Composite material element, in particular for watercraft

Abstract

The invention relates to a composite material element (20), in particular for manufacturing a planing hull as well as other boats and boat components. The composite material element (20) is characterized in that it has at least one inherently flame-retardant mixed layer (22) made from a cork material (24) and biogenic binder (26). The invention further relates to a method for manufacturing such a composite material element (20) and a planing hull (34) having the composite material element (20).

Description

[0001] Composite element, especially for watercraft

[0002] The present invention relates to a composite material element which can be used in particular for the manufacture of watercraft, such as sports boats or gliders.

[0003] A planing boat, in the field of water sports, is a watercraft or sports equipment designed to "glide" across the water's surface rather than through it. Unlike traditional watercraft that rely on static buoyancy and remain partially or fully submerged in the water (such as displacement boats or ships), a planing boat utilizes the dynamic lift generated by rapid movement across the water's surface. A planing boat's design is similar to a water sports equipment, such as a surfboard, motorboat, or sailboat.

[0004] A key challenge in the design of a glider is the interplay of propulsion power, weight, and shape. Regardless of this, adequate fire protection is also essential for motorized boats.

[0005] Commonly used materials in modern boatbuilding are plastics, wood, steel, and aluminum. The most common boat materials used in the recreational boating sector are glass fiber reinforced plastic (GRP) and carbon fiber reinforced plastic (CFRP). Woods such as teak, mahogany, or oak are commonly used for the interior, and the deck is also often covered with wood. Sports boats, such as planing boats, are primarily made of GRP and / or wood. Aluminum is also used less frequently. Steel is primarily used for the construction of large vessels.

[0006] Fiber-reinforced plastic boats are made from resin-impregnated fiber mats / fabrics. Strength is adjusted by the thickness and number of layers. Almost any design is possible; the material is lightweight, non-corrosive, and requires less maintenance than wood or metal. Common binders are petrochemical polyester and epoxy resins. These thermally reactive resins must be processed under strict safety conditions. In the event of a fire, toxic gases and decomposition products are released that are harmful to health and the environment. In the event of a fire, the plastic boats are very difficult to extinguish, and toxic fumes are released. Another disadvantage is that plastic boats can break under hard impacts due to their low elongation, thus reducing safety on the high seas.

[0007] Wooden boats are very durable in saltwater, but they require a lot of maintenance. Traditional boatbuilding woods are teak, mahogany, oak, larch, and spruce, with tropical mahogany being the most commonly used. Contact with freshwater can quickly lead to mold or rot. The raw material, made from renewable resources, ensures a good carbon footprint, but petroleum-based varnishes and binding agents are usually used, and the use of tropical woods is controversial. Wooden boats perform poorly in the event of a fire.

[0008] Aluminum is primarily used to build workboats, but also sports and leisure boats. When properly treated and bimetallic corrosion (or crevice corrosion / pitting) is avoided, natural aluminum is particularly easy to care for and virtually maintenance-free. Aluminum is readily available, but it is difficult to extract, and recycling is very energy-intensive, resulting in high CO2 emissions. These boats are heavier and significantly more expensive than fiberglass.

[0009] Aluminum is an excellent heat conductor, so aluminum boats require extensive insulation to stay warm in winter and cool in summer. In the event of a fire, the temperature is rapidly dissipated, reaching the melting point within a short time. Material failure is possible even at temperatures below the melting point. Extinguishing measures must be carried out quickly and require large quantities of extinguishing agent. The use of water can cause the vessel to sink.

[0010] Large ships are predominantly made of steel. Thanks to its elasticity, they are suitable for strong waves. Disadvantages include their susceptibility to corrosion, especially in salt water, and their high deadweight, which makes the transition to electric mobility virtually impossible. Scrapping and recycling work well. Steel is also readily available. However, steel processing is CO2-intensive.

[0011] Steel does not burn, but it rapidly loses strength at high temperatures. Above 300°C, steel begins to lose strength, and this decreases rapidly above 400°C. At temperatures of 500–550°C, the steel core fails. In a fire involving burning cellulose-containing materials such as wood, paper, and / or plastic, the steel reaches the critical temperature of 500–550°C in less than 15 minutes.

[0012] Small motorized boats pose a fire risk due to flammable fuels or batteries, which entails consequential risks in the event of a fire. Insurance companies consider fire to be one of the most common causes of boat damage or total loss.

