DE102018122098A1 - Process for making a foamed sheet - Google Patents

Process for making a foamed sheet Download PDF

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Publication number
DE102018122098A1
DE102018122098A1 DE102018122098.7A DE102018122098A DE102018122098A1 DE 102018122098 A1 DE102018122098 A1 DE 102018122098A1 DE 102018122098 A DE102018122098 A DE 102018122098A DE 102018122098 A1 DE102018122098 A1 DE 102018122098A1
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DE
Germany
Prior art keywords
procedure according
foam beads
lattice structure
thermoplastic
foam
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.)
Pending
Application number
DE102018122098.7A
Other languages
German (de)
Inventor
Nils Gerber
Amin Shabani
Ahmad Al-Sheyyab
Steven Schmidt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rehau Industries SE and Co KG
Original Assignee
Rehau AG and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rehau AG and Co filed Critical Rehau AG and Co
Priority to DE102018122098.7A priority Critical patent/DE102018122098A1/en
Publication of DE102018122098A1 publication Critical patent/DE102018122098A1/en
Pending legal-status Critical Current

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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

Die Erfindung betrifft ein Verfahren zur Herstellung einer geschäumten Platte (100), insbesondere für Isolationszwecke, wobei zunächst eine plattenförmige, Hohlräume (1) bildende Gitterstruktur (2) zur Aufnahme von Schaummaterial (3) bereitgestellt wird. Danach wird das Schaummaterial (3) in Form von thermoplastischen, vorexpandierten Schaumperlen (4) als Schüttgut in die Hohlräume (1) eingefüllt und danach erfolgt durch Energiezufuhr eine finale Expandierung der Schaumperlen (4). Diese werden hierdurch stoffschlüssig untereinander sowie mit den Wandungen der Hohlräume (1) verbunden.

Figure DE102018122098A1_0000
The invention relates to a method for producing a foamed plate (100), in particular for insulation purposes, wherein first a plate-shaped lattice structure (2) forming cavities (1) is provided for receiving foam material (3). Thereafter, the foam material (3) in the form of thermoplastic, pre-expanded foam beads (4) is poured into the cavities (1) as bulk material and then the foam beads (4) are finally expanded by supplying energy. As a result, these are integrally connected to one another and to the walls of the cavities (1).
Figure DE102018122098A1_0000

Description

Die Erfindung betrifft ein Verfahren zur Herstellung einer geschäumten Platte, insbesondere für Isolationszwecke, bei dem eine plattenförmige, Hohlräume bildende Gitterstruktur zur Aufnahme von Schaummaterial bereitgestellt wird.The invention relates to a method for producing a foamed plate, in particular for insulation purposes, in which a plate-shaped, cavity-forming lattice structure for receiving foam material is provided.

Übliche Schaumplatten, wie sie im Stand der Technik bekannt sind, weisen charakteristisch eine sowohl gute thermische als auch gute akustische Isolationswirkung auf, sind jedoch hinsichtlich ihrer mechanischen Eigenschaften limitiert. Wabenstrukturen hingegen besitzen bessere mechanische Eigenschaften, weisen jedoch Nachteile in Bezug auf die genannten Isolationseigenschaften auf. Die Kombination von Schäumen einerseits und Wabenplatten andererseits verbindet die Vorteile beider Konzepte. Im Stand der Technik sind derartige hybrid-Bauweisen in Form von Wabenplatten bekannt, welche mit syntaktischen Epoxid-Schäumen (z. Epoxid-Matrix mit Glashohlkugeln) gefüllt oder alternativ mit Polyurethanschaum ausgeschäumt sind. Nachteilig bei diesen beiden bekannten Konzepten ist, dass es sich jeweils um duromere Schäume handelt, welche nachteilig hinsichtlich der Recyclierbarkeit sind. Ferner kann das zur Herstellung von Polyurethanschaum benötigte Isocyanat Allergien auslösen und steht außerdem im Verdacht, Krebs zu verursachen.Conventional foam sheets, as are known in the prior art, typically have both good thermal and good acoustic insulation properties, but are limited in terms of their mechanical properties. Honeycomb structures, on the other hand, have better mechanical properties, but have disadvantages with regard to the insulation properties mentioned. The combination of foams on the one hand and honeycomb panels on the other hand combines the advantages of both concepts. In the prior art, hybrid designs of this type are known in the form of honeycomb panels which are filled with syntactic epoxy foams (for example epoxy matrix with hollow glass spheres) or are alternatively foamed with polyurethane foam. A disadvantage of these two known concepts is that each is a thermoset foam which is disadvantageous with regard to recyclability. Furthermore, the isocyanate required for the production of polyurethane foam can trigger allergies and is also suspected of causing cancer.

