BE1027200B1 - COMPOSITE PROFILE PIECES WITH A LOW DENSITY POLYESTER FOAM CORE - Google Patents

Abstract

The invention relates to a method for producing a composite profile piece and the composite profile pieces obtained, which have a core made of foam that was foamed in the open air, its density being up to 250 kg / m3, preferably 40 to 150 kg / m3, and on at least one of its sides comprises a functional element which has been applied by means of collateral coextrusion, the method comprising the following steps: (a) metering the components of the foam core, in premix or metered individually, into the feed device of a first extruder; (b) plasticizing and mixing the components of the foam core at high temperature to melt and homogenize these components; (c) introducing a foaming gas and homogenizing the constituents of the foam core and the gas; (d) cooling the mass obtained; (e) extruding this mass in the open air through a temperature controlled nozzle having a predetermined cross-sectional shape, thereby causing the formation of the foam core; (f) cooling the foam core; (g) metering the constituents of the functional element, in premix or metered in individually, into the feed device of a second extruder; (h) plasticizing and mixing the components of the functional element at a high temperature to melt and homogenize these components; (i) cooling the obtained mass and (j) guiding the core of foam as a centering element in the vicinity of a nozzle of the second extruder and extruding through this nozzle, which is temperature-controlled, wherein it has a cross-section of a predetermined shape, the formation of the functional Element that causes an application to at least one surface of the foam core.

Description

COMPOSITE PROFILE PIECES WITH A POLYESTER FOAM CORE LOW DENSITY

DESCRIPTION Technical area

The present invention relates to composite profile pieces comprising a core of low density polyester foam, and a method for producing such composite profile pieces. State of the art

The simple foaming of polyester is known and well documented in the literature. By foaming down to low densities of 40 to 80 kg / m? optimal performance characteristics of the insulation can be achieved, but this has a negative effect on the mechanical properties. This is because these foams can be compressed and deformed quickly and easily.

In the special case of polyester foams, the prior art mostly relates to foams that have been extruded in the form of films, thin layers or sheets, one or more layers being laminated, post-extruded or even agglomerated on one or both main sides of the same. EP0836937B1 teaches the coextrusion of a non-foamed PET thin film onto a PET foam. EP2345538 teaches the flame retardant treatment of a PET foam by adding a non-foamed top layer which contains fire retardants. While the methods of coextrusion or lamination for applying this cover layer are mentioned, the preferred method uses the agglomeration of powders on a major surface of the foam at high temperature (typically 280 ° C) and low pressure. However, this approach does not offer the flexibility of the post-extrusion technique with regard to the design of the outer layer, which in this case must be horizontal and flat in order to be able to “smooth out” the powder in order to control its thickness. The production output is also limited by the dwell time required for the agglomeration process. The production of the powder represents an additional step upstream of the application, whereas in a post-extrusion the components are dosed, melted, intimately mixed and applied in the desired geometry of a complex profile piece in a single step using the post-extrusion tool .

The coextrusion of a dense layer on foams (very) low density is problematic. EP0553522A1, for example, teaches the production of composite foams with at least one coextruded layer. According to this document, it is of crucial importance to control both the temperatures of the individual material flows and the pressure in the coextrusion tool, as otherwise the foam layer would either collapse if the temperature of the material flow of the outer layer is too high or expand too little would if the temperature of the material flow of the outer layer is too low, whereby this material flow would be too viscous for sufficient expansion of the foam. In addition, a pressure must be achieved that is sufficient to prevent foaming in the coextrusion tool, which is why the viscosities of the material flows must be sufficient within a temperature interval which must be observed very precisely for each of the substances used.

Expressed more generally, the coextrusion is accompanied by numerous specifications with regard to the temperature, the viscosities and the possible density values, so that it is generally difficult or even impossible to achieve composite elements with a core made of foam (very) low density. In addition, even if certain composite elements can be obtained with a core made of low density foam, their appearance is usually less than satisfactory. Obviously, this is particularly troublesome in applications that require small manufacturing-related tolerances in terms of dimensions, such as in the case of composite profile pieces which are used in many fields, in particular for window or facade elements, in the automotive sector, etc.

