Canadian Patents Database / Patent 2407880 Summary

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(12) Patent: (11) CA 2407880
(54) English Title: PROCESS TO MANUFACTURE HIGH IMPACT NATURAL COMPOSITES
(54) French Title: METHODE DE FABRICATION DE COMPOSITES A HAUTE RESISTANCE AU CHOC CONTENANT DES FIBRES NATURELLES
(51) International Patent Classification (IPC):
  • C08J 5/04 (2006.01)
  • B29C 43/00 (2006.01)
  • C08F 255/02 (2006.01)
  • C08L 23/04 (2006.01)
  • C08L 23/10 (2006.01)
  • C08L 23/12 (2006.01)
  • C08L 29/04 (2006.01)
  • C08L 31/04 (2006.01)
  • C08L 51/06 (2006.01)
  • C08L 97/02 (2006.01)
  • C08L 1/00 (2006.01)
(72) Inventors (Country):
  • SAIN, MOHINI M. (Canada)
  • MUHAMMAD, PERVAIZ (Canada)
(73) Owners (Country):
  • SAIN, MOHINI M. (Canada)
  • MUHAMMAD, PERVAIZ (Canada)
(71) Applicants (Country):
  • SAIN, MOHINI M. (Canada)
  • MUHAMMAD, PERVAIZ (Canada)
(74) Agent: NA
(45) Issued: 2011-02-01
(22) Filed Date: 2002-10-26
(41) Open to Public Inspection: 2004-04-26
Examination requested: 2003-06-10
(30) Availability of licence: N/A
(30) Language of filing: English

English Abstract

The use of natural fibers as reinforcing filler in thermoplastics is a relatively new innovation and has great potential to replace glass fiber products in building, consumer goods, furniture and automotive industry. Our published results demonstrated that laying natural fiber mat and polymer film in a definite pattern and orientation can enhance mechanical strength. In this invention, a unique process has been developed to manufacture high impact strength composite that contains loose natural fiber and/or a combination of loose natural fiber and natural fiber mat to develop green composites outstanding impact strength and other mechanical properties. Loose fibers used in this process can be obtained from agro-plant and wood. Mats, if used, can be obtained from similar sources. Polymer those are used include thermoplastic polyolefins (TPOs), acrylic and polyester films. This invention is especially useful for natural composites with natural fiber content above 40% by weight up to 93 wt% fiber. Film stacking and fiber spraying methods were used to construct sheet, laminates and thermoforming and compression molding were used to design a product. A range of impact strength was obtained which varies from 100 J/m to as high as 250 J/m with a significant increase in flexural and tensile strengths. Products having uniform density profiles yield maximum enhancement in impact properties.


French Abstract

L'emploi de fibres naturelles comme charge de renfort dans les thermoplastiques est une innovation assez récente et présente de grandes possibilités pour remplacer les produits en fibres de verre dans les industries de la construction, des biens à la consommation, du meuble et de l'automobile. Les résultats que nous avons publiés montrent que la pose d'un mat de fibres naturelles et d'un film de polymère selon une orientation et un motif définis peut accroître la résistance mécanique. Dans la présente invention, un procédé unique a été mis au point pour la fabrication d'un composite à haute résistance au choc contenant des fibres naturelles lâches et/ou une combinaison de fibres naturelles lâches et d'un mat de fibres naturelles pour l'élaboration de composites verts ayant de remarquables propriétés mécaniques et de résistance au choc. Les fibres lâches utilisées dans ce procédé peuvent provenir du bois et de végétaux agricoles. S'ils sont employés, les mats peuvent provenir de sources analogues. Les polymères utilisés comprennent des films de polyester, d'acrylique et de polyoléfines thermoplastiques. La présente invention est particulièrement utile pour des composites naturels contenant plus de 40 % par poids de fibres naturelles et jusqu'à 93 % par poids de fibres. Des méthodes de projection de fibres et d'empilage de films ont été employées pour la fabrication de feuils, de stratifiés et le thermoformage et le moulage par compression ont été employés pour la conception d'un produit. On a réalisé une plage de résistance au choc comprise entre 100 J/m et 250 J/m avec accroissement significatif des résistances à la flexion et à la traction. Les produits ayant des profils de densité uniformes présentent les propriétés maximales de résistance au choc.


Note: Claims are shown in the official language in which they were submitted.


Claims

1. A manufacturing process to produce thermoplastic composite in which
reinforcement fibers in the form of loose bundle layers are stacked
alternately
with thermoplastic matrix, whereby each layer of loose fiber is covered by at
least
one film or foil of matrix material on each side, thereafter hot pressing the
alternate film stack/lay-up at high temperature followed by cooling under same
consolidation pressure to manufacture desired composite material,
characterized
in that the loose, random, and un-processed fibers are used and distributed
evenly
in the said film stacking arrangement where each layer of fiber and matrix
material has equal pre-defined quantity by weight.
2. A process according to claim 1, characterized in that fiber mats can be
used in
similar lay-up method.
3. A process according to claim 1, characterized in that interfacial bonding
between
cellulose fibers and matrix is introduced by using pre-treated matrix films
with
maleic-anhydride polymers of polypropylene (MA-PP) or polyethylene (MA-PE).