Vor diesem Hintergrund liegt der Erfindung die Aufgabe zugrunde, ein Verfahren mit den eingangs beschriebenen Merkmalen anzugeben, welches gegenüber dem Stand der Technik ökologische Vorteile bietet.Against this background, the invention has for its object to provide a method with the features described above, which offers ecological advantages over the prior art.

Diese Aufgabe wird erfindungsgemäß gelöst durch ein Verfahren zur Herstellung einer geschäumten Platte, insbesondere für Isolationszwecke,

  • - wobei zunächst eine plattenförmige, Hohlräume bildende Gitterstruktur zur Aufnahme von Schaummaterial bereitgestellt wird,
  • - wobei danach das Schaummaterial in Form von thermoplastischen, vorexpandierten Schaumperlen als Schüttgut in die Hohlräume eingefüllt wird und
  • - wobei danach durch Energiezufuhr eine finale Expandierung der Schaumperlen erfolgt und diese hierdurch stoffschlüssig untereinander sowie mit den Wandungen der Hohlräume verbunden werden.
This object is achieved according to the invention by a method for producing a foamed board, in particular for insulation purposes,
  • first of all a plate-shaped, cavity-forming lattice structure for receiving foam material is provided,
  • - After which the foam material in the form of thermoplastic, pre-expanded foam beads is poured into the cavities as bulk material and
  • - Thereafter, a final expansion of the foam beads takes place by supplying energy, and these are thereby integrally connected to one another and to the walls of the cavities.

Erfindungsgemäß wurde erkannt, dass durch den Einsatz von thermoplastischen Schaumperlen, welche im Stand der Technik als solche bereits bekannt sind (im englischen Sprachraum als sog. „bead foams“ bekannt, die z.B. unter den Markennamen ARPRO® oder CLEARPOR® vertrieben werden), die Recyclierbarkeit des Gitterstruktur-Schaummaterial-Verbundes deutlich verbessert werden kann. Darüber hinaus ergeben sich weitere ökologische Vorteile insbesondere gegenüber dem gesundheitlich bedenklichen Poyturethan. Ferner ist das mit dem erfindungsgemäßen Verfahren erzeugte Verbundprodukt bei entsprechender Auswahl des Gitterstruktur-Materials thermisch umformbar und kann somit in seiner Form an den konkreten Anwendungszweck angepasst werden. Im Rahmen der Erfindung liegt es insbesondere, dass die finale Expandierung der Schaumperlen in Form eines Sintervorganges erfolgt, der gegebenenfalls unter erhöhtem Druck stattfindet.According to the invention, it was recognized that through the use of thermoplastic foam beads, which are already known as such in the prior art (known as “bead foams” in the English-speaking world, which are sold, for example, under the brand names ARPRO® or CLEARPOR®), the Recyclability of the lattice structure-foam material composite can be significantly improved. In addition, there are further ecological advantages, in particular compared to the health-threatening polyurethane. Furthermore, the composite product produced by the method according to the invention can be thermally deformed with a corresponding selection of the lattice structure material and its shape can thus be adapted to the specific application. It is particularly within the scope of the invention that the final expansion of the foam beads takes place in the form of a sintering process, which may take place under increased pressure.

