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EP1966337A2 - Procede et dispositif pour fabriquer des elements de construction - Google Patents

Procede et dispositif pour fabriquer des elements de construction

Info

Publication number
EP1966337A2
EP1966337A2 EP06829261A EP06829261A EP1966337A2 EP 1966337 A2 EP1966337 A2 EP 1966337A2 EP 06829261 A EP06829261 A EP 06829261A EP 06829261 A EP06829261 A EP 06829261A EP 1966337 A2 EP1966337 A2 EP 1966337A2
Authority
EP
European Patent Office
Prior art keywords
solid particles
reactive mixture
spray
polyurethane reactive
nonwoven fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06829261A
Other languages
German (de)
English (en)
Inventor
Ingo Kleba
Guido Wirtz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hennecke GmbH
Original Assignee
Hennecke GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hennecke GmbH filed Critical Hennecke GmbH
Publication of EP1966337A2 publication Critical patent/EP1966337A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/04—Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/70—Spray-mixers, e.g. for mixing intersecting sheets of material
    • B01F25/72—Spray-mixers, e.g. for mixing intersecting sheets of material with nozzles
    • B01F25/721—Spray-mixers, e.g. for mixing intersecting sheets of material with nozzles for spraying a fluid on falling particles or on a liquid curtain
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by spraying components on the web
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B32B2264/065—Lignocellulosic particles, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/101—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/105—Metal

