Fibre mat, moulded piece produced therefrom and method for production thereof

• US 20040266292A1
• Filed: 08/20/2004
• Published: 12/30/2004
• Est. Priority Date: 10/17/2001
• Status: Abandoned Application

• Current Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Original Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Inventors: Engel, Ansgar, Gassan, Jochen
• Application Number:
  US10/492,579
• Publication Number:
  US 20040266292A1
• Time in Patent Office: Days
• US Class Current: 442/59
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: B27N 3/007 and at least partly composed of recycled material
• CPC Class Codes: B27N 3/12 from fibres
• CPC Class Codes: B27N 3/18 Auxiliary operations, e.g. preheating, humidifying, cutting-off
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer

Abstract

A fibre mat as intermediate in the production of moulded pieces with preferably the same wall thickness is disclosed, comprising fibres made overwhelmingly of cellulose which are pressed together with a plastic in a homogeneous mixture. The plastic is in the form of fire with a length in the range of 30-100 mm and the cellulose fibres have a length of 10-100 mm. The cellulose fibres preferably comprise natural fibres, formed from, flax, sisal, hemp, kenaf, technical viscose fibres or mixtures thereof, or from regenerated cellulose, particularly synthetic cellulose obtained from wood.

Claims

1. A fiber mat for use as an intermediate product in the production of moulded pieces of substantially the same wall thickness, comprising:

fibers, which are compressed with plastic material in a homogeneous mixture and comprise predominantly cellulose fibers, wherein the plastic material is in the form of fibers with a length in the range of about 30-100 mm and the cellulose fibers have a length of about 10-100 mm.

2. The fiber mat according to claim 1, wherein the cellulose fibers comprise natural fibers of hemp, flax, sisal, kenaf, technical viscose fibers or mixtures thereof.

3. The fiber mat according to claim 1, wherein the cellulose fibers comprise regenerated cellulose fibers.

4. The fiber mat according to claim 1, wherein the cellulose fibers have a length in the range of about 50-100 mm.

5. The fiber mat according to claim 4, wherein an average length of the cellulose fibers is about 70 mm+/−

20%.

6. The fiber mat according to claim 1, wherein a proportion of cellulose fibers in a total weight of the fiber mat is between about 10 and 90%.

7. The fiber mat according to claim 1, wherein the cellulose fibers are pre-treated chemically, thermally or chemico-physically.

8. The fiber mat according to claim 1, wherein the plastic material fibers comprise polypropylene.

9. The fiber mat according to claim 1, wherein the plastic material fibers have a fineness of 3.3-25 dtex and any cross-sectional shape.

10. The fiber mat according to claim 1, wherein the mat is bonded by needling the fibers.

11. The fiber mat according to claim 1, further comprising hydrophobing agents, softeners, flameproofing agents and/or adhesives.

12. The fiber mat according to claim 1, further comprising a needled fiber top layer on at least one side of the mat that is made of polypropylene/polyester with a basis weight up to about 300 g/m².

13. A moulded piece produced from a fiber mat, the fiber mat comprising:

fibers, which are compressed with plastic material in a homogeneous mixture and comprise predominantly cellulose fibers, wherein the plastic material is in the form of fibers with a length in the range of about 30-100 mm, the cellulose fibers have a length of about 10-100 mm, and said moulded piece contains uniformly distributed natural fibers with a length in a range of about 10-100 mm in a homogeneous plastic material layer.

14. The moulded piece according to claim 13, wherein the piece has a density of approximately 0.9 g/cm³.

15. The moulded piece according to claim 13, wherein the piece has a water absorption in the range of about 4-6% by weight.

16. The moulded piece according to claim 13, further comprising a decorative layer bonded directly to the compressed fiber mat.

21. The moulded piece according to claim 13, wherein the cellulose fibers comprise natural fibers of hemp, flax, sisal, kenaf, technical viscose fibers or mixtures thereof.

22. The moulded piece according to claim 13, wherein the cellulose fibers comprise regenerated cellulose fibers.

23. The moulded piece according to claim 13, wherein the cellulose fibers have a length in the range of about 50-100 mm.

24. The moulded piece according to claim 23, wherein an average length of the cellulose fibers is about 70 mm+/−

20%.

25. The moulded piece according to claim 13, wherein a proportion of cellulose fibers in a total weight of the fiber mat is between about 10 and 90%.

26. The moulded piece according to claim 13, wherein the cellulose fibers are pre-treated chemically, thermally or chemico-physically.

27. The moulded piece according to claim 13, wherein the plastic material fibers comprise polypropylene.

28. The moulded piece according to claim 13, wherein the plastic material fibers have a fineness of 3.3-25 dtex and any cross-sectional shape.

29. The moulded piece according to claim 13, wherein the mat is bonded by needling the fibers.

30. The moulded piece according to claim 13, further comprising hydrophobing agents, softeners, flameproofing agents and/or adhesives.

31. The moulded piece according to claim 13, further comprising a needled fiber top layer on at least one side of the mat that is made of polypropylene/polyester with a basis weight up to about 300 g/m².

17. A method of producing a moulded piece, comprising:

forming a fiber mat comprising fibers, which are compressed with plastic material in a homogeneous mixture and comprise predominantly cellulose fibers wherein the plastic material is in the form of fibers with a length in the range of about 30-100 mm and the cellulose fibers have a length of about 10-100 mm.; and

heating the fiber mat before compressing to a temperature of approximately 180-200 degrees Celsius.

18. The method according to claim 17, wherein a pre-compression is implemented during heating.

19. The method according to claim 17, wherein at the same time as compression of the fiber mat, a decorative layer is applied onto the mat using a one-shot method.

20. The method according to claim 17, wherein a form tool has a temperature of less than about 80 degrees Celsius during compression.