WO2008000436A1 - Fibrous part, and method for the production thereof - Google Patents
Fibrous part, and method for the production thereof Download PDFInfo
- Publication number
- WO2008000436A1 WO2008000436A1 PCT/EP2007/005638 EP2007005638W WO2008000436A1 WO 2008000436 A1 WO2008000436 A1 WO 2008000436A1 EP 2007005638 W EP2007005638 W EP 2007005638W WO 2008000436 A1 WO2008000436 A1 WO 2008000436A1
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- WO
- WIPO (PCT)
- Prior art keywords
- fibers
- binder
- fiber part
- heat
- carbon dioxide
- 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
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Classifications
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/12—Condensation polymers of aldehydes or ketones
- C04B26/122—Phenol-formaldehyde condensation polymers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/02—Selection of the hardening environment
- C04B40/0231—Carbon dioxide hardening
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
- C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
- C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
- C08G8/10—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with phenol
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- 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
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
- B29K2995/0017—Heat stable
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
- C04B2111/00706—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like around pipelines or the like
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
Definitions
- the present invention relates to a fiber part according to the preamble of claim 1, a method for producing a molded part according to the preamble of claim 10 and a use of a carbon dioxide-curing binder for producing a molded part from fibers.
- a fiber part, in particular a molded part, for the purposes of the present invention is used in particular for heat or heat insulation and / or storage or covering, preferably in exhaust systems of an internal combustion engine or motor vehicle, in the engine compartment of a motor vehicle or the like, for example, an element of an exhaust system, in particular an elbow, a front pipe, an inlet hopper, a particulate filter, a catalyst, a monolith, a muffler or the like.
- the present invention relates in particular to fiber parts, which are used at higher or elevated temperatures, preferably greater than 200 0 C, in particular of about 300 ° C to 1100 0 C or higher.
- the present invention has for its object to provide a fiber part, a method for producing a fiber part and a use of a carbon dioxide-curing binder for producing a molded part, so that a simple and inexpensive production of a molded part of fibers or a fiber part is made possible.
- One aspect of the present invention is to use a binder for the fibers which cures under carbon dioxide. This leads to several advantages.
- the proposed binder allows a simple and inexpensive production of a molded part from the fibers.
- solidification can be achieved very quickly, for example within 60 seconds. This allows compared to the prior art lower cycle times and higher productivity for example, the same number of molds gene.
- Another advantage is that in principle no heating for curing of the binder - that is, for solidification of the fiber part or the fibers to the fiber molding - is required. This noticeably reduces the energy expenditure compared with the prior art. Furthermore, this is beneficial for shorter cycle times, since a warm-up and cooling can be omitted.
- a certain (small) heating for example to about 50 to 100 ° C, in particular about 70 0 C, possible to accelerate the hardening of the binder (further).
- the binder contains or consists of at least one phenolic resin. Particular preference is given to using a resol.
- the term "by carbon dioxide” is to be understood as meaning that a gas is used which contains or consists of carbon dioxide of at least 25% by volume, preferably at least 50% by volume. Either it is sufficient to expose the fiber part or binder to be cured to this gas, in particular by displacing the normal air. Particularly preferably, the fiber part or binder is flowed through by the gas.
- Fig. 1 is a schematic representation of a proposed production of a proposed fiber part
- FIG. 2 shows a schematic representation of the production of a molded part from the fiber part or from fibers provided with binder.
- FIG. 1 illustrates, in a schematic diagram only, a preferred production of a proposed fiber part 1, in particular of mineral or heat-resistant fibers 2.
- the fibers 2 are in particular continuous filaments as starting material.
- the fiber part 1 is not further tailored or shaped and is in particular in endless form or as wool or the like before.
- the fibers 2 used are preferably glass fibers, in particular E or ECR glass fibers.
- other mineral fibers in particular silicate fibers or calcium silicate fibers, can also be used.
- the fibers 2 are heat-resistant at least to 300 ° C., preferably high-temperature resistant, preferably up to 600 ° C., in particular up to 800 ° C., very particularly preferably up to 1100 ° C. or more.