In order to be able to comply in particular with the requirements with regard to geometrical tolerances, there are other solutions on the market, namely compact profile pieces that have cavities which provide structural reinforcement and a certain insulating effect. Nevertheless, these solutions are significantly less effective in terms of thermal or sound insulation and in terms of compressive strength, or even in terms of geometry / design.

In order to remedy at least some of these disadvantages, there are still composite profile pieces of this type, which are formed from a similar, slightly or not at all foamed structure, in the interior of which a polyurethane foam was then injected and foamed to their properties of insulation or to improve the compressive strength.

Finally and in general, it should be noted that the existing solutions do not make it possible to obtain composite profile pieces that have both a core (very) low density, in particular made of polyester, and one or more outer layers with a protective or other effect, wherein the manufacturing tolerances are low. In addition, the known methods, even for composite profile pieces that do not meet all of these conditions, are either difficult to control or require numerous handling operations, so that they are of no economic interest. Object of the invention

An object of the present invention is therefore to find a solution that makes it possible to provide composite profile pieces that are very light (ie of (very) low density) and / or have a very strong insulating effect, in particular at least certain sides of the profile piece are provided with one or more functional elements. It would be desirable to be able to use thermoplastic material of any kind for these functional elements without having to compromise on the foaming of the core. In addition, it would be desirable that the manufacturing process can be carried out in an integrated manner, or at least without unnecessary handling operations during the process, in the shortest possible period of time. General description of the invention

In order to achieve the above-mentioned object, the present invention provides, in a first aspect, a method for the production of a profile piece, which has a core made of polyester foam, which has been foamed freely in the open air, its density up to 250 kg / m? is and preferably in the range from 30 to 180 kg / m?, in particular in the range from 40 to 150 kg / m?, and very particularly in the range from 50 to 100 kg / m? and on at least one of its surfaces comprises a functional element that was applied by means of so-called collateral coextrusion, the method comprising the following steps: a) Dosing the components of the foam core, in premix or individually, into the feed device of a first Extruders; b) plasticizing and mixing the components of the foam core at high temperature in order to melt and homogenize these components; c) introducing a foaming gas and homogenizing the constituents of the foam core and the gas; d) cooling the mass obtained; e) extruding this mass in the open air through a temperature-controlled nozzle having a predetermined cross-sectional shape, thereby causing the formation of the foam core; f) cooling the foam core; g) metering the constituents of the functional element, in premix or metered in individually, into the feed device of a second extruder;

h) plasticizing and mixing the components of the functional element at high temperature in order to melt and homogenize these components; i) cooling the mass obtained; 5 j) extruding this mass in a so-called collateral coextrusion die; Guiding the core of foam as a centering element for the mass that comes from the collateral coextrusion nozzle, which is temperature-controlled, wherein it has a cross-section of a predetermined shape, the formation of the functional element, through which an application on at least one surface of the core of foam causes.

The above manufacturing process, which is referred to as collateral coextrusion, enables aspects to be achieved at the same time, the implementation of which in a single product was previously considered difficult or even impossible, without a complex and labor-intensive process having to be carried out. This is essentially made possible by the unique approach of the process of using the foam core as a centering element for the creation of the functional element or elements.

The advantages of composite profile pieces that can be achieved by means of such a method are numerous. Since the foaming of the foam core takes place unhindered in the open air, firstly the foam core can have a low density, namely less than 100 kg / m 2. or even less than 80 kg / m ?. It is thus possible to obtain profile pieces that are very light or very efficient in terms of the insulating effect. Second, the polymer-like constituents of the functional element (s) can be chosen very freely (and thus in such a way that they are suitable for the intended use of the composite profile pieces), in particular with regard to their nature, their extrusion temperature, their viscosity, their shape and / or geometric Extension etc. concerns. Thirdly, the functional element or elements may or may not be foamed in turn, depending on needs or the requirements placed on the end product.

