Method for producing a plastic composite for a vehicle and plastic composite of this type

Abstract

Th invention relates to a method for producing a plastic composite (10) for a vehicle. The method comprises the following steps: (S1) recycling at least one fishing net, wherein said fishing net is cleaned and cut in order to produce fibers (14) and / or flakes; (S2) introducing the unmelted recycled fishing net into a plastic matrix (12) in order to form a mixture; and (S3) heating the mixture until the plastic matrix (12) at least partially melts in order to form the plastic composite.

Description

[0001] 24-2114 PIF

[0002] 1

[0003] Method for producing a plastic composite for a vehicle and such a plastic composite

[0004] The invention relates generally to the field of plastic composites. In particular, the invention relates to a method for producing a plastic composite for a vehicle and to such a plastic composite.

[0005] Fishing nets are often left behind in open waters. This can endanger animals and contributes to environmental pollution. For this reason, among others, the need for recycling used fishing nets is increasing.

[0006] Fiber-reinforced plastics are also widely used in the automotive industry. Fiber-reinforced plastics typically consist of a plastic matrix and reinforcing fibers.

[0007] The object of the present invention is to at least partially overcome the disadvantages of the prior art. In particular, the invention aims to provide an improved method for producing a plastic composite for a vehicle. The invention also aims to provide an improved plastic composite for a vehicle.

[0008] The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description.

[0009] A first aspect of the present disclosure relates to a process for manufacturing a plastic composite for a vehicle, in particular for a plastic part of a vehicle. The process comprises the following steps:

[0010] • Recycling at least one fishing net, whereby it is cleaned and cut to produce fibers and / or scales,

[0011] • Introducing the unmelted recycled fishing net into a plastic matrix to form a mixture,

[0012] • Heating the mixture until the polymer matrix at least partially melts to form a polymer composite. 24-2114 PIF

[0013] 2

[0014] A process for producing a plastic composite for a vehicle, such as for a component in the interior of a vehicle, which is predominantly made of plastic, is proposed. This process can produce a polymer-based granulate for manufacturing a plastic part. In a first process step, at least one used fishing net can be collected and cleaned. In the context of this disclosure, cleaning a fishing net can include desalting the net. Subsequently, the at least one fishing net can be shredded or cut to obtain smaller fibers and / or flakes. The fibers and / or flakes thus obtained are preferably not further processed. This means that the fibers are preferably not heated and, in particular, not completely melted.The fibers and / or scales preferably remain mostly in solid form.

[0015] In a second process step, which is preferably carried out after the first process step, the shredded fibers and / or scales can be mixed or embedded in a plastic material such as polypropylene (PP) or polyamide (PA), i.e., in a plastic matrix (also called a polymer matrix), to form a mixture. The fibers and / or scales preferably remain unmelted in the plastic matrix. This means that the fibers and / or scales preferably retain their structure within the plastic matrix. After the unmelted recycled (at least one) fishing net has been introduced into the plastic matrix, the mixture can be blended. This creates a homogeneous distribution of the fibers and / or scales within the plastic matrix. In a third process step, which is preferably carried out after the second process step, the mixture can be warmed or heated.The mixture can also be homogenized. The temperature is specifically chosen so that the polymer matrix melts at least partially, while the fibers and / or scales preferably remain solid, i.e., retain their structure.

[0016] The at least one fishing net can consist predominantly of a plastic that differs from the plastic of the matrix. In particular, the at least one fishing net can have a melting point that differs from the melting point of the matrix. This advantageously ensures that the fishing net fibers remain predominantly unmelted when the mixture is heated. 24-2114 PIF

[0017] 3

[0018] This process allows for the production of a fiber-reinforced plastic composite for vehicles. Consequently, further fiber-reinforced plastic parts for vehicles can be manufactured. This process also enables the reuse of fishing nets. Furthermore, the use of fishing net fibers as reinforcement material can lead to a reduction in the weight of the plastic parts, which can be advantageous for the automotive industry. The process promotes the circular economy by transforming waste materials into new products.

[0019] The fishing net fibers can act as a reinforcing material, increasing the tensile strength, flexural strength, and impact resistance of a plastic part. This can lead to higher mechanical strength, fracture resistance, and ductility of the plastic part.

[0020] According to one embodiment, the method further includes the following step:

[0021] • Forms of plastic composites.

[0022] In an optional fourth process step, the heated and at least partially molten mixture is pressed or injected into a mold. This allows, for example, the production of a finished plastic part. The mixture can be deformed or shaped, particularly under the influence of heat. Through the shaping process, and especially the application of heat, the plastic matrix and the fibers and / or scales can bond together. However, the fibers and / or scales preferably remain largely unmelted.