- the fibers 2 are preferably drawn endlessly from a melt and have a constant diameter.
- the fiber diameter is at least 3 microns, preferably at least 4 microns and more preferably at least 6 microns or more. According to a very particularly preferred embodiment, the diameter is substantially 9 to 10 microns with a tolerance of at most 3 microns.
- the fibers 2 are preferably - as already mentioned - continuous filaments.
- the fiber part 1 can basically also be formed from fibers of finite or specific length. Alternatively or additionally, the endless fibers 2 can also be cut. Furthermore, during fabrication and cutting of the fiber part 1, a shortening of the fibers 2 takes place anyway.
- the fiber part 1 furthermore has a binder 3 which is applied, for example sprayed on, in particular to the fibers 2, for example in liquid or dry form or in any other suitable form.
- the fibers 2 are preferably textured, in particular by means of a nozzle 4, as indicated in FIG. 1.
- the fibers 2 initially present as fiber strand are textured by supplied gas, for example compressed air, and output, in particular, wool-like.
- the binder 3 is preferably added during the texturing, in particular in the nozzle 4 or by means of the nozzle 4 or through a separate or integrated nozzle, in particular sprayed on or otherwise applied to the fibers 2.
- the fibers 2 need not be completely covered by the binder 3, although this may be desirable. However, at least partial covering, wetting or adhesion of binder 3 is preferably sufficient.
- the binder 3 preferably cures quickly by carbon dioxide - that is, under the action of carbon dioxide.
- the binder 3 contains in particular at least one corresponding phenolic resin, more preferably at least one resol.
- the phenol resin or resol as binder 3 available under the trade name "Carbophen” from Wilsontenes Albertus Chemische Werke GmbH, Dusseldorf, Germany, or under the trade name "SuperEko 2000” from Erg-Odlew, Poland
- FIG. 2 shows in a schematic representation how preferably by means of a molding tool 5, in particular a three-dimensional fiber molded part 6 is produced from the fiber part 1 or the fibers 2 with the binder 3.
- the mold 5 is filled with the particular wool-like, not solidified fiber part 1 or the preferably wooleartig present fibers 2 with the binder 3. The mold 5 then gives the desired shape.
- a gas containing or consisting of carbon dioxide fed via an inlet 7 to the interior of the mold 5 and the shaped fiber part 1 and for example via an optional outlet 8 again led off.
- the fiber part 1 is traversed by the carbon dioxide or gas.
- the interior of the mold 5 or the fiber part 1 is flooded with gas containing only carbon dioxide or carbon dioxide, ie, it does not flow through continuously.
- the curing of the binder 3 - that is solidifying the fiber part 1 - is very fast, especially within 60 seconds, more preferably within 5 to 30 seconds.
- the molded part 6 is produced in a very simple manner, in particular fast and energy-saving.
- a (slight) heating may in principle be carried out, for example to 50 to 100 ° C., in particular about 70 ° C. This heating accelerates the hardening of the binder 3 under the influence of carbon dioxide.
- the mold 5 may be preheated or generally heated.
- the gas conducted through the mold 5 or molded part 1 can also be preheated to a corresponding temperature.
- the finished molded part 6 is in particular a semi-finished product.
- the molding 6 is in particular for heat or heat insulation, sheathing, cladding and / or storage, preferably a component such as a manifold, front pipe, inlet funnel, particulate filter, catalyst, monolith or muffler, an exhaust system or an engine or im Engine compartment used.
- a component such as a manifold, front pipe, inlet funnel, particulate filter, catalyst, monolith or muffler, an exhaust system or an engine or im Engine compartment used.
- the molded part 6 is attached to the associated component and / or installed in an associated cover or a housing. In particular, this attachment or installation can be carried out automatically - for example, by a robot, not shown, or the like - due to the defined shape of the mold part 6.
- the cover or the housing can then be attached, for example screwed, welded or glued.
