both UF and PF resin have been employed); assembly (culm fibers of one layer at right angles to fibers in the other layer); Hot-pressing (at 120 0 C for UF and 160% for PF); and Trimming.
  • US 5,876,649 teaches shaped load-carrying structures fabricated using bamboo linear fibers with a compatible bonding material and synthetic polymers such as polyesters, epoxies, and polyolefins.
  • the structures are manufactured by coating at least one of bamboo culms, split bamboo culms, bamboo fiber tape, or prepared bamboo fibers with a bonding material to produce a core.
  • the core is then combined with a polymer matrix and extruded or molded to form a structure having the desired shape.
  • the structures compare favorably with wood, steel, and concrete regarding strength, longevity, price and ability to withstand earthquakes.
  • the structures may be used as beams, columns, telephone poles, and marine piles.
  • binding agents give surprisingly good bonding between the bamboo and the polymer matrix, maleated polypropylene, maleated polyethylene, maleic anhydride, hydroxyl methacrylate, silane compounds, N- vinyl pyridine, N-vinyl caprolactam, N-vinyl carbazole, methacrylic acid, ethyl methacrylate, isobutyl methacrylate, sodium styrene sulfonate, bis-vinyl phosphate, divinyl ether-ethylene glycol, vinyl acetate, vinyl toluene, vinylidene chloride, chloroprene, isoprene, dimethylaminoethyl methacrylate, isocetylvinyl ether, acrylonitrile, glycidyl methacrylate, N-vinyl pyrrolidone, acrylic acid, ethyl acrylate, itaconic acid, methyl acrylate, sodium vinyl s
  • plastics extruding line is connected to a die that allows the bamboo fibers primed with at least one of the above binders to fill the outside circumference of a die.
  • the mixture of primed bamboo fibers, plastic is extruded as a column and enters powered pullers that are capable of extracting the column to form any practical length.
  • the thus-prepared composite structure is transferred to a water-cooled bath where it is cooled to ambient temperatures and the sawed ends are capped.
  • the bamboo fibers are primed by coating at least one of the above binders by immersing the bamboo fiber in a bath of the primer, spraying the binder onto the bamboo fiber, or brushing the primer onto the bamboo fiber.
  • the primed bamboo fiber is secured to a carrying core of wood or metal to form a core assembly and this core assembly is inserted into a mold and positioned so as to allow clearance for the plastic matrix to flow around all exposed surfaces in desired thicknesses.
  • plastics have an almost unlimited life span -when exposed to the elements. This explains the ability of fiberglass to dominate the marine market where wood and steel require too much maintenance. However, plastics by themselves lack sufficient tension and compression strength to stand alone as load-carrying structures. The marine industry solved this problem with the addition of glass fibers to the plastic matrix resulting in fiberglass. This engineered composite has three times the load-carrying capability of steel of an equal weight. The cost of glass fiber reinforced plastics has limited this material to special products and niche markets. Asian and some South American bamboo species such as Gradua and Tonkin cane have tension strength close to steel and compressional strength exceeding concrete. At 1/100 the cost of glass fiber, linear bamboo fiber can be more competitive with traditional materials. By utilizing fiber in a plastic matrix the resulting composite is very strong and has the nearly unlimited life span of the plastic exterior.
  • the bamboo linear fiber In order to produce beams and columns from the composite, the bamboo linear fiber must bond to the plastic matrix .
  • the elongation of the plastic glue allows the load to be evenly distributed along all of the unidirectional bamboo fibers. This is the key to the exceptional strength of the composite structures.
  • a bonding material of at least one of the materials named above, preferably acrylic acid, is used, allowing difficult matrices, such as polyethylene, to bond to the bamboo fibers 6.
  • a bamboo culm is split to its desired size.
  • the fibers 6 may take the form of a full width split bamboo culm, smaller slices, or a tape.
  • the linear bamboo fiber is treated with at least one bonding agent as described above, most preferably acrylic acid or maleic anhydride or salt or ester derivatives thereof, to promote the adhesion of the fibers to the synthetic polymer matrix.
