CN104203559A - 结构元件及其制造方法 - Google Patents

结构元件及其制造方法 Download PDF

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Publication number
CN104203559A
CN104203559A CN201380016659.XA CN201380016659A CN104203559A CN 104203559 A CN104203559 A CN 104203559A CN 201380016659 A CN201380016659 A CN 201380016659A CN 104203559 A CN104203559 A CN 104203559A
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China
Prior art keywords
structural detail
resin
thermal element
foam block
cover layer
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Granted
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CN201380016659.XA
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English (en)
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CN104203559B (zh
Inventor
D.拉库特
M.高尔
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Airex AG
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Airex AG
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Abstract

本发明涉及一种在夹层复合部件中作为核心层使用的结构元件，其中所述结构元件(2)由彼此焊接在一起的多个主体段(4,5)构成，所述主体段由挤出泡沫热塑性塑料、特别是PET制成，并且其中所述结构元件(2)具有用于与覆盖层粘附性结合的第一正面(1)，其中可施加树脂(8)的第一正面的表面具有开孔(6)。此外，以使所述表面部分密封的方式通过热元件切割、特别是热丝切割的方式制造第一正面(1)的表面。

Description

结构元件及其制造方法
技术领域
本发明涉及前文部分的权利要求1的用作夹层复合部件中的核心层的结构元件；根据权利要求15的夹层复合部件(sandwich composite element)，特别是在制造风力发电装置用的风机叶片的用途和/或在应用于海事领域(maritime sector)(特别用于生产船体和船甲板)、在轨道交通领域中(火车车厢的火车前体(train fronts)、车顶、地板、墙壁)、在道路货物运输领域中(公交车车顶、地板、前体)的用途、在建筑领域中的结构用途(例如屋顶)的夹层复合部件；以及前文部分的权利要求10的用于制造这种类型的结构元件的方法。
背景技术
EP 1 536 944 B2描述了一种通用的结构元件，其适于并且旨在作为用于制造风力发电装置内的风机叶片的夹层复合部件中的核心层而使用。已知的结构元件以多个在同一平面上彼此相邻布置且彼此互相连接的由聚对苯二甲酸乙二酯(PET)制成的主体段(body segment)而著称，所述主体段被焊接在其邻接的侧面上从而形成了从俯视图看在该结构元件的正面(face side)上相互连接的焊缝，所述平滑的焊缝形成低孔的或无孔的塑料中间层，其由主体段的熔融塑料以网状结构(reticulated web structure)的形式制成的，所述网状结构起强化作用。
已知的平面结构元件沿垂直于相交焊缝所在范围内的平面将具有多个相互焊接的主体段的泡沫块切割(通过锯切)成多个板形的结构元件而获得。处理由此获得的结构元件以形成夹层复合部件，其中使用粘合树脂(adhesiveresin)使通过锯切泡沫块形成的正面分别与覆盖层(例如铝片)结合，或者直接层压至纤维强化的覆盖层而无需另外的粘合层。所述已知的结构元件已被证明可作为夹层复合部件中的核心层。但是，特别是在相等的覆盖层的结合力的情况下，需要努力减少该结构元件的树脂吸附，以由此获得总层厚小并且由此对于相同的体积和相同的机械负载能力重量较小的夹层复合部件。在层压工艺的情况时、特别是其中借助真空将层压树脂吸入层结构的情况下，减少树脂吸附是特别有意义的，因为加载真空的缘故，层压树脂倾向于填补所有可能到达的空隙，并由此构成总重量中相当大的比例。