Definitions

  • the invention relates to a method and an apparatus for producing construction elements, in which a polyurethane (PUR) reactive mixture and solid particles are applied to a nonwoven fabric, wherein a density of 0.01 to 10.0 g of solid particles / cm 2 of coated nonwoven fabric Surface is adjusted, and then pressed with the not yet fully reacted polyurethane reactive mixture coated and containing solid particles nonwoven fabric and cured.
  • PUR polyurethane
  • the first applications consisted of adding polyurethane milled short glass fibers to the reactive plastic to maintain the required strength values. But this is an expensive process, mainly because of the complex system components and the high material usage. The weight savings were comparatively low.
  • the object of the present invention was therefore to provide a simple method and a simple device for producing high-strength and at the same time lightweight construction elements based on fiber webs, with which construction elements with a homogeneous surface and with the formation of the desired contours can be produced without having to do any additional rework or lamination.
  • the invention relates to a method for the production of structural elements, wherein a polyurethane reactive mixture and solid particles are applied to a nonwoven fabric, wherein a density of 0.01 to 10.0 g solid particles / cm 2 coated nonwoven surface is adjusted, and then the is pressed with the unreacted polyurethane reactive mixture coated and containing solid particles nonwoven fabric and cured.
  • the PUR reactive mixture is sprayed onto the nonwoven surface.
  • the PUR reactive mixture and the solid particles is preferably applied to both sides of the nonwoven fabric.
  • the PUR reactive mixture and the solid particles are preferably applied to both outer sides of the multilayer substrate.
  • the process can be carried out continuously or batchwise. In this case, after reacting with the nonwoven fabric and the solid particles, the polyurethane reactive mixture forms a composite.
  • the solid particles are wetted substantially on all sides with polyurethane reactive mixture, which leads to a significant increase in viscosity and Tixotropleiter of the polyurethane reaction mixture. This in turn causes the polyurethane reactive mixture can be applied without running on slopes or even on vertical surfaces.
  • Another important factor is the effect that the mixture penetrates the nonwoven fabric more slowly due to the increase in viscosity and the degree of thixotropy, so that it is possible to set via the solids content how much polyurethane reactive mixture remains on the surface and how much penetrates into the interior of the composite component.
  • This additional degree of freedom makes it possible to achieve the optimum compromise between adequate bonding of the composite, low weight and good surface of the structural element.
  • the filler also has a positive influence on the microstructure on the surface of the structural element.
  • the flow behavior of the pure polyurethane reactive mixture through the substrate, which contains at least one fiber fleece, is comparable to the flow of a liquid through a bed.
  • the gravity or the pressure difference, which is applied by the closing of the tool, leads to a flow of the liquid through the bed (the fiber mat).
  • the liquid does not form a planar surface to the atmosphere because of the fiber structure; instead, the polyurethane reactive mixture forms an inhomogeneous surface due to the interaction of boundary or surface tensions to the fiber material and the air and the flow behavior. This causes air bubbles between the fibers.
  • the wetted with the polyurethane reactive mixture, fine-grained filler can better fill these spaces on the surface and thereby significantly improve the microstructure on the surface. This is achieved on the one hand by the increased viscosity due to the higher viscosity and on the other hand due to the breaking up of the interface between the reactive mixture, air and fibers by the solid particles. As a result, the tendency to form a curved surface between the fibers at the surface due to the interfacial forces is significantly lower.
  • a particular effect which occurs in the process is that, in the reaction of the tixotropic PUR reactive mixture during the shaping process in a press, the PUR reactive mixture penetrates into the at least one fiber fleece and wets all the fibers which then stick together
  • solid particles wetted by PUR reactive mixture are partially filtered off by the at least one nonwoven fabric and remain suspended on the surface of the at least one nonwoven fabric and thereby fill in all the gaps between the individual fibers.
  • a spacer element e.g. a honeycomb core
  • a multilayer substrate e.g. with a nonwoven spacer fibrous web structure, preferably with a nonwoven honeycomb nonwoven structure, is preferably applied on both sides, i. each applied to the outside of the nonwoven fabrics, the PUR reactive mixture and the solid particles.
  • an increase in viscosity and Tixotroptechnik of the PUR reactive mixture by the solid particles is preferably applied on both sides, i. each applied to the outside of the nonwoven fabrics.
  • the tixotropic PUR reactive mixture penetrates the nonwoven fabrics, wets the nonwoven fabrics and the spacer, which bond together and form a composite.
  • the wetted with PUR reactive mixture solid particles are filtered off from the fiber webs in part and remain hanging on the outer sides of the fiber webs, so that arise due to the spacer element, preferably the honeycomb core, particularly lightweight and high-strength structural elements with a perfect, homogeneous surface.
  • the effect occurs that the PUR reactive mixture due to the viscosity increase and Tixotropierung penetrates the nonwoven fabric slower and penetrates slower in the honeycomb core behind the nonwoven fabric, so that can be adjusted on the solids content, how much reactive plastic remains on the surface and how much penetrates into the interior of the composite component.
  • the optimum compromise between sufficient bonding of the composite, low component weight and good surface of the component can be achieved.
  • solid particles in different amounts at different points of the substrate, so that the solid particles are present at different points in different densities (in g solid particles / cm 2 of sprayed nonwoven surface).
