CN104582951B - 夹心板及其制造方法 - Google Patents

夹心板及其制造方法 Download PDF

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CN104582951B
CN104582951B CN201380037053.4A CN201380037053A CN104582951B CN 104582951 B CN104582951 B CN 104582951B CN 201380037053 A CN201380037053 A CN 201380037053A CN 104582951 B CN104582951 B CN 104582951B
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filled board
sandwich layer
fiber
fibre
carrier
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CN104582951A (zh
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托尔斯滕·伯格尔
彼得·克劳克
托比亚斯·莱韦
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ThyssenKrupp Steel Europe AG
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ThyssenKrupp Steel Europe AG
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Abstract

本发明涉及一种夹心板，特别是用于制造建筑元件或车辆车身部件，其包括金属覆盖板(1.1，1.2)以及位于覆盖板之间由聚合物形成的至少一个芯层(1.3)，该芯层(1.3)与覆盖板(1.1，1.2)一体接合。芯层(1.3)包括含纤维载体，载体的纤维由聚氨酯基环绕，其中聚氨酯基由水性无溶剂的聚氨酯分散体形成，其中纤维具有相对短纤维段的形式，其在聚氨酯基中的纤维长度最大为50mm。载体的纤维优选由矿物纤维特别是陶瓷纤维构成。本发明的夹心板(1)具有低成本且轻量的芯层，其增加了夹心板的潜在用途。还公开了一种制造该夹心板的方法。