Thermoplastischen Schaumperlen werden üblicherweise mittels Heißdampf final expandiert. Im Rahmen der Erfindung hat sich jedoch gezeigt, dass insbesondere eine Energiezufuhr durch Strahlung, insbesondere durch Mikrowellenstrahlung oder auch thermische Induktion von Vorteil ist. Die genannten Methoden besitzen den Vorteil, dass der Energieeintrag durch die Wandungen der Gitterstruktur hindurch erfolgen und somit insbesondere eine problemlose finale Expansion der Schaumperlen durch einen seitlichen Energieeintrag an einer Schmalseite der Gitterplatte erfolgen kann. Somit ist es z.B. möglich, zwecks finaler Expansion der Schaumperlen die Quelle des Energieeintrags seitlich entlang einer Schmalseite der Platte vorbeizufahren und/oder die Platte mit einer Schmalsseite entlang der z.B. ortsfesten Quelle vorbeizufahren. Alternativ kann jedoch auch im Rahmen der Erfindung die finale Expansion der thermoplastischen Schaumperlen durch Heißdampf hervorgerufen werden, mit dem zweckmäßigerweise mindestens eine Plattenoberfläche beaufschlagt wird.Thermoplastic foam beads are usually finally expanded using superheated steam. Within the scope of the invention, however, it has been shown that in particular an energy supply by radiation, in particular by microwave radiation or also thermal induction, is advantageous. The methods mentioned have the advantage that the energy input takes place through the walls of the lattice structure and thus, in particular, a problem-free final expansion of the foam beads can take place through a lateral energy input on a narrow side of the lattice plate. So it is e.g. possible, for the final expansion of the foam beads, to pass the source of the energy input laterally along a narrow side of the plate and / or to drive the plate with a narrow side along the e.g. drive past stationary source. Alternatively, however, the final expansion of the thermoplastic foam beads can also be brought about by superheated steam, which is expediently applied to at least one plate surface.

Vorzugsweise ist die Gitterstruktur wabenförmig ausgebildet. Die thermoplastischen Schaumperlen enthalten, bzw. bestehen vorzugsweise aus PE, PP, PS, TPU, PBT, PET oder PEI, wobei auch Mischungen der vorgenannten Materialien im Rahmen der Erfindung liegen. Vorzugsweise enthalten die thermoplastischen Schaumperlen bzw. bestehen diese aus recycliertem Thermoplast-Material.The lattice structure is preferably honeycomb-shaped. The thermoplastic foam beads preferably contain or consist of PE, PP, PS, TPU, PBT, PET or PEI, mixtures of the aforementioned materials also being within the scope of the invention. The thermoplastic foam beads preferably contain or consist of recycled thermoplastic material.

Im Rahmen der Erfindung liegt es insbesondere, dass die Schaumperlen mit funktionellen Additiven, vorzugsweise flammhemmenden und/oder elektrisch leitenden und/oder klebrigen und/oder antibakteriellen und/oder elektromagnetische Wellen und/oder Strahlung absorbierenden Additiven versehen werden. In den beiden letztgenannten Fällen können die Additive inbesondere zur Verbesserung des Energieeintrags durch eine Energiequelle in die Schaumperlen beitragen. Zweckmäßigerweise werden lediglich die oberflächennahen Bereiche der einzelnen Schaumperlen mit den funktionellen Additiven versehen. Hierdurch kann Additiv-Material eingespart werden, ohne dass die durch die Additive hervorgerufenen funktionellen Eigenschaften des aus den Schaumperlen hergestellten Schaummaterials wesentlich beeinträchtigt werden. Vorzugsweise werden vorexpandierte Schaumperlen mit einer durchschnittlichen Größe von 0,1 bis 5 mm, z.B. 0,5 bis 3 mm, in die Hohlräume eingefüllt.It is particularly within the scope of the invention that the foam beads are provided with functional additives, preferably flame-retardant and / or electrically conductive and / or sticky and / or antibacterial and / or electromagnetic waves and / or radiation-absorbing additives. In the latter two cases, the additives can in particular contribute to improving the energy input by an energy source into the foam beads. Expediently, only the near-surface areas of the individual foam beads are provided with the functional additives. In this way, additive material can be saved without the additives The functional properties of the foam material produced from the foam beads are significantly impaired. Pre-expanded foam beads with an average size of 0.1 to 5 mm, for example 0.5 to 3 mm, are preferably filled into the cavities.