[0023] It should be noted that the third and fourth process steps can be carried out simultaneously. This means that the forming of the plastic composite can take place under the influence of heat, whereby the heated mixture is warmed or heated to such an extent that the plastic matrix can at least partially melt. After the fourth process step, the formed plastic composite can first harden and / or cool down. The process can therefore be further used to manufacture a plastic part for a vehicle.

[0024] According to one embodiment, the plastic matrix comprises granules of polypropylene and / or polyamide. This means that the plastic matrix is ​​preferably in granular form. This form allows for good dosing and handling. The choice of the appropriate plastic for the matrix can depend on the specific requirements of the composite, such as mechanical strength, heat resistance, chemical resistance, and cost. Polypropylene and / or polyamide are used for 24-2114 PIF.

[0025] 4. The plastic matrix is ​​preferred. By using such a matrix, good compatibility and bonding with the recycled fishing net fibers can be achieved.

[0026] However, other possible plastic materials may be considered for the plastic matrix. The plastic matrix can consist of polyethylene, polyvinyl chloride, polybutylene terephthalate, polycarbonate, acrylonitrile butadiene styrene copolymers, polyurethane, and / or bio-based polymers.

[0027] According to one embodiment, the mixture is heated to a temperature between 100°C and 250°C. This means that the mixture is preferably heated to the melting temperature of the polymer matrix.

[0028] According to one embodiment, at least one fishing net contains polyamide. Furthermore, at least one fishing net has a melting point between 250°C and 280°C. Polyamide typically has a melting point between 250°C and 280°C. Fishing net fibers, such as polyamide (nylon), generally have good heat resistance and chemical resistance. This can positively influence the properties of a plastic part containing such a composite material.

[0029] According to one embodiment, the fibers produced from the fishing net are between 1 mm and 25 mm long. This specific fiber length is based on the understanding that reinforcing fibers in this length range particularly effectively improve the mechanical properties such as load-bearing capacity, tensile strength, and fracture toughness of the resulting plastic composite and / or a plastic part manufactured with such a composite.

[0030] Shorter fibers under 1 mm in length can lead to reduced fiber-matrix bonding and force transmission, while longer fibers over 25 mm can impair the processability and homogeneity of the plastic compound. The range of 1 mm to 25 mm can therefore represent a balanced compromise to maximize mechanical properties without compromising processability.

[0031] A second aspect of the present disclosure relates to a plastic composite for a vehicle, which is manufactured according to a process as described above and / or below. 24-2114 PIF

[0032] 5

[0033] Such a plastic composite can be used to manufacture a plastic part for a vehicle. This plastic part can be an interior component, such as a door panel, dashboard component, cable fastener, or luggage rack bracket, or an exterior component, such as a front grille surround or tailgate trim.

[0034] A third aspect of the present disclosure may therefore relate to a plastic part manufactured with a plastic composite, as described above and / or below.

[0035] All advantages, disclosures and / or statements described above and / or below in relation to the process apply equally to the plastic composite, and vice versa.

[0036] Exemplary embodiments of the invention are described below with reference to the figures. The figures show:

[0037] Fig. 1 shows a flowchart of a process for producing a plastic composite according to an exemplary embodiment, and

[0038] Fig. 2 shows a plastic part manufactured with a plastic composite according to an exemplary embodiment.

[0039] Similar, similar-looking, identical, or equivalent elements are marked with similar or identical reference symbols in the figures. The figures are merely schematic and not to scale.

[0040] Fig. 1 shows a flowchart of a process for manufacturing a plastic part 10 according to an exemplary embodiment. Fig. 1 is described below with reference to Fig. 2. Fig. 2 schematically shows a plastic part 10 manufactured with a plastic composite, wherein the plastic composite can be manufactured using a process according to the invention. In a first process step S1, at least one fishing net is recycled. The fishing net is preferably a used fishing net. During recycling, the fishing net is preferably first cleaned to remove dirt and foreign matter. Subsequently, the fishing net is cut or shredded to produce individual fibers 14 and / or scales. The fibers 14 obtained from the recycled fishing net preferably have a length of 1 mm to 25 mm. These recycled fishing net fibers 14 can then be processed in a second process step S2 in 24-2114 PIF.