Description

夹心板及其制造方法
技术领域
本发明涉及一种夹心板，其特别是用于制造建筑元件或车辆车身部件，其具有金属覆盖板以及布置在覆盖板之间的至少一个由聚合物形成的芯层，该芯层与覆盖板一体接合。特别地，本发明涉及一种通过利用压力和加热将金属覆盖板一体接合到布置在金属覆盖板间由聚合物形成的芯层进而制造夹心
背景技术
此类夹心材料是已知的。
由申请人发明的被称为“LITECOR”的夹心板由两层覆盖钢板和塑料制成的芯层构成。该夹心板呈现相对轻的重量同时具有好的抗弯刚度，特别适用于车辆车身结构。芯层材料由热塑性共聚物形成。
发明内容
本发明基于以下目的，即获得上述类型的夹心板，使得其具有便宜的芯层，并具有更高级别的刚度属性，特别地其是可冷成型的，而其可能的使用范围不受限制。本发明意在扩展此类夹心板的可能用途。
上述目标是通过提出具有权利要求1所述特征的夹心板以及具有权利要求9所述特征的制造方法来实现的。
本发明的夹心板的芯层包括含纤维的载体，载体的纤维由聚氨酯基体环绕，其中后者由水性、无溶剂的聚氨酯分散体形成，其中纤维具有相对短纤维段的形式，其在聚氨酯基体中的总长最大为50mm。
借助含纤维的载体，提供了结合环绕纤维的聚氨酯基体的基体，其作为用于夹心板的便宜且轻量的芯层。借助由聚氨酯基体环绕或预浸渍的短纤维段，夹心板可以冷成型并且具有特别好的结果。
多种便宜的纤维类型可以用作本发明夹心板的芯层的纤维。纤维可以用来影响夹心板的特性，因此扩展其可能的使用范围。
根据本发明夹心板的一个优选实施例，芯层的纤维由矿物纤维优选是陶瓷纤维形成。因此可以实现轻量耐热的夹心板，同时具有很好的抗弯刚度。
本发明的另一优选实施例的特征在于，聚氨酯分散体包括封闭型异氰酸酯，或者封闭型异氰酸酯被添加到水性无溶剂的聚氨酯分散体中，用以制造芯层。诸如陶瓷纤维和玻璃纤维的耐热纤维是脆的并且仅以较小程度形成。为了特别是增加以水性无溶剂PU分散体浸渍的用作本发明夹心板芯层的含纤维载体的弹性和粘接强度，封闭型NCO(异氰酸酯)被添加到PU分散体中。术语“封闭型”指的是PU分散体中的NCO含量在室温下(约20℃)被隔离，只有在到达某一温度时其才被活化。这允许聚氨酯分散体更高的交联。优选地，芳香族异氰酸酯(如单体的二苯基甲烷二异氰酸酯)和/或脂肪族异氰酸酯(如异佛尔酮二异氰酸酯)作为封闭型NCO而被添加。
在本发明的另一实施例中，用于夹心板芯层的含纤维载体具有铺设网格、编织物、针织物或非编织物的形式。还可以通过含纤维载体的结构影响本发明夹心板的抗弯刚度和成型能力。特别地为了实现高抗弯刚度，优选地含纤维载体具有编织物的形式。相反，利用具有非编织物形式的纤维层可以更为成功地实现很好的成型能力。
优选地，本发明夹心板芯层的厚度在0.4mm至2.0mm的范围内，优选最大为1.5mm。
用于本发明夹心板的适当覆盖板是由铝材料、镁材料或钢材料以及它们的组合制成的板。特别优选地是使用钢材料制成的覆盖板，其中覆盖板的厚度在0.1mm至1.0mm的范围内，优选在0.2mm至0.8mm的范围内。钢材料是相对便宜的材料，其对温度变化具有高耐受力，具有高断裂强度以及很好的成型能力，特别是有利的深冲性能和/或压花性能。这里使用的钢外板通常具有250-350MPa范围内的屈服点。还可以使用具有更高屈服强度的其他刚度级别。
本发明的另一实施例提出覆盖板具有腐蚀保护层，以便实现低材料成本同时本发明建筑元件的长使用寿命。腐蚀保护层例如是通过热浸镀和/或电解涂覆金属覆盖板来实现的。典型的热浸镀是：Z：99％Zn，ZA：95％Zn+5％Al；AZ：5％Al+43.4％Zn+1.6％Si；AS：88-92％Al+8-12％Si。
本发明夹心板的另一优选实施例提出覆盖板具有不同的厚度和/或不同的腐蚀保护层。因此可以实现在高抗弯刚度、低组件重量和高耐腐蚀性方面优化的夹心板。
在本发明夹心板的另一实施例中，至少一个覆盖板具有由锌构成的腐蚀保护层。作为替代或者此外，至少一个覆盖板还可以具有由铝构成的腐蚀保护层。
其他可以与传统热浸镀和电解镀一道使用的方式是CVD涂覆、PVD涂覆和/或溶胶-凝胶涂覆。此外，覆盖板还可以或者已经经受进一步的精加工，例如通过阳极氧化工艺。从而可以获得任意所需的着色。
根据本发明夹心板的另一实施例，至少一个覆盖板具有有机层，例如是漆或漆箔或漆膜的形式。从而可以获得本发明夹心板的任意所需着色。优选地有机层具有发光属性(发光特性)。
本发明方法的一个优选实施例的特征在于，在芯层被接合到覆盖板之前，其被穿透和/或机械脱水。因此在含纤维载体由水性无溶剂聚氨酯分散体浸渍后，含纤维载体中的水分被有效减少。因此可以实现对金属覆盖板处内部腐蚀的可靠防护。当芯层是由多个含纤维载体通过水性无溶剂PU发分散体的逐层应用而形成的时候，可以例如实现水分的减少，上述PU分散体优选添加有封闭型NCO，其中PU分散体例如通过至少一个尖刺辊或橡胶披覆辊等被压入相应的纤维层，以及/或者多余的水可通过挤压去除。与之相反，当仅使用一个纤维层时，水分的减少例如可以通过增加纤维层的多孔性来实现。