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4. A process according to claim 1 and 2, characterized in that reinforcement
fibers
fall in one of following categories:
a. Cellulose bast fibers obtained from plants of hemp, flax, kenaf, sisal and
jute.
b. Agri-residue fibers, such as rice husk and wheat straw.
c. Virgin or recycled wood fibers.
5. A process according to claim 1 to 3, characterized in that matrix selected
is from
thermoplastic family of polymers consisting either of homo polypropylene (PP)
or
co-polymers of polypropylene and polyethylene.
6. The thermoplastic polymer manufactured through the said inventive process
consists essentially the following:
1. Alternate stacked layers of loose ligno-cellulose fibers and/or mats in
combination with thermoplastic matrix films distributed evenly in stacked
lay-up.
2. The matrix films may or may not be treated with coupling agent.
7. The manufacturing process of compression molding consists following steps:
1. Film stacking of fiber layers and matrix films in alternate arrangement in
such a way that each layer of natural fibers is covered on both sides by at
least one film of matrix.
2. Hot pressing of film stack at elevated temperature and pressure followed
by cooling under same consolidation to manufacture desired thermoplastic
composite.
8. Thermoforming process can be also used to make three dimensional/intricate
products by using same raw materials as mentioned in claim 4 and 5.
9. In the product of claim 6, the reinforcement material belongs to any of
plant
fibers, agri-residuals or virgin/recycled wood fibers as mentioned in claim 4.



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10. The matrix in the product of claim 6 is essentially of thermoplastic
family as
mentioned in claim 5.
11. The coupling agents in the product of claim 6 can be either impregnated
into
thermoplastic films or cellulose fibers as mentioned below:
a. The matrix is treated with maleic-anhydrie co-polymers of polypropylene
or polyethylene.
b. Reinforcement fibers can be treated with Silane solutions through quick
aqous method if required.
12. The commercial use of said product according to any claims 6 to 10 in auto
sector, general purpose household, upholstery and semi-structural construction
applications as mentioned in potential application section.


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A single figure which represents the drawing illustrating the invention.

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Admin Status

Title Date
(22) Filed 2002-10-26
Examination Requested 2003-06-10
(41) Open to Public Inspection 2004-04-26
(45) Issued 2011-02-01
Lapsed 2015-10-26

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Filing $150.00 2002-10-26
Request for Examination $200.00 2003-06-10
Maintenance Fee - Application - New Act 2 2004-10-26 $50.00 2004-08-04
Maintenance Fee - Application - New Act 3 2005-10-26 $50.00 2005-08-22
Maintenance Fee - Application - New Act 4 2006-10-26 $50.00 2006-09-29
Maintenance Fee - Application - New Act 5 2007-10-26 $100.00 2007-08-14
Maintenance Fee - Application - New Act 6 2008-10-27 $100.00 2008-09-05
Maintenance Fee - Application - New Act 7 2009-10-26 $100.00 2009-09-01
Maintenance Fee - Application - New Act 8 2010-10-26 $100.00 2010-09-03
Final $150.00 2010-11-22
Maintenance Fee - Patent - New Act 9 2011-10-26 $100.00 2011-08-17
Maintenance Fee - Patent - New Act 10 2012-10-26 $125.00 2012-09-25
Maintenance Fee - Patent - New Act 11 2013-10-28 $125.00 2013-08-12

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Claims 2009-04-20 2 56
Abstract 2002-10-26 1 38
Description 2002-10-26 3 114
Claims 2002-10-26 3 112
Drawings 2002-10-26 2 42
Drawings 2003-06-10 7 202
Claims 2003-06-10 3 104
Description 2003-06-10 12 549
Representative Drawing 2004-03-31 1 17
Cover Page 2004-03-31 2 61
Abstract 2007-12-04 1 37
Description 2007-12-04 12 527
Claims 2007-12-04 2 59
Drawings 2007-12-04 8 617
Abstract 2008-11-14 1 36
Description 2008-11-14 12 519
Claims 2008-11-14 2 56
Drawings 2008-11-14 8 701
Abstract 2009-09-29 1 35
Drawings 2010-03-25 3 190
Claims 2010-03-25 2 57
Description 2010-03-25 14 919
Abstract 2010-03-25 1 36
Representative Drawing 2011-01-11 1 16
Cover Page 2011-01-11 1 61
Fees 2006-09-29 1 19
Prosecution-Amendment 2009-01-30 1 33
Fees 2006-08-21 2 95
Fees 2004-08-04 1 60
Correspondence 2002-12-03 1 14
Prosecution-Amendment 2003-06-10 22 825
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Correspondence 2006-01-03 1 13
Correspondence 2005-10-17 1 21
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Correspondence 2006-09-06 1 22
Fees 2006-08-21 3 141
Correspondence 2006-11-02 1 16
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Correspondence 2007-01-04 1 14
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Prosecution-Amendment 2007-12-04 25 1,318
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