[0041] 6. The unmelted fishing net fibers 14 (i.e., in their originally produced state) are introduced into a plastic matrix 12. The plastic matrix 12 can serve as the base material into which the fibers 14 are integrated. This can be various plastics such as polypropylene, polyamide, or other thermoplastic polymers. The introduction of the unmelted fishing net fibers 14 into the plastic matrix 12 leads to the formation of a mixture. The plastic matrix 12 is preferably initially in the form of granules. To achieve an advantageous distribution of the fibers 14 in the plastic matrix 12, the mixture can be homogenized.

[0042] This mixture, comprising plastic matrix 12 and fishing net fibers 14, is subsequently heated in a third process step S3 until the plastic matrix 12 at least partially melts. A plastic composite can be produced in this process. The heated mixture can also be cooled to form the plastic composite. The plastic composite can be further processed into granules. The fibers 14 and / or the scales preferably remain unmelted. This is particularly possible because the plastic matrix 12 preferably has a melting point that differs from the melting point of the at least one fishing net. The mixture is preferably heated to a temperature between 100°C and 250°C.

[0043] In a fourth, optional process step S4, which is preferably carried out after the third process step S3, the heated mixture, i.e., the plastic composite, can be shaped to produce a plastic part 10. This can be done, in particular, under the influence of heat. This means that a mass that is at least predominantly liquid or viscous (i.e., the heated and optionally cooled mixture) can, for example, be compression molded. Alternatively, the plastic composite, in the form of granules, can be introduced into a mold. This shaping step can be carried out by various processes such as injection molding, blow molding, or thermoforming. The optional fourth process step S4 can be carried out using a compression molding device. The plastic composite, which can be in the form of granules, can also be formed into the plastic part 10 under pressure.

[0044] Alternatively, it is conceivable that the mixture is heated only during the shaping step, i.e., during the execution of the fourth process step S4, and thus can partially melt. The third process step S3 and the optional fourth process step S4 can therefore alternatively be carried out simultaneously. 24-2114 PIF

[0045] 7

[0046] Using such a plastic composite, a plastic part 10 for a vehicle can be manufactured. Specific examples of such plastic parts 10 in vehicles would be interior parts such as door panels, dashboards, or center consoles, but also exterior parts such as wheel covers, spoilers, or tailgate trim.

[0047] By integrating recycled fishing net fibers 14 and / or scales into the plastic matrix 12, the mechanical properties of the resulting plastic composite, and in particular of a plastic part 10 for vehicles manufactured with the plastic composite, can be significantly improved. The fibers 14 and / or scales can reinforce the matrix and increase the tensile strength, fracture toughness, and stiffness of the plastic composite. Furthermore, the impact strength can be increased, enabling a plastic part 10 manufactured with such a plastic composite to better withstand dynamic loads. The heat resistance can also be increased by using such fibers 14, allowing a plastic part 10 manufactured with such a plastic composite to remain more dimensionally stable at elevated temperatures.

[0048] An additional advantage of the process is its contribution to a circular economy, as the reinforcing fibers can be obtained from recycled fishing nets. This allows for the production of a high-quality plastic part 10 using recycled materials, which can contribute to resource conservation.

[0049] It should be further noted that the terms "comprising" and "comprising" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features and steps described with reference to one of the above embodiments may also be used in combination with other features and steps of other embodiments described above. Reference numerals in the claims are not to be considered limitations.

[0050] 24-2114 PIF

[0051] 8

[0052] Reference symbol list

[0053] 10 plastic part 12 plastic matrix

[0054] 14 fibers

[0055] 51 first procedural step

[0056] 52 second process step S3 third process step

[0057] S4 fourth process step

Claims

-2114 PIF 9 Claims 1. Method for producing a plastic composite (10) for a vehicle, comprising the following steps: • (S1) Recycling at least one fishing net, whereby it is cleaned and cut to produce fibers (14) and / or scales, • (S2) Introducing the unmelted recycled fishing net into a plastic matrix (12) to form a mixture, and (S3) Heating the mixture until the plastic matrix (12) melts at least partially, to form the plastic composite.

2. The method according to claim 1, further comprising the following step: • (S4) Forms of the mixture.

3. Method according to one of the preceding claims, wherein the plastic matrix (12) comprises granules of polypropylene and / or polyamide.

4. Method according to one of the preceding claims, wherein the mixture is heated to a temperature between 100°C and 250°C.

5. Method according to one of the preceding claims, wherein the at least one fishing net has a polyamide component and in particular has a melting temperature between 250°C and 280°C.

6. Method according to one of the preceding claims, wherein the fibers (14) produced from the fishing net are between 1 mm and 25 mm long.

7. Plastic composite (10) for a vehicle which is manufactured according to a method according to one of claims 1 to 6.

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