Zweckmäßigerweise besteht die Gitterstruktur aus einem, vorzugsweise thermoplastischen Polymer und/oder Papier und/oder Metall und/oder Keramik. Im Rahmen der Erfindung liegt es ferner, dass mindestens eine, vorzugsweise beide Plattenoberflächen der Gitterstruktur mit einer Decklage versehen, insbesondere verbunden werden. Die z.B. weniger als 5 mm, insbebondere weniger als 3 mm dicken Decklagen schützen das Schaummaterial mechanisch und verleihen der Platte eine einwandfreie optische und auch haptische Gestalt. Die Decklage kann bzw. beide Decklagen können jeweils aus einem, vorzugsweise faserverstärkten, Thermoplast oder Duroplast und/oder Holz und/oder Metall bestehen. Die Faserverstärkung kann beispielsweise in Form eines thermoplastischen Organosheets oder auch in Form von duroplastischen Faserverbunden realisiert werden. Durch eine entsprechende Materialauswahl bzgl. der Decklage(n) kann die eingangs beschriebene nachträgliche Umformbarkeit der Platte auch hier gewährleistet werden. Im Rahmen der Erfindung liegt es ferner, dass die mindestens eine Decklage mit einem, vorzugsweise thermoplastischen oder duroplastischen Klebstoff mit der jeweiligen Plattenoberfläche verbunden wird.The lattice structure expediently consists of a, preferably thermoplastic polymer and / or paper and / or metal and / or ceramic. It is also within the scope of the invention that at least one, preferably both, plate surfaces of the lattice structure are provided with a cover layer, in particular are connected. The e.g. Less than 5 mm, in particular less than 3 mm thick top layers mechanically protect the foam material and give the plate a perfect visual and haptic shape. The top layer or both top layers can each consist of a, preferably fiber-reinforced, thermoplastic or thermoset and / or wood and / or metal. The fiber reinforcement can be implemented, for example, in the form of a thermoplastic organosheet or in the form of thermosetting fiber composites. The subsequent formability of the plate described at the beginning can also be ensured here by a corresponding choice of material with regard to the top layer (s). It is also within the scope of the invention that the at least one cover layer is connected to the respective plate surface with a, preferably thermoplastic or thermosetting adhesive.

Gemäß einer Ausführungsform der Erfindung erfolgt zunächst die finale Expansion der Schaumperlen, bevor die mindestens eine Decklage auf die Plattenoberfläche aufgebracht wird. Alternativ hierzu liegt es jedoch auch im Rahmen der Erfindung, dass die mindestens eine Decklage vor der finalen Expansion der Schaumperlen auf die Gitterstruktur aufgebracht wird. Dies hat den Vorteil, dass während der finalen Expansion der Schaumperlen unmittelbar auch ein stoffschlüssiger Verbund des finalen Schaummaterials mit der mindestens einen Decklage und/oder ein stoffschlüssiger Verbund der Oberfläche der plattenförmigen Gitterstruktur mit der mindestens einen Decklage hergestellt werden kann.
Wie bereits erwähnt, liegt es im Rahmen der Erfindung ferner, dass die fertig hergestellte Platte mittels eines thermischen Verfahrens umgeformt wird, um sie z.B. in eine gewünschte Raumform zu überführen, wie z.B eine Winkel- oder Bogenform.According to one embodiment of the invention, the foam beads are finally expanded before the at least one cover layer is applied to the plate surface. As an alternative to this, however, it is also within the scope of the invention that the at least one cover layer is applied to the lattice structure before the final expansion of the foam beads. This has the advantage that, during the final expansion of the foam beads, a material bond between the final foam material and the at least one cover layer and / or a material bond between the surface of the plate-shaped lattice structure and the at least one cover layer can be produced directly.
As already mentioned, it is also within the scope of the invention that the finished plate is shaped by means of a thermal process, for example in order to convert it into a desired spatial shape, such as an angular or arc shape.

Gegenstand der Erfindung ist ferner eine geschäumte Platte, insbesondere zu Isolationszwecken, welche mit dem vorstehenden erfindungsgemäßen Verfahren hergestellt worden ist. Die erfindungsgemäß hergestellte Platte findet ihre Anwendung beispielsweise als Bauteil, z.B. Interieur-Bauteil in Fahrzeugen, wie zum Beispiel Kraftfahrzeugen oder Flugzeugen, als Bauteil im Möbelbereich oder aber auch als Bauteil, insbesondere Wand-oder Türelement im Bauwesen. Andere Anwendungen jeglicher Art werden hierdurch jedoch nicht ausgeschlossen.The invention further relates to a foamed board, in particular for insulation purposes, which has been produced using the above method according to the invention. The plate produced according to the invention is used, for example, as a component, e.g. Interior component in vehicles, such as motor vehicles or aircraft, as a component in the furniture sector or as a component, in particular a wall or door element in construction. This does not exclude other applications of any kind.