- the temperature at which the binder 3 burns may be below the operating temperature of the associated component or the exhaust system, the engine or the like. This can result in normal operation that the binder 3 at least partially burns.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Textile Engineering (AREA)
- Health & Medical Sciences (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Dispersion Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Toxicology (AREA)
- General Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Exhaust Gas After Treatment (AREA)
- Reinforced Plastic Materials (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
FASERTEIL UND VERFAHREN ZU SEINEM HERSTELLUNG FIBER PART AND METHOD FOR ITS MANUFACTURE
Die vorliegende Erfindung betrifft ein Faserteil gemäß dem Oberbegriff des Anspruchs 1 , ein Verfahren zur Herstellung eines Formteils gemäß dem Oberbegriff des Anspruchs 10 sowie eine Verwendung eines durch Kohlendioxid aushärtenden Bindemittel zur Herstellung eines Formteils aus Fasern.The present invention relates to a fiber part according to the preamble of claim 1, a method for producing a molded part according to the preamble of claim 10 and a use of a carbon dioxide-curing binder for producing a molded part from fibers.
Ein Faserteil, insbesondere Formteil, im Sinne der vorliegenden Erfindung dient insbesondere der Hitze- bzw. Wärmeisolierung und/oder Lagerung bzw. Abdeckung, vorzugsweise bei Abgasanlagen eines Verbrennungsmotors bzw. Kraftfahrzeugs, im Motorraum eines Kraftfahrzeugs oder dergleichen, beispielsweise eines Elements einer Abgasanlage, insbesondere eines Krümmers, eines Vorrohrs, eines Eingangstrichters, eines Partikelfilters, eines Katalysators, eines Monolithen, eines Schalldämpfers oder dergleichen.A fiber part, in particular a molded part, for the purposes of the present invention is used in particular for heat or heat insulation and / or storage or covering, preferably in exhaust systems of an internal combustion engine or motor vehicle, in the engine compartment of a motor vehicle or the like, for example, an element of an exhaust system, in particular an elbow, a front pipe, an inlet hopper, a particulate filter, a catalyst, a monolith, a muffler or the like.
Die vorliegende Erfindung bezieht sich insbesondere auf Faserteile, die bei höheren oder hohen Temperaturen eingesetzt werden, vorzugsweise von mehr als 200 0C, insbesondere von ca. 300 °C bis 1100 0C oder darüber.The present invention relates in particular to fiber parts, which are used at higher or elevated temperatures, preferably greater than 200 0 C, in particular of about 300 ° C to 1100 0 C or higher.
Es ist grundsätzlich bekannt, ein Faserteil mit einem flüssigen Bindemittelgemisch aus organischen oder anorganischen Bestandteilen zu tränken. Das konfektionierte und getränkte Faserteil wird dann in einem beheizten Formwerkzeug ausgebacken bzw. ausgehärtet, so daß ein Formteil hergestellt wird, das bei der Montage automatisiert in ein Gehäuse eingebaut werden kann. Nachteilig ist jedoch, daß die Herstellung des Formteils einen beträchtlichem Zeit- und Energieaufwand erfordert. Zunächst ist das Tränken verhältnismäßig aufwendig und kann nur unmittelbar vor der Herstellung eines Formteils erfolgen. Weiter ist dann die eigentliche Herstellung des Formteils - also das Ausbacken bzw. Aushärten - sehr zeit- und energieaufwendig.It is generally known to impregnate a fiber part with a liquid binder mixture of organic or inorganic constituents. The prefabricated and impregnated fiber part is then baked or cured in a heated mold, so that a molded part is produced, which can be automatically installed in a housing during assembly. The disadvantage, however, is that the production of the molding requires a considerable amount of time and energy. First, the impregnation is relatively expensive and can only be done immediately before the production of a molding. Next is then the actual production of the molding - ie the baking or curing - very time and energy consuming.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, eine Faserteil, ein Verfahren zur Herstellung eines Faserteils sowie eine Verwendung eines durch Kohlendioxid aushärtenden Bindemittels zur Herstellung eines Formteils anzugeben, so daß eine einfache und kostengünstige Herstellung eines Formteils aus Fasern bzw. einem Faserteil ermöglicht wird.The present invention has for its object to provide a fiber part, a method for producing a fiber part and a use of a carbon dioxide-curing binder for producing a molded part, so that a simple and inexpensive production of a molded part of fibers or a fiber part is made possible.