在并不涉及PET泡沫的WO 2005/047377 A1中针对类似问题建议，将泡沫设计成具有更小空隙的泡沫作为解决方案。但是，这最终导致了在结构元件和覆盖层之间不令人满意的粘附性或粘附作用。
另一种描述于同样不涉及PET泡沫的WO 2004/007600 A1中的解决方法是通过施加压力和温度使泡沫材料压缩。但是，这导致了泡沫具有相对较高的密度并且由于需要额外的工作步骤而使得该方法并不经济实惠。
US 2005/0060895 A1涉及通过由聚苯乙烯制成的多个泡沫化结构元件制造冲浪板，以常见的方法步骤使所述结构元件成行并将其焊接在一起。从所公开的文件中可知，使用热金属丝切割法来成形相互焊接的结构元件。
US 6,213,540 A1描述了一种制造吸收能量的产品的方法，其中使用由热的金属丝制成的网穿过泡沫块，从而由此在泡沫块内产生加强结构的焊缝。这一公开的文件也不涉及减少树脂的吸收。
在GB 2474431 A中描述了一种制造用作夹层复合部件中的核心层的结构元件，首先将塑料层一个叠一个地挤出，并且在随后的层被挤出前由红外线加热装置分别加热较低的层，以使层整体性地互相连接。然后使用热金属丝切割装置将层的配置分割成大块，之后使用热金属丝切割装置将其依次切割成板形的结构元件。所公开的文件并不涉及在进一步加工结构元件以形成夹层复合部件期间减少该结构元件的树脂吸附的问题。
发明内容
从上述现有技术出发，本发明基于以下目的：详细说明适合用作夹层复合部件中的核心层的结构元件，所述结构元件属于特别是在至少近似等于覆盖层的粘附力的情况下，使树脂吸附降至可连接该结构元件的覆盖层。优选地，应当不需要额外的加工步骤和明显增加该结构元件的密度就能实现这一目的。
此外，该目的包括制造这样的结构元件的特定方法以及具有这样的结构元件作为的核心层的夹层复合部件。
该目的是通过与所述结构元件有关的权利要求1的特征、与所述方法有关的权利要求10的特征以及与所述夹层复合部件有关的权利要求15的特征来实现的。本发明的优选方案在从属权利要求中详细说明。说明书、权利要求和/或附图公开的所有至少两个特征的组合均落入本发明的范围内。
为了避免重复，根据装置所公开的特征应当被认为是根据方法所公开的并且是可要求保护的。同样地，根据方法所公开的特征应当被认为是根据装置所公开的并且是可要求保护的。
本发明已经认识到，第一正面(和还优选平行于第一正面的第二正面)的表面质量(利用表面质量可使优选为板形的结构元件结合或层压至覆盖层以形成夹层复合部件)对树脂吸附是关键的，因为树脂、特别是粘合或层压树脂可通过泡沫开孔渗透进入泡沫(不然的话，所述泡沫优选是完全闭孔的)，所述泡沫通过用于分离、即分开结构单元和泡沫块的分离层是开口的，其中，从一定的渗透深度且由此从一定的渗透量起，粘合或层压树脂、特别是聚酯树脂、乙烯基酯树脂、环氧树脂或酚醛树脂不再对粘合作用具有积极影响，而仅增加了结构元件的重量，这不利于轻质构造(lightweight-building)的用途，在所述轻质构造中使用这样的结构元件形成的夹层复合部件应被用作支撑用结构部件。此外，本发明认识到，光滑、无孔的表面同样对覆盖层的结合性具有不利影响，因为不能将粘合树脂令人满意地固定在结构元件中。为了实现该目的，本发明因此建议以这样的方式来制造结构元件的第一正面的表面，同样具有开孔，这确保了树脂在结构元件中所需的锚定(anchoring)，然而重要的是，热密封(即闭合)部分表面以减少树脂吸附。这种效果是基于以下事实：由于表面被部分地热密封，从而与根据现有技术(其中通过锯切形成第一正面)的结构元件相比可渗透树脂的孔更少。根据本发明，符合这些特征的表面会通过热元件切割、特别是热线切割(hot-wire cutting)来制造的，优选通过热元件切割将该结构元件从泡沫块中分离出来，进行元件切割过程，使得所述表面不是完全密封而是保留开孔，以便确保树脂的锚定。
依照DIN 67530-1982以60°角测量的第一和(若使用)第二正面的表面的光泽度值指示了加热元件切割过程的方法或针对结构元件的第一和/或第二正面的表面的方法的正确进行，其特征在于在覆盖层的结合性良好的同时树脂吸附较少。下文还会对所述光泽度的作详细说明。根据本发明其应在2～10光泽度单位之间。
优选地，优选在注入过程中使用聚酯树脂、乙烯基酯树脂、环氧树脂或酚醛树脂来制造夹层复合部件。由于切割过程采用了比现有技术中所使用的锯子长出一个数量级的锯子，因而乍看时使用热热切割元件是不利的。