[0013] Motorboats often have a GRP composite body, which is flammable and burns releasing toxic gases. If burning GRP lands on the ground, the fire spreads very quickly. If a vessel made of glass-fiber-reinforced plastic (GRP) catches fire, it is very difficult to extinguish. In the event of a fire, GRP boats are often totaled, leaving only melted, charred plastic.

[0014] Ship fires spread quickly; 15 minutes of unfought fire typically result in the total loss of the vessel. The average response time for firefighters is approximately 15 minutes; for fires at sea, this can increase dramatically – for most vessels, external assistance arrives too late. The destruction of the buoyancy aid can lead to leaks or even total failure of the buoyancy aid, resulting in the sinking of the vessel.

[0015] Because escape routes are severely limited on a boat, unlike in buildings, the release of toxic gases in the event of a fire can lead to personal injury through inhalation. Metal boats conduct the resulting heat and significantly heat up the surrounding area. Large quantities of extinguishing water can cause the vessel to sink. Boat fires also have harmful environmental impacts, partly because fuel can be released if the buoyancy aid fails and the boat sinks. Furthermore, environmentally harmful materials or substances can enter the water when the boat burns.

[0016] The transition to electric mobility in shipping has already begun. Lightweight boat construction is crucial to compensate for the higher drive weight of electric vehicles and ensure the longest possible range.

[0017] Thermosetting bioresins made from renewable raw materials have not yet been sufficiently developed and researched in many respects. Novel biogenic furan resins made from polyfurfuryl alcohol (PFA) are obtained through linear polymerization from renewable raw materials such as bagasse, a byproduct of sugar production from sugar cane or corn. These low-VOC, heat-resistant resin systems cure at temperatures above 100°C, preferably above 150°C, and produce a hydrophobic, rigid, cross-linked macromolecular structure with a high affinity for mineral or natural fibers. Special grades have been developed for glass fiber-reinforced composites. Below 50°C, the binder can be stored for several months, even when mixed with other components to form a ready-to-react mixture. Other resins, such as epoxy or polyester resins, require processing within a few hours.Due to its high water content, PFA is largely unsuitable for the wood industry.

[0018] The use of insulating core materials in GRP / CFRP boat building is generally known. The petroleum-based PET / PVC / XPS foam cores preferred here are considered environmentally hazardous, highly flammable, and burn rapidly with significant smoke development. Commercially available PU-bonded cork panels exhibit high swelling of up to over 10% and are therefore unsuitable as core materials for sandwich structures in boat building. Furthermore, PU is also highly flammable.

[0019] Basalt fabric has a higher tensile strength than glass fibers. Basalt is non-toxic and inert, produces no gas or smoke, is UV-resistant, chemical-resistant, and sterile, with excellent dielectric strength, abrasion resistance, and thermal and sound insulation. Basalt fabric is temperature-resistant from -260°C to 700°C.

[0020] The melting point is 1,450 °C.

[0021] The object of the invention is to provide an environmentally friendly and lightweight composite element with good insulation properties, suitable for the production of a glider, and with improved properties compared to the disadvantages of the prior art. The composite element should be made predominantly from renewable raw materials, be cost-effective, harmless to health, and easy to manufacture. In particular, it should have good fire protection properties, which significantly extend the time until the boat is lost in the event of a fire. Furthermore, a process for the production and recycling of such a composite element should be provided.

[0022] The invention is achieved by a composite material element having the features of independent claim 1. Furthermore, the object is achieved by a method having the features of the independent method claim.

[0023] The composite material element according to the invention therefore has an inherently flame-retardant mixture layer of cork material and biogenic binder.

[0024] For the purposes of this invention, the term "biogenic" means that the binder is primarily made entirely from renewable raw materials. Flame resistance can be increased and individually adjusted by adding preferably inorganic flame retardants. The manufacturing process can be accelerated by using additive catalysts.