Im folgenden wird die Erfindung anhand einer lediglich ein Ausführungsbeispiel darstellenden Zeichnung ausführlich erläutert:

  • 1 ein erstes erfindungsgemäßes Verfahren zur Herstellung einer geschäumten Platte und
  • 2 ein weiteres, alternatives erfindungsgemäßes Verfahren zur Herstellung einer geschäumten Platte.
The invention is explained in detail below with the aid of a drawing illustrating only one exemplary embodiment:
  • 1 a first inventive method for producing a foamed sheet and
  • 2nd another, alternative method according to the invention for producing a foamed sheet.

Die beiden Figuren zeigen jeweils ein Verfahren zur Herstellung einer geschäumten Platte 100 für Isolationszwecke im Baubereich.The two figures each show a method for producing a foamed sheet 100 for insulation purposes in construction.

In der für beide Figuern geltenden obersten Abbildung wird zunächst eine plattenförmige, Hohlräume 1 bildende Gitterstruktur 2 zur Aufnahme von Schaummaterial 3 bereitgestellt, in die danach das Schaummaterial 3 in Form von thermoplastischen, vorexpandierten Schaumperlen 4 als Schüttgut in die Hohlräume 1 eingefüllt wird. Die oberste Abbildung zeigt bereits mit den vorexpandierten Schaumperlen 4 gefüllte Gitterstruktur 2, welche wabenförmig ausgebildet ist. Die thermoplastischen Schaumperlen 4 bestehen im Ausführungsbeispiel aus recycliertem, voerexpandiertem Polystryrol (EPS) oder Polypropylen (EPP). Die vorexpandierten Schaumperlen 4, welche in die Hohlräume 1 eingefüllt werden, weisen eine durchschnittliche Größe, insbesondere eine Kugelform mit einen durchschnittlichen Durchmesser von 0,1 bis 5 mm auf, z.B. 0,5 bis 3 mm. Die Gitterstruktur 2 besteht ebenfalls aus einem thermoplastischen Polymer, zum Beispiel Polystyrol oder Polypropylen.In the top illustration, which applies to both figures, there is first a plate-shaped, hollow space 1 forming lattice structure 2nd to hold foam material 3rd provided, in which afterwards the foam material 3rd in the form of thermoplastic, pre-expanded foam beads 4th as bulk in the cavities 1 is filled. The top picture already shows the pre-expanded foam beads 4th filled lattice structure 2nd , which is honeycomb-shaped. The thermoplastic foam beads 4th consist in the embodiment of recycled, pre-expanded polystyrene (EPS) or polypropylene (EPP). The pre-expanded foam pearls 4th which in the cavities 1 are filled, have an average size, in particular a spherical shape with an average diameter of 0.1 to 5 mm, for example 0.5 to 3 mm. The lattice structure 2nd also consists of a thermoplastic polymer, for example polystyrene or polypropylene.

Die vorexpandierten Schaumperlen 4 sind vorab mit funktionellen, z.B. flammhemmenden Additiven (nicht näher dargestellt) versehen worden. Gegebenenfalls können auch elektromagnetische Wellen absorbierende Additive eingesetzt werden, welche beispielsweise einen Energieeintrag in die Schaumperlen 4 mittels thermischer Induktion verbessert. Im Ausführungsbeispiel sind lediglich die oberflächennahen Bereiche der einzelnen Schaumperlen 4 mit den funktionellen Additiven versehen, beispielsweise beträgt die Eindringtiefe der Additive in die einzelnen Schaumperlen 4 weniger als 20 %, insbesondere weniger als 10 % der Perlengröße, insbesondere des Durchmessers der einzelnen Schaumperlen 4.The pre-expanded foam pearls 4th have previously been provided with functional, for example flame-retardant, additives (not shown in more detail). If necessary, additives which absorb electromagnetic waves can also be used, which, for example, introduce energy into the foam beads 4th improved by means of thermal induction. In the exemplary embodiment, only the regions of the individual foam beads near the surface are 4th provided with the functional additives, for example the depth of penetration of the additives into the individual foam beads 4th less than 20%, in particular less than 10% of the pearl size, in particular the diameter of the individual foam pearls 4th .