本发明方法的另一优选实施例提出由覆盖板和芯层制成的夹心板在芯层与覆盖板一体接合之后立即被冷却，并且在冷却的同时压制或轧制。从而可以辅助与去除水相关联的芯层的体积收缩或压实。特别地，进而可以实现复合体(夹心板)中应力的受控减小。
附图说明
下文参考附图中示出的多个实施例来详细说明本发明。
图1示出了本发明夹心板的截面图；以及
图2示出了制造本发明夹心板的系统。
具体实施方式
附图中示出的夹心板1包括两个金属覆盖层1.1、1.2和含纤维的耐热芯层1.3。
覆盖层1.1、1.2优选地由具有腐蚀保护层的钢板构成。这里优选地使用锌或铝基的腐蚀保护层。每个覆盖层(覆盖板)1.1、1.2的厚度例如约0.1-0.8mm，优选最大0.5mm，特别优选最大0.4mm。在图1示出的实施例中，两个覆盖板1.1、1.2的厚度实质上相同，例如约0.3mm，并且他们包括相同类型的材料。然而，还可以使用不同厚度和/或包括不同材料类型的覆盖板1.1、1.2来制造复合体1。特别地，覆盖板1.1、1.2可以具有不同的腐蚀保护层：例如覆盖板1.1或1.2可以包括具有高热反射率的铝基涂层，而覆盖板1.2或1.1包括锌基涂层。
芯层1.3由至少一个纤维层或一个含纤维载体构成，并且载体的纤维由聚氨酯基体环绕。该聚氨酯基体是通过将含纤维载体渗透/浸渍水性无溶剂聚氨酯分散体而制备的。本文中的术语“预浸料”指的是预浸渍纤维，其中聚氨酯基体中的纤维具有连续长丝纤维的形式或者相对短的纤维段的形式，例如纤维长度最大为50mm。PU分散体或PU基用作粘合剂(胶)。
优选地聚氨酯分散体还包括封闭型NCO(异氰酸酯)，其在室温下是钝化的，并且仅在加热到某一温度(例如50℃)时活化。芳族和脂族异氰酸酯适用于此类阻滞剂，例如是单体二苯基甲烷二异氰酸酯和异佛尔酮二异氰酸酯。使用适当的阻滞剂可以获得聚氨酯分散体更强的交联。PU分散体和封闭型NCO的混合比率取决于活化温度，并且还取决于含纤维载体内所需的交联水平。
载体的纤维由耐高温的矿物纤维构成，优选由不燃的陶瓷纤维构成。含纤维载体这里具有铺设网格、编织物或非编织物的形式。用于制造芯层1.3的含纤维载体是多孔的，即液体可通过。
制造本发明的夹心板1使用了预制半成品形式的芯层1.3，其例如是所谓的预浸料的形式。本文中术语“预浸料”指的是预浸渍纤维，其中聚氨酯基体中的纤维具有连续长丝纤维的形式或者相对短的纤维段的形式，例如纤维长度最大为50mm。
本发明夹心板1的芯层1.3的厚度在0.4mm至2.0mm的范围内，优选最大为1.5mm。该层耐受至少300℃的温度，优选耐受至少700℃。芯层1.3还可以包括无卤矿物阻燃剂，其对于减少浓烟的产生非常有效。
含纤维的芯层1.3不仅向本发明的夹心板1提供对温度变化的高耐受度以及良好的热隔离，与由热塑材料制成的传统芯层相比还提供了明显高刚度级属性。该高刚度级属性允许使用相对薄的金属覆盖层1.1、1.2，因而可以减少夹心板1的重量。
图1中可以看到复合体1的每个覆盖板1.1、1.2明显薄于芯层1.3。为了获得轻量夹心板，芯层1.3的厚度至少1.5倍于、优选2倍于、更优2.5倍于两个覆盖板1.1、1.2中最薄那个的厚度。
图2示出了制造本发明的夹心材料1的方法的示图。优选地覆盖板1.1、1.2和预制的芯层1.3以线圈的形式被提供，并且从线圈展开。或者还可以提供按尺寸切割的坯料(平板)形式的组件1.1、1.2和1.3，并且将它们彼此接合。
覆盖板1.1、1.2和预制芯层1.3被引入加热压机2中，优选为双带压机。复合体在压机2中被加热至约120℃至180℃，优选最大160℃。压机特别是双带压机2产生的压力可以是实质上恒定的。施加的压力例如可以最高达30bar。然而，压机2还可以有利地以不同压力操作：例如在被分为加热区2.1、保温区2.2和冷却区2.3的双带压机2中，保温区2.2中的压力明显高于后面的冷却区(冷却阶段)。
如上所述，PU基用作粘合剂(胶)，特别是当封闭型NCO(异氰酸酯)已被添加到水性无溶剂PU分散体中，其中纤维层已被浸渍入该分散体中。加热由覆盖板1.1、1.2和预制芯层1.3制成的复合体将活化和/或去活PU基的粘性功能。根据本发明预制的芯层1.3不需要额外的粘合促进层用于一体接合到覆盖板1.1、1.2，特别是不需要有机粘合促进层。
冷却区2.3中的压力有利地是中等的，其中复合体在冷却区2.3中优选被冷却到室温，从而辅助或者能够辅助因从PU基去除水引起的芯层的压实(体积收缩)。该过程可控降低了通常在复合体中存在的应力。
在双带压机2的下游，制造的夹心板1被卷成线圈3或者通过切割设备4依长度切割成个体平板5。
本发明的夹心板1在塑料成型工艺中特别是通过深冲和/或压花给出了良好结果。为此例如坯料被从带状的适当复合体1切出，并且在成型压机(未示出)中冷成型，以获得三维组件，例如车辆车身部件。由于聚氨酯基体中的纤维长度短，这里的组件特别是车辆车身部件可以几乎任意所需形状或轮廓以及多种尺寸来进行制造。
本发明的夹心板1还可以有利地用于例如造船、飞机制造、铁路车辆制造、厂房工程以及家具制造。
本发明不限于附图中示出的实施例。本发明的夹心板具有多种可设想的变体，并且相应地制造其的方法变体与所示出的实施例也不同。例如，覆盖板1.1、1.2还可以包括铝材料和/或镁材料。