The advantages of the method per se are also significant. In fact, the principle of collateral coextrusion, which was developed by the inventors, allows the advantages of conventional coextrusion, such as the rapidity and the lack of intermediate handling operations, to be combined with the advantages of known non-continuous processes, that is, one To bring the core of low density in connection with an outer protective layer made of a different material, or even with additional functional configurations such as sealing lips, clamping profiles, etc. Since the extrusion of the functional element takes place as soon as the core made of foam has sufficient stability, which is attached to the is due to at least partial cooling of the foam which forms the core, the process sequence is in principle not delayed.

In particular, the method of the invention can be carried out in an integrated manner without unnecessary handling operations. In addition, several functional elements can be added to the profile piece, either by as many extruders or, advantageously, by a single extruder, depending on the arrangement of the functional elements. For example, it is possible to apply two or more sealing lips to several surfaces of the foam core or to a functional element with which the foam core is provided, with only a single pass in an extruder, the nozzle of which is configured in an expedient manner .

In a particularly advantageous variant, the production method according to the invention also comprises the step f) of processing and / or adapting the cross section of the profile piece with regard to the shape and / or the dimensions, preferably by milling, planing, cutting, thermoforming, local compression, subsequent expansion, ..., after step f).

Editing and / or adapting can prove to be particularly useful in the case of applications that are very demanding in terms of the geometric tolerances and / or in terms of the geometric complexity of the cross-section of the composite profile piece.

The core made of polyester foam generally comprises one or more polyester (co) polymers selected from (co) polymers, which come from material recycling or not, being made of polyethylene terephthalate (PET), thermoplastic polyester elastomers (TPC- ET, TPC, TPE-E), PETG, PEN, PCDT, .... or any mixture thereof. In addition, within the scope of the present invention, the polyester foam which forms the core can comprise amounts of up to 49% by weight of further (co) polymers which are or have been made compatible with the polyester (s) used, for example thermoplastic elastomers (TPE), non-polar homopolymers or copolymers of polyethylene (LDPE, LLDPE, MDPE, HDPE., ...), metallocene polyethylene (comonomer butene, hexene, octene), homopolymers or copolymers of polypropylene, polar copolymers and / or terpolymers of Polyethylene (EVA, EBA, EMA, EEA, E-AMH, E- GMA, E-BA-GMA, ...), polystyrene homopolymers or copolymers (ABS, HIPS, SAN), polyphenylene oxide (PPO), polycarbonates (PC ), Polyamides (PAG, 66,

6.66, 10, 12, ...), thermoplastic polyamide elastomers (TPA), urethane-based thermoplastic elastomers (TPU), crosslinkable ethylene (co) polymers that are provided with silane graft groups, for example.

As already mentioned above, the present invention makes it possible to choose the nature of the (co) polymers of the functional element or elements in a particularly free manner. In practice, the element or elements comprise one or more (co) polymers selected from thermoplastic (co) polymers, including thermoplastic elastomers (TPE), in particular polyesters (identical or different from that of the foam core) , polar copolymers of polyethylene, polyamides, polycarbonates, poly (phenylene oxide) compounds, polystyrenes, thermoplastic elastomers based on urethane (TPU), non-polar homopolymers or copolymers of polyethylene (LDPE, LLDPE, MDPE, HDPE, ...), metallocene polyethylene (Comonomer butene, hexene, octene), homopolymers or copolymers of polypropylene, polar copolymers and / or terpolymers of polyethylene (EVA, EBA, EMA, EEA, E-AMH, E-GMA, E-BA-GMA, ...) , Polystyrene homopolymers or copolymers (ABS, HIPS, SAN, ...), polyphenylene oxide (PPO), polycarbonates (PC), polyamides (PA6, 66, 6.66, 10, 12, ...), thermoplastic polyamide elastomers (TPA) , thermoplastic elastomers based on urethane (TPU), cross-linked are ethylene (co) polymers, for example provided with silane graft groups, ..., whereby they are reinforced with glass fibers or not.

