FIELD OF INVENTION
The present invention relates to natural fibre based composite material and
particularly to jute based composite materials in which jute fibre is combined with
a synthetic fibre (hereinafter referred to as JUPP board). The composite material
of the present invention is of high tensile strength, recyclable, environment
friendly and can be moulded to any predetermined shape. The present invention
also provides a process for manufacturing such composite materials. The present
invention further relates to product comprising the said natural fibre based
composite material and other synthetic and a process for manufacture of the
same. The composite materials of the present invention have wide applications in
various industries which require,strength along with mouldability and particularly
in automobiles, commercial vehicles as well as in the vehicle component industry.
BACKGROUND OF THE INVENTION
Conventionally, pure jute is used for various finishing applications such as in
automobile and vehicular interiors. The fibre materials, which are popular for such
applications, are manufactured by non-woven preparations from refined jute rolls
involving the steps of carding, inter-locking, needle-punching, etc. However pure
jute felt cannot be moulded satisfactorily and, therefore, requires various bonding
agents to provide a shape to the material. Moreover, jute is a coarse natural fibre
with low tensile strength and pure mechanical properties and is, therefore, not
durable. In addition, jute is also hygroscopic in nature.
Due to such drawbacks, attempts have been made to use synthetic fibres in
place of natural fibres. However, such synthetic fibres lack in tensile strength and
are also not environment friendly.
Composite materials are made mainly by compounding non-woven felt with resin
penetration in required amounts and subsequently moulding of the same to
predetermined shape. Decorative coverings are also added by lamination.
However, such known synthetic fibres do not exhibit the amount of tensile
strength required for most applications. Moreover, the processes for
manufacturing such composite materials involve large number of process steps.
Such materials are also not recyclable posing a threat to the environment after
they are disposed. There is also presence of styrene vapour smell, which is not desirable to the end user.
OBJECT OF THE INVENTION
Therefore the primary object of the present invention is to provide a composite material, which has good
mechanical properties and is mouldable.
Another object of the present invention is to provide a composite material, which is recyclable and hence
environmental friendly.
Another object of the present invention is to provide a composite material, which is lightweight and has
high energy-absorption capacity.
A further object of the present invention is to provide a process for manufacturing a composite material
which involves less number of process steps and hence requires less time to manufacture, which is cost
efficient and results in a strong and durable product.
The applicants have now surprisingly found that when a natural fibre like jute is compounded with a
synthetic fibre such as polypropylene (hereinafter referred to as ""PP") in predetermined amounts, it
results in a composite material, which has superior mechanical properties than either of the individual
constituents.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a fibre based composite materials
comprising a selective natural fibre like jute and synthetic fibre like polypropylene wherein the jute fibre
and polypropylene is in the ratio ranging from 2:3 to 3:2.
According to another aspect of the present invention there is provided a layered product comprising fibre
based composite material formed of jute and PP in defined ratio and selective synthetic materials.
According to another aspect of the present invention there is provided a process for manufacture of a
composite material comprising combining the selective natural fibre and the synthetic fibre in the
proportion of 2:3 to 3:2, preferably 1:1, blending them homogeneously and heating to a predetermined
temperature and cooling the same.
A process for manufacture of the product comprising of combing jute with polypropylene in the ratio of
ranging from 2:3 to 3 : 2, preferably 1:1, homogenous blending of the fibres with interlocking, heating
the blend to 50°C, cooling the same followed by needle punching of single or multiple layers of synthetic
material like polypropylene, polyester to form the composite material.
DETAILED DESCRIPTION OF THE INVENTION
The said composite material of present invention has the natural fibre, jute and the synthetic
fibre, PP in the ratio of 2:3 or 3:2, preferably 1:1.
The said material has a reasonable degree of strength, which is substantially higher than either
of jute or synthetic materials.
It can withstand wear and tear, which such a material would be subject to when used for making
car and vehicle interiors. The composite materials can be moulded to any predetermined shape.
The composite material contains the natural and synthetic fibre in any desired ratio depending
on the desired end properties. Preferably, the said ratio of natural and synthetic fibre is 1:1.
The composite material of present invention can be moulded to achieve materials of desired
thickness and density based on the end use. A composite material of the present invention with
the ratio of jute and polypropylene in the ration of 1:1 has a thickness of 1.5 to 2.5 mm and a
density of 1.1 to 1.4 gm/cm^.