  • the synthetic polymer may be a thermosetting resin or a thermoplastic resin.
  • the molted plastic is used to completely envelope the bamboo fiber and the mixture of bamboo fiber and synthetic polymer is formed of desired length for the structures.
  • the bamboo culms are not split, but are left in their original hollow shape. These bamboo culms are treated with at least one of the bonding materials named above and are inserted into a mold. The synthetic polymer is then introduced into the mold to bond to, and surround, the bamboo culms. In this way, support columns of exceptional load- carrying ability and the ability to withstand seismic events and other horizontal pressures are produced.
  • US application no 20050048273 relates to the field of composite materials, and more particularly to load bearing and other structural materials with bamboo and other non- wood cellulosic cores, and methods to make such cores and composites. More particularly it teaches a method and apparatus for pultrusion of a plastic member having a bamboo-reinforced core.
  • the apparatus includes an input and series of die assemblies for taking bamboo tape and embedding it in an appropriately shaped composite member.
  • a pultrusion and saw assembly maintain production at an efficient and desired rate for the particular shape(s) and type of end product being produced.
  • Alternative embodiments are also shown for the processing of bamboo into tape and ribbon forms usable by a pultrusion machine.
  • the Indian patent 179504 teaches a method of manufacture of jute composite products.
  • the said method comprise formation of resin solution, addition of filler and additives to form slurry, impregnation of jute cloth in the slurry, drying the impregnated jute cloth and pressing it to multilayered product according to need.
  • the composite product formed from this composite have cross breaking strength, compressive strength and the tensile strength which are low. Accordingly the product from jute composite is not suited to with stand certain conditions like seismic variations.
  • bamboo products have the physical property of Water absorption, which is more than 10%. Also they have lower tensile strength, lower cross breaking point. These are formed from bamboo and not a composite of bamboo with other natural fibre. Moreover, it is prone to fire with every possibility of termite attack and U.V. non-resistant.
  • the main object of the present invention is to provide natural fibre thermoset composites product having high tensile strength high compressive strength, high cross breaking point, Low water absorption properties comprising bamboo and jute and adapted to form board, panelling sheet components.
  • Another object of the present invention is to provide a method to produce natural fibre reinforced thermoset composite product comprising bamboo and jute of any form or of any fibre or mixture and adapted to form board, panelling sheet components
  • a further object is to provide the natural fibre thermoset composite wherein binder is selected from Phenolic, U. F. and /or MF resin, modified there of unsaturated polyester resin and a combination of any of those in different ratio.
  • natural fibre thermoset composite product of high tensile strength, high compressive strength, high cross breaking point, low water absorption properties comprising bamboo and jute fibre, with or without other natural fibres selected from Bulrush (Hogla), Hem, Sisal, Banana and pine apple, coconut fiber (coir), wheat flour, walnut shell flour, cashew nut shell flour, rice husk, sugar cane bagasee, wheat straw, rice straw, jute stick powder, wheat bran, resins, fillers and additives wherein the bamboo and jute are present in the ratio of 1:99 to 99:1 and said natural fibres in amount of 1% - 90% by wt., when present, of the fillers, additives and reinforcement material.
  • bamboo and jute fibre with or without other natural fibres selected from Bulrush (Hogla), Hem, Sisal, Banana and pine apple, coconut fiber (coir), wheat flour, walnut shell flour, cashew nut shell flour, rice husk, sugar cane bagasee, wheat straw, rice straw,
  • a method of manufacturing natural fibre thermoset composite product of high tensile strength comprising : i) forming slurry with resin solution, fillers and additives; ii) impregnation, coating or spraying (other processing methods like coating, spraying, or a dry method, like spraying resin solution , coating or no solvent method,) of bamboo and jute with or without other natural fibres selected from
  • the natural fibre thermoset composite product of high tensile strength, high compressive strength, high cross breaking point, low water absorption properties of present invention is formed mono or multilayered products like floor board/panelling sheet/ components.