Gemäß 1 wird nun auf die mit den vorexpandierten Schaumperlen 4 gefüllte plattenförmige Gitterstruktur 2 beidseitig jeweils eine Decklage 5 aufgebracht, welche ebenfalls aus einem thermoplastischen Polymer, beispielsweise Polysytyrol oder Polypropylen besteht. Im Bedarfsfall können die Decklagen 5 faserverstärkt ausgebildet sein.According to 1 is now on the with the pre-expanded foam beads 4th filled plate-shaped lattice structure 2nd a top layer on both sides 5 applied, which also consists of a thermoplastic polymer, such as polysytyrene or polypropylene. If necessary, the top layers 5 be fiber-reinforced.

Nach dem Aufbringen der Decklagen 5 wird der so erhaltene Schichtaufbau in eine Form 6 eingelegt und diese in einen (nicht näher dargestellten) Behandlungsofen eingebracht. Im Behandlungsofen erfolgt durch Energiezufuhr mittels einer Energiequelle 7 eine finale Expandierung der Schaumperlen 4. Dieses werden hierdurch stoffschlüssig untereinander sowie mit den Wandungen der Hohlräume 1 verbunden. Dieser Expansionsvorgang kann auch unter erhöhtem Druck durchgeführt werden. Im Ausführungsbeispiel erfolgt die Energiezufuhr durch seitliche, auf eine Schmalseite der plattenförmigen Gitterstruktur 2 gerichtete Mikrowelleneinstrahlung 8. Alternativ kann der Energieeintrag auch durch thermische Induktion erfolgen, wobei in diesem Zusammenhang die vorgenannten entsprechenden Additive den Schaumperlen 4 den Energieeintrag verbessern. Zum Eintrag der Energie in die gesamte plattenförmige Gitterstruktur 2 und damit das gesamte Schaummaterial 3 kann es zweckmäßig sein, dass die Energiequelle 7 seitlich an der plattenförmigen Gitterstruktur 2 vorbeigeführt wird (1) oder alternativ die Gitterstruktur 2 an der ortsfesten Energiequelle 7 vorbeigefahren wird (2). Dies ist möglich, da die eingebrachte Energie durch die Wandungen der Gitterstruktur 2 hindurchdringen kann.After applying the top layers 5 the layer structure obtained in this way becomes a mold 6 inserted and placed in a treatment furnace (not shown). In the treatment furnace, energy is supplied by means of an energy source 7 a final expansion of the foam beads 4th . As a result, these become cohesive with one another and with the walls of the cavities 1 connected. This expansion process can also be carried out under increased pressure. In the exemplary embodiment, the energy is supplied by lateral, on a narrow side of the plate-shaped lattice structure 2nd directed microwave radiation 8th . Alternatively, the energy can also be introduced by thermal induction, in which connection the aforementioned corresponding additives to the foam beads 4th improve the energy input. For the entry of energy into the entire plate-shaped lattice structure 2nd and thus the entire foam material 3rd it may be appropriate for the energy source 7 on the side of the plate-shaped lattice structure 2nd is led past ( 1 ) or alternatively the lattice structure 2nd at the stationary energy source 7 is driven past ( 2nd ). This is possible because the energy introduced through the walls of the lattice structure 2nd can penetrate.

Zur Verbesserung der Anbindung der Decklagen 5 an das Schaumaterial 3 und/oder der Oberfläche der Gitterstruktur 2 können diese mit einem vorzugsweise thermoplastischen Klebstoff (nicht näher dargestellt) mit der jeweiligen Plattenoberfläche verbunden werden. Der Klebstoff kann hierbei direkt bei Auftrag wirksam sein oder aber auch alternativ im Rahmen des oben beschriebenen Energieeintrages aktiviert werden (Schmelzklebstoff).To improve the connection of the top layers 5 to the foam material 3rd and / or the surface of the lattice structure 2nd can be connected to the respective plate surface with a preferably thermoplastic adhesive (not shown in detail). The adhesive can be effective when applied or alternatively activated as part of the energy input described above (hot melt adhesive).