如前所述，依照DIN 67530-1982以60°角测量的第一正面的表面光泽度值(优选还包括与其平行的第二正面的表面光泽度值)介于2和10个光泽度单位之间，优选介于2和8个光泽度单位之间，甚至更优选介于3和6光泽度单位之间。在这种情况下，100光泽度单位对应于玻璃参照体(甚至是抛光的黑色玻璃板)。当测量光泽度值时，应考虑到在热元件切割期间照射方向沿着平行于切割方向。使用光泽度值作为用于描述第一和优选还有第二正面的表面的参数是基于如下构思：具有过少的孔的和特别是完全密封的及具有过小的树脂吸附的表面达到了过高的光泽度值，其与较差的结合作用相关联；另一方面，过多的孔的表面、如现有技术中通过锯切所得到的表面具有过低的光泽度值，尽管其与优异的粘附相关，也和过多的树脂吸附有关。
为得到表面优化的结构元件的努力和为热元件切割过程中的时间优化的努力是相悖的，因为本领域技术人员通常会同时使温度和进料速度最大化以优化热元件切割过程，而为了获得本发明的具有特定光泽度单位的表面有必要在尽可能低的热元件温度工作，然后这会造成较大的阻力并因此也造成了较慢的进料速度，从而造成了相对较慢的热元件切割过程，这产生了所需的表面质量，为了一方面减少树脂吸附并同时确保(仍然)良好的粘附性，将其充分密封，但不会达到过高的程度。
本发明结构元件的特征在于较少的树脂吸附和在复合材料中与固定在第一正面上的覆盖层具有良好的粘附性或结合特性或强度。优选地，包括该结构元件的夹层复合部件不是仅包括有一个覆盖层，而是包括两个平行覆盖层，在所述两个平行覆盖层之间可容纳有结构元件，每个覆盖层进一步优选在浸渍过程中被粘接或层压在正面上，通过热元件切割以一定程度热密封表面(即仍具有开孔)的方式形成所述正面的表面。优选地，所述覆盖层是玻璃纤维强化的塑料，此外，进一步优选地，渗入玻璃纤维材料的树脂同时也是连接该结构元件的树脂。
此外，所述结构元件的区别在于在夹层复合部件中充当支持功能，由于这个原因它应特别具有至少0.7MPa的压阻、至少30MPa的压力模数、至少0.4MPa的抗剪强度和至少10MPa的剪切模量。
本发明的结构元件适于特别是作为在浸入过程中制造的夹层复合部件中的核心层，其中在干燥状态下使用优选设置在两侧的无纺或纺织布构建该结构元件，并随后使用来自于储存容器的液态层压树脂浸渍该结构元件，借助于真空将层压树脂吸入层结构中。优选地，连接覆盖层与结构元件的树脂同时也是覆盖层树脂，使用该树脂浸渍无纺布或纺织布、特别是玻璃纤维毡。
使第一和优选还有第二正面中约35％～约85％、优选约40％～约75％的面积部分密封被证明是特别有利的。
当结构元件的密度选为50kg/m3～250kg/m3之间的值，甚至更优选为60kg/m3～150kg/m3之间的值时，是特别优选的。
非常特别优选地，挤出泡沫热塑性材料(extrusion-foamed thermoplasticmaterial)是聚对苯二甲酸乙二酯(PET)。特别优选地，平均孔径(在焊缝以外的区域中)在0.1mm～1.0mm之间、优选在0.2mm～0.8mm之间。分离出本发明的结构元件的泡沫块是按照EP 1 536 944 B2中的制造方法制造的是非常特别优选的，其中将会使用热元件切割装置、特别是热线切割装置来代替EP 1 536 944 B2中使用的锯子将结构元件从泡沫块中分离，以便建造根据本发明概念的第一和优选还有第二平行正面的表面。
关于本文所公开的制造泡沫块的方法特征和还有关于本文所公开的材料参数，EP 1 536 944 B2应该视为在本发明发展范围内的公开并将其并入本申请。
非常特别优选地，制造第一正面的表面使得在第一正面上的(或进入第一正面的)树脂吸附(resin absorption)小于600g/m2，和/或在100g/m2～600g/m2之间、优选在150g/m2～500g/m2之间选择。树脂吸附是指通过开孔在第一正面的每一面积部分的结构元件中所吸附的树脂的量。以下描述了一种确定树脂吸附的方案：
通过确定在用树脂浸渍前后结构元件的密度来确定树脂吸附。为了使浸渍后的树脂更加明显而优选将其着色。优选将以下树脂组分作为用于实施测量的树脂：树脂组分是来自Walter  AG公司(8956Killwangen)。产品编号列于括号内：
100份的Crystic 192LV聚酯树脂(产品编号：900.0.0.0007)，
2份的M60固化剂(产品编号：891.2.0.0002)，
1份的0.4％CO促进剂(产品编号：892.0.0.0001)，
1.5份的Crystic色浆橙(产品编号：910.0.4.3290)，以及
0.04份的BBK 10％抑制剂(产品编号：895.0.0010)。