  • This can be done, for example, by the fact that the content of solid particles used in the PUR reactive mixture is varied by, for example, the amount of metered solid particles is varied in a continuous mixing of the solid particles in the PUR reactive mixture or by using isocyanate or polyol components having different solids contents.
  • this can also be done by applying different amounts of solid particles to the sprayed-on layer of PUR reactive mixture - at different points of the substrate.
  • the solid particles preferably have a bulk density according to DIN EN ISO60 of 0.1 g / cm 3 to 2 g / cm 3 .
  • a bulk density according to DIN EN ISO60 of 0.1 g / cm 3 to 2 g / cm 3 .
  • very light solid particles in the range of 0.1 to 1.5 g / cm 3 , more preferably from 0.1 to 1 g / cm 3 .
  • solid particles with higher bulk densities are also useful in individual cases.
  • densities of the solid particles on the nonwoven fabric are from 0.01 to 10.0 g of solid particles / cm 2 of sprayed nonwoven surface, preferably from 0.05 g / cm 2 to 5 g / cm 2 , more preferably from 0, 1 g / cm 2 to 1 g / cm 2 set.
  • densities of 0.01 g / cm 2 to 3 g / cm 2 are particularly suitable for producing homogeneous surfaces and densities of 0.5 g / cm 2 to 10 g / cm 2 are particularly suitable for also burglary edges and "stress points" compensate.
  • An essential parameter for carrying out the process is the ratio of the mass of solid particles to the mass of PUR reactive mixture which are applied to the substrate surface. This ratio is preferably 0.01 to 10, more preferably 0.1 to 5 and most preferably 1 to 3.
  • the ratio mass of solid particles to the mass of PUR reactive mixture determines, depending on the starting viscosity of the PUR reactive mixture, the degree of Tixotroping On the one hand, it determines how far the PUR reactive mixture penetrates into the substrate or penetrates into the honeycomb core and on the other hand, as can be inclined obliquely to be sprayed surface against the horizontal.
  • PUR reactive mixture In the production of composite elements, it is preferred to apply only as much PUR reactive mixture as to wet and bond substantially all the fibers of the at least one nonwoven fabric, but at the same time substantially free all cavities in the spacer element or honeycomb core leave.
  • the amount of solid particles applied is preferably adjusted so that only as much solid particles are applied to the nonwoven fabric as are necessary to compensate for uneven surfaces or broken edges or contracted stress points.
  • the optimum amount of PUR reactive mixture and solid particles to be applied can be readily ascertained by a person skilled in the art by simple tests in which different amounts of PUR reactive mixture and solid particles are applied to the nonwoven fabric or composite element.
  • powders made of recycled, finely ground PUR foams, especially rigid foams are suitable as particle mixtures.
  • a particle mix size of preferably 10-30, e.g. about 20% by weight over 300 ⁇ m, 30-50, e.g. about 40% by weight over 100 ⁇ m and under 300 ⁇ m as well as 30-50, e.g. about 40 wt .-% below 100 microns (values determined by sieving).
  • microfibers with number-average fiber lengths of preferably 5 .mu.m to 500 .mu.m and a diameter-length ratio of preferably 1.0 to 0.01 are suitable as solid particles in the process.
  • the microfibers preferably consist of the same material as the at least one nonwoven fabric to be coated. This results in homogeneous and at the same time fibrous surface structures. It is then important to ensure that broken edges in the composite elements with spacers (for example, honeycomb core) or absorbed stress points to compensate, so as to achieve a perfect formation of the contours and wall thicknesses.
  • solid particles with platelet form with number-average plate diameters eg determined by microscopic analysis
  • number-average plate diameters eg determined by microscopic analysis
  • thickness-diameter ratios preferably 1.0 to 0.01
  • platelets made of glass or mineral are suitable for increasing the impression resistance of the surface.
  • AIs solid particles may preferably glass, mineral, metal, plastic or natural products such as hemp or jute can be used. In general, one will use especially those solid particles that are particularly easy. Preference is therefore given to plastics.
  • metal powders are particularly suitable, with which an optical Metallic effect is possible.
  • solid particles and mixtures of different solid particles with respect to materials and / or structure and / or particle size distribution can be used. However, it is also possible to use mixtures of the same material and the same structure and of different volume-average particle size.
  • the at least one nonwoven fabric contained in a composite element preferably contains glass, mineral, metal, plastic or even natural fibers, e.g. Hemp or jute. Natural fibers are particularly suitable, since they are quite high-strength, but especially light and resource-friendly.
  • the application of the PUR reactive mixture to the at least one nonwoven fabric can take place, for example, in a casting process as a film.
  • preference is given to applying the PUR reactive mixture in a spray application because thereby the wetting of the at least one fiber fleece is best.
  • larger application widths and higher feed speeds of the spray mixing head are possible by spraying, so that substantially higher production capacities are possible in this way.
  • heat is supplied to the composite element containing at least one nonwoven fabric, optionally at least one spacer element and / or further elements, PUR reactive mixture and solid particles during the pressing process.
  • the chemical reaction can be done by thermal activation. This provides the additional advantage of having sufficient time available for the spraying or wetting process of the at least one nonwoven fabric with PUR reactive mixture and nevertheless achieving short curing times and thus short production cycles.
  • the invention also relates to a spray head for spraying solid polyurethane-reactive polyurethane mixture comprising
  • At least one first channel section for pneumatically conveying the solid particles comprising an inlet opening for a gas stream and a substantially concentrically arranged in the first channel section intake for the Feststoffbar- particles, wherein the direction of flow extended center of gravity of the first channel portion and in the spraying direction the spray nozzle extended axis of the spray form an angle ⁇ in the range of 10 ° to 120 °, and