Beim Ausführungsbeispiel gemäß 2 hingegen wird zunächst die mit den Schaumperlen 4 gefüllte Gitterstruktur 2 in eine Form 6 eingebracht und diese in den Behandlungsofen eingeschoben. Dort erfolgt analog zu 1 durch einen Energieeintrag eine finale Expansion der Schaumperlen 4 unter Herstellung der genannten stoffschlüssigen Verbindungen. Erst nach Abschluss dieses Vorgangs werden die Decklagen 5 auf die mit der finalen Schaumstruktur versehenen Gitterplatte 2 aufgebracht und in einem zweiten Vorgang mit Energieeintrag im selben oder einem weiteren Behandlungsofen die stoffschlüssige Verbindung zwischen den Decklagen 5 und der geschäumten Gitterplatte2 hergestellt.In the embodiment according to 2nd on the other hand, the one with the foam beads 4th filled lattice structure 2nd into a shape 6 introduced and inserted into the treatment furnace. There is analogous to 1 through an energy input a final expansion of the foam beads 4th producing the cohesive connections mentioned. The top layers only become available after this process has been completed 5 on the grid plate provided with the final foam structure 2nd applied and in a second process with energy input in the same or another treatment furnace, the integral connection between the cover layers 5 and the foamed grid plate 2.

Im Bedarfsfall kann die fertig hergestellte Platte 100 mittels eines thermischen Verfahrens umgeformt werden, um sie in eine gewünschte Raumform zu überführen, wie z.B eine Winkel- oder Bogenform (nicht näher dargestellt).If necessary, the finished plate can 100 can be reshaped by means of a thermal process in order to convert them into a desired spatial shape, such as, for example, an angle or arc shape (not shown in more detail).

Wenngleich die Ausführungsbeispiele eine Anwendung im Baubereich betreffen, so ist die Anwendung der erfindungsgemäßen Lehre hierauf grundsätzlich nicht beschränkt. Jegliche andere Anwendung liegt grundsätzlich auch im Rahmen der Erfindung.Although the exemplary embodiments relate to an application in the construction sector, the application of the teaching according to the invention is in principle not restricted to this. Any other application is also fundamentally within the scope of the invention.

Claims (14)