BESTÄTIGUNGSKOPfE Die obige Aufgabe wird durch ein Faserteil gemäß Anspruch 1, ein Verfahren gemäß Anspruch 10 oder eine Verwendung gemäß Anspruch 18 gelöst. Vorteilhafte Weiterbildungen sind Gegenstand der Unteransprüche.confirmation head The above object is achieved by a fiber part according to claim 1, a method according to claim 10 or a use according to claim 18. Advantageous developments are the subject of the dependent claims.
Ein Aspekt der vorliegenden Erfindung liegt darin, ein Bindemittel für die Fasern einzusetzen, das unter bzw. durch Kohlendioxid aushärtet. Dies führt zu mehreren Vorteilen.One aspect of the present invention is to use a binder for the fibers which cures under carbon dioxide. This leads to several advantages.
Das vorschlagsgemäße Bindemittel gestattet eine einfache und kostengünstige Herstellung eines Formteils aus den Fasern. Eine Verfestigung kann nämlich sehr schnell, beispielsweise innerhalb von 60 Sekunden, erreicht werden. Dies gestattet gegenüber dem Stand der Technik geringere Taktzeiten bzw. eine höhere Produktivität bei beispielsweise gleicher Anzahl von Formwerkzeu- gen.The proposed binder allows a simple and inexpensive production of a molded part from the fibers. In fact, solidification can be achieved very quickly, for example within 60 seconds. This allows compared to the prior art lower cycle times and higher productivity for example, the same number of molds gene.
Ein weiterer Vorteil besteht darin, daß grundsätzlich keine Erwärmung zum Aushärten des Bindemittels - also zur Verfestigung des Faserteils bzw. der Fasern zum Faserformteil - erforderlich ist. Dies verringert den Energieauf- wand gegenüber dem Stand der Technik merklich. Des weiteren ist dies kürzeren Taktzeiten zuträglich, da ein Aufwärmen und Abkühlen entfallen kann.Another advantage is that in principle no heating for curing of the binder - that is, for solidification of the fiber part or the fibers to the fiber molding - is required. This noticeably reduces the energy expenditure compared with the prior art. Furthermore, this is beneficial for shorter cycle times, since a warm-up and cooling can be omitted.
Grundsätzlich ist jedoch auch eine gewisse (geringe) Erwärmung beispielsweise auf etwa 50 bis 100°C, insbesondere etwa 7O0C, möglich, um das Aus- härten des Bindemittels (weiter) zu beschleunigen.In principle, however, a certain (small) heating, for example to about 50 to 100 ° C, in particular about 70 0 C, possible to accelerate the hardening of the binder (further).
Vorzugsweise enthält das Bindemittel mindestens ein Phenol-Harz oder besteht daraus. Besonders bevorzugt wird ein Resol eingesetzt.Preferably, the binder contains or consists of at least one phenolic resin. Particular preference is given to using a resol.