[0025] The energy required to extract bio-based raw materials is significantly lower than that required for oil production. However, high bio-contents in plastics often mean that the products no longer meet strict fire safety guidelines. Cork, on the other hand, offers excellent fire protection. The material is classified in fire protection class B1 and is therefore considered flame-retardant. Studies show that cork produces less smoke when burned than plastics, and that the smoke density and toxicity are less critical than with plastics. Cork does not contain any pollutants that are harmful to the environment. Cork is resistant to moisture. This is made possible by the biopolymer suberin, which is embedded in the cork's cell walls and has a hydrophobic effect. Cork does not swell like wood, for example. Lacquer layers do not peel off if damaged, even outdoors due to weathering. Cork is also resistant to rot.Cork itself contains high levels of tannins and low levels of protein, making it resistant to fungi and mold. Cork is lightweight, buoyant, elastic, water- and gas-tight, largely acid-resistant, a good insulator of heat, sound, vibrations, and electricity, and extremely durable. Cork owes its great performance to a minimum of solid materials and a maximum of air. Cork is harvested from the cork oak tree and grows continuously. Cork oak forests are natural CO2 reservoirs.

[0026] Contrary to previous expert opinion, it has been shown that the use of biogenic furan resins made from polyfurfuryl alcohol (PFA) is suitable for the production of a composite element according to the invention. One of the unique properties of polyfurfuryl alcohol is its excellent resistance to high temperatures. It is flame-retardant and offers an inherently fire-resistant matrix. Its fire behavior is characterized by high thermal stability, a low release rate of combustible volatiles, and high carbonization. Its hydrophobic properties prevent water ingress into the composite material.

[0027] In the following, the term “mixed layer” is used for the flame-retardant layer according to the invention made of an inherently flame-retardant mixture of cork material and biogenic binder.

[0028] The mixed layer is preferably arranged in the interior between two laminate layers. The mixed layer can also be arranged directly as the top or bottom layer. It is also possible to arrange several mixed layers according to the invention within a multilayer composite element. The composite element according to the invention can further comprise one or more layers of other materials.

[0029] In the following, the term prepreg layer is used for the flame-retardant layer according to the invention consisting of an inherently flame-retardant structure of a fabric layer coated with a biogenic binder and sprinkled with cork material.

[0030] The prepreg layer can serve as an additional layer of the composite element according to the invention or be cured on its own to form the composite element according to the invention. Preferably, at least two prepreg layers are used, which are cured either face-to-face or stacked in the same orientation. Any number of prepreg layers can be used. It is also possible to cure one or more prepreg layers with one or more additional layers.

[0031] As explained, the use of insulating core materials in GRP / CFRP boat building is known, but is disadvantageous due, among other things, to their high flammability.

[0032] These disadvantages are effectively compensated for by the inherently flame-retardant mixture of cork material and biogenic binders. The addition of unthinkable inorganic flame retardants has proven particularly effective in this regard. Even with small amounts of ecologically harmless additive flame retardants, fire protection properties far exceeding the state of the art in boatbuilding can be achieved.

[0033] Flame retardancy can be inherent or supplementary, either additively or as a coating. Conventional elements in boatbuilding have a maximum of two types of flame retardancy.

[0034] The fire protection properties can be advantageously influenced by the volume fraction (quantity), type (type and category) and method of addition of the flame retardant.

[0035] Flame retardants can be divided into additive flame retardants, reactive flame retardants, inherent flame retardants and flame retardant coatings.

[0036] Halogenated flame retardants pose a significant health and environmental hazard, especially in the event of fire. Most inorganic flame retardants, in contrast, are considered harmless and are therefore preferred. Volume fractions of 0% to 20% of the entire composite element are considered appropriate, preferably 0% or 5% to 10% within the composite layer. The preferred inorganic flame retardants can be incorporated into the biogenic binder or the mixture of cork material and biogenic binder, as well as the cork mixture of the prepreg layer, and / or applied as a coating to the composite layer, additional layers, and / or prepreg layers.

[0037] Solid and liquid inorganic flame retardants combine well with biogenic resins. Some, such as Biotecta and Ecogard BioPlus, contain no harmful components and are VOC-free.

[0038] The properties of the composite layer or the resulting composite element can be influenced by varying the size and density of the cork material, the viscosity of the biogenic binder, the mixing ratio, and the filler quantity. The high volume fraction of cork provides thermal and acoustic insulation.

[0039] According to the invention, the cork material can have a grain size of 0 - 20 mm and a density between 50 kg / m 3 - 300 kg / m 3 with grain sizes up to 6 mm and densities of 70 kg / m 3 - 200 kg / m 3 have proven particularly suitable. According to the invention, the viscosity of the binder can be altered, for example, by adding water.

[0040] The density of the mixture layer is defined by the mixing ratio and filling quantity as well as by pressure and is, according to experience, between 50 kg / m 3 - 1,200 kg / m 3 , in most applications between 200 kg / m 3 - 400 kg / m 3 .

