Fibre composite material and method of manufacture

• US 5,948,706 A
• Filed: 11/19/1997
• Issued: 09/07/1999
• Est. Priority Date: 11/19/1996
• Status: Expired due to Fees

• Current Assignee: Deutsches Zentrum Fã¼R Luft- Und Raumfahrt E.V.
• Original Assignee: Deutsches Zentrum Fã¼R Luft- Und Raumfahrt E.V.
• Inventors: Riedel, Ulrich, Chowanietz, Michael
• Primary Examiner(s): ZIRKER, DANIEL R
• Application Number:
  US08/974,127
• Time in Patent Office: 657 Days
• Field of Search: 530/201, 442/59, 442/147, 442/161
• US Class Current: 442/59
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 23/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2317/10 Natural fibres, e.g. wool, cotton
• CPC Class Codes: B32B 38/08 Impregnating
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 9/04 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: C08J 2393/02 Shellac
• CPC Class Codes: C08J 5/045 with vegetable or animal fibrous material
• CPC Class Codes: C08K 3/26 Carbonates; Bicarbonates
• CPC Class Codes: C08K 3/32 Phosphorus-containing compounds
• CPC Class Codes: C08L 93/02 Shellac French polish C09F
• CPC Class Codes: E04C 2/246 combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• 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

The invention relates to a fiber composite with a fibrous material for reinforcement and a matrix material consisting essentially of shellac. The invention also relates to a process for producing a fiber composite with the steps:

dissolving the shellac in a solvent,

impregnating the fibrous material,

heating the impregnated fibrous material and

compressing the impregnated fibrous material and simultaneously curing the matrix material.

The production process is alternatively characterized by the steps:

dissolving the shellac in a solvent,

obtaining a solid by removing the solvent,

pulverizing the solid,

working the pulverized solid into the fibrous material,

heating the fibrous material mixed with the pulverized solid, in the process of which the solid softens and permeates the fibrous material, and

compressing the permeated fibrous material and simultaneously curing the matrix material.

The fiber composite according to the invention is distinguished by the fact that it can be handled well for processing purposes and has good mechanical properties.

Claims

1. A fibre composite including a fibrous material for reinforcement and a matrix material, the matrix material comprising:

a thermoset mixture of shellac.

2. The fibre composite according to claim 1, wherein the thermoset mixture of shellac includes a crosslinking agent.

3. The fibre composite according to claim 2, wherein the crosslinking agent is selected from the group consisting of oxalic acid, urea, aluminum chloride, ammonium zirconium carbonate and ammonium compounds.

4. The fibre composite according to claim 3, wherein the matrix material comprises 90% to 95% shellac and 5 to 10% urea and less than 5% other constituents.

5. The fibre composite according to claim 1, wherein the thermoset mixture of shellac includes a plasticizer.

6. The fibre composite according to claim 5, wherein the plasticizer is selected from the group consisting of citric acid esters, glycerin, oleic acid, sodium stearate, potassium stearate and calcium stearate.

7. The fibre composite according to claim 1, wherein the thermoset mixture of shellac includes a flame retardant.

8. The fibre composite according to claim 7, wherein the flame retardant is selected from the group consisting of ammonium salt, ammonium polyphosphate, magnesium salt, magnesium hydroxide, aluminum salt, aluminum hydroxide, boron salts or mixtures of these components.

9. The fibre composite according to claim 1, wherein the fibres are selected from the group consisting of fleeces, woven fabrics, knitted fabrics or yarns.

10. The fibre composite according to claim 1, wherein the fibres consist of natural fibres.

11. The fibre composite according to claim 10, wherein the natural fibers are selected from the group consisting of ramie, flax, sisal, jute and hemp.

12. Building elements, including a surface coating with the fibre composite according to claim 1.

13. A fibre composite material comprising:

a thermosetting shellac; and

reinforcement fibres.

14. The fibre composite material according to claim 13, further comprising a crosslinking agent.