  • the ratio of bamboo to jute in the said composite product is 1:99 to 99:1 of the reinforcement material.
  • the natural fibre thermoset composite product of high tensile strength high compressive strength, high cross breaking point, low water absorption properties of present invention has following enhanced physical properties. It is cost effective compared to fibre glass and having more or less similar properties :-
  • the natural fibre thermoset composite product of high tensile strength, high compressive strength, high cross breaking point, low water absorption properties of present invention comprises bamboo in 10 to 90% by weight, and/or jute in 5 to 90% by weight. Jute can be used as raw Jute, Jute Felt, Jute Cloth of any form or any other Jute fiber form and bamboo is in the form of strips, weaving mat, ordinary mat, powder, granules or any other form of reinforcement material.
  • the filler of 10 to 90% in weight is selected from Aluminium Try-hydrate, Calcium Carbonate, Coconut Shell Dust, Marble, Mica, Talc, Zinc Stearate , Rubber , chlorinated paraffin wax and Fly Ash, carbon blacks, fumed silica, precipitated silica, Alumina, ZnO,TiO2, Calcium Stearate, nanoclays like monmorillonite, bentonite, china clay, borates, phosphate, sulfate salts, Calcium Oxide, Magnesium Oxide, Slate dust, graphite, dolamite, wallastonite, Gypsum, Barytes, wheat flour, walnut shell flour, rice husk, sugar cane bagasee, wheat straw, rice straw, jute stick powder, cashew nut shell flour, Wheat bran, tributyl, Tin Oxide, sodium pentachlorophenate, borax, sodium floride, ammonium hydrogen phosphate and ammonium poly phosphate at 1%:40% and 40%: 1% or part
  • Resin in 5 to 80% weight is selected from Phenol Formaldehyde(PF), Phenol Urea Formaldehyde (PUF),Urea Formaldehyde(UF), Melamine Formaldehyde (MF), Phenol Melamine Formaldehyde(PMF), Melamine Urea Formaldehyde(MUF) and the modified form of these resins as polymer.
  • Substituted phenols employed in the formation of the Phenolic resins include, for example, alkyl substituted phenols, aryl substituted phenols, aralkyl substituted phenols, cycloalkyl substituted phenols, alkenyl-substituted phenols, alkoxy substituted phenos, aryloxy substituted phenols, and halogen-substuted phenols, the foregoing substituents possibly containing from 1 to 20 and preferably from 1 to 8 carbon atoms.
  • Suitable phenols for preparing the resole resin composition of the present intention include; hydroxybenzene (phenol), o-cresol, m-cresol, p-cresol, 3.5- xylenol,3.4 xylenol, 3.4.5 - trimethylphenol, 3-ethyl phenol, 3.5-diethyl phenol, p-butyl phenol, 3.5- dibutyl phenol, p-amyl phenol, p-cyclohexyl phenol, p-octyl phenol, 3.5 dicyclohexyl phenol p-phenyl phenol, pcrotyl phenol, phenylethyl, 3.5 dimethoxy phenol, 3.4.5- trimethoxy phenol, p-ethoxy phenol, p-butoxy phenol, 3-methyl-4-methoxy phenol, p- phenoxy phenol and mixture thereof.
  • Ordinary phenol normally is preferred for most applications on resin.
  • Formaldehyde can be used along or in combination with any of the aldehydes or other equivalents heretofore employed in the formation of phyenolic resin including for example, acetaldehyde, propionaldehyde, butylaldehyde furfuraldehyde and benzaldehyde.
  • the aldehydes employed have the formula R'CHO wherein R' is a hydrogen or hydrocarbon radical generally of 1-8 carbon atoms.
  • Unsaturated polyester resin and the like by alone or mixture with P.F., M.F., U. F. in proportion of 10% to 90% and 90% to 10% of resin.