[0041] It has also been shown that the addition of non-toxic liquid flame retardants has a positive effect on the elongation at break of the inherently brittle, biogenic PFA.

[0042] The composite element according to the invention can be produced by pressing, vacuum processes, using an autoclave (a pressure chamber), heating (baking), microwaves, and / or gluing and / or acid and / or other curing systems. Any molds can be used into which the mixture of cork material and biogenic binder and / or prepreg layers is / are introduced for curing to produce simple and / or complex shapes. The mixture of cork material and biogenic binder can also be used as a filament.

[0043] Cured, pressed, and / or bonded blocks can be cut into layers or sheets of various thicknesses. Alternatively, instead of board-like, flat composite elements, complex shapes can be cut or manufactured directly from the resulting composite layer.

[0044] The mixture of cork material and biogenic binder can be combined with fabrics and / or other material layers to form the composite element according to the invention. The additional layers can be coated and / or impregnated and / or saturated and / or otherwise refined and / or treated with additional materials and / or material combinations, such as binders, flame retardants, impregnation, sealant, varnish.

[0045] It is also possible to incorporate additional reinforcement elements such as wooden rods, cattails, metal grids and / or components such as cable harnesses, solar panels, heating elements, pipes, locking devices as well as cavities and air ducts into the composite element.

[0046] The use of the mixed layer according to the invention itself, i.e. without an additional layer made of a different material, is fundamentally possible and advantageous, for example as an overlying boat floor covering, which, due to its low swelling behavior, can be laid seamlessly over the entire surface, unlike conventional cork floorboards, and combines anti-slip properties with fire protection. However, the mixed layer itself is less resilient than other materials. In this respect, a particularly advantageous composite material element results, in particular, from the addition of additional layers, in particular outer layers (classic sandwich structure) made of other materials with other desired properties. However, inner layers are also possible; these structures combine high strength with the typical appearance of cork boards and are suitable, for example, for the interior fittings of sports boats.Furan resin derived from polyfurfuryl alcohols or furfuryl alcohols has proven particularly effective as a biogenic binder made from renewable raw materials. Other biogenic binders made from sugar, such as sugarcane bagasse, other biomasses made from cellulose, hemicellulose, lignin, starch (e.g., corn starch), chitin / chitosan, algae, or fats and vegetable oils such as linseed oil, sesame, or vegetable alcohols, as well as other renewable raw materials, can be mixed with the cork material in combination or as the sole binder.

[0047] It has been shown that the grain size or grain diameter of the cork material in the mixed layer can be from 0.1 mm to about 20 mm, preferably cork is used in sizes of 0.5 - 6 mm and as cork flour, also called cork powder or cork dust, from 0 - 0.5 mm.

[0048] Preferably, the inherently flame-retardant mixture layer is made entirely from renewable raw materials and has a 100% bio-content. However, a catalyst can also be incorporated, for example, to increase the process speed. Currently, the catalyst can still consist of components of non-renewable origin. The same applies to additive flame retardants, which are predominantly derived from inorganic substances. Additions of 3-10% have proven effective for these additives.

[0049] A key advantage of the inherently flame-retardant mixture is that it is moisture-resistant and resistant to rot and mold. This makes it particularly suitable for training watercraft. Due to its lightweight construction, it is particularly well-suited for small, fast sports boats such as gliders.

[0050] The composite material element according to the invention can, for example, for the production of a glider, have two further layers of 350g / m 2 Basalt fabric, with the mixture layer positioned between the basalt layers. The following mixture layer formulation has proven advantageous for the production of the glider:

[0051] 11.99 kg cork material with a grain size of 0.5 - 1 mm

[0052] 10.56 kg bioresin, pre-mixed with 0.53 kg hardener 2.16 kg Ecogard Bio Plus flame retardant

[0053] The mixture is applied at 250g per square meter between the 19 m 2 A cut of basalt fabric is applied. According to the invention, additional basalt layers and / or mixed layers can also be provided.

