NATURAL FIBRE AND METHOD OF PRODUCTION AND USE IN MODULAR CONSTRUCTION

• US 20150175763A1
• Filed: 05/29/2013
• Published: 06/25/2015
• Est. Priority Date: 05/30/2012
• Status: Abandoned Application

• Current Assignee: Sunkeeper Limited
• Original Assignee: Sunkeeper Limited
• Inventors: Kinmount, John, Binns, David
• Application Number:
  US14/404,605
• Publication Number:
  US 20150175763A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29B 13/02 by heating B29B13/06, B29B13/08 take precedence
• CPC Class Codes: B29B 13/06 by drying B29B13/08 takes precedence ; drying moulded articles or half products B29C37/0092
• CPC Class Codes: B29B 13/10 by grinding, e.g. by triturating; by sieving; by filtering
• CPC Class Codes: B29B 7/10 rotary
• CPC Class Codes: B29B 7/24 for feeding
• CPC Class Codes: B29B 7/286 measuring properties of the mixture, e.g. temperature, density B29B7/283 takes precedence
• CPC Class Codes: B29B 7/82 Heating or cooling
• CPC Class Codes: B29B 7/905 with means for pretreatment of the charges or fibres
• CPC Class Codes: B29B 9/06 in the form of filamentary material, e.g. combined with extrusion
• CPC Class Codes: B29B 9/14 fibre-reinforced
• CPC Class Codes: B29B 9/16 Auxiliary treatment of granules
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 70/12 using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2025/08 Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/04 : cellular or porous
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29K 2311/10 : Natural fibres, e.g. wool or cotton
• CPC Class Codes: B29K 2511/10 : Natural fibres, e.g. wool or cotton
• CPC Class Codes: C08J 2201/03 : Extrusion of the foamable blend
• CPC Class Codes: C08J 2203/04 : N2 releasing, ex azodicarbonamide or nitroso compound
• CPC Class Codes: C08J 2323/06 : Polyethene
• CPC Class Codes: C08J 2397/00 : Characterised by the use of lignin-containing materials
• CPC Class Codes: C08J 2397/02 : Lignocellulosic material, e.g. wood, straw or bagasse
• CPC Class Codes: C08J 2423/06 : Polyethene
• CPC Class Codes: C08J 5/045 : with vegetable or animal fibrous material
• CPC Class Codes: C08J 5/06 : using pretreated fibrous materials
• CPC Class Codes: C08J 5/10 : characterised by the additives used in the polymer mixture
• CPC Class Codes: C08J 9/0061 : characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/0085 : Use of fibrous compounding ingredients C08J9/0076 takes precedence
• CPC Class Codes: C08J 9/103 : Azodicarbonamide
• CPC Class Codes: C08L 23/12 : Polypropene
• CPC Class Codes: C08L 23/18 : Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
• CPC Class Codes: C08L 97/02 : Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E04B 1/34315 : characterised by separable parts
• CPC Class Codes: E04B 1/5831 : of substantially rectangular form
• CPC Class Codes: E04B 2001/5881 : using an undercut groove, e.g. dovetail groove
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20

Abstract

The present invention provides a method of producing reinforced composite containing fibre in a polymer matrix comprising the steps of: a. heating and drying a natural fibre-containing material in a hot blending chamber; b. sieving the dried natural fibre-containing material to produce a loose, soft and clean natural fibre free of contaminants and unwanted elements; c. shredding the fibre; d. pre-heating the shredded fibre; e. blending polymer, a nitrogen blowing agent a lubricant with the shredded fibre and optionally a coupling agent; and f. heating the blended mixture to the melting point of the polymer. Also provided is a composite produced by the method and a composite comprising a natural fibre-containing material, a polymer, a nitrogen blowing agent, a lubricant and optionally a coupling agent. Various modular constructions and a weighing assembly made from the composite are also provided.

Claims

1. A method of producing reinforced composite containing fibre in a polymer matrix comprising the steps of:

a. heating and drying a natural fibre-containing material in a hot blending chamber;

b. sieving the dried natural fibre-containing material to produce a loose, soft and clean natural fibre free of contaminants and unwanted elements;

c. shredding the fibre;

d. pre-heating the shredded fibre;

e. blending polymer, a nitrogen blowing agent and a lubricant with the shredded fibre; and

f. heating the blended mixture to the melting point of the polymer.

