WO2010103143A1

WO2010103143A1 - Thermocompressible felt

Info

Publication number: WO2010103143A1
Application number: PCT/ES2010/000101
Authority: WO
Inventors: Tomás VILLAGRASA PIE
Original assignee: Villagrasa Pie Tomas
Priority date: 2009-03-13
Filing date: 2010-03-12
Publication date: 2010-09-16
Also published as: ES2345087B1; ES2345087A1; WO2010103143A4

Abstract

Felt comprising an expandable polymer or copolymer, 10% to 30% by weight, which, in the condensation or fusion thereof, liberates gas for the formation of microcells, a thermosetting binder or conglomerant, 20% to 45% by weight, the balance, making up 100%, being fibres of recycled origin. In an alternative embodiment the felt presents an anti-moisture surface barrier or addition of fireproofing agent.

Description

DESCRIPTION

THERMOCOMPRESSABLE FELT. OBJECT OF THE INVENTION The present invention relates to a thermocompressible felt, for use in decorative and other panels, susceptible of application in various fields such as construction, the automobile and others.

Background of the invention. At present, the use of thermocompressible materials, in many cases flame retardant, extends mostly in the manufacture of cars, trains, ships, etc; and also under construction.

The textile-based felt is made of cotton fibers, vegetable, artificial or synthetic fibers; redoubled or not, in various proportions. Among the fibers used for the manufacture of felt, together with cotton as the main component, stand out the fibers of vegetable origin, such as hemp, flax or jute, among others. Artificial fibers such as rayon, viscose, and others, and synthetic fibers such as all commercially used polymers are also commonly used. To the above mentioned components a binder or binder is added, to provide consistency and minimum stiffness. Said binders are thermosetting synthetic resins or mixtures thereof, they can also sometimes be modified thermoplastic resins or low melting polymer fibers. Industrially, the felt can be found in two states, depending on the progress in the production process:

- Prepolymerized state, in which the binder has not yet fully condensed, and therefore can be used for the production of thermoformed parts. Polymerized state, in which the binder is almost completely condensed, forming three-dimensional networks, which provide mechanical properties to the material.

To condense or polymerize the structural monomer of the binder it is necessary to provide heat and high pressure inside a metal mold. The temperature and pressure parameters depend on the regulatory objectives, and the type of material used. Once the felt has completely polymerized, it has greater consistency and stiffness provided by the binding of the binder with the fibers. In short, the final properties of the felt will depend on the material used, in terms of fibers, of the binder or binder, also of its percentages, and even of the parameters of temperature, pressure, as well as the geometry of the mold.

That is why by varying the binder and its polymerization process, different final products can be obtained, that is, felts of different densities or pieces of different geometries with their characteristic mechanical properties.

The felts are applicable to a wide variety of industries, especially to the automobile industry and also to construction. All these materials must have certain impact resistance, acoustic and thermal properties, resistance to bending and others. They must also meet requirements of resistance to combustion. Currently, in the industry, mainly the automotive industry, a wide variety of interior panels is known, whose decorative function entails or requires certain safety, welfare and other functions. A large part of the pieces, such as interior roof coverings or door panels, must comply with their regulations for resistance to bending and acoustic absorption.

To understand the requirements of resistance to bending, it is necessary to see how and why they are performed. Take as an example a roof covering of a conventional car.

Currently the materials used are polyurethane foam to which is added by mixing, high tenacity glass fibers, coming from "rowings" that are cut to the required length. Special nonwovens with various finishes (water repellent, flame retardant, others) are added. These nonwovens are called skin, and one of its functions is to retain the glass fibers and facilitate subsequent thermoforming.

The economic cost of this process is high, both for the cost of the foam and for the glass fibers, as well as for the nonwovens that make leather. Leaving aside the processes for the decorative finish that are not of interest. The main requirements of a roof covering are: Good resistance to bending under different conditions of humidity and temperature.

Good sound absorption - Self-supporting: That is, adapt to the body shape and keep it in time, - Thermal insulation.

High dimensional stability. Low or zero emissions. - Resistance to combustion.

Recyclability of the material.

The current solution has the following drawbacks: a) improved dimensional stability, b) sound absorption is improved, c) thermal insulation is improved, _d d) emissions, although minimal, of glass microfibers, this means toxicity, e) no It is satisfactorily recyclable.

Flexural strength is physically evaluable with Young's module. Experience shows that thermocompressed materials, with equal thickness and with equal weight (weight per unit area), those that resist the most resistance to bending are those that have the greatest capacity to absorb or dissipate energy in the form of pressure at which submits This is thus compared to high thermal insulation materials, whose properties need high viscoelasticity.

Hence, the importance of the viscoelasticity of the material and its ability to absorb mechanical energy, be it in the form of acoustic, mechanical pressure or vibration produced by heat.

The acoustic absorption depends on the resonance, in other words, on the viscoelastic property of the materials that comprise the coating. In short, the ability to absorb deformations, but in this case, it also depends on the resistance to the passage of air. Materials that have a high sound absorption capacity are materials that have a lot of pore, which also has a large surface area. This loss of load when the air passes is the one that reduces the sound pressure.