Bei der vorliegenden Erfindung ist das Aushärten "durch Kohlendioxid" dahingehend zu verstehen, daß ein Gas eingesetzt wird, das Kohlendioxid zu mindestens 25 Vol.-%, vorzugsweise mindestens 50 Vol.-%, enthält oder daraus besteht. Entweder genügt es, das zu härtende Faserteil bzw. Bindemittel diesem Gas auszusetzen, insbesondere unter Verdrängung der normalen Luft. Besonders bevorzugt wird das Faserteil bzw. Bindemittel von dem Gas durchströmt. Weitere Aspekte, Vorteile, Merkmale und Eigenschaften der vorliegenden Erfindung ergeben sich aus den Ansprüchen und der folgenden Beschreibung eines bevorzugten Ausführungsbeispiels anhand der Zeichnung. Es zeigt:In the present invention, the term "by carbon dioxide" is to be understood as meaning that a gas is used which contains or consists of carbon dioxide of at least 25% by volume, preferably at least 50% by volume. Either it is sufficient to expose the fiber part or binder to be cured to this gas, in particular by displacing the normal air. Particularly preferably, the fiber part or binder is flowed through by the gas. Further aspects, advantages, features and characteristics of the present invention will become apparent from the claims and the following description of a preferred embodiment with reference to the drawing. It shows:
Fig. 1 eine schematische Darstellung einer vorschlagsgemäßen Herstellung eines vorschlagsgemäßen Faserteils; undFig. 1 is a schematic representation of a proposed production of a proposed fiber part; and
Fig. 2 eine schematische Darstellung der Herstellung eines Formteils aus dem Faserteil bzw. aus mit Bindemittel versehenen Fasern.2 shows a schematic representation of the production of a molded part from the fiber part or from fibers provided with binder.
Fig. 1 veranschaulicht in einer nur schematischen Prinzipskizze eine bevorzugte Herstellung eines vorschlagsgemäßen Faserteils 1 aus insbesondere mineralischen bzw. hitzebeständigen Fasern 2.FIG. 1 illustrates, in a schematic diagram only, a preferred production of a proposed fiber part 1, in particular of mineral or heat-resistant fibers 2.
Bei den Fasern 2 handelt es sich insbesondere um Endlosfasern als Ausgangsmaterial. Bei der Darstellung in Fig. 1 ist das Faserteil 1 noch nicht weiter konfektioniert bzw. geformt und liegt insbesondere in endloser Form bzw. als Wolle oder dergleichen vor.The fibers 2 are in particular continuous filaments as starting material. In the illustration in Fig. 1, the fiber part 1 is not further tailored or shaped and is in particular in endless form or as wool or the like before.
Als Fasern 2 werden vorzugsweise Glasfasern, insbesondere E- oder ECR- Glasfasern, verwendet. Jedoch können auch sonstige mineralische Fasern, insbesondere Silikatfasern oder Kalziumsilikatfasern, eingesetzt werden.The fibers 2 used are preferably glass fibers, in particular E or ECR glass fibers. However, other mineral fibers, in particular silicate fibers or calcium silicate fibers, can also be used.
Die Fasern 2 sind hitzebeständig zumindest bis 300 0C, vorzugsweise hochtemperaturbeständig, vorzugsweise bis 600 0C, insbesondere bis 800 0C, ganz besonders bevorzugt bis 1100 0C oder mehr.The fibers 2 are heat-resistant at least to 300 ° C., preferably high-temperature resistant, preferably up to 600 ° C., in particular up to 800 ° C., very particularly preferably up to 1100 ° C. or more.
Die Fasern 2 sind vorzugsweise endlos aus einer Schmelze gezogen und wei- sen einen konstanten Durchmesser auf.The fibers 2 are preferably drawn endlessly from a melt and have a constant diameter.
Der Faserdurchmesser beträgt mindestens 3 μm, vorzugsweise mindestens 4 μm und insbesondere mindestens 6 μm oder mehr. Gemäß einer ganz besonders bevorzugten Ausführungsform beträgt der Durchmesser im wesentlichen 9 bis 10 μm mit einer Toleranz von höchstens 3 μm. Bei den Fasern 2 handelt es sich vorzugsweise - wie bereits erwähnt - um Endlosfasern. Jedoch kann das Faserteil 1 grundsätzlich auch aus Fasern endlicher bzw. bestimmter Länge gebildet werden. Alternativ oder zusätzlich können die endlosen Fasern 2 auch geschnitten werden. Des weiteren erfolgt beim Konfektionieren und Abschneiden des Faserteils 1 ohnehin eine Verkürzung der Fasern 2.The fiber diameter is at least 3 microns, preferably at least 4 microns and more preferably at least 6 microns or more. According to a very particularly preferred embodiment, the diameter is substantially 9 to 10 microns with a tolerance of at most 3 microns. The fibers 2 are preferably - as already mentioned - continuous filaments. However, the fiber part 1 can basically also be formed from fibers of finite or specific length. Alternatively or additionally, the endless fibers 2 can also be cut. Furthermore, during fabrication and cutting of the fiber part 1, a shortening of the fibers 2 takes place anyway.
