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WO2006010520A1 - Materiau composite a proprietes d'absorption d'energie ameliorees et procede de fabrication associe - Google Patents

Materiau composite a proprietes d'absorption d'energie ameliorees et procede de fabrication associe Download PDF

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Publication number
WO2006010520A1
WO2006010520A1 PCT/EP2005/007810 EP2005007810W WO2006010520A1 WO 2006010520 A1 WO2006010520 A1 WO 2006010520A1 EP 2005007810 W EP2005007810 W EP 2005007810W WO 2006010520 A1 WO2006010520 A1 WO 2006010520A1
Authority
WO
WIPO (PCT)
Prior art keywords
polyurethane
particles
expanded
volume
mould
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.)
Ceased
Application number
PCT/EP2005/007810
Other languages
English (en)
Inventor
Antonio Vismara.
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of WO2006010520A1 publication Critical patent/WO2006010520A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/586—Moulds with a cavity increasing in size during foaming
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers

Definitions

  • the present invention relates to a composite material with improved energy-absorbing properties and to a method for producing this material.
  • the material according to the invention can, for example, be used for the interiors of motor vehicles, furnishing parts, padding, etc.
  • expanded polyurethane obtained by making isocyanate react with substances provided with active hydrogen (such as, for example, polyhydric alcohols), is injected into the mould, where it is left to expand until it takes on the final shape desired for the product.
  • This material is characterized by relatively low resistance to compression, yielding even to small compression force. This feature enables a soft-touch surface effect to be achieved that is very much appreciated for the impression of softness to the touch. Furthermore, open-cell expanded polyurethane is permeable to air, as is often required in the applications mentioned above (furnishing, padding, car interiors, ... ) .
  • Deformable materials have been proposed with high energy- absorption consisting of a mass of granules with relatively low deformability that are bound by polyurethane with greater deformability. These materials are obtained by completely filling a mould with the granules (for example of expanded polypropylene) and injecting the polyurethane that has not yet expanded into the gaps between the particles. The polyurethane is then left to expand inside the mould to form a continuous material. The particles, having already filled the mould before injection of the polyurethane, cannot move away from one another because they remain in contact with one another even after expansion of the polyurethane.
  • the general object of the present invention is to obviate the aforementioned drawbacks by providing a composite material that has great energy-absorbing qualities whilst maintaining softness under relatively low deformation stress such as to produce a soft-touch effect.
  • a further object of the invention is to provide a material that is both cheap and light, whilst having good mechanical properties.
  • Another object of the invention is to provide a rapid and cheap method to produce a material with the above features.
  • a composite material comprising a matrix of expanded polyurethane in which granular particles of plastic material having greater rigidity than that of the expanded polyurethane are dispersed isotropically, characterized in that the granular particles are spaced apart from one another by the interposition of expanded polyurethane.
  • FIG. 1 shows a graph of the resistance/compression of composite materials curves according to the invention and of expanded polyurethane
  • FIG. 2 shows two stages of the process of formation of the material according to the invention.
  • the material according to the invention consists of a matrix of flexible polyurethane foam into which granular particles are dispersed (for example in polyethylene, polypropylene, expanded polystyrene or their copolymers, or in rigid or semirigid expanded polyurethane, or in expanded resins of other families of plastics such as acrylics, PET etc.) having greater rigidity than that of foam.
  • the granular particles are dispersed isotropically in the polyurethane matrix in such a way as not to touch one another by the interposing of a layer of expanded foam between one granule and another.
  • the material according to the invention thus has softness and soft-touch features at low compression whereas it is rigid and capable of absorbing considerable quantities of energy in the event of great compression.
  • figure 1 the M5, MlO, Mil and Ml2 curves are shown that express the resistance (expressed in MPa) provided by different types of material in function of the percentage volumetric compression.
  • the M12 curve refers to a material (the M12 material) made only of expanded polyurethane foam; the MlO and Mil curves refer to material made with a dispersion of spherical particles of expanded polystyrene (PSE) in a matrix of expanded polyurethane (PUR) foam; the M5 curve refers to a material made from granules of expanded polyethylene (PEE) in a polyurethane matrix.
  • PSE expanded polystyrene
  • PUR expanded polyurethane
  • PEE expanded polyethylene
  • the resistance/compression curve gradient expressed in KPa/%, can be used as an indicative parameter of the rigidity of the materials.
