Composites of polyhydroxy fatty acids and fibrous materials

• US 6,010,870 A
• Filed: 11/03/1998
• Issued: 01/04/2000
• Est. Priority Date: 11/23/1995
• Status: Expired due to Fees

• Current Assignee: HP-Chemie Pelzer Research and Development Ltd.
• Original Assignee: HP-Chemie Pelzer Research and Development Ltd.
• Inventors: Steinbuchel, Alexander, Pelzer, Helmut
• Primary Examiner(s): Nutter, Nathan M.
• Application Number:
  US09/068,893
• Time in Patent Office: 427 Days
• Field of Search: 435/41, 435/132, 435/134, 435/155, 435/170, 523/124, 523/128
• US Class Current: 435/41
• CPC Class Codes: B60R 13/08 Insulating elements, e.g. for sound insulation sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178
• CPC Class Codes: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: B60R 13/0838 for engine compartments
• CPC Class Codes: B60R 13/0861 for covering undersurfaces of vehicles, e.g. wheel houses
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/26 Natural polymers, natural resins or derivatives thereof according to C08L1/00 - C08L5/00, C08L89/00, C08L93/00, C08L97/00 or C08L99/00
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence
• CPC Class Codes: D04H 1/4258 Regenerated cellulose series
• CPC Class Codes: D04H 1/4266 Natural fibres not provided for in group D04H1/425
• CPC Class Codes: D04H 1/4334 Polyamides
• CPC Class Codes: D04H 1/435 Polyesters
• CPC Class Codes: D04H 1/587 characterised by the bonding agents used
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D04H 1/645 Impregnation followed by a solidification process
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials

Abstract

The present invention relates to the use of a composite material made of a fibrous material and binders in the form of a polymer of hydroxyfatty acids for the preparation of molded parts in the automobile field, in particular, for acoustic attenuation in the areas of the hood, bulkhead (on both sides), tunnel, door, roof, footwell, pumps, A to D pillars and air distribution duct, and as an optionally self-supporting base for interior trims, especially for instrument panel covers, tunnel linings, door trims, seat back linings, A to D pillar linings and spare wheel covers, and as parts with a double function, especially as roof liner, rear shelf, filling piece, trunk mat or undershield.

Claims

1. A process for the preparation of a composite material made of a fibrous material and binders in the form of a polymer of hydroxyfatty acids the monomers of which are derived from saturated or unsaturated 3-hydroxyfatty acids having from 4 to 16 carbon atoms in the fatty acid residue, characterized in that microorganisms producing said polymer of hydroxyfatty acids are grown in the presence of fibrous material, wherein said fibrous material serves as a nutrient for the microorganisms, and another carbon source, the microorganisms are harvested along with the fibers, and pressed in a dried or moist condition, optionally using additional fibrous materials, into composite materials.

2. The process according to claim 1, characterized in that microorganisms producing polymers of hydroxyfatty acids are grown in the presence of fibrous material without another carbon source, the microorganisms utilizing part of the fibrous material as a carbon source, the microorganisms are harvested along with the fibers, and pressed in a dried or moist condition, optionally using additional fibrous materials, into composite materials.

3. The process according to claims 1 or 2, characterized in that a PHF-synthetic gene expressing recombinant microorganism is used as said microorganism.

4. The process according to claims 1 or 2, characterized in that said polymer of hydroxyfatty acids is derived from monomers of one or more different hydroxyfatty acids.

5. The process according to claim 4, characterized in that said polymer of hydroxyfatty acids is selected from poly(3-hydroxybutyric acid) (PHB), poly(3-hydroxybutyric acid/3-hydroxyvaleric acid) copolymer (PHB/HV) and poly(3-hydroxydecanoic acid), or mixtures thereof.

6. The process according to claims 1 or 2, characterized in that said composite material contains from 5 to 50% by weight of said polymer of hydroxyfatty acids.

7. The process according to claims 1 or 2, characterized in that said fibrous material is selected from flax, sisal, hemp, wood wool, mechanical wood pulp, wood fibers, coirs, leather, cotton wad, hay, straw, sawdust, wood shavings, pine chips, glumes of grains, seed scraps, oat flakes, cereals, bran, paper strips, cotton scraps, synthetic fibers, such as polybutylene terephthalates, polyethylene terephthalates, nylon 6, nylon 66, nylon 12, viscose and rayon.

8. A composite material connpsing a fibrous material and binders in the form of a polymer of hydroxyfatty acids produced according to claim 1 or 2 for the preparation of molded parts in the automobile field.

9. The composite material of claim 8, wherein said molded parts are adapted for use as acoustic attenuation in the areas of an automobile selected from the group consisting of a hood, a bulkhead (on both sides), a tunnel, a door, a roof, a footwell, pumps, A to D pillars, and air distribution duct.

10. The composite material of claim 8, wherein said molded parts are adapted for use as a base for interior trims of an automobile selected from the group consisting of instrument panel covers, tunnel linings, door trims, seat back linings, A to D pillar linings and spare wheel covers, said base being optionally self-supporting, or as automobile parts selected from the group consisting of roof liners, rear shelves, filling pieces, trunk mats and undershields.

11. The process according to claim 6, charactenzed in that said composite material contains from 10 to 35% by weight of said polymer of hydroxyfatty acids.