从试样中切出的较大结构元件优选具有以下尺寸：长度200mm、宽度200mm、厚度20mm，其中针对每个结构元件测试三个样品并计算平均值。通过准确称重和使用游标卡尺测量的体积确定来测定每个单独试样的总密度Rd1(以kg/m3为单位)。
图9所描述的结构被用于树脂浸渍。将下列材料由下至上在各自顶部上层叠在玻璃板17上：
·Unifilo 450g/m2的由玻璃纤维18制成的连续的细丝毡，Bolleter+Co.AG,9320Arbon
·Release Ply F聚酯剥离布(蓝)19,SuterKunststoffe AG,3312Fraubrunnen
·具有边缘斜带材(strip)和在由XPVC C70.55泡沫20制成的试样之间的带材的试样层
·Release Ply F聚酯剥离布(蓝)19
·Unifilo 450g/m2由玻璃纤维18制成的连续细丝毡
·VAP膜21,Aero Consultants Ltd,8606
根据图10的4x 3的试样排列被证明有利于试样层。待检查的结构元件的试样是随机分布的。
使用真空密封带22(AT 200Y,黄色,Aero Consultants,8606瑞士)密封该结构。
Otto Fischer AG公司(2008Zurich)的9mm螺旋钢带23被分别插入入口和出口区域，并且在其中心分别连接Tecalto AG公司(8048Zurich)的Normaplast T软管接头TS10(Normaplast T hose connector)TS10。
将足够长的PE软管(自然色，Maagtechnik AG公司,8600Dübendorf)与两个软管接头连接。在实际的浸渍过程之前，抽真空1小时，在入口侧24将软管夹紧并在出口侧25处施加真空。
检查气密性后，经由在入口侧8处的打开的软管将树脂从含3kg树脂混合物的储存容器中吸出。几分钟后，树脂应当之后均匀移动并从入口至出口尽可能成直线。决不能形成气泡并且在通过入口8吸入空气前就将该入口夹紧关闭。
然后，每隔一段距离检查在仍残留于容器内的树脂中是否以明显增厚的方式开始凝胶化。从这个时间点开始，将整个结构保持在真空下又一小时。
随即，将VAP膜除去并在试样的两侧将Release ply F膜慢慢地剥离，其中必须确保尽可能少的树脂仍与剥离膜结合。
使试样上的树脂过夜完全固化。固化后，在锯子上将各个试样修整至边缘长为185～190mm，以消除边缘的影响。
类似地，在试验之前，通过准确称重和使用游标卡尺进行的体积测量来测定总密度Rd2(以kg/m3为单位)。在树脂吸附后还要测量试样的厚度。
然后，如下来计算样品侧面每m2吸附的树脂数量的计算结果：
树脂吸附[g/m2]＝0.5x(Rd2-Rd1)[kg/m3]x树脂吸附后的厚度[mm]
因子0.5反映了只参考第一正面并且只要在树脂不仅渗透进第一正面还渗透进第二正面的情况下，该因子就是必要的。
由每个结构元件的三次测定产生平均值。
在本发明的发展中，提供了前面提到的平行于第一正面的第二正面的树脂吸附同样具有前面提到的树脂吸附值。
在本发明的发展中，有利地提供了从夹层复合部件试样的核心层上剥离覆盖层时的特定剥离能量为至少100J/m2，优选超过200J/m2。优选如下来确定特定的剥离能量：
将玻璃纤维强化树脂层压在20mm厚的泡沫核心层的两侧以形成夹层复合板。所述玻璃纤维层的标准结构为：
-300g/m2CSM
-600g/m2GF纺织布
-450g/m2CSM
-核心层
-450g/m2CSM
-600g/m2GF纺织布
-300g/m2CSM
用在终端应用的树脂作为树脂使用。将适用期设为40分钟的聚酯树脂，优选WalterAG公司(8956Killwangen,瑞士)的Crystic 196MV用作标准。
根据图11将样品从夹层复合板上锯下。分别剥离3个样品的上部覆盖层和剥离3个样品的下部覆盖层。为了能剥离覆盖层，使用垂直和平行于覆盖层的两个切割锯将待测量的覆盖层的25mm长的部分暴露出来并予以穿孔。
将样品的下半部固定在根据图12的拉伸测试机器上的加紧装置26中。通过钩子28和链条29将待测量的覆盖层的剩余的、穿孔部分(perforatedpart)27固定在测力传感器上。
在泡沫和上覆盖层之间的边界层中形成裂缝并以100mm/min的测试速度将其扩大至约100mm的长度。随后，使横向构件(cross member)返回至开始的位置。在这种情况下，将力表示为横向构件的路径的函数并得到类似于图13的测量曲线。剥离能量由加载曲线30和卸载曲线31围成的面积32来确定。该面积32除以撕开的面积(样品宽度x撕开长度)从而得到所需的特定剥离能量。为了确定撕开长度，在显微镜下标记撕开端部。由总共6个样品的结果产生平均值。