  • At least one second channel section for pneumatically conveying the solid particles, into which the first channel section opens, wherein the direction of flow extended center of gravity of the first channel section and the direction of flow extended axis of gravity at the outlet opening of the second channel section an angle ß in the range of 60 ° to 170 And wherein the outlet opening of the second channel section is disposed substantially in the immediate vicinity of the spray nozzle for the polyurethane reactive mixture and is substantially aligned with the area of the spray jet emerging from the spray nozzle for the polyurethane reactive mixture.
  • spray mixing heads it is possible to use customary PUR mixing heads which work according to the high or low pressure mixing method. Round or flat jet spray nozzles can be adapted to these mixing heads and work by means of pressure or air atomization.
  • the angle ⁇ is preferably in the range from 20 ° to 90 °, particularly preferably from 30 ° to 60 °.
  • the second channel section may be curved, for example.
  • the second channel section can also be connected, for example, in the form of a bend to the first channel section.
  • the angle ⁇ is preferably in the range from 90 ° to 160 °, particularly preferably from 120 ° to 150 °.
  • the spray head contains at least two first channel sections connected in parallel, and preferably correspondingly at least two second channel sections, which are arranged symmetrically to the spray jet from the spray nozzle.
  • the second channel section is formed in the region of the outlet from the spray nozzle as an annular channel around the spray nozzle.
  • both the second channel section and the first channel section can be designed as an annular channel around the spray mixing head or around the spray nozzle.
  • construction elements from at least one nonwoven fabric, reactive plastic and solid particles can be carried out discontinuously, in particular for simple elements, but also, preferably, for more complicated elements.
  • the respective peripheral devices or presses must also be equipped.
  • the spray head can be used in particular in the method according to the invention.
  • FIG. 3 shows a section of a three-layer construction element produced by the method according to the invention
  • FIG. 5 shows the schematic illustration of the substrate shown in FIG. 4 immediately before the pressing and curing process
  • FIG. 6 is a schematic illustration of the structural element resulting from the substrate shown in FIGS. 4 and 5.
  • FIG. 5 shows the schematic illustration of the substrate shown in FIG. 4 immediately before the pressing and curing process
  • FIG. 6 is a schematic illustration of the structural element resulting from the substrate shown in FIGS. 4 and 5.
  • FIG. 6 is a schematic illustration of the structural element resulting from the substrate shown in FIGS. 4 and 5.
  • FIG. 7 is a schematic representation of a spray head for spraying loaded with solid particles PUR reactive mixture
  • Fig. 8 is a schematic representation of a continuous plant for the production of structural elements.
  • Fig. 1 shows schematically the spray application of PUR and solid particles on a three-layered substrate 1, consisting of two fiber webs 2a and 2b, e.g. from jute fibers, and a spacing element arranged therebetween, for example a honeycomb core 3.
  • a respective spray mixing head 4a or 4b With a respective spray mixing head 4a or 4b, the respectively free surfaces of both fiber webs 2a and 2b are coated with PUR reactive mixture.
  • powdery solid particles e.g. from ground recycled polyurethane, applied by means of a separately arranged application device 5a or 5b on the already applied layers 6a and 6b of PUR reactive mixture.
  • the arrows 50a, 50b indicate the direction of movement of the application organs 4a, 4b, 5a and 5b.
  • upstream processes can be done with handling equipment or by hand.
  • the substrate thus prepared is usually clamped in a frame (not shown in FIG. 1). This can be done automatically or by hand.
  • the spray mixing heads 4a, 4b for the PUR reactive mixture and the application organs 5a, 5b for the solid particles are passed over the substrate and the substrate is sprayed with PUR reactive mixture and immediately afterwards with solid particles.
  • FIG. 1 Another embodiment, not shown in Figure 1 is that only one spray mixing head for the PUR reactive mixture and only one applicator for solid particles are used and either these order organs are moved from one side of the substrate to the other side or in firmly positioned applicators the Substrate is turned after the coating of one side to spray on the other side.
  • FIG. 2 shows the multilayer substrate 1 shown in FIG. 1 after coating with PUR reactive mixture and solid particles during the pressing and curing process.
  • the coated substrate is deposited either automatically or by hand on the tool lower part 7b of a press (not shown in FIG. 2).
  • the press contracts (indicated by the arrows 51a, 51b), wherein the two fiber webs 2a, 2b are compressed.
  • the honeycomb core 3 is substantially not compressed.
  • Tool upper part 7a and lower tool part 7b are preferably heated (not shown in Figure 2), so that immediately after the closing of the press, the chemical reaction is carried out by so-called thermal activation.
  • the PUR reactive mixture penetrates the fiber webs 2a, 2b and also wets the honeycomb core 3, so that the individual fibers in the fiber webs stick together, but above all also with the honeycomb core and give a firm bond after curing.
  • the solid particles which are wetted on all sides with reactive mixture during the spray application and during the pressing process, remain at least partially on the surface of the fiber webs and fill the gaps between the individual fibers.
  • FIG. 3 shows a detail of the three-layer construction element 10 that can be produced according to the process shown in FIGS. 1 and 2.
  • the three-layer construction element comprises a honeycomb core 3 and the fiber webs 2a and 2b, which are pressed onto one side of the honeycomb core and glued thereto.
  • the surface of the construction element 10 is completely flat due to the solid particles 9 embedded in the interstices between the individual fibers and wetted with polyurethane.
  • Fig. 4 shows the schematic representation of a single-layer substrate during the spray application.
  • the nonwoven fabric 11, PUR reactive mixture and solid particles, each with one spray head per side are applied simultaneously on both sides (indicated by arrows 52a, 52b in FIG. 4).
  • the fiber fleece usually warps, so that the required wall thicknesses are not maintained at these "stress points.”