[0054] Due to the high proportion of renewable raw materials, the material mix of the glider manufactured according to the invention, consisting of a mixed layer between two layers of basalt, binds more CO2 than is emitted during processing. The glider therefore represents a carbon sink. More than 33 kg of CO2 are bound per kg of raw material, less the energy input. This is due to the fact that the cork oaks, which provide the cork for the material mix, bind enormous amounts of CO2 over their lifetime. Cork is extracted from living trees, which is why cork plantations act as CO2 sinks beyond the harvest. The entire glider is therefore a carbon sink with a volume of approximately 600 kg CC^e. A conventionally manufactured glider made of a PVC foam-GFRP composite has a CC^e footprint of over 50 kg for the entire glider, i.e. greenhouse gases are emitted in the context of the production of the raw materials and the manufacture of the glider.A single glider manufactured according to the invention can compensate for the CO2 emissions of more than 9 conventional gliders.

[0055] The glider manufactured according to the invention, made from a composite layer between two basalt layers, weighs 30.40 kg less than a corresponding glider made of fiberglass, about half the weight of one made from 8 mm wood and about a third of one made from 3 mm aluminum sheet. The lightweight construction facilitates the transition to electric mobility. With the same shape, a lighter boat requires less propulsion power, allowing the use of a smaller engine, which consumes less fuel and is therefore more environmentally friendly. In addition, the payload can be increased, and thanks to the lower center of gravity, stability can be increased and the draft reduced.

[0056] In addition to basalt, various other materials are also suitable for combination with the mixed layer. Additional layers include layers made of inorganic fibers, metal, solid wood, laminated wood, plywood, organic compounds, such as various plant parts, natural fibers, fibers from natural polymers, algae, and fungi.

[0057] The layers of natural fibers consist, for example, of plant fibers such as hemp, flax, jute, coconut, cotton, animal fibers, or mineral fibers. The layers of inorganic fibers consist, for example, of glass, basalt, quartz, or metal. The layers of natural polymer fibers consist, for example, of chitin or regenerated cellulose. The additional layers can be added as the sole additive or in combination with one another.

[0058] To compare the invention with the state of the art, a test setup was implemented. During the test, the test specimen is held by two supports with a 4.5 kg mass, 22 times its own weight, statically loaded on one side and exposed from below to a burner with a continuous flame. The burner burns a conventional gas mixture of propane and butane, which burns at a temperature of 1,925 °C. The aim of the test is to measure the time until the structure fails under the load. The measurement results are shown in Table 1 below. This test illustrates how the composite element according to the invention behaves in a conceivable scenario compared to a conventional material.

[0059] Table 1) Material behavior in fire test

[0060] [...]

[0061] Explanations:

[0062] Flame development: 0 = no flame development to 5 = fire of the entire test specimen

[0063] Smoke development: 0 = no smoke development to 5 = dense opaque smoke

[0064] The test specimens in the format 24 x 24 x 1 cm (W x D x H) are sandwich structures with cover layers of 280 g / m 2 Fiberglass fabric. All test specimens contain the same amount of flame retardant, with test specimens 1 and 2 enriched with the flame retardant BDP (bisphenol A bis(diphenyl phosphate)), and the third test specimen with the water-based flame retardant "Ecogard Bio-Plus." This cannot be mixed into epoxy, but is significantly more environmentally friendly, which is why it was selected for the fire test.

[0065] The first test specimen corresponds to the classic lightweight construction used in boat building. A 70 kg / m 3 PVC foam core with 280 g / m 2Fiberglass fabric laminated. For bonding, the laminates were impregnated with epoxy resin enriched with 17g of the flame retardant BDP (bisphenol A bis(diphenyl phosphate)). The second and third test specimens are versions of the composite element according to the invention consisting of a mixed layer between two further layers. The mixed layer consists of 96g of cork material 1-2mm, 77g PFA (polyfurfuryl alcohol), and 17g of flame retardant (9%). The second test specimen is enriched with BDP (bisphenol A bis(diphenyl phosphate)) in the same way as the first, and the third with "Ecogard Bio-Plus." The other layers are reinforced with 280g / m 2 Fiberglass fabric formed.

[0066] Each test specimen was individually exposed to the flame. During the first two minutes, the deflection was measured every 20 seconds, and the flame intensity, smoke development, and delamination of the laminate were qualitatively recorded. The first test specimen experienced significant deflection and failed completely after one minute. Heavy smoke development and ignition of the material were observed. The bottom laminate layer (side facing the flame) delaminated.