  • the M12 material which is made only of polyurethane foam, has a relatively low resistance/compression gradient, around 0.2 KPa/% up to about 50% of volumetric compression.
  • the expanded polyurethane is compressed, noticeably varying its volume without opposing great resistance.
  • This features translates into a soft-touch effect that is well known in the prior art.
  • the resistance/compression gradient of the material must advantageously not exceed 0.5 KPa/%.
  • the M12 material is not able to absorb great quantities of energy, yielding easily without ever opposing great resistance to compression up to 70% in volume.
  • the Mil and MlO materials according to the invention are made with isotropic dispersion of granules (or balls) of polystyrene in the polyurethane foam.
  • the balls have greater rigidity than the foam (for example around 2 KPa/%), and are dispersed therein in such a way as not to come into contact with one another. Their percentage in net volume (respectively 8% and 14%) is in fact relatively low to the point that each ball is "suspended" in the polyurethane matrix.
  • the gradients of the Mil and MlO curves for low volumetric compression percentages are comparable with those of the M12 curve of the expanded polyurethane (below 0.5 KPa/%).
  • the foam is compressed without the rigid balls interacting with one another or being noticeably deformed.
  • the MlO, Mil materials first have softness that is comparable with that of the expanded polyurethane (M12).
  • the characteristic MlO 7 Mil curve rises up, displaying very- steep gradients (up to 2 KPa/% or more) .
  • the MlO material has a net volume percentage of PSE balls (around 14%) that is greater than the Mil material (about 8%). This higher PSE balls content explains the fact that the MlO curve "rises up” at lower volumetric compression than the Mil curve. As the balls in the MlO material are denser, a lesser volumetric compression percentage will be sufficient to make them come into contact with one another, thus increasing the energy absorption capacity of the material.
  • the MlO and Mil materials in addition to maintaining the special soft-touch of the polyurethane, are also permeable to air, as is the expanded foam.
  • the M5 material is made of granular particles in expanded polyethylene (PEE), and not in polystyrene (PSE) as in the case of MlO and Mil materials. Note from figure 1 how in this case the composite material displays conspicuous resistance to compression only when its volume is reduced by about 50%. At low compression, the material M5 even displays greater compliance than the (M12) simple polyurethane.
  • a chamber 12 is filled with granules (or balls) 13 made from a material chosen for example from between polyethylene, polypropylene or polystyrene.
  • the chamber 12 must have a volume that is equal to the gross volume of the granules (or the apparent volume of the amassed granules, including the gaps between one ball and another) in such a way as to be completely filled by the particles 13.
  • non-expanded polyurethane is then injected ("non-expanded polyurethane" is defined as a mixture of isocyanate and polyhydric alcohol that, by reacting, give rise to expanded polyurethane).
  • catalyzing agents can also be injected to promote the expansion reaction.
  • the polyurethane 14 is made to expand inside the chamber 12 in such a way as to occupy all the gaps present between the granules 13. It should be noted that at this stage of the process the balls 13 are still in contact with one another, as they cannot move away from one another as long as they are inside the chamber 12. Once the polyurethane 14 has been evenly distributed in the gaps between the balls 13, the mixture that has been created is placed in a mould 15 having a greater volume than the gross volume of the granules 13 (and therefore also of the chamber 12).
  • the polyurethane 14 continues to expand until it fills the entire volume. During this expansion phase, the polyurethane drags the balls 13 away from one another, interposing itself between one granule and another to give rise to isotropic dispersal of the particles 13 in the foam matrix.
  • the geometry of the chamber 12 could be varied once the polyurethane has completed the first expansion phase going to occupy the gaps between the granules 13.
  • the geometry of the chamber 12 is varied in such a way as to increase its volume and make it take on the desired shape for the molding of the material.
  • the total net volume of the granules 13 is less than 60% of the total volume of the material, preferably less than 30%.
  • the granules may furthermore have the shape of small spheres having a diameter that is preferably less than 10% of the minimum characteristic dimension of the final mould 15.
  • the granules could also have a cylindrical shape, like a grain of rice or the like.
  • the granules could also be treated superficially to obtain improved properties of adhesion to the polyurethane matrix.
  • the treatment for example, could lead to surface roughness of the granule suitable for promoting the adhesion of the polyurethane at the moment of the molding of the composite material.
  • a composite material has in fact been created having a soft-touch property and which at the same time is able to absorb great quantities of energy. Furthermore, the material according to the invention is permeable to air, similarly to expanded polyurethane foam. It should also be noted that the composite material is very light and has relatively low costs if it is considered that the granular particles are made from a material that is typically cheaper than expanded polyurethane.