Claims (16)

1.一种夹心板，用于制造建筑元件或车辆车身部件，其包括金属覆盖板(1.1，1.2)以及位于覆盖板之间由聚合物形成的至少一个芯层(1.3)，该芯层(1.3)与覆盖板(1.1，1.2)一体接合，其特征在于，
芯层(1.3)包括含纤维载体，载体的纤维由聚氨酯基体环绕，其中聚氨酯基体由水性无溶剂的聚氨酯分散体形成，其中纤维具有短纤维段的形式，其在聚氨酯基体中的纤维长度最大为50mm，其中载体的纤维由不燃的陶瓷纤维构成。
2.根据权利要求1所述的夹心板，其特征在于，所述聚氨酯分散体包括封闭型异氰酸酯。
3.根据权利要求1或2所述的夹心板，其特征在于，含纤维载体具有铺设网格的形式。
4.根据权利要求1或2所述的夹心板，其特征在于，含纤维载体具有编织物的形式。
5.根据权利要求1或2所述的夹心板，其特征在于，含纤维载体具有非编织物的形式。
6.根据权利要求1-2中任一权利要求所述的夹心板，其特征在于，芯层(1.3)的厚度在0.4mm至2.0mm的范围内。
7.根据权利要求1-2中任一权利要求所述的夹心板，其特征在于，覆盖板(1.1，1.2)是由铝材料、镁材料、钢材料或它们的任意组合制成的板。
8.根据权利要求1-2中任一权利要求所述的夹心板，其特征在于，每个覆盖板(1.1，1.2)的厚度在0.1mm至1.0mm的范围内。
9.根据权利要求1-2中任一权利要求所述的夹心板，其特征在于，覆盖板(1.1，1.2)中的至少一个具有腐蚀保护层。
10.一种制造夹心板的方法，该夹心板用于建筑行业或车辆车身结构，该方法通过利用压力和热将金属覆盖板(1.1，1.2)一体接合到位于覆盖板(1.1，1.2)之间由聚合物形成的芯层(1.3)，其特征在于，预制芯层(1.3)被用作芯层并且包括含纤维载体，载体的纤维由聚氨酯基体环绕，其中聚氨酯基体是由水性无溶剂的聚氨酯分散体形成的，其中纤维具有短纤维段的形式，其在聚氨酯基体中的纤维长度最大为50mm，其中由不燃的陶瓷纤维制成的载体被用作含纤维载体。
11.根据权利要求10所述的方法，其特征在于，封闭型异氰酸酯被添加到聚氨酯分散体中。
12.根据权利要求11所述的方法，其特征在于，芳族和/或脂肪族异氰酸酯作为封闭型异氰酸酯而被添加。
13.根据权利要求10-11中任一权利要求所述的方法，其特征在于，在芯层(1.3)被接合到覆盖板(1.1，1.2)之前，其被穿透和/或机械脱水。
14.根据权利要求10-11中任一权利要求所述的方法，其特征在于，由铝材料、镁材料、钢材料或它们的任意组合形成的覆盖板(1.1，1.2)被使用。
15.根据权利要求10-11中任一权利要求所述的方法，其特征在于，由钢材料形成的覆盖板(1.1，1.2)被使用，其具有腐蚀保护层。
16.根据权利要求10-11中任一权利要求所述的方法，其特征在于，由覆盖板(1.1，1.2)和芯层(1.3)形成的夹心板(1)在芯层和覆盖板一体粘接之后立即被冷却，并且在冷却期间同时被压制或轧制。
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