Das Faserteil 1 weist ferner ein Bindemittel 3 auf, das insbesondere auf die Fasern 2 beispielsweise in flüssiger oder trockener Form oder sonstiger geeig- neter Form aufgebracht, beispielsweise aufgesprüht, wird.The fiber part 1 furthermore has a binder 3 which is applied, for example sprayed on, in particular to the fibers 2, for example in liquid or dry form or in any other suitable form.
Beim Darstellungsbeispiel werden die Fasern 2 vorzugsweise texturiert, insbesondere mittels einer Düse 4, wie in Fig. 1 angedeutet. Vorzugsweise werden die zunächst als Faserstrang vorliegenden Fasern 2 durch zugeführtes Gas, beispielsweise Druckluft, texturiert und insbesondere wolleartig ausgegeben.In the illustrated embodiment, the fibers 2 are preferably textured, in particular by means of a nozzle 4, as indicated in FIG. 1. Preferably, the fibers 2 initially present as fiber strand are textured by supplied gas, for example compressed air, and output, in particular, wool-like.
Das Bindemittel 3 wird vorzugsweise während der Texturierung, insbesondere in der Düse 4 oder mittels der Düse 4 oder durch eine separate oder darin in- tegrierte Düse, zugegeben, insbesondere aufgesprüht oder in sonstiger Weise auf die Fasern 2 aufgebracht. Die Fasern 2 müssen dabei nicht vollständig von dem Bindemittel 3 bedeckt werden, auch wenn dies wünschenswert sein kann. Vorzugsweise genügt jedoch eine zumindest teilweise Bedeckung, Benetzung oder Anhaftung von Bindemittel 3.The binder 3 is preferably added during the texturing, in particular in the nozzle 4 or by means of the nozzle 4 or through a separate or integrated nozzle, in particular sprayed on or otherwise applied to the fibers 2. The fibers 2 need not be completely covered by the binder 3, although this may be desirable. However, at least partial covering, wetting or adhesion of binder 3 is preferably sufficient.
Das Bindemittel 3 härtet vorzugsweise durch Kohlendioxid - also unter der Einwirkung von Kohlendioxid - rasch aus.The binder 3 preferably cures quickly by carbon dioxide - that is, under the action of carbon dioxide.
Das Bindemittel 3 enthält vorschlagsgemäß insbesondere mindestens ein ent- sprechendes Phenol-Harz, besonders bevorzugt mindestens ein Resol. Ganz besonders bevorzugt wird das unter dem Handelsnamen "Carbophen" der Firma Hüttenes Albertus Chemische Werke GmbH, Düsseldorf, Deutschland, oder unter dem Handelsnamen "SuperEko 2000" der Firma Erg-Odlew, Polen, erhältliche Phenol-Harz bzw. Resol als Bindemittel 3 eingesetzt. Fig. 2 zeigt in einer schematischen Darstellung, wie vorzugsweise mittels eines Formwerkzeugs 5, ein insbesondere dreidimensionales Faserformteil 6 aus dem Faserteil 1 bzw. den Fasern 2 mit dem Bindemittel 3 hergestellt wird.According to the proposal, the binder 3 contains in particular at least one corresponding phenolic resin, more preferably at least one resol. Very particular preference is given to using the phenol resin or resol as binder 3 available under the trade name "Carbophen" from Hüttenes Albertus Chemische Werke GmbH, Dusseldorf, Germany, or under the trade name "SuperEko 2000" from Erg-Odlew, Poland , FIG. 2 shows in a schematic representation how preferably by means of a molding tool 5, in particular a three-dimensional fiber molded part 6 is produced from the fiber part 1 or the fibers 2 with the binder 3.
