"COMPOSITE MATERIAL AND ITS USE"

The present invention relates to a composite material formed of basalt fiber and agglomerated cork, resin, preferably green, their method of production and use.

Prior Art

CoreCork is one of the "state of the art" materials which features are closest related to the material found in the nucleus of cork in the presented invention. This product is initially extracted from the cork oak, is then generally used in the production of stoppers giving rise to waste which then are crushed and used in the production of agglomerates, among others. We can thus say that it is a natural product (100% ecologic) .

One of the resins that can be used is the commonly known as "eco green resin" which is considered environmentally friendly. The basalt fiber may be any tissue from any weave, weight and strength and is considered 100% natural.

Summary

The aim of the present invention is to provide a composite material comprising the following elements:

a. Cork or agglomerated cork presenting small cells with air and cork;

b. Resin;

c. Basalt fiber. In a preferred embodiment of the invention, the composite material adds to the initial formulation other materials in the form of additional layers.

In another preferred embodiment of the invention, the composite uses resin of natural source or ecologic.

In another preferred embodiment of the invention, the composite material uses a junction made of basalt fiber layers .

In yet another preferred embodiment of the invention, the composite material uses basalt fiber is prepared by treatment of basaltic rock, comprising plagioclase mineral, olivine and pyroxene .

In a preferred embodiment of the invention, the composite material uses cork agglomerate which shows small cells with air and cork.

In another preferred embodiment of the invention, the composite material uses basalt fiber resistant to ultraviolet light.

It is also a further object of this invention to describe the process for obtention of the composite material by applying vacuum to the composite wrapping it with a plastic film bag hermetically closed (Vacuum bagging) or injection of resin into two closed molds by vacuum assisted (RTM) or vacuum infusion involving the composite airtight plastic film (Scrimp / VARTM) or by pressing.

In a preferred embodiment, the basalt fiber junction used in the process is made in layers.

It is a further object of this invention to describe the use of composite material in aeronautics, aerospace, transportation, sports and industry.

It is a further object of this invention to describe a stopper comprising the composite material described.

General Description

The present invention relates to a composite material consisting of agglomerated cork, resin of ecologic source and basalt fiber, their method of production and use.

The material presented has high strength, is lightweight, with high impact absorption and thermic and acoustic isolation that responds to various challenges. This material has competitive advantages in terms of price and associated technology .

This composite material will highlight various uses including its use in aeronautics, aerospace, transportation, sports and general industry.

This composite junction is in response to the market that is increasingly interested in green products and low pollution, resulting in a composite that is ecological alternative to synthetic composites.

The preferred production system that was tested is the application of vacuum to the composite, surrounded by an airtight plastic film bag (Vacuum bagging) , however it can be applied other techniques, including injection of resin into two closed molds by vacuum assisted (RTM) , vacuum infusion involving composite plastic film closed tightly (Scrimp / VARTM) by pressing using a press using two closed molds, etc ..

Altogether, this material develops a superior behavior with respect to resistance, elasticity, impact, isolation and lightness .

The material presented is now technologically similar to carbon fiber composites, and its main difference in the mechanical behavior, that is inferior in mechanical strength but superior in impact absorption. The cost is considerably lower than those presented for the composites of the state of the art and it is an environmentally friendly material, unlike those containing synthetic fibers, resins and synthetic cores.

The high impact absorption capacity solves safety problems presented by the prior state of the art materials, mainly because of better impact absorption and as such exhibit fewer tendencies to fracture and enhance the capabilities of comfort in use. This invention also presents a good thermal and acoustic insulation and also has a good ability of modeling to the desired shape by the end user. The use of ecologic materials 100% biodegradable makes this an environmentally friendly option .

The basalt fiber composite material used in this invention presents a resistance very similar to the carbon fiber, as shown in Table 1.

Table 1 - Comparison of the characteristics of basalt fiber and carbon fiber.

This type of fiber is also resistant to UV and has a lower elastic modulus when compared to carbon fiber.

The result of agglomerated cork with basalt fiber bound with a resin preferably ecological has unexpected behavior. The resistance, impact absorption, and flexibility coupled with thermal, acoustic and fire resistance, places this new material at a high level in relation to its competitor composites such as compounds using fibers having synthetic cores / or natural cores with synthetic fibers / or natural fibers having synthetic cores. The resin is used in small quantities but since its source is ecological it enhances the percentage of natural and ecologic properties of the composite .

Brief Description of the Figures

For an easier understanding of the invention it is joined figures in attachment, which represents preferred embodiments of the invention which, however, are not intended to limit the scope of this invention.

Figure 1 shows a representative scheme of the composition in layers (left side) and a representation of the application of a force on the material in that this has a lower breakdown than other composites (right side) , where the following elements are shown, as follows:

1- Basalt Fiber;

2- Cork;

3- Air;

4- Impact Point.

Figure 2 shows a representative scheme of the first test, containing a core layer of cork, a basalt fiber layer and the top two layers of basalt fiber underneath) , where the following elements are shown, as follows:

1- Basalt Fiber; 6- Cork with air.

Figure 3 shows a representative scheme of the first probe containing a core layer of cork, two layers of basalt fiber on the top and three layers of basalt fiber underneath, where the following elements are shown, as follows:

1- Basalt Fiber;

6- Cork with air.

Figure 4 represents a scheme where another core is used, together with a layer of cork and basalt fiber, where the following elements are shown, as follows:

I- Basalt Fiber;

6- Cork with air;

II- Other cores.