[0067] The second and third test specimens withstood the load for the full 2 ​​minutes. The test specimen with BDP as a flame retardant deflected only marginally. This test specimen also ignited, although the intensity was significantly lower than test specimen 1, and significantly less smoke development was observed. The second test specimen delaminated on one side, on the side facing the flame, while the third test specimen withstood the load. It did not ignite; very little smoke development and no deflection were observed, and no delamination occurred. Due to the excellent results of this test specimen, an identical test specimen was tested without any time limit. It was found that even after 45 minutes of continuous flame exposure, no smoke development and no deflection could be observed. Only after cooling was slight delamination of the laminate layer on the side facing the flame detected.The composite element according to the invention has high value-added potential and can be reused or recycled in subsequent life cycles. The composite element according to the invention can be shredded and incorporated into a fresh mixture of cork material and biogenic binder with a proportion of up to 50% as recyclate. Recycling of composite elements laminated according to the invention can increase the strength of the composite element, which is preferably enriched with recyclate.

[0068] The composite material element is not only suitable for the production of recreational boats, especially gliders, but can also be used in other areas where flame-retardant, environmentally friendly, lightweight, and durable materials are required. Examples include aircraft construction, automotive engineering, and vehicle construction in general. Composite material elements according to the invention are also suitable for components in the energy sector, such as wind turbine blades, heat pump housings, or even general building components, such as bathroom paneling.

[0069] According to the invention, the flame-retardant property is based on the inherently flame-resistant mixture layer. However, it is also possible to increase and individually adjust the flame resistance by adding, for example, liquid inorganic flame retardants. The addition of further additives, such as catalysts to accelerate the production process, as well as recycled material and / or fillers, is also possible.

[0070] A method according to the invention for producing a composite material element comprises the following process steps:

[0071] Dosing of cork material and biogenic binder,

[0072] - Mixing the components, preferably in a closed mixing system, until homogeneous conditions are achieved within the mixture,

[0073] - Reaction to form a composite element.

[0074] Adding recycled material would require shredding or grinding the secondary raw material. Optionally, a catalyst and / or additives and / or recycled material can also be added. Elements and / or components can also be incorporated into the mixture. In principle, any number of additional layers and / or prepreg layers can be added above, below, and / or between the mixture layers.

[0075] According to the invention, the composite element can be cured as a sheet or molded part. Particularly suitable are pressing (cold / hot), vacuum processes, use of an autoclave (a pressure chamber), heating (baking), microwaving, or curing with acid and other hardening systems. Molded parts are produced using a mold.

[0076] In an additional process step, a mixture layer pressed by pressure and heat can be mechanically deformed immediately after pressing.

[0077] The preparation of the mixture and material application to form the composite element can be carried out manually or by suitable processes and is dosed according to the target density.

[0078] The production of a prepreg layer is preferably carried out by the following process steps:

[0079] Dosing of cork material and biogenic binder,

[0080] Coating and / or impregnating the carrier layer with binder, sprinkling the binder-impregnated and / or coated carrier layer with cork material.

[0081] Preferably, further substances from the group additive, recyclate and / or filler can be added.

[0082] For the inventive method for producing a small sports boat, such as a glider, pressing under vacuum, using an autoclave (pressure chamber) or a mechanical pneumatic / hydraulic press, each using a heatable mold, has proven particularly advantageous. The inventive method for producing a glider as a two-shell molded part can preferably comprise the following process steps:

[0083] Dosing and mixing of cork, binder and flame retardant, - Cutting the laminate layers of basalt fabric,

[0084] Draping one layer of basalt fabric each onto the heatable press molds for an upper and lower shell,

[0085] - even application and smoothing of 250g cork-binder mixture per square meter,

[0086] - Laying the second basalt fabric layer,

[0087] - pressing at 150 °C for 10 minutes,

[0088] Cooling the press down to 70 °C, removing the molded parts.

[0089] After the two molded components have cured to form the laminated composite element, they are positioned and bonded together. This is done using a resin system containing 5% flame retardant. The joint is reinforced on the inside and outside with a 100 mm wide strip of basalt fabric.

[0090] In summary, it was shown that the composite element according to the invention can withstand loads for a much longer period of time in the event of a fire than conventional materials. The composite element according to the invention is a resource-saving, environmentally friendly, high-performance alternative with outstanding fire protection properties and can contribute to protecting human lives. The lightweight construction combined with very high fire protection facilitates the transition to electromobility, and sensitive areas around the electric drive can be protected more effectively thanks to the adjustable fire protection properties of the composite element according to the invention.