  • the Additives in amount of 0.1 to 30% are selected from Ammonium Phosphate, Zinc Borate, Antimony Tri-Oxide and Borax of filler.
  • the products from Jute bamboo Composites of the present invention are as below: -
  • the panels/ sheet formed of the said composite may be used for various purposes: Railway Coach Components like Packing Ring, Packing for Cranes, Seat-cum-Back Rest besides ceiling, Floor Board, Panelling and Chequered Board etc. Household Components i.e. Doors, Windows, Furniture of different size and shapes and Corrugated and Plain Sheets.
  • the composites may be formed into products like plain and corrugated sheet to make low cost housing in rural areas and Tsunami effected/Earthquake prone area within a very short period.
  • the resin is dissolved in methanol, water and any suitable solvent.
  • a slurry is made from the resin along with cross linking agents and fillers.
  • the bamboo and the jute in the ratio of 1:99 to 99:1 of reinforcement material is impregnated in the slurry (all other different methods as discussed earlier) and dried. It is further dried out into required size and made multi-layered as per required size and thickness and pressing at a pressure of 0.1-20 tons per square inches for a period of 0.5-60 minutes at a temperature of 70-200 0 C and finally trimming the multi-layered pressed material/components in required size to form moulded natural fibre thermoset composite products i.e. floor board/panelling sheet/ components with finishing and painting as per the requirement of the customers.
  • the resin is present in amount of 5 to 80% weight.
  • the resin solution is formed by reacting phenols with formaldehyde in the molar ratio (1.0:0.6 to 2.5) in both acid and alkaline condition.
  • Substituted phenols employed in the formation of the Phenolic resins include, for example, alkyl substituted phenols, aryl substituted phenols, aralkyl substituted phenols, cycloalkyl substituted phenols, alkenyl-substituted phenols, alkoxy substituted phenos, aryloxy substituted phenols, and halogen-substituted phenols, the foregoing substituents possibly containing from 1 to 26 and preferably from 1 to 9 carbon atoms.
  • Suitable phenols for preparing the resole resin composition of the present intention include; hydroxybenzene (phenol), o-cresol, m-cresol, p-cresol, 3.5- xylenol,3.4 xylenol, 3.4.5 - trimethylphenol, 3-ethyl phenol, 3.5-diethyl phenol, p-butyl phenol, 3.5- dibutyl phenol, p-amyl phenol, p-cyclohexyl phenol, p-octyl phenol, 3.5 dicyclohexyl phenol p-phenyl phenol, pcrotyl phenol, phenylethyl, 3.5 dimethoxy phenol, 3.4.5- trimethoxy phenol, p-ethoxy phenol, p-butoxy phenol, 3-methyl-4-methoxy phenol, p- phenoxy phenol and mixture thereof.
  • Ordinary phenol normally is preferred for most applications in preparation of resin
  • Formaldehyde can be used along or in combination with any of the aldehydes or other equivalents heretofore employed in the formation of phyenolic resin including for example, acetaldehyde, propionaldehyde, butylaldehyde furfuraldehyde and benzaldehyde.
  • the aldehydes employed have the formula R'CHO wherein R' is a hydrogen or hydrocarbon radical generally of 1-8 carbon atoms.
  • the resin solution may also be formed by reacting urea with formaldehyde in the molar ratio (1.0:3.0) in presence of alkaline catalyst or by reacting Melamine with formaldehyde in the molar ratio (1.0:3.0) in presence of alkaline catalyst or as a mixture of PUF, PMF or MUF in required proportion.
  • UF,MF,PMF,MUF,PUF formaldehyde can be used alone or in combination with any of the aldehydes or their equivalents heretofore employed in the formation of Phenolic resin including, for example, acetaldehyde, propionaldehyde, butylaldehyde, furfuraldehyde, and benzaldehyde.
  • the aldehydes employed have the formula R'CHO wherein R' is a hydrogen or hydrocarbon radical generally of 1-8 carbon atoms.