在结构元件的实施方式是非常特别优选的，其中如开头提及的，除由热元件切割制造的第一正面外，该结构元件还具有平行于第一正面设置的第二正面，其以类似于第一正面的方式制造。优选地，树脂吸附和/或光泽度和/或剥离强度的数值落入根据与第一正面有关的发展所具体说明的范围。
优选地，在底面积为2～3m2的平面平行板(plane-parallel plate)的第一和第二正面之间测得的结构元件的厚度公差(tolerance)，即最大的厚度公差小于1.0mm、优选小于0.5mm。
关于结构元件的设计有不同的可能性。根据第一优选的实施方式，结构元件仅在第一或第二正面的俯视图中具有平行的平滑焊缝，其平面范围优选垂直地延伸至第一正面的平面范围。就加载于第一正面的压力而言，平行的焊缝随后以强化的方式起作用。这种类型的结构元件不仅在第一正面的表面质量方面与EP 1 536 944 B2中公开的结构元件不同，而且在焊缝的设置方面也与EP 1 536 944 B2中公开的结构元件不同。根据可替代的优选实施方式，依照EP 1 536 944 B2的描述和权利要求的方案构造和设置焊缝，即形成由交叉焊缝构成的网络(以俯视图看在第一侧面上)，所述交叉焊缝形成了以强化的方式起作用的网状结构。所指的分别是以俯视图看焊缝在第一正面上的排列。
使用结构元件作为支撑构件是特别有利的，如果泡沫塑料主要具有闭孔的结构，那么所提供的闭孔以体积百分比值计占结构元件体积的范围在92～98体积％之间。该百分比是通过从100％中减去开孔的百分比来确定的。依照ASTM D 1056–07标准通过在真空中进行水吸附来确定或定义该值。由在该标准中所描述的方法得到的重量百分比值可被事先转换成体积百分比值，其中重量百分比值乘以结构元件的密度并且除以水的密度。
为了实现垂直于其平面范围或垂直于第一正面的结构元件的高压缩刚性，本发明的拓展中有利地给出了垂直于主体段的挤出方向布置第一正面，即垂直于沿挤出方向取向的聚合物结构的整个范围。优选地，沿垂直于在主体段之间设置的焊缝的平面范围额外地或替代地布置第一正面，使得从俯视图看焊接线结构形成于第一平面上。
本发明还涉及制造上述根据本发明的范围构成的结构元件的方法，其中根据该方法，优选首先通过从热塑性塑料、特别是PET中挤出起沫的方式制造板-或棒形的主体段。然后将它们平面地、特别是无间隙地(即不含空隙)纵向焊接在一起以形成泡沫块，挤出方向优选在主体段的纵向范围的方向上延伸。随之，优选以垂直于在主体段之间形成的平滑焊缝的平面范围将泡沫块分割成单独的结构元件。由此，在具有含开孔的表面的结构元件上形成第一正面并且还优选与其平行的第二正面。优选地，由该方法制造的结构元件只由塑料构成、即特别地不含结合剂。
根据本发明，不是通过锯子而是通过热元件焊接、特别是热线焊接明确地以使第一正面和优选还有第二正面的表面密封至一定程度(保留孔)的方式将泡沫块分割成结构元件。
已经证明热元件(特别是热线)的温度是实施该方法的关键，特别是与热元件相对于泡沫块的相对速度相结合。使用选自300℃～700℃之间、特别是在400℃～700℃之间、优选在500℃～700℃的数值范围中的热元件温度实现了针对所需的表面质量的良好结果，其中至少在切割或分离过程的开始时提供该温度。优选地，在切割或分离过程期间至少基本保持该温度。
此外，额外重要的是，结合上文示出的用于分离的温度，通过移动热元件和/或泡沫块而形成的热元件和泡沫块之间的相对速度可在50mm/min～150mm/min之间的数值范围选择。
上述温度和进料速度特别适用于厚度(包括夹带的空气)在50kg/m3～250kg/m3之间、优选在60kg/m3～150kg/m3之间的泡沫材料。
已经发现，用于实现所需的光泽度值的最佳的进料速度取决于待处理的泡沫块的密度。对于密度为60kg/m3的泡沫块，热元件的进料速度优选在100mm/min～140mm/min之间选择。对于密度为100kg/m3的泡沫块，进料速度优选在65mm/min～85mm/min之间选择。对于密度为130kg/m3的泡沫块，进料速度优选在50mm/min～70mm/min之间选择
这又与这样的事实相关：即的通过热元件单位部分密封面积所需的密封能量取决于泡沫块的密度。
在这种情况下，发现了以下的函数关系适用于计算该能量：
E＝1/2x(U x I)/(v x L)
此处，E表示输入单位部分密封面积的能量。通过施加于热元件的电压U和通过该热元件的电流的电流密度I的乘积来计算所使用的电能。该乘积除以热元件(特别是热线)的进料速度v和垂直于进料方向测量的热元件的长度L的乘积。能量的单位为Wh/m2，其中W表示瓦特，h表示时间以及m2表示平方米。因子1/2所考虑到的事实是对于每个热元件来说同时形成两个部分密封的表面。
优选地，在这种情况下，平行于热元件的纵向范围测量的泡沫块的宽度对应于该热元件长度的至少60％、优选70％～95％。