Das Formwerkzeug 5 wird mit dem insbesondere wolleartigen, nicht verfestigten Faserteil 1 bzw. den vorzugsweise wolleartig vorliegenden Fasern 2 mit dem Bindemittel 3 gefüllt. Das Formwerkzeug 5 gibt dann die gewünschte Form.The mold 5 is filled with the particular wool-like, not solidified fiber part 1 or the preferably wooleartig present fibers 2 with the binder 3. The mold 5 then gives the desired shape.
Weiter erfolgt eine Verfestigung bzw. Aushärtung insbesondere in dem Formwerkzeug 5. Hierzu wird beim Darstellungsbeispiel ein Gas, das Kohlendioxid enthält oder daraus besteht, wie eingangs erläutert, über einen Einlaß 7 dem Innenraum des Formwerkzeugs 5 bzw. dem geformten Faserteil 1 zugeführt und beispielsweise über einen optionalen Auslaß 8 wieder abge- führt.For this purpose, in the illustrated example, a gas containing or consisting of carbon dioxide, as explained above, fed via an inlet 7 to the interior of the mold 5 and the shaped fiber part 1 and for example via an optional outlet 8 again led off.
Vorzugsweise wird das Faserteil 1 von dem Kohlendioxid bzw. Gas durchströmt. Grundsätzlich kann es jedoch auch genügen, wenn der Innenraum des Formwerkzeugs 5 bzw. das Faserteil 1 nur mit Kohlendioxid bzw. Kohlendi- oxid enthaltendem Gas geflutet wird, also nicht fortlaufend durchströmt wird.Preferably, the fiber part 1 is traversed by the carbon dioxide or gas. In principle, however, it may also be sufficient if the interior of the mold 5 or the fiber part 1 is flooded with gas containing only carbon dioxide or carbon dioxide, ie, it does not flow through continuously.
Das Aushärten des Bindemittels 3 - also Verfestigen des Faserteils 1 - erfolgt sehr schnell, insbesondere innerhalb von 60 Sekunden, besonders bevorzugt innerhalb von 5 bis 30 Sekunden. So wird das Formteil 6 auf sehr einfache - insbesondere schnelle und energiesparende - Weise hergestellt.The curing of the binder 3 - that is solidifying the fiber part 1 - is very fast, especially within 60 seconds, more preferably within 5 to 30 seconds. Thus, the molded part 6 is produced in a very simple manner, in particular fast and energy-saving.
Zur Beschleunigung der Verfestigung bzw. Aushärtung kann grundsätzlich eine (leichte) Erwärmung erfolgen, beispielsweise auf 50 bis 100°C, insbesondere etwa 70°C. Diese Erwärmung beschleunigt das Aushärten des Bin- demittels 3 unter dem Einfluß von Kohlendioxid.In order to accelerate the solidification or hardening, a (slight) heating may in principle be carried out, for example to 50 to 100 ° C., in particular about 70 ° C. This heating accelerates the hardening of the binder 3 under the influence of carbon dioxide.
Zum Erwärmen bzw. Vorwärmen kann das Formwerkzeug 5 vorgewärmt bzw. generell geheizt sein. Alternativ oder zusätzlich kann auch das durch das Formwerkzeug 5 bzw. Formteil 1 geleitete Gas auf eine entsprechende Tem- peratur vorgewärmt sein. Bei dem fertigen Formteil 6 handelt es sich insbesondere um ein Halbfabrikat.For heating or preheating, the mold 5 may be preheated or generally heated. Alternatively or additionally, the gas conducted through the mold 5 or molded part 1 can also be preheated to a corresponding temperature. The finished molded part 6 is in particular a semi-finished product.