Detailed description of embodiments of the invention

The present invention relates to a composite material consisting of cork agglomerate, ecological resin and basalt fiber and its use. The percentages of each element are variable, depending on the characteristics and the purpose for which the composite is designed.

The basalt fiber is an environmentally friendly material that behaves better than the glass fibers and very close to the performance of the carbon fiber. Among the natural fibers used in the art and production basalt fiber are the best in strength and elasticity. The composite of cork agglomerate with basalt fiber and resin, uses the same processes and production principles known in the art including the application of vacuum to the composite wrapping it with a plastic film bag hermetically sealed (Vacuum bagging), injection of resin into two closed molds by vacuum assisted (RTM) , vacuum infusion involving the composite with the airtight plastic film (Scrimp / VARTM) by pressing using a press using two closed molds.

The result of this union had an unexpected effect, as among the natural composites yet had never been aware of a material as good mechanically to replace the composites of glass fibers and carbon with synthetic cores and to absorb impact so efficiently.

The junction core cork to basalt fiber occurs so as to create a natural material (ecological) but with similar characteristics as synthetic composites (such as carbon fiber with foam cores or others) . Among the tests done so far, it delivered totally unexpected very positive results regarding to strength and elasticity. The material gets more elasticity and maintains the properties of resistance to force. Never before has been disclosed a material nearly 100% natural (very small percentage that do not reach the 5% level) with these features. Another distinct advantage is the price, which for technical characteristics presented here, is much lower than the other composites. The price of the basalt fiber is equal to or slightly lower than the glass fibers and the core is made of agglomerated cork from cork waste which makes the material cheaper than any foam or nucleus existing in the market. To date it is not known to the state of the art a natural material with such potential in the field of composites. With a wide applicability in many markets, this composite helps reduce pollution (carbon emissions, oil use) being an effective alternative with a reduced environmental impact, since there has been a 10% growth in the production of composite materials. The durability of this composite (because they are natural materials) associated with the low cost of production promotes its application in various products, which undoubtedly will help protect future generations from the impact of oil and its derivatives.

In this case both the basalt fiber and the core cork have unique absorption of forces. Markets using composites with synthetic compounds such as aviation, boating, water sports, construction, transport, etc.., didn't have at their disposal ecological or natural materials that respond to such technical needs. This new material that is presented in this invention responds positively to these markets at a competitive cost being a material virtually 100% natural.

The use of core cork instead of synthetic cores or the addition of agglomerated cork together with other cores leads to significant changes in their behavior due to the weight, since cork is lighter and achieves a greater absorption of impact by absorbing energy and transmitting the same by its mass. The break point of synthetic cores is faster than that of cork. I.e. the core cork is more elastic, easier to work and shape, which makes the material more adaptable to any type in terms of design. The use of core cork with the basalt fibers and resin shows a great ecological impact absorption capacity, allowing greater comfort in using this material.

The resin used may be of any base but preferably will be ecological or of natural base. The aggregator of natural or ecological base enhances ecological percentage of the composite .

The production method was one of the methods available on the market, in which its capabilities already demonstrated of effectivness helped the production.

The curing process is similar or doesn't differ from the curing process of other composites.

The composite with basalt fiber, cork agglomerate and resin is a very effective alternative to the mechanical strength of carbon fiber composites. The data resemble in terms of strength, but the elasticity and impact absorption is better than in the case of carbon fiber composite.

The composite material has the junction of basalt fiber in layers, cork agglomerate and resin preferably environmentally friendly .

This combination results in a waterproof material of high mechanical resistance, resistance to fire, heat and sound. The basalt fiber is a consequence of the treatment of basaltic rock, comprising of plagioclase mineral, olivine and pyroxene. It has a high thermic resistance, heat insulation and sound, vibration resistance, durability, and lightness. The cork agglomerate is produced with small cells of air and closed cork that exhibit elasticity, flexibility and unique compressibility .

Tests conducted to the ecological composite of basalt fiber and cork agglomerate with resin are shown in attachment, being this base by approximately 100% in its composition of natural raw materials. Tests were conducted on pieces of composite material with 70% cork, 20% resin and 10% basalt fiber, however for the preparation of the material may be used any percentage up to 99%. The results were very positive, yielding a weight per square meter with a range of between 4.90 kg/m ² to 9.60 kg/m ² , a density of between 449 kg/m ³ to 713 kg/m ³ . As to the results of flexural strength carried out according to standard test "ASTM C393" results were obtained from 34 MPa to 51 MPa, modulus of elasticity between 4.2 GPa and 5.2 GPa, strain at peak stress from 0.9% to 2.0% and finally elongation from 6.4 mm to 12.0 mm. These tests are merely exemplary and do not invalidate any other compositions . Table 2 - Comparison of the results obtained

compositions of composite material with basalt fiber.

Material / ID FMP-01/B FMP-02/D

Core Agglomerated cork Agglomerated cork

(corecork NL10) (corecork NL10)

Core width (mm) 10 mm 10 mm

Fiber Basalt fiber Basalt fiber

(Biaxial 650 gr (Biaxial (Biaxial 0/90) 650 gr 0/90)

Resin Greenpoxy 55 / GP Greenpoxy 55 / GP

505 505

Layer composition Basalt Fiber Basalt Fiber

Corecork NL10 10 mm Basalt Fiber

Basalt Fiber Corecork NL10 10 mm

Basalt Fiber Basalt Fiber

Basalt Fiber

Table 3 - Comparison of the results obtained

compositions of composite material with basalt fiber.

The tested samples have the same direction of the fibers. Test specimens cut in other direction have different mechanical results. The following claims highlight particular embodiments of the invention .