如果根据以下线性的函数关系来计算通过热元件、特别是热线产生的单位部分密封面积的能量，那么就可实现所得到的相应正面的表面的最佳光泽度值：
E[Wh/m2]＝m[Whm/kg]x泡沫块密度[kg/m3]+b[Wh/m2]
在这种情况下，优选在+0.12～+0.20Whm/kg之间、甚至更优选在+0.12～+0.18Whm/kg之间的数值范围选择m值。同时，优选在-0.5～+0.5Wh/m2之间、甚至更优选在-0.5～0.00Wh/m2之间的数值范围选择b值。
因此，对于60kg/m3的密度来说，优选单位面积输入的能量(密封能量)为以下优选的极限值：6.7Wh/m2～12.5Wh/m2、特别是6.7Wh/m2～10.8Wh/m2。对于密度为100kg/m3泡沫块的来说，优选的能量范围在11.5Wh/m2～20.5Wh/m2之间、优选在11.5Wh/m2～18.0Wh/m2之间。对于密度为130kg/m3泡沫块的来说，引入的能量为以下优选的极限值：15.1Wh/m2～26.5Wh/m2，特别是15.1Wh/m2～23.4Wh/m2。
基于以下的表格，可以看出，如果优选的切割速度和切割温度的范围(参见右栏)不符合，那么表面结果、光泽度值就会落在权利要求的范围之外。由于结合度的范围为最小至不存在，因此无法测量较差设置情况下的剥离强度。
优选地，使用多个平行的热元件、特别是热线同时将泡沫块切割成多个结构元件。优选地，在该过程中使用超过30个、甚至更优选超过40个、特别是在40～100个之间的热元件(优选热线)。
特别有利的是，如果通过平面熔融(例如通过热刀片)待连接的主体段侧面并随后将它们连接在一起的方式将主体段焊接在一起，那么熔融区域就固化成低孔隙率或无孔的中间塑料层形式的平面焊缝，该过程优选无需另外的添加剂、例如粘合树脂，从而这样的结构元件只由塑料组成，具体为热塑性塑料、特别是PET。
根据本发明，以实现前面提及的光泽度值在2～10的数值范围内的方式设置热元件温度并同时选择热元件或元件和泡沫块之间的相对速度。
已经证实若在0.25mm～2.0mm、特别在0.25mm～1.00mm、优选在0.40mm～0.80mm的直径数值范围内选择热线、优选圆柱形热线的直径是非常特别优选的。
本发明还呈现夹层复合部件在特别是用于制造风力发电装置用的风机叶片的用途和/或在海事领域(maritime sector)(特别用于生产船体和船甲板)、在轨道运输领域中(特别用于制造火车车厢的火车前体(train fronts)、车顶、地板、壁构件)、在道路货物运输的领域中(特别用于制造公交车车顶、地板、前体)的用途，特别是应用于建筑领域(例如屋顶)中的结构用途，除本发明的结构元件之外，该夹层复合部件包括与结构元件连接的至少一个覆盖层、特别是中间容纳结构元件的两个覆盖层，至少一个覆盖层由玻璃纤维强化塑料制成是优选的。
本发明优选适用于在树脂浸渍过程中制造夹层复合部件。在这种情况下，包括核心材料的纤维复合物(无纺布或纺织布)于干燥状态下形成。随后，其被真空密封膜所覆盖并在边缘处被密封。在所述膜上施加的真空最终拉动储存容器中的液态树脂穿过该结构，从而浸渍该复合材料。硬化或树脂反应通常在室温下发生，但也可以在高温下发生。
因此，本发明还涉及在树脂浸渍过程中制造的夹层复合部件，重要的是，通过真空将树脂，实际上是层压树脂吸进层结构中，特别优选的是，连接覆盖层和结构元件的树脂同时也是覆盖层的树脂，使用该树脂来浸渍覆盖层的无纺布或纺织布。
更特比优选的是，如果主体段具有可使得该主体段被无缝地连接在一起的横截面，那么优选通过焊接将该主体段无缝地连接在一起。
附图说明
基于附图，从下文对优选示例性的实施方式的描述能得出本发明的优点、特征和细节。在附图中：
图1示出了结构元件的第一正面的俯视图，
图2示出了在填充有粘合树脂以根据说明书的概述部分所描述的方法确定树脂吸附之后通过垂直于第一正面的平面范围的结构元件的断面图，
图3示出了通过现有技术的的结构元件的由锯切形成的正面的断面图，该结构元件填充有树脂以确定树脂吸附，
图4示出了沿纵向侧面彼此焊接的两个主体段，
图5示出了由多个相互焊接的主体段构成的泡沫块，所述泡沫块利用垂直于结构元件中焊缝的平面范围的热线切割，
图6示出了由根据图5的两个或任选多个以得到相交焊缝的方式彼此焊接的泡沫块制造的替代泡沫块，借助于热线将所述泡沫块切割成结构元件，
图7示出了从根据图5的泡沫块得到的结构元件，
图8示出了从根据图6的泡沫块得到的结构元件，
图9示出了用于测量树脂吸附的层结构，
图10示出了用于测量树脂吸附的试样排列，
图11示出了用于测量具体剥离能量的从夹层复合板锯下的样品，