The composite materials of the present invention comprises of a compounded combination of
jute and PP. Further variations with single layer of the said composite material in combination
with layers of other materials are possible. For example, multiple layer end products wherein, a
layer of the said composite of jute and PP along with another layer of composite material
comprising of polyester and PP are workable. In another aspect, a middle layer of said
composite of jute and PP is sandwiched between two outer layers of another
composite such as comprising polyester and PP are also workable. Other
variations of the composite materials of the present invention are also possible.
Due to the presence of a natural fibre, the composite material is environment
friendly and is recyclable. It has good formability, is lightweight, has exceptional
fracture characteristics and has high-energy absorption capacity.
The process of the present invention comprises essentially of combining
predetermined amounts of the natural fibre and the synthetic fibre. The fibres
may be initially prepared and then blended homogeneously and heated at a
predetermined temperature. The fibres are initially prepared by cutting the jute
fibres and cleaning it. The polypropylene fibre is opened in the blow room. The
fibres are then carded. After the pre-treatment, the fibres undergo proper and
homogenous blending with interlocking. The blend is then heated to a
temperature of 50°C and then allowed to cool.
DESCRIPTION OF PREFERRED EMBODIMENT
The preferred embodiments of the present invention is illustrated with reference
to accompanying figures wherein
Figure 1 illustrates a single layer composite material of the present invention.
Figure 2 illustrates a multi-layer composite material of the present invention.
Figure 1 illustrates the single layer variety of the composite material. The material
has a single layer (1) comprising PP and jute in the weight ratio of 1:1.
Figure 2 illustrates the multi-layer variation of the end product from the composite
material of the present invention. The multi-layered or sandwich construction
comprises three layers of materials. The middle layer (2) is formed of the
composite material of present invention as illustrated in figure 1 which is
sandwiched between two layers of synthetic felt (3) comprising of 30% wt
polyester and 70% wt PP composite material.
The invention will now be demonstrated with reference to non-limiting illustrative
examples.
EXAMPLES
PROCESS FOR MANUFACTURING OF COMPOSITE MATERIALS (JUPP
BOARD FELTS)
A. Manufacture of Homogeneous felts
The jute and PP fibres in proportion of 1:1 are prepared by cutting and cleaning
the jute fibres. The polypropylene fibre is opened in blow room. The fibres are
then carded. Jute cutting and PP fibre bales are fed to the Bale Opener in 1:1
proportion, with predetermined metered application of emulsion which is within
the range of 1 to 1.5% of the total weight of the fibre. Here the blending with
interlocking takes place and the emulsion-applied material is pneumatically
transported to Maturing Chambers. The blend is heated to a temperature of 50°C
and then allowed to cool to room temperature. The homogeneous material is
allowed to mature for 24 to 36 hours, which makes it processable. The material is
then fed to 3-drum Willow where further opening and mixing of fibre takes place
in 3 stages, before being conveyed to Gravimetric Feeder. This feeder is adjusted
to allow metered quantity of material fed to the carding system at regular
intervals. The carded fleece is then transported to the Cross Lapper, where a
multilayered bath is produced and is quite voluminous. This voluminous bath is
then fed to Needle Looms through Compressive Ball Feeder. The fibres of the
bath are interlocked which takes place due to barbs in the fitting needles.
Punching is made from both and bottom to ensure uniform interlock across the
cross section of felt. The felt thus produced is then finished by passing it through
calendars and thereafter through edge trimmer, where the edges are cut to
ensure correct width of felt. The trimmed felt is then wound to roll in the winder.
The roll of desired length is then dotted from the winder.
B. Manufacture of sandwich felts
Here the entire process and concept is the same, except that the synthetic felt is
separately processed with purely synthetic fibre. Two layers, top and bottom, of
synthetic felt with PP and jute homogeneous felt in the middle is needle-punched
again to obtain a composite sandwich matrix. The same is then calendared and
edge-trimmed before being wound to roll form in the winder.
SPECIFICATION OF THE MOULDED JUPP BOARD
The moulded JUPP board of the present invention made with jute fibres and PP
in the ratio of 1:1 has typically the following characteristics as detailed "hereto in
the accompanying Table 1 to 3.
Table 1 illustrates a few properties of the composite material of the present
invention with jute and polypropylene in the ratio of 1:1 along with the
corresponding properties of its constituents, jute and polypropylene.