Das Formteil 6 wird insbesondere zur Hitze- bzw. Wärmeisolierung, Um- mantelung, Verkleidung und/oder Lagerung, vorzugsweise eines Bauteils, wie eines Krümmers, Vorrohrs, Eingangstrichters, Partikelfilters, Katalysators, Monolithen oder Schalldämpfers, einer Abgasanlage oder eines Motors bzw. im Motorraum eingesetzt. Vorzugsweise wird das Formteil 6 an dem zugeordneten Bauteil angebracht und/oder in eine zugeordnete Abdeckung bzw. ein Gehäuse eingebaut. Diese Anbringung bzw. dieser Einbau kann insbeson- dere automatisiert - beispielsweise durch einen nicht dargestellten Roboter oder dergleichen - aufgrund der definierten Form des Form teils 6 erfolgen.The molding 6 is in particular for heat or heat insulation, sheathing, cladding and / or storage, preferably a component such as a manifold, front pipe, inlet funnel, particulate filter, catalyst, monolith or muffler, an exhaust system or an engine or im Engine compartment used. Preferably, the molded part 6 is attached to the associated component and / or installed in an associated cover or a housing. In particular, this attachment or installation can be carried out automatically - for example, by a robot, not shown, or the like - due to the defined shape of the mold part 6.
Die Abdeckung bzw. das Gehäuse kann dann befestigt, beispielsweise angeschraubt, verschweißt oder verklebt werden.The cover or the housing can then be attached, for example screwed, welded or glued.
Die Temperatur, bei der das Bindemittel 3 verbrennt, liegt ggf. unter der Betriebstemperatur des zugeordneten Bauteils bzw. der Abgasanlage, des Motors oder dergleichen. Dies kann im normalen Betrieb dazu führen, daß das Bindemittel 3 zumindest teilweise verbrennt. The temperature at which the binder 3 burns may be below the operating temperature of the associated component or the exhaust system, the engine or the like. This can result in normal operation that the binder 3 at least partially burns.
Claims
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102006030112 | 2006-06-28 | ||
| DE102006030112.9 | 2006-06-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2008000436A1 true WO2008000436A1 (en) | 2008-01-03 |
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ID=38578636
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2007/005638 Ceased WO2008000436A1 (en) | 2006-06-28 | 2007-06-26 | Fibrous part, and method for the production thereof |
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| Country | Link |
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| WO (1) | WO2008000436A1 (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1353345A (en) * | 1970-06-08 | 1974-05-15 | Fiberglas Canada Ltd | Binder formulation based on calcium catalyzed phenol formaldehyde resins and mineral fibre products bonded therewith |
| US3935139A (en) * | 1973-07-18 | 1976-01-27 | Fibreglass Limited | Binder compositions |
| EP0323096A2 (en) * | 1987-12-24 | 1989-07-05 | Foseco International Limited | Production of articles of bonded particulate material and binder compostions for use therein |
| KR920000739B1 (en) * | 1987-01-31 | 1992-01-21 | 주식회사 금강 | A concertrated material for the glass duct and its manufacturing method |
| US5902442A (en) * | 1993-05-17 | 1999-05-11 | Borden Chemical, Inc. | Method for bonding lignocellulosic material with phenol-formaldehyde resin and carbon dioxide |
-
2007
- 2007-06-26 WO PCT/EP2007/005638 patent/WO2008000436A1/en not_active Ceased
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1353345A (en) * | 1970-06-08 | 1974-05-15 | Fiberglas Canada Ltd | Binder formulation based on calcium catalyzed phenol formaldehyde resins and mineral fibre products bonded therewith |
| US3935139A (en) * | 1973-07-18 | 1976-01-27 | Fibreglass Limited | Binder compositions |
| KR920000739B1 (en) * | 1987-01-31 | 1992-01-21 | 주식회사 금강 | A concertrated material for the glass duct and its manufacturing method |
| EP0323096A2 (en) * | 1987-12-24 | 1989-07-05 | Foseco International Limited | Production of articles of bonded particulate material and binder compostions for use therein |
| US5902442A (en) * | 1993-05-17 | 1999-05-11 | Borden Chemical, Inc. | Method for bonding lignocellulosic material with phenol-formaldehyde resin and carbon dioxide |
Non-Patent Citations (1)
| Title |
|---|
| DATABASE WPI Week 199301, Derwent World Patents Index; AN 1993-006617, XP002455818 * |
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