  • the points become 12a, 12b, 12c, 12d, 12e and 12f increases the amount of solid particles applied and possibly also of PUR Relux ⁇ schung.
  • Figure 5 shows the schematic representation of the substrate shown in Figure 4, the nonwoven fabric 11, immediately before the pressing and curing process. It is located between the upper tool part 7a 'and lower tool part 7b', which are then moved together by the press. The direction of movement of the press is indicated by the arrows 53a, 53b. During the pressing process, the curing of the PUR reactive mixture then takes place.
  • FIG. 6 shows the schematic representation of the construction element 10 'resulting from the substrate shown in FIGS. 4 and 5.
  • the PUR reactive mixture has penetrated the entire nonwoven fabric 11 and wetted substantially all fibers so that they bond together and form a solid composite.
  • the solid particles wetted on all sides with PUR reactive mixture which lead to a marked increase in viscosity and to a tixotropization of the PUR reactive mixture, are thereby partly filtered out by the fiber fleece 11 itself and remain on the surface. This causes, on the one hand, the entire surface of the construction element 10 'to be almost completely flat and, above all, that the required wall thicknesses are maintained at the "stress points".
  • Figure 7 shows a schematic representation of a spray head 20 for spraying laden with solid particles PUR reactive mixture.
  • the spray head 20 includes a spray mixing head 21 for spraying PUR reactive mixture through a spray nozzle 22 and a discharge device for the solid particles comprising two parallel to each other operated first channel sections 23 and two hydraulically thereafter second channel sections 24.
  • a spray mixing head 21 for spraying PUR reactive mixture through a spray nozzle 22
  • a discharge device for the solid particles comprising two parallel to each other operated first channel sections 23 and two hydraulically thereafter second channel sections 24.
  • the first and the second channel sections 23, 24 arranged substantially symmetrically about the spraying jet 22 in the spray direction of the spray nozzle 22 extended axis.
  • the first channel sections 23 for pneumatically conveying the solid particles each contain an inlet opening 26 for a gas stream and in each case one substantially in the first channel section 23 concentrically arranged intake manifold 25 for the solid particles.
  • the inlet opening 26 and the intake pipe 25 are arranged in the upstream part of the first channel section 23.
  • Ström gas Ström
  • Their flow direction is indicated by arrows 55.
  • the center of gravity axis 27 of the first channel section which is extended in the direction of flow and the axis 28 of the spray jet which extends in the spraying direction of the spray nozzle form an angle ⁇ , which is approximately 45 ° here.
  • the two first channel sections 23 each open into one of the two second channel sections 24 for pneumatically conveying the solid particles.
  • the center of gravity axis 27 of the first channel section 23, which is expanded in the direction of flow, and the center of gravity axis 29, which is expanded in the direction of flow, form an angle ⁇ at the outlet opening 30 of the second channel section 24, which is approximately 135 ° here.
  • the angle ⁇ is achieved that in the second channel section 24, the solid particles - gas flow - dispersion is deflected. This deflection causes the separation of solid particles and transport air due to the centrifugal forces.
  • the outlet openings 30 of the second channel section 24 are arranged substantially in the immediate vicinity of the spray nozzle 22 for the PUR reactive mixture and substantially aligned with the region of the spray jet emerging from the spray nozzle 22.
  • the PUR reactive mixture emerging from the spray mixing head 21 via the spray nozzle 22 leaves the spray nozzle 22 as spray jet 31.
  • the deflection of the solid particles-gas stream dispersion caused by the angle ⁇ flows through the centrifugal forces separated solid particles on the outer web and enter the spray jet 31 of the PUR reactive mixture and are mixed therein and wetted on all sides with reactive plastic.
  • the conveying air is directed away from the spray jet 31 of the reactive mixture and surrounds the spray jet and thus prevents the formation of harmful litter aerosols. This effect is particularly effective when the flow system for the solid particles, i. in particular, the second channel section 24 is formed as an annular channel around the spray nozzle 22 for the reactive mixture.
  • FIG. 8 shows a schematic representation of a continuous plant 45 for the production of three-layer construction elements 44 containing two fiber webs 2a, 2b and a spacer arranged therebetween, for example a honeycomb core 3.
  • the nonwoven fabrics are continuously unwound from coils 40a, 40b. Sheets of honeycomb core material, so-called honeycomb cores 3, are pushed between these two non-woven fabrics. This can be done, for example, by means of handling devices (not shown), which take over the plates from a stacker.
  • After contacting this three-layer substrate it is sprayed on both sides by spray heads with a loaded with solid particles PUR reactive mixture. This can be done, for example, with the spray head shown in FIG. It will be in the Sprayed jet of solid particles, mixed and wetted on all sides with reactive plastic.
  • the compound of fiber webs, honeycomb core, PUR reactive mixture and solid particles is conveyed into the continuously operating press 41.
  • the fiber leaves 2a, 2b are compacted without impairing the honeycomb core 3.
  • the PUR reactive mixture permeates the fiber webs, wets all the fibers and also the honeycomb core 3, so that after leaving the continuously operating press 41, i. after reacting the reactive mixture, a very light and high strength structural element, e.g. a panel 42 is formed, which is cut by the cutting device 43 into sections of desired length.
  • Tixotroping also aids in "filtering" the solid particles through the fibrous webs, which causes the solid particles on the surfaces of the fibrous webs to fill in the gaps between the fibers, thus creating structural elements with a nearly flat surface.
  • FIG. 8 shows a vertical arrangement of a continuous installation for producing three-layered construction elements. A horizontal arrangement is also possible.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • Materials Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Moulding By Coating Moulds (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