As has already been mentioned, the functional element or elements may in turn be foamed or not. If they are foamed, the manufacturing process can furthermore comprise the step h ') of introducing a foaming gas into the second extruder and homogenizing the constituents and the gas before step I).

Depending on the requirements of the intended application of the composite profile pieces, it may be advantageous, especially in the case of foamed functional elements, a step k), in particular a step k1) of calibrating the functional element and / or, as required, a step k2 ) of pulling the composite profile piece.

A special feature of the present method for producing a profile piece is that it creates the possibility in a very simple manner to add further elements to the composite profile pieces or to join them together in one piece. For example, in an advantageous variant, the method comprises a step of incorporating third / additional functional elements into and / or onto the core made of foam and / or into one of the functional elements, in particular reinforcing elements, for example reinforcing elements made of organic or inorganic fibers that are woven, non-woven, knitted, textile or metallic, before step j).

As already mentioned above, the method for producing a composite profile piece is advantageously implemented in such a way that steps g) and the following are carried out immediately after the core made of foam has solidified, that is, if it has sufficient dimensional stability to apply the functional element.

It should be noted that steps g) and the following can be carried out in succession in several extruders or simultaneously in a single extruder in order to apply several functional elements.

Another important aspect of the invention relates to foam profile pieces that have a core made of polyester foam, which was foamed in the open air, its density up to 250 kg / m}, preferably 30 to 180 kg / m?, In particular 40 to 150 kg / m? especially 50 to 100 kg / m? and comprise on at least one of their surfaces a functional element which was applied by what is known as collateral coextrusion, preferably by means of a method for producing a profile piece as described in the present document.

In a second aspect, the invention further provides composite foam profile pieces that have a core made of polyester foam, which was foamed in the open air, its density up to 250 kg / m?, Preferably 30 to 180 kg / m? in particular 40 to 150 kg / m °, very particularly 50 to 100 kg / m? and comprise on at least one of their surfaces a functional element which has been applied by means of collateral coextrusion, preferably by means of a method for producing a profile piece as described in the present document.

As already mentioned, the foam core has preferably been reproduced by processing and / or adapting its shape and / or its dimensions, preferably by milling, planing, cutting, thermoforming, local compression, downstream expansion , ....

In certain embodiments, third functional elements are incorporated in the core made of foam and / or on this in the composite foam profile pieces, which are in particular reinforcement elements, for example metallic reinforcement elements.

A third aspect of the invention relates to the use of a composite profile piece according to the invention or a composite profile piece, which was obtained with a method according to the invention, in applications of thermal insulation and / or sound insulation, sealing, damping for the purpose of attenuating or canceling oscillations or vibrations , stiffening or weight reduction, as building or load-bearing elements and / or those that serve to seal doors, windows and facades or for decorative purposes, etc ... In particular in the building industry, in the automotive sector, in aviation or in other areas .

In summary, it should be noted that the invention in a first aspect provides a method that aims to modify a polyester foam (for example made of PET), open-cell or closed-cell type, by adding one or more functional elements that are foamed or not to be attached to this. They partially or completely cover the outer surface of the foam. These functional elements can be of various composition depending on the end use and the properties to be achieved. They can surround the foam core or form a protective jacket around it, but they can also give the foam another special function, such as the possibility of clamping, sealing properties, etc. The functional element can generally be a mechanical reinforcement, a Better cushioning of impacts, UV protection, fire protection, modification of the look or feel of the foam, etc.

For example, a functional element composed of polyolefins or thermoplastic elastomers is used either to aesthetically and haptically modify the foam covered therewith, or to seal the composite profile piece obtained.

Adding a functional element made of polyester, polyamide, polycarbonate, poly (phenylene oxide), polystyrene, with reinforcement by glass fibers or not, makes it possible, for example, to improve the hardness and compressive strength of polyester foams (for example made of PET).