图12示出了用于测量剥离能量的实验装置，将图9的样品固定在拉伸测试机器上的夹紧装置中，和
图13示出了由用于测量剥离能量的拉伸测试机器记录的测量曲线，其中拉伸力表示为横向路径的函数。
具体实施方式
在这些附图中，相同元件和具有相同功能的元件用相同的参考数字标记。
图1以俯视图示出了第一正面1，更准确的是由泡沫PET制成的结构元件2的第一正面的表面。能够看见焊缝3，其平面范围以垂直于第一正面的平面范围并且以平面方式使两个通过PET的挤出起泡方式得到的主体段4,5彼此连接。可以看出，主体段4,5本身具有蜂窝状结构类型，这归因于挤压PET穿过位于挤出机末端的孔型喷嘴(hole-type nozzle)并且使单线(individualstrand)在整个区域的范围内彼此自动焊接，即无焊缝。
结构元件2的第一正面1的表面具有的光泽度值为4.3。
可以看见多个开孔6，其是通过由热线将结构元件2从泡沫块中分离出来而形成的。热密封孔6之间的区域7中的第一正面1的表面。
图2示出了垂直于第一正面1的平面范围的穿过结构元件2的断面图。第二正面(然而，在图2的示意图中其被切掉)平行于第一正面1。图2还可看到在低孔(密封)区域可见的焊缝3。
按照在说明书的概述部分提到的方法，第一正面填充有(用于确定树脂吸附的)粘合树脂8。可以看见粘合树脂8(聚酯树脂)通过开孔6进入孔结构一定的渗透深度。树脂吸附为150g/m2。相比于图3，其示出了穿过现有技术中具有由锯切(sewing)形成第一正面的结构元件的对应断面图，根据图2可知示例性实施方式的树脂渗透深度较小，并且特别地，相比于图3中的现有技术的示例性实施方式，根据图2的示例性实施方式中的粘合树脂8可以渗透穿过几乎很少的可行开孔进入第一正面1，这整体使得图2的示例性实施方式的树脂吸附相当少，结果是使用图2的结构元件2所制造的夹层部件的整体重量较小。
在图4中示出了制造结构元件的方法步骤。可以看见在挤出方向E上挤出的两个板形的主体段4,5，其例如具有约5cm的厚度范围、约1m的宽度范围和约2m的长度范围。在使互相对置的侧面10,11熔融后沿箭头方向9连接主体段4,5。实施该步骤时使用多个主体段，从而得到了例如图5所示的泡沫块12。图5的泡沫块12由4个主体段和3个平行焊缝3组成。如图7和图8所示，使用仅以示例性方式描绘为热线的热元件13将泡沫块12切割成板形的结构元件2。
在这种情况下，分离或切割方向14优选垂直于挤出方向E、垂直于焊缝3的平面范围。在示出的示例性的实施方式中热元件的温度为640°，而热元件13移动穿过泡沫块12的速度为84mm/min，从而得到了具有包括开孔和一定程度上热密封区域的所需表面的正面1。在背离第一正面1的一侧，结构元件具有平行于第一正面1的第二正面15，其同样通过热元件切割来制造。优选地，同时使用多个平行的热元件13将泡沫块12分离成多个结构元件。
在图6中，通过焊接、具体通过焊接立方形结构元件的沿垂直于侧面和垂直于正面取向的高端16将图5的两个泡沫块连接在一起以形成经连接泡沫块12，使得泡沫块具有从俯视图看在第一正面上相交的焊缝，从而提供多条平行的焊缝，其被至少一个垂直于它们的焊缝切割。实际上，可能发生的是，相互焊接的泡沫块的平行焊缝不是理想地相互齐平，而是以阶梯的方式彼此偏移地排列。甚至需要这种偏移以增加稳定性。如果接着借助于热元件13以类似于图5的泡沫块12的方式将图6的泡沫块12切割成结构元件2，那么就得到了如图8所示的结构元件2，在第一正面上可能看到相交的焊缝，其平面范围是沿挤出方向E，即垂直于第一正面1和与其平行的第二正面15的平面范围。
可以制造夹层复合部件，因为优选以树脂的方式使覆盖层、特别是由玻璃纤维强化的塑料制成的覆盖层粘接于例如图7或8所示的结构元件2的第一和第二正面1,15上。
附图标记
1 第一正面
2 结构元件
3 焊缝
4 主体段
5 主体段
6 孔
7 热密封区域
8 粘合树脂
9 箭头方向
10 侧面
11 侧面
12 泡沫块
13 热元件
14 切割方向
15 第二正面
16 高端
17 玻璃板
18 由玻璃纤维制成的连续细丝毡
19 聚酯剥离布
20 试样层
21 VAP膜
22 真空密封带
23 螺旋钢带9mm
24 输入端
25 输出端
26 夹紧装置
27 插筋，待测量的覆盖层的穿孔部分
28 钩子
29 链条
30 加载曲线
31 卸载曲线
32 封闭区域
E 挤出方向

Claims (16)

1.一种结构元件，其作为夹层复合部件中的核心层使用，其中所述结构元件(2)由多个相互焊接的主体段(4,5)形成，所述主体段由挤出泡沫热塑性塑料、特别是PET制成，并且其中所述结构元件(2)具有用于与覆盖层结合的第一正面(1)，其中能够填充有树脂(8)的所述第一正面(1)的表面具有开孔(6)，其中以一定程度热密封所述表面的方式通过热元件切割、特别是通过热丝切割的方式制造所述第一正面(1)的表面，其特征在于：