[0091] The invention is explained with reference to the following figures, which are to be understood as examples only and are not intended to limit the invention. They show:

[0092] Figure 1: A schematic representation of a composite material element according to the invention consisting of a mixture layer in cross section,

[0093] Figure 2: a variant of a composite material element according to the invention with a further mixture layer and optional further layers in cross section, Figure 3: the variant according to Figure 2 as a molded part in cross section,

[0094] Figure 4: a schematic diagram of a composite material element according to the invention consisting of a prepreg layer in cross section,

[0095] Figure 5: a variant of a composite material element according to the invention with a further prepreg layer, mixture layers and a further layer in cross section,

[0096] Figure 6: a design variant corresponding to the design variant according to Figure 5 as a molded part in cross section,

[0097] Figure 7: a variant of a composite material element according to the invention in cross section, with two further layers, an upper layer and a lower layer,

[0098] Figure 8: a design variant corresponding to the design variant according to Figure 7 as a molded part in cross section,

[0099] Figure 9: a simplified three-dimensional drawing of a glider,

[0100] Figure 10: a simplified dimensional drawing of the slider from Fig. 9,

[0101] Figure 11 : a simplified three-dimensional drawing of two glider half-shells,

[0102] Figure 12: a simplified dimensional drawing of the glider half shells.

[0103] Figure 1 shows a composite material element 20 according to the invention in cross section, formed from a mixture layer 22 of a cork material 24, in particular a cork material 24, and a biogenic binder 26. The cork material 24 and the biogenic binder 26 together form a mixture layer 22.

[0104] In the exemplary embodiment shown in Figure 2, the mixture layer 22 is arranged between two further layers 28. A second further layer 28 is additionally arranged on the upper side, and a further mixture layer 22 is arranged above this.

[0105] Figure 3 shows the exemplary embodiment according to Figure 2.

[0106] Figure 4 shows a composite material element 20 according to the invention in cross section, formed from cork material 24 and biogenic binder 26 on a further layer 28, designed as a carrier layer 28. The cork material 24 and the biogenic binder 26 on the carrier layer 28 together form a prepreg layer 30.

[0107] In the exemplary embodiment shown in Figure 5, the mixture layer 22 is arranged between a prepreg layer 30 (bottom) and another layer 28. A second prepreg layer 30 is additionally arranged on the top side, and a further mixture layer 22 is arranged above it.

[0108] Figure 6 shows the exemplary embodiment according to Figure 5.

[0109] Figure 7 shows a variant in which the mixture layer 22 is arranged between two further layers 28, which thus form an upper layer and a lower layer.

[0110] Figure 8 shows the design variant corresponding to Figure 7.

[0111] According to the invention, the biogenic binder 26 can be enriched with additives such as flame retardants and / or catalysts. According to the invention, the mixture layer 22 can be enriched with additives, recycled material, and / or filler.

[0112] According to the invention, the additional layer 28 can consist of any desired material and / or material composite. According to the invention, the additional layer 28 can be coated and / or impregnated and / or saturated and / or otherwise refined and / or treated with additional materials and / or material combinations, such as binders, flame retardants, impregnation, sealing, varnishing. The embodiment shown in Figures 7 and 8 shows, by way of example, the composite material element 20 according to the invention in cross section for producing a slider 34. In the embodiment for producing the slider 34, the mixed layer 22, formed from 0.5-1 mm cork material and biological binder, is arranged between two additional layers 28. The additional layers can be formed, for example, from basalt fabric 32, preferably with a density of approximately 350 g / m 2 .

[0113] Figures 9 and 10 show sketches of the glider 34, which, due to its design, starts gliding particularly quickly.

[0114] Figures 11 and 12 show the molded components of the slider 34 from Figures 9 and 10, the sky-side upper shell 36 and water-side lower shell 38, which form the slider 34 when glued together.

[0115] The invention is not limited to the composite material elements shown as examples, but also encompasses further embodiments. In particular, the structure can differ from the embodiments shown, for example, depending on the requirements of the composite material element 20. Thus, the mixed layer 22 according to the invention can, in principle, also be used as a semi-finished product. It is particularly suitable, for example, for the production of a wide variety of composite components.