Thermal insulation and dimensional stability, have much to do with the above, and also with the chemical structure of the components. The presence of multiple bonds in the joints and their ability to relocate are conditions of the utmost importance to absorb heat.

Description of the invention

The thermocompressible felt, object of the proposed invention, comprises a felt that has improved mechanical properties of rigidity and self-support, with the advantage of not emitting harmful gases due to its composition, and which also has zero emission of toxic microparticles or fibers , being susceptible to being flame retardant.

According to the invention, the felt also comprises the vegetable, artificial, synthetic, or low melting polymer fibers; an expandable polymer or copolymer, mainly by the release of gas in its condensation or fusion, and a thermosetting binder or binder. The aforementioned reaction that occurs in the thermocompression of the felt can come from the oxidation or sublimation of any of the following polymers:

- ABS or ABS / SAN in pellets with micropore treatment, capable of expanding. - PP (polypropylene) with micropore treatment, capable of expanding,

PS (polystyrene) with micropore treatment, capable of expanding. PP (polypropylene) or PS (polystyrene) and / or ABS / SAN already expanded recycled into small particles. These materials come entirely from the recovery of packaging, food containers, defective or unused materials from the construction, including recoveries of bumper interiors or car door panels, etc.

Any other type of polymer or copolymer whose condemnation or fusion or sublimation releases gas (mostly CO2).

Polymers that have been treated to expand, contain in many cases functional groups, which the sublimate release CO ₂ (carbon dioxide), this gas is trapped in small cells, giving vegetable felt with binder or binder thermosetting additional rigidity, but at the same time elasticity since these are tiny cells distributed throughout the volume that are capable of absorbing energy by being able to deform. In addition the level is achieved of rigidity, with noticeably lower piece weight

Vegetable fibers, especially cotton fibers, behave due to their microtube configuration with great sonic and thermal absorption as we have seen before. According to its composition, this felt has no harmful emissions, as opposed to plant felts with phenolic type binders or foam parts mentioned above. It should be emphasized the fact of the non-emission of solid particles as opposed to the emission of microfibers by the felts containing glass fiber or rock wool. The thermosetting binder has the advantage of chemical non-reversibility as opposed to thermoplastic binder felts. This characteristic is very important for, for example, dimensional stability under various climates.

It is also provided that the piece produced with felt has moisture barriers to be added in the same felt production process, or later in the thermoforming. Said barriers may be aluminum or non-woven sheets of polyester, or polyamide polyester, or viscose polyester, or oxidized polyacrylonitrile.

It is worth highlighting the recyclability of the material, since all its composition is totally and easily recyclable.

Preferred embodiment of the invention

In preferred embodiment of the thermocompressible felt comprises the following components: polymer or expandable copolymer 10-30% by weight. - Thermosetting binder or binder: 20-45% by weight.

Fibers (vegetable, artificial or synthetic / optionally mixed with thermoplastics): to complete 100%.

In an alternative embodiment, the felt comprises a surface barrier formed by an aluminum or nonwoven sheet. In an alternative embodiment there is the possibility of adding a flame retardant agent.

Once the nature of the invention has been sufficiently described, as well as an example of a preferred embodiment, it is stated to the appropriate effects that the materials, shape, size and arrangement of the described elements may be modified, as long as this does not involve an alteration of the essential characteristics of the invention that are claimed below.

Claims

1.- Thermocompressible felt, of the type that comprises some vegetable fibers, characterized in that it comprises an expandable polymer or copolymer that in its condensation, fusion or sublimation releases gas, and a thermosetting binder or binder.

2. Felt, according to the preceding claim, characterized in that the vegetable fibers are mixed with thermoplastic fibers.

3. Felt, according to any of the preceding claims, characterized in that it comprises expandable polymer or copolymer of 10% to 30% by weight, thermosetting binder or binder of 20% to 45% by weight, and vegetable or mixed fibers with synthetic or artificial fibers until 100% complete.

4. Felt according to any of the preceding claims, characterized in that the expandable polymer or copolymer facilitates the creation of inner gas microcells.

5. Felt according to any of claims 1 to 3 and claim 4, characterized in that the expandable polymer or copolymer comprises ABS, ABS

SAN with micropore treatment, capable of expanding, polypropylene with micropore treatment capable of expanding, polystyrene with micropore treatment capable of expanding, polypropylene or polystyrene, ABS or ABS / SAN already expanded recycled into small particles and any polymer or copolymer whose sublimation release gas

6. Felt, according to any of the preceding claims, characterized in that it comprises a moisture barrier.

7. Felt, according to any of the preceding claims, characterized in that it includes a flame retardant agent.

8. Felt according to claim 6, characterized in that the moisture barrier is at least one aluminum foil.

9. Felt, according to claim 6, characterized in that the moisture barrier is at least one non-woven sheet of polyester, polyester-polyamide, or viscose polyester or oxidized polyacrylonitrile.