  • the modified resin Phenolic, Melamine and Urea may also be formed by reacting Phenolic, Melamine and Urea with Formaldehyde modified by any of the material namely, Cresol, Cryslic Acid, Cardanol, Resorcinol, Cashew Nut Shell Liquid (CNSL), Ligno Sulphate Liquer (LSL) and Hydrolised Shellac in presence of Acid/Alkali catalyst in proportion of 1% to 90% by wt. and any of the above material in 100% may react with required proportion of Formaldehyde.
  • Formaldehyde modified by any of the material namely, Cresol, Cryslic Acid, Cardanol, Resorcinol, Cashew Nut Shell Liquid (CNSL), Ligno Sulphate Liquer (LSL) and Hydrolised Shellac in presence of Acid/Alkali catalyst in proportion of 1% to 90% by wt. and any of the above material in 100% may react with required proportion of Formaldehyde.
  • Linear unsaturated polyester is obtained by reacting, in the presence of an inhibitor and of a metal catalyst, together: 5-30 mol % of one or more ethylenically unsaturated decarboxylic acids (A) selected from the group consisting of maleic acid, maleic anhydride and fumaric acid, 20-45 mol % of one or more other aliphatic or aromatic acids (B) selected from the group consisting of phthalic acid, phthalic anhydride, isophthalic acid or terephthalic acid, and 40-60 mol % of two or more polyhydric alcohols (C) selected from the group consisting of triethylene glycol, dipropylene glycol, tripropylene glycol, Bisphenol A, trimethylol ethane, trimethylol propane, polyethylene glycol and derivatives thereof, polypropylene glycol derivatives thereof, polyethylene oxides, and trimethylol propane polymers wherein said polyhydric alcohols have an overall hydroxy functionality of 2 or 3 per molecule and a mole
  • the said resins are dissolved in methanol, ethanol, acetone, Water or their mixtures in different proportions and Hardner and further admixed with filler and other additives to form a slurry;
  • Phenol Formaldehyde 1:0.9 mol ratio
  • Phenol Formaldehyde 1:2.0 mol ratio
  • Catalyst NaoH 0.02 mol
  • the boards have the following properties: SL. PROPERTY VALUE
  • the method of forming the composite is as in experiment 1. However the proportion of bamboo and jute has been varied. In 3 a jute: bamboo: is 99:1, in 3b it is 1:1, in 3c it is 1:99 of reinforcement material. The properties of the composite product are given below:-
  • the composite product of the present invention with the bamboo and jute in defined ratio provide the required properties like tensile strength, compressive Strength , Water Absorption, and the like properties are not possible from the material invented earlier from Natural Fibre and Natural Fibre Composite.
  • Figure 1 Flow diagram of process of manufacture of composite of present invention
  • Figure 2 Graph illustrating the water absorption of composite with various proportions of bamboo to jute
  • Figure 3 Graph illustrating tensile strength of composite with various proportions of bamboo to jute
  • Figure 4 Graph illustrating compressive strength of composite with various proportions of bamboo to jute
  • Figure 1 illustrates the process for formation of the composite product of the present invention by way of a flow chart.
  • the resin components are mixed and form the resin to be used in the present process.
  • the additives and fillers are added to form the resin solution and the slurry is formed by addition of water methanol and hardener and mixed in a machine.
  • the slurry is taken to the impregnating machine with oven and cutter for impregnation of bamboo and jute and followed by drying and cutting of the impregnated bamboo jute composite.
  • it is passed to the hydraulic press for moulding of the impregnated material. This is the forwarded to the trimming machine for cutting the impregnating material according to desired size.
  • the product thus form is painted as per requirement.
  • Figure 2 illustrates the water absorption property of the bamboo jute composite of the present invention.
  • the ratio of jute/bamboo is plotted against water absorption. It is found that with increase of ratio of jute.bamboo the water absorption property increases and at the ratio of 99:1 of the reinforcement material the water absorption property is the best.
  • Figure 3 illustrates the tensile strength of the bamboo jute composite with respect to the ratio of jute and bamboo in the composition.