TABLE 1: COMPARISON OF A FEW PROPERTIES OF THE COMPOSITE
MATERIAL OF THE PRESENT INVENTION (JUPP BOARD) WITH ITS
CONSTITUENTS
Table 1 thus illustrates the superiority of the- composite material of the present
invention as compared to either of its constituents, jute and polypropylene, in
terms of its tensile strength or its capacity for elongation.
Table 2 illustrates the specification of composite material of the present invention
with jute and polypropylene in the ratio of 1:1.
Table 2 illustrates the water absorption capacity of the composite material of the
present invention which is typically low making it suitable for vehicle interior
finishings. The composite material of the present invention also has a low smell
unlike its constituent, PP, which is known to smell of styrene. The composite
material of the present invention is also mouldable making it suitable for moulding
to any predetermined shape. The flammability of the composite material of the
present invention is also very low (< 80 mm/min) making its very safe for
finishings of vehicular interiors.
Test results of the moulded JUPP board of the present invention show better
performance of the composite material as compared to conventionally used hard
board and synthetic material (PP injection moulded) as illustrated in
accompanying Table 3.
TABLE 3: COMPARISON OF A FEW PARAMETERS OF THE COMPOSITE
MATERIAL OF THE PRESENT INVENTION (JUPP BOARD) WITH
CONVENTIONALLY USED MATERIALS
Table 3 illustrates the thermal conductivity and sound adsorption of the
composite material of the present invention which is lower than other
conventionally used material making it suitable for finishings of vehicular interiors.
In addition the bending strength of the composite material of the present
invention is also higher than the conventional materials.
WE CLAIM:
1. A fibre based composite material comprising a selective natural fibre like jute
and synthetic fibre like polypropylene wherein the jute fibre and polypropylene is
in the ratio ranging from 2:3 to 3:2.
2. A composite material of claim Iwherein the jute fibre and polypropylene are
preferably in the ratio of 1:1.
3. A composite material of claim 1 wherein the said composite material has tensile
strength of from 29 -to 31 kg/cm^.
4. A composite material of claim 1 wherein the said composite material has
elongation of from 240 to 270 mm.
5. A process for manufacture of a composite material as claimed in claim 1
comprising combining the selective natural fibre and the synthetic fibre in the
proportion of from 2:3 to 3:2, preferably 1:1, blending them homogenously and
heating to a predetermined temperature and cooling the same.
6. A process for manufacture of a composite material as claimed in claim
Scomprising combining a natural fibre jute and synthetic fibre polypropylene,
homogeneous blending of the fibres with interlocking and heating the blend to
predetermined temperature and cooling the same.
7. A process for manufacture of a composite material as claimed in claims 5 to 6
wherein the blend is heated to 50°C.
8. A layered product comprising fibre based composite material comprising jute
and polypropylene in defined ratio and selective synthetic materials.
9. A product as claimed in claim 9 wherein the other synthetic materials are
selected from polypropylene, polyester.
10. A product as claimed in claims 8 to 9 wherein the composite material of present
invention is present in single or multiple layers with layer(s) of polypropylene,
polyester.
11. A process for manufacture of the product as claimed in claims 8to 10
comprising of combining jute with polypropylene in the ratio of ranging from 2:3
to 3:2, preferably 1:1, homogenous blending of the fibres with interlocking,
heating the blend to 50°C, cooling the same followed by needle punching of
single or multiple layers of synthetic material like polypropylene, polyester to
form the composite material.
12. A fibre based composite material substantially as described herein with
reference to examples and drawings.
13. A process for manufacture of fibre based composite material substantially as
described herein with reference to examples.
14. A layered product comprising the composite material substantially as described
herein with reference to examples and drawings.
15. A process for manufacture of the product comprising the composite material
substantially as described herein with reference to examples and drawings.

The present invention discloses a fibre based composite material comprising a
selective natural fibre like jute and synthetic fibre like polypropylene wherein the
jute fibre and polypropylene is in the ratio ranging from 2:3 to 3:2, preferably 1:1,
and process for manufacturing the same involving combining predetermined
amounts of the constituents followed by heating. The composite material of the
present invention can also be present as a single layer along with other layers of
composite material comprising of single or multiple layers of polypropylene and
polyester and the like. The composite material of the present invention has
superior mechanical properties or strength than the individual constituents and
can withstand wear and tear. It has good formability, is lightweight, and has
exceptional fracture characteristics and high-energy absorption capacity. It is
recyclable and is, hence, environment friendly. There is no smell of styrene
making it more desirable for end users. The material of the present invention may
be used in finishing materials in automobile and vehicular interiors.