La présente invention concerne un procédé et un dispositif pour fabriquer des éléments de construction. Le procédé selon cette invention consiste à déposer un mélange réactif de polyuréthane (PUR) et des particules solides sur un non-tissé, ce qui permet d'obtenir une surface de non-tissé à revêtement présentant une densité de 0,01 à 10,0 g de particules solides/cm<SUP>2</SUP>, puis à comprimer et à faire durcir le non-tissé qui est revêtu avec le mélange réactif de polyuréthane n'ayant pas encore réagi et qui contient les particules solides.
EP06829261A 2005-12-15 2006-12-04 Procede et dispositif pour fabriquer des elements de construction Withdrawn EP1966337A2 (fr)

Applications Claiming Priority (2)

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DE102005059890 2005-12-15
PCT/EP2006/011604 WO2007073825A2 (fr) 2005-12-15 2006-12-04 Procede et dispositif pour fabriquer des elements de construction

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EP1966337A2 true EP1966337A2 (fr) 2008-09-10

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EP (1) EP1966337A2 (fr)
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JP2013503210A (ja) * 2009-08-26 2013-01-31 バイエル・マテリアルサイエンス・アクチェンゲゼルシャフト 吸音軟質成形フォームの製造方法
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US20140000297A1 (en) * 2012-06-29 2014-01-02 Air Liquide Industrial U.S. L.P. Production of Particles from Liquids or Suspensions with Liquid Cryogens
GB2545481A (en) * 2015-12-18 2017-06-21 Rolls Royce Plc An assembly and a method of using the assembly
DE102017008097B4 (de) * 2017-08-29 2019-06-27 Webasto SE Fahrzeug-Sandwichbauteil und Verfahren zum Herstellen eines Fahrzeug-Sandwichbauteils
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JP7528075B2 (ja) 2018-07-27 2024-08-05 ビーエーエスエフ ソシエタス・ヨーロピア 自動車部品としてのパネル構造、同パネル構造の製造方法及びそれを使用する方法
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WO2007073825A2 (fr) 2007-07-05
US20070164131A1 (en) 2007-07-19
US20110189392A1 (en) 2011-08-04

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