2. A method according to claim 1, wherein a coupling agent is also added at step e.

3. A method according to claim 1, wherein the natural fibre containing material comprises rice husk fibre.

5. A method according to claim 1, wherein the nitrogen blowing agent is azodicarbonamide.

6. A method according to claim 1, wherein the blending step is carried out at a specific gravity at or below 1.1.

7. A method according to claim 1, further comprising the step of cooling the blended mixture to provide a dry blend.

8. A method according to claim 7, further comprising the step of subjecting the dry blend to an extrusion process to produce pellets.

9. A method according to claim 8, wherein the extrusion process includes the step of heating the dry blend to a melting point of a selected thermosetting resin of said polymer during the extrusion process.

10. A method according to claim 1 wherein the rice husk material is heated in a hot blending chamber to about 110°

C.

11. A method according to claim 1, wherein the shredding is activated at about 100°

C.

12. A method according to claim 1, wherein the shredding produces a substantially short and soft fibre lignin.

13. A method according to claim 1, wherein the fibre is pre-heated in the blending means to around 100°

C.

14. A method according to claim 13, wherein the mixture is heated to between around 140°

C. and 190°

C. during the extrusion process.

15. A method according to claim 1, wherein the polymer includes chain and/or network polymer.

16. A method according to claim 15, wherein the chain polymer includes thermoplastic material.

17. A method according to claim 15, wherein the network polymer includes thermosetting resin.

18. A method according to claim 1, wherein the lubricant comprises wax, fatty acid alcohol, stearate or a combination thereof.

4. (canceled)

19. (canceled)

20. A composite comprising a natural fibre containing material, a polymer, a nitrogen blowing agent, a lubricant and optionally a coupling agent.

21. A composite according to claim 20, wherein the natural fibre comprises rice husk.

22. A composite according to claim 21, wherein the natural fibre consists of rice husk.

23. A composite according to claim 20, wherein the polymer comprises high density polypropylene and/or methyl butadiene styrene.

24. A composite according to claim 20, wherein the nitrogen blowing agent comprises azodicarbonamide.

25. A composite according to claim 20, wherein the coupling agent comprises glycidyl methacrylate.

26. A modular construction member suitable for use in a modular construction system, wherein the modular construction member is constructed using the composite of claim 20.

27. A modular construction member according to claim 26 wherein the modular construction member is a connector member for use in a modular construction system.

28. A modular construction member according to claim 26 wherein the modular construction member is a panel or beam suitable for use in a modular construction system.

29. A modular construction member according to claim 26 wherein the modular construction member weighs less than 25 kg.

30. A modular construction formed using one or more panels and/or beams as claimed in claim 28.

31. A modular construction according to claim 30 further comprising one or more connectors according to claim 27.

32. A modular construction according to claim 30 or 31 wherein the panels and/or beams and/or connector members are joined by slotting adjacent parts together.

33. A modular construction according to claim 30 wherein the modular construction is an emergency housing shelter or as low cost housing.

34. A modular construction according to claim 30 wherein the modular construction is a temporary construction.

35. A modular construction according to claim 30 wherein the panels and/or beams and/or connector members are configured within the construction when assembled so that the construction can be easily extended if required.

36. A modular construction according to claim 30 wherein the modular construction is fire-resistant.

47. A modular assembly according to claim 37 wherein the first and second plate members are formed from the composite of claim 20.

37. A modular assembly comprising:

first and second plate members; and

means for providing a channel between at least part of one plate and said other plate wherein said first plate member has a base plate and at least one retaining means for retaining said second plate member on said first plate.

38. A modular assembly according to claim 37 further comprising at least one sensor member inserted in said channel means and held between said first and second plates.

39. A modular assembly according to claim 37 wherein said means for providing a channel is an at least one channel member within said base plate.

40. A modular assembly according to claim 38 wherein said sensor member is a sensor suitable for measuring the weight of an article placed on the second plate of the modular construction.

41. A modular assembly according to claim 37 wherein said second plate has substantially identical front and rear faces, and can be held by said retaining means with either face facing the base plate of said first plate member.

42. A modular assembly according to claim 39 wherein said base plate is substantially rectangular and said at least one channel member extends along substantially the length of said base plate

43. A modular assembly according to claim 41 further comprising at one or more substantially parallel channel members.

44. A modular assembly according to claim 37 wherein said at least one retaining means comprises at least one arm extending substantially vertically upwardly from an outer edge of said base plate, and a lip extending substantially horizontally inwardly from said arm parallel to said base plate.

45. A modular assembly according to claim 44 wherein said base plate is substantially rectangular, and said retaining means are provided along at least some of both long edges of said base plate.

46. A modular assembly according to claim 45 wherein said retaining means extend along substantially all of the long edges of said base plate.

48-49. -49. (canceled)