根据DIN 67530-1982在60°下测量的所述第一正面(1)的表面的光泽度值介于2个光泽度单位和10个光泽度单位之间。
2.根据权利要求1所述的结构元件，其特征在于，在所述第一正面(1)上的树脂吸附小于600g/m2和/或介于100g/m2和600g/m2之间，优选介于150g/m2和500g/m2之间。
3.根据权利要求1或2的结构元件，其特征在于，根据DIN 67530-1982在60°下测量的所述第一正面(1)的表面的光泽度值介于2个光泽度单位和8个光泽度单位之间，优选介于3个光泽度单位和6个光泽度单位之间。
4.根据前述权利要求中任一项所述的结构元件，其特征在于，用于剥离固定在所述第一正面(1)上的覆盖层的具体剥离能量至少为100J/m2，优选至少为200J/m2。
5.根据前述权利要求中任一项所述的结构元件，其特征在于，提供平行于所述第一正面(1)的第二正面(15)，所述第二正面(15)的表面具有开孔(6)并且能够填充树脂(8)，其中通过热元件切割、特别是热丝切割以一定程度热密封所述表面的方式制造所述第二正面(15)的表面。
6.根据权利要求5所述的结构元件，其特征在于，所述结构元件(2)的厚度公差小于1.0mm、优选小于0.5mm，其是对在第一和第二正面(1,15)之间的平面平行板测得的。
7.根据前述权利要求中任一项所述的结构元件，其特征在于，提供唯一的平行焊缝(3)或者平行焊缝(3)和与平行焊缝(3)相交的、优选以直角相交的焊缝(3)，其形成了以强化方式作用的网状结构。
8.根据前述权利要求中任一项所述的结构元件，其特征在于，所述泡沫塑料主要是闭孔的。
9.根据前述权利要求中任一项所述的结构元件，其特征在于，所述第一正面(1)沿垂直于与挤出方向(E)垂直定向的聚合物结构范围延伸，和/或沿垂直于在所述主体段(4,5)之间设置的焊缝(3)的平面范围延伸。
10.一种用于制造根据前述权利要求中任一项所述的结构元件的方法，其包括以下步骤：
通过热塑性塑料的挤出起泡方式制造优选为板形或棒形的主体段(4,5)，
将所述主体段(4,5)纵向地、平面地焊接在一起以形成泡沫块(12)，
优选在所述主体段(4,5)之间形成的平滑焊缝(3)的平面范围的横向上将所述泡沫块(12)切割成各个结构元件(2)，并且在该过程中，分别在表面具有开孔的所述结构元件(2)上形成第一正面(1)，其中通过热元件焊接、优选热线焊接实施将所述泡沫块(12)切割成所述结构元件(2)，其特征在于：
至少在切割步骤开始时设置所述热元件的温度为300℃～700℃之间的数值范围，以及在所述切割期间在热元件(13)和泡沫块(12)之间形成范围在50mm/min～150mm/min之间的相对速度，并由此一定程度热密封所述第一正面(1)的表面。
11.根据权利要求10所述的方法，其特征在于，所述焊接在一起是通过平面熔融待连接的所述主体段(4,5)的侧面(10,11)、随后将其连接在一起以及固化熔融区域同时形成以低孔的或无孔的塑料中间层形式的平滑焊缝(3)的方式实施。
12.根据权利要求10或11所述的方法，其特征在于，至少在切割步骤开始时设置所述热元件的温度为在300℃～700℃之间、优选在400℃～700℃之间的数值范围。
13.根据权利要求10或12所述的方法，其特征在于，通过热元件输入单位部分密封面积能量，根据以下线性的函数关系来计算所述能量：
E[Wh/m2]＝m[Whm/kg]x泡沫块密度[kg/m3]+b[Wh/m2]
其中m在1.2～2.0之间、优选在1.2～1.8之间的数值范围选择，并且b在-0.5～+0.5之间、优选在-0.5～0.00之间的数值范围选择。
14.根据权利要求10～13中任一项所述的方法，其特征在于，使用直径在0.25mm～2.0mm之间、特别是在0.25mm～1.00mm之间、优选在0.40mm～0.80mm之间的直径数值范围的热线作为热元件(13)。
15.一种具有根据权利要求1～9所述的结构元件(2)作为核心层的夹层复合部件，在特别用于制造风力发电装置用的风机叶片中的用途和/或在海事领域中和/或在轨道运输领域中和/或在道路货物运输中的用途和/或应用于建筑领域中的结构用途，其中通过粘合树脂(8)的方式将覆盖层、特别是由玻璃纤维强化塑料制成的或包含玻璃纤维强化塑料的覆盖层固定在所述第一正面(1)上。
16.根据权利要求15的夹层复合部件，其特征在于，在浸渍过程中固定所述第一覆盖层、优选还有第二覆盖层。
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