Verfahren zur Herstellung einer geschäumten Platte (100), insbesondere für Isolationszwecke, - wobei zunächst eine plattenförmige, Hohlräume (1) bildende Gitterstruktur (2) zur Aufnahme von Schaummaterial (3) bereitgestellt wird, - wobei danach das Schaummaterial (3) in Form von thermoplastischen, vorexpandierten Schaumperlen (4) als Schüttgut in die Hohlräume (1) eingefüllt wird und - wobei danach durch Energiezufuhr eine finale Expandierung der Schaumperlen (4) erfolgt und diese hierdurch stoffschlüssig untereinander sowie mit den Wandungen der Hohlräume (1) verbunden werden.Process for producing a foamed sheet (100), in particular for insulation purposes, - First of all, a plate-shaped, hollow space (1) forming lattice structure (2) for receiving foam material (3) is provided, - Thereafter the foam material (3) in the form of thermoplastic, pre-expanded foam beads (4) is poured into the cavities (1) as bulk material and - Thereafter, a final expansion of the foam beads (4) takes place by supplying energy, and these are thereby integrally connected to one another and to the walls of the cavities (1). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Energiezufuhr durch Mikrowellenstrahlung (8) oder thermische Induktion erfolgt.Procedure according to Claim 1 , characterized in that the energy is supplied by microwave radiation (8) or thermal induction. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Gitterstruktur (2) wabenförmig ausgebildet ist.Procedure according to Claim 1 or 2nd , characterized in that the lattice structure (2) is honeycomb-shaped. Verfahren nach nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die thermoplastischen Schaumperlen (4) aus, vorzugsweise recycliertem, PE, PP, PS, TPU, PBT, PET oder PEI bestehen.Method according to one of the Claims 1 to 3rd , characterized in that the thermoplastic foam beads (4) consist of, preferably recycled, PE, PP, PS, TPU, PBT, PET or PEI. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Schaumperlen (4) mit funktionellen Additiven, insbesondere flammhemmenden und/oder elektrisch leitenden und/oder klebrigen und/oder antibakteriellen und/oder elektromagnetische Wellen absorbierenden Additiven versehen werden.Procedure according to one of the Claims 1 to 4th , characterized in that the foam beads (4) are provided with functional additives, in particular flame-retardant and / or electrically conductive and / or sticky and / or antibacterial and / or electromagnetic wave-absorbing additives. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass lediglich die oberflächennahen Bereiche der einzelnen Schaumperlen (4) mit den funktionellen Additiven versehen werden.Procedure according to Claim 5 , characterized in that only the near-surface areas of the individual foam beads (4) are provided with the functional additives. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass vorexpandierte Schaumperlen (4) mit einer durchschnittlichen Größe von ... bis ... mm in die Hohlräume (1) eingefüllt werden. Procedure according to one of the Claims 1 to 6 , characterized in that pre-expanded foam beads (4) with an average size of ... to ... mm are filled into the cavities (1). Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die Gitterstruktur (2) aus einem, vorzugsweise thermoplastischen Polymer und/oder Papier und/oder Metall und/oder Keramik besteht.Procedure according to one of the Claims 1 to 7 , characterized in that the lattice structure (2) consists of a, preferably thermoplastic polymer and / or paper and / or metal and / or ceramic. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass mindestens eine, vorzugsweise beide Plattenoberflächen der Gitterstruktur (2) mit einer Decklage (5) versehen werden.Procedure according to one of the Claims 1 to 8th , characterized in that at least one, preferably both, plate surfaces of the lattice structure (2) are provided with a cover layer (5). Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die mindestens eine Decklage (5) aus einem, vorzugsweise faserverstärkten, Thermoplast oder Duroplast und/oder Holz und/oder Metall besteht.Procedure according to Claim 9 , characterized in that the at least one cover layer (5) consists of a, preferably fiber-reinforced, thermoplastic or thermoset and / or wood and / or metal. Verfahren nach Anspruch 9 oder 10, dadurch gekennzeichnet, dass die mindestens eine Decklage (5) mit einem, vorzugsweise thermoplastischen oder duroplastischen Klebstoff mit der jeweiligen Plattenoberfläche verbunden wird.Procedure according to Claim 9 or 10th , characterized in that the at least one cover layer (5) is connected to the respective plate surface with a, preferably thermoplastic or thermosetting adhesive. Verfahren nach nach einem der Ansprüche 9 bis 11, dadurch gekennzeichnet, dass die mindestens eine Decklage (5) vor oder nach der finalen Expansion der Schaumperlen (4) auf die Gitterstruktur (2) aufgebracht wird.Method according to one of the Claims 9 to 11 , characterized in that the at least one cover layer (5) is applied to the lattice structure (2) before or after the final expansion of the foam beads (4). Verfahren nach einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, dass die fertig hergestellte geschäumte Platte (100) mittels eines thermischen Verfahrens umgeformt wird.Procedure according to one of the Claims 1 to 12th , characterized in that the finished foamed plate (100) is formed by means of a thermal process. Geschäumte Platte (100), insbesondere zu Isolationszwecken, hergestellt mit einem Verfahren nach einem der Ansprüche 1 bis 13.Foamed plate (100), in particular for insulation purposes, produced by a method according to one of the Claims 1 to 13 .
DE102018122098.7A 2018-09-11 2018-09-11 Process for making a foamed sheet Pending DE102018122098A1 (en)

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DE102020204873A1 (en) 2020-04-17 2021-10-21 Volkswagen Aktiengesellschaft Process for the production of a sandwich component

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US2744042A (en) * 1951-06-21 1956-05-01 Goodyear Tire & Rubber Laminated panels
EP0314442A2 (en) * 1987-10-28 1989-05-03 WILSDON & CO. LTD Composite panel core
WO2006134079A1 (en) * 2005-06-15 2006-12-21 Antoine Antoine Composite part such as a panel, comprising a honeycomb structure
DE102013223347A1 (en) * 2013-11-15 2015-05-21 Evonik Industries Ag Honeycomb filled with poly (meth) acrylimide foam

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2744042A (en) * 1951-06-21 1956-05-01 Goodyear Tire & Rubber Laminated panels
EP0314442A2 (en) * 1987-10-28 1989-05-03 WILSDON & CO. LTD Composite panel core
WO2006134079A1 (en) * 2005-06-15 2006-12-21 Antoine Antoine Composite part such as a panel, comprising a honeycomb structure
DE102013223347A1 (en) * 2013-11-15 2015-05-21 Evonik Industries Ag Honeycomb filled with poly (meth) acrylimide foam

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102020204873A1 (en) 2020-04-17 2021-10-21 Volkswagen Aktiengesellschaft Process for the production of a sandwich component

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