As already mentioned, the functional elements may or may not be foamed. The foaming of the functional element makes it possible, for example, to improve the properties of the thermal insulation and at the same time to increase the hardness of the composite profile pieces, if this is desirable (optimization of the ratio of performance characteristics / weight of the composite).

The functional elements are applied by means of collateral coextrusion, specifically in thicknesses that are, for example, 100 µm to 5 mm. Description of the drawings

Further features and characteristic features of the invention will emerge from the detailed description of some advantageous embodiments, as set out below for the purpose of explanation, reference being made to the accompanying drawings. 1 shows a cross-section A) a compartmentalized hollow profile piece of the prior art and B) a composite profile piece according to the invention for the same use, which comprises a core made of foam to which a functional element has been applied, namely an edge layer that is Connection elements is provided; and FIG. 2: a cross section A) a compartmentalized hollow profile piece of the prior art and B) a composite profile piece according to the invention for the same use, which comprises a core made of foam to which a functional element has been applied, namely an edge layer provided with fastening elements is, these being intended for example for the connections of the profile piece of FIG.

Claims (16)

PATENT CLAIMS 1. Process for the production of a composite profile piece, which has a core made of polyester foam, which was foamed freely in the open air, its density up to 250 kg / m? is and preferably in the range from 40 to 150 kg / m? especially in the range from 50 to 100 kg / m? and on at least one of its surfaces comprises a functional element that was applied by means of so-called collateral coextrusion, the method comprising the following steps: a) Dosing the components of the foam core, in premix or individually, into the feed device of a first Extruders; b) plasticizing and mixing the components of the foam core at high temperature in order to melt and homogenize these components; c) introducing a foaming gas and homogenizing the constituents of the foam core and the gas; d) cooling the mass obtained; e) extruding this mass in the open air through a temperature-controlled nozzle having a predetermined cross-sectional shape, thereby causing the formation of the foam core; f) cooling the foam core; g) metering the components of the functional element, in premix or individually metered, into the feed device of a second extruder h) plasticizing and mixing the components of the functional element at high temperature in order to melt and homogenize these components; i) cooling the mass obtained; j) Extruding this mass in a so-called collateral coextrusion nozzle, this comprising guiding the foam core as a centering element for the mass which comes from the collateral coextrusion nozzle, which is temperature-controlled, it has a cross-section of a predetermined shape, which the formation of the functional element through which it is applied to at least one surface of the foam core. 2. A method for producing a composite profile piece according to claim 1, wherein it further comprises the following step f) processing and / or adapting the cross section of the profile piece with regard to the shape and / or the dimensions, preferably by milling, planing, cutting, Thermoforming, local compression, subsequent expansion, after step f). 3. A method for producing a profile piece according to claim 1 or 2, wherein the core of polyester foam comprises one or more polyester (co) polymers, which come from material recycling or not, being made of polyethylene terephthalate (PET), thermoplastic polyester elastomers (TPC- ET, TPC, TPE-E), PETG, PEN, PCDT or any mixture thereof. 4. A method of manufacturing a composite profile according to any one of claims 1 to 3, wherein the functional element comprises one or more (co) polymers derived or not from material recycling, being selected from thermoplastic (co) polymers, These include thermoplastic elastomers (TPE), in particular polyesters, polar copolymers of polyethylene, polyamides, polycarbonates, poly (phenylene oxide) compounds, polystyrenes, thermoplastic elastomers based on urethane (TPU), non-polar homopolymers or copolymers of polyethylene (LDPE, LLDPE, MDPE , HDPE, ...), metallocene-polyethylene (comonomer butene, hexene, octene), homopolymers or copolymers of polypropylene, polar copolymers and / or terpolymers of polyethylene (EVA, EBA, EMA, EEA, E-AMH, E- GMA, E-BA-GMA, ...), polystyrene homopolymers or copolymers (ABS, HIPS, SAN, ...), polyphenylene oxide (PPO), polycarbonates (PC), polyamides (PA6, 66, 6.66, 10, 12, ...), thermoplastic polyamide elastomers (TPA), urethane-based thermoplastic elastomers (TPU), crosslinkable ethylene (co) polymers that are provided with silane graft groups, for example, or their mixtures, whereby they are reinforced with glass fibers or not. 5. A method of manufacturing a composite profile according to any one of the preceding claims, further comprising the following step h ’) introducing a foaming gas into the second extruder and homogenizing the components and the gas prior to step 1). 