[0116] It has also been shown that the inherently flame-retardant mixed layer 22 according to the invention is also suitable, for example, as a coating for boat decks. This is advantageous because the mixed layer 22 exhibits extremely low swelling behavior, is water-resistant and slip-resistant, provides thermal insulation, and has very low thermal conductivity. The mixed layer 22 can be laid on the floor in the form of solid elements, for example, as tiles. In a particularly advantageous embodiment, however, it is also possible to apply the mixed layer 22 to the floor while still in a liquid state. It can be poured and then hardens. This results in a seamless, extremely even floor covering. Reference numeral 20 - Composite element

[0117] 22 - Mixed situation

[0118] 24 - Cork material

[0119] 26 - biogenic binder

[0120] 28 - Additional layer, carrier layer 30 - Prepreg layer

[0121] 32 - Basalt fabric

[0122] 34 - Glider

[0123] 36 - Upper shell

[0124] 38 - Lower shell

Claims

Patent claims 1. Composite material element (20), in particular for producing a glider and other boats and boat components, characterized in that it has at least one inherently flame-retardant mixture layer (22) made of a cork material (24) and biogenic binder (26).

2. Composite material element (20) according to claim 1, characterized in that it has at least one further layer (28) made of a different material, which can be designed as a carrier layer.

3. Composite element (20) according to claim 1 or claim 2, characterized in that the mixture layer (22) contains an additive flame retardant.

4. Composite material element (20) according to one of claims 1 to 3, characterized in that the mixture layer (22) is fully reacted.

5. Composite material element (20) according to one of claims 2 to 4, characterized in that the mixture layer (22) is arranged between two further layers (28) made of a different material and / or prepreg layers (30) which serve as laminate layers.

6. Composite element (20) according to one of claims 1 to 5, characterized in that the cork material (24) has a density of about 50 kg / m 3 - 300 kg / m 3 , especially 70 kg / m 3 - 200 kg / m3 and has a grain size of 0 - 20 mm, in particular up to 6 mm.

7. Composite material element (20) according to one of claims 1 to 6, characterized in that the biogenic binder (26) is produced on the basis of a substance from the group consisting of sugar, cellulose, hemicellulose, lignin, starch, chitin / chitosan, fats, vegetable oils, vegetable alcohols, fungi, algae, bagasse, corn, lignin, fructose, linseed oil or sesame or is a lignin resin, lignin-HMF resin, furan resin made from polyfurfuryl alcohols or furfuryl alcohols.

8. Composite material element (20) according to one of claims 2 to 7, characterized in that the further layer (28) is formed from inorganic fibers, metal, solid wood, laminated wood, plywood, organic compounds, for example various plant parts, natural fibers, fibers from natural polymers, algae, fungi.

9. Composite material element (20) according to one of claims 2 to 8, characterized in that the further layer (28) is coated and / or impregnated and / or soaked and / or otherwise refined and / or treated with further materials and / or material combinations such as binders, flame retardants, impregnation, sealing, painting.

10. Composite material element (20) according to one of claims 1 to 9, characterized in that the mixed layer (22) comprises reinforcing elements such as wooden rods, cattails, stalks, metal grids and / or components such as cable harnesses, solar panels, heating elements, pipes, closing devices and / or cavities and / or air ducts.

11. Composite material element (20) according to one of claims 1 to 10, characterized by a recycled material content of up to 50%.

12. Composite material element (20) according to one of claims 1 to 11, characterized in that the biogenic binder (26) and / or the mixture layer (22) contains further additives from the group consisting of catalyst, hardener, wetting agent, plasticizer, release agent, solvent, diluent, thickener, drying agents, desiccant, emulsifier, moisturizer, heat stabilizer, impact modifier.

13. Use of a composite material element (20) according to one of claims 1 to 12 in a product from the group consisting of a watercraft, land vehicle, aircraft, energy generator, building, device, technical installation or furniture.

14. A method for producing a composite material element (20) with at least one inherently flame-retardant mixture layer (22) made of a cork material (24) and biogenic binder (26), comprising the following process steps: Dosing of cork material (24) and biogenic binder (26), - Mixing the components, preferably in a closed mixing system, until homogeneous conditions are achieved within the mixture, - Reaction from the group of pressing, vacuum processes, autoclaving, heating, gluing or enrichment with acid to form the composite element (20).

15. The method according to claim 14, characterized by adding a further substance from the group, additive, recyclate, filler, element, component, further layer (28) and / or prepreg layer (30).

16. Method according to one of claims 14 and 15, characterized by a subsequent additional method step in which the mixture layer (22) pressed by means of pressure and heat is mechanically deformed immediately after pressing and reacts to form the composite material element (20).

17. Slider (34) comprising a composite material element (20) according to one of claims 1 to 12.

Images