Landscapes

  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

L'invention concerne un procédé pour produire un matériau composite selon les opérations suivantes: mélanger des particules (13) de matière plastique avec un mélange de réactifs aptes à l'expansion de polyuréthanne, placer le mélange formé dans un moule (15) dont le volume est supérieur au volume brut des particules contenues dans le mélange, faire réagir les réactifs pour réaliser l'expansion du polyuréthanne (14) dans le moule (15) jusqu'à ce que celui-ci soit rempli, les particules (13) s'éloignant les unes des autres sous l'effet de l'expansion du polyuréthanne entre elles.
PCT/EP2005/007810 2004-07-27 2005-07-18 Materiau composite a proprietes d'absorption d'energie ameliorees et procede de fabrication associe Ceased WO2006010520A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMI2004A001515 2004-07-27
ITMI20041515 ITMI20041515A1 (it) 2004-07-27 2004-07-27 "materiale composito con proprieta' di assorbimento dell'energia migliorate e metodo per produrre tale materiale"

Publications (1)

Publication Number Publication Date
WO2006010520A1 true WO2006010520A1 (fr) 2006-02-02

Family

ID=34972324

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2005/007810 Ceased WO2006010520A1 (fr) 2004-07-27 2005-07-18 Materiau composite a proprietes d'absorption d'energie ameliorees et procede de fabrication associe

Country Status (2)

Country Link
IT (1) ITMI20041515A1 (fr)
WO (1) WO2006010520A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013049132A1 (fr) * 2011-09-27 2013-04-04 Simpet Holdings LLC Systèmes pour former des matériaux d'agrégat à partir de matériaux en poudre pouvant fondre à la chaleur
US8801414B2 (en) 2010-03-25 2014-08-12 Simpet Holdings LLC Systems for forming aggregate materials from heat fusable powdered materials

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3503840A (en) * 1968-04-24 1970-03-31 Du Pont Composite cellular cushioning structures
GB1451132A (en) * 1974-01-21 1976-09-29 Dow Chemical Co Foam materials and the preparation thereof
US4061701A (en) * 1972-12-20 1977-12-06 Basf Aktiengesellschaft Manufacture of soft and resilient foams

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3503840A (en) * 1968-04-24 1970-03-31 Du Pont Composite cellular cushioning structures
US4061701A (en) * 1972-12-20 1977-12-06 Basf Aktiengesellschaft Manufacture of soft and resilient foams
GB1451132A (en) * 1974-01-21 1976-09-29 Dow Chemical Co Foam materials and the preparation thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8801414B2 (en) 2010-03-25 2014-08-12 Simpet Holdings LLC Systems for forming aggregate materials from heat fusable powdered materials
US9522491B2 (en) 2010-03-25 2016-12-20 Simpet Holdings LLC Systems for forming aggregate materials from heat fusable powered materials
WO2013049132A1 (fr) * 2011-09-27 2013-04-04 Simpet Holdings LLC Systèmes pour former des matériaux d'agrégat à partir de matériaux en poudre pouvant fondre à la chaleur

Also Published As

Publication number Publication date
ITMI20041515A1 (it) 2004-10-27

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