6. A method for manufacturing a composite profile piece according to any one of the preceding claims, further comprising the following step k) calibrating the functional element and / or drawing the profile piece. 7. A method for producing a composite profile piece according to any one of the preceding claims, further comprising the step of incorporating third functional elements in and / or onto the core made of foam, in particular reinforcing elements, for example reinforcing elements made of organic or inorganic fibers, which are woven, non-woven, knitted, textile or metallic, before step j). 8. A method for producing a composite profile piece according to any one of the preceding claims, wherein steps g) and following are carried out successively in several extruders or simultaneously in a single extruder in order to apply several functional elements. 9. A method for producing a composite profile piece according to any one of the preceding claims, wherein all steps are integrated. 10. Composite foam profile piece, which has a core made of polyester foam, which was foamed in the open air, its density up to 250 kg / m?, Preferably 40 to 150 kg / m? especially 50 to 100 kgim? and comprises on at least one of its surfaces a functional element which has been applied by means of so-called collateral coextrusion, preferably by means of a method for producing a profile piece according to any one of the preceding claims. 11. composite foam profile piece according to claim 10, wherein the core made of foam has undergone a reproduction by processing and / or adapting its shape and / or its dimensions, preferably by milling, planing, cutting, thermoforming, local compression and / or downstream Expand. 12. Composite foam profile piece according to claim 10 or 11, wherein the core made of polyester foam comprises one or more polyester (co) polymers which come from material recycling or not, which are made from polyethylene terephthalate (PET), thermoplastic polyester elastomers (TPC-ET, TPC, TPE-E), PETG, PEN, PCDT or any mixture thereof. 13. The composite foam profile piece according to any one of claims 10 to 12, wherein the functional element comprises one or more (co) polymers derived from material recycling or not, being selected from thermoplastic (co) polymers, including thermoplastic elastomers (TPE) include, in particular polyesters, polar copolymers of polyethylene, polyamides, polycarbonates, poly (phenylene oxide) compounds, polystyrenes, thermoplastic elastomers based on urethane (TPU), non-polar homopolymers or copolymers of polyethylene (LDPE, LLDPE, MDPE, HDPE ,. ..), metallocene polyethylene (comonomer butene, hexene, octene), Homopolymers or copolymers of polypropylene, polar copolymers and / or terpolymers of polyethylene (EVA, EBA, EMA, EEA, E-AMH, E- GMA, E-BA-GMA, ...), polystyrene homopolymers or copolymers (ABS, HIPS, SAN), polyphenylene oxide (PPO), polycarbonates (PC), polyamides (PA6, 66, 6.66, 10, 12, ...), thermoplastic polyamide elastomers (TPA), thermoplastic elastomers based on urethane (TPU), crosslinkable ethylene (co) polymers, the for example, are provided with silane graft groups, or mixtures thereof, where they are reinforced with glass fibers or not. 14. The composite foam profile piece according to any one of claims 10 to 13, wherein the functional element is foamed. 15. Composite foam profile piece according to any one of claims 10 to 14, in which third functional elements are incorporated into the core of foam and / or on this, in particular reinforcement elements, for example metallic reinforcement elements. 16. Use of a composite profile piece according to any one of claims 10 to 15 or a composite profile piece obtained by a manufacturing process according to any one of claims 1 to 9 in thermal and / or soundproofing, sealing, attenuation or attenuation applications of oscillations or vibrations, stiffening, as structural elements and / or those that serve to seal doors, windows and facades or for decorative purposes, especially in construction, in the automotive sector, in aviation.