  • the ratio of jute:bamboo is plotted against the tensile strength and it is found that the best tensile strength is achieved when the jute/bamboo ratio is 1 :99 of the reinforcement material.
  • Figure 4 illustrates the cross breaking strength of the bamboo jute composite with respect to the ratio of jute and bamboo in the composition.
  • the ratio of jute:bamboo is plotted against the cross breaking strength and it is found that the best cross breaking strength is achieved when the jute/bamboo ratio is 1 :99 of the reinforcement material.
  • Figure 5 illustrates the compressive strength of the bamboo jute composite with respect to the ratio of jute and bamboo in the composition.
  • the ratio of jute:bamboo is plotted against the compressive strength and it is found that the best compressive strength is achieved when the jute/bamboo ratio is 1:99.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

L'invention porte sur un composite thermodurcissable de fibres naturelles caractérisé par sa forte résistance à la traction, sa forte résistance à la compression, sa forte résistance à la flexion, et son fort taux d'absorption d'eau, et sur son procédé de fabrication. Le produit comporte du bambou, du jute, des résines, des charges et des additifs, le bambou et le jute, matériaux de renfort, étant présents dans un rapport allant de 1:99 à 99:1. Le procédé de fabrication comporte les étapes suivantes: formation d'un coulis de résines, de charges et facultativement d'additifs; imprégnation du bambou et du jute par le coulis; dessiccation du composite de bambou et de jute imprégné dans un four à une température de 100 °C à 200 °C; découpage du composite sec en éléments de taille voulue; empilement d'éléments découpée en couches en fonction de l'épaisseur requise; compression des couche à la presse hydraulique à raison de 1 à 3 tonnes par pouce carré pendant un temps et à une température définis. Le composite peut servir de dalles de sol, de panneaux, et de couverture, etc.
EP06780561A 2005-08-16 2006-08-10 Composite thermodurcissable de fibres naturelles et son procede de fabrication Withdrawn EP1919987A1 (fr)

Applications Claiming Priority (2)

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PCT/IN2006/000287 WO2007020657A1 (fr) 2005-08-16 2006-08-10 Composite thermodurcissable de fibres naturelles et son procede de fabrication

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CA2681528C (fr) 2007-03-21 2018-10-23 Ashtech Industries, Llc Materiaux utilitaires integrant une matrice de microparticules
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CN101214667A (zh) * 2008-01-14 2008-07-09 南京林业大学 单板加压浸胶增强型复合集装箱底板及其制造方法
CN101574825B (zh) * 2008-05-05 2013-03-27 萌立尔有限公司 一种彩色竹集成材的加工方法
DE102008031082A1 (de) * 2008-07-01 2010-01-07 Kaindl Decor Gmbh Imprägnierung mit Hybridharzen
GB2469014A (en) * 2008-11-28 2010-10-06 Adrianne Jacqueline Jones Biodegradable composition
CN102234440B (zh) * 2011-04-28 2012-10-31 朱奎 一种用于矿井的建筑模板
EA031433B1 (ru) 2011-09-21 2019-01-31 Доналдсон Компани, Инк. Тонкие волокна, изготовленные из полимера, сшитого с композицией, содержащей альдегидную смолу
EP2788409B1 (fr) 2011-12-05 2016-02-24 Csir Objet ignifugé et son procédé de fabrication
FR2988640B1 (fr) * 2012-03-30 2014-04-18 Oleg Muzyrya Materiau composite isolant acoustiquement et thermiquement
EP2964817A1 (fr) 2013-03-09 2016-01-13 Donaldson Company, Inc. Fines fibres composées d'additifs réactifs
WO2018172959A2 (fr) * 2017-03-21 2018-09-27 Unilin, Bvba Planche et procédé de fabrication d'une planche
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EA201992222A1 (ru) 2017-09-28 2020-02-10 Юнилин, Бвба Плита и способ изготовления плиты
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