DE4335583C1 - Process for producing composite materials from individual elements from filling phases incorporated in a structural phase - Google Patents

Abstract

Process for producing composite materials from individual elements from filling phases incorporated in a structural phase by means of a supply-, nozzle- and pressure-regulating system. In comparison with conventional processes such as foaming or the multistage production of composite materials, with the process described high strength, a closed-cell character, weight saving and three-dimensionally similar load-bearing capacity can be achieved in one operation. A number of material phases are brought together in a nozzle system and expelled into a feed channel under changing partial pressures which are equal in their overall sum. A counterpressure is created in this feed channel by feeding against gravity or forcing into a mould, with the result that, by the nozzle arrangement and material flow control and subsequent solidification at least of the structural phase, a solid body having a three-dimensional grid structure (framework, skeleton) is produced from a structural phase in which fillers are incorporated. The useful factor of this process is ether the internal structure produced (lightweight material) or the inclusion of the individual fillers in a stable shell (controlled emission of contents into the environment upon dissolution of the structural phase).

Description

The invention relates to a method for producing composite materials according to claim 1.

Compared to conventional methods for changing material properties such as foaming or the production of sandwich honeycomb panels with higher strengths, Achieve resilience and porosity similar to three dimensions in one operation.

The three-dimensional networking of the inner structure allows blanks to be transferred after a transfer deform in a viscous state even while maintaining the internal structure.

Compared to conventional methods for storing highly toxic substances such as radioactive Substances in glass melts can be used to achieve inclusions that counteract Destruction, for example by devitrification due to the enclosed radioactive substances, are more resistant due to the coating with non-radioactive glasses.

Compared to conventional methods for the controlled release of ingredients to the environment, such as in the field of fertilizer application, can be Possibility to vary the strength and chemistry of the envelope phase individually variable Reach long-term care.

The product can be used in the area:

Building materials
Building blocks,
Components such as prefabricated components, bridge elements,
Building materials for shipbuilding, body construction,
Building materials for the permafrost area (possible specific weight <1.0 as of H₂O, high thermal insulation, high resistance to frost explosions due to closed pore or packing structure),
Building materials for landfill waterproofing (possible similar chemistry such as bedrock, tightness, elasticity).

Insulation materials

Medical prosthetics
Lightweight building materials, provision of suitable growth points for newly formed substances in the body through the structure of the filling phase and the framework phase

Saving of high quality raw materials by encapsulated installation of lower quality
Raw materials,
for example of low-grade steel or silicates as the filling phase, stainless steel as the scaffolding phase

Materials with specific desired properties by post-treatment of the material, for example by rolling, tempering
Clothing agents and ropes

Inclusion of highly toxic substances as packing, this means that there is little leakage of the toxic substances into the environment mechanical destruction of the inclusion body

Storage and controlled release of highly diffuse gases such as hydrogen (large pore space, amount of diffusion rate released and material depending on the material)

Provide a large surface for chemical reactants

The invention has for its object various substances in the flowable state Expulsion with mutually variable proportions through a supply and Nozzle system and subsequent solidification through solidification or chemical reaction in one Solid with predeterminable three-dimensional distribution of the various components To transfer single bodies with predeterminable interface configuration. The peculiarity The method is that different material phases are combined in such a way in a nozzle system and are carried out that generated by the nozzle arrangement and material flow control Distribution of the phases in the further processing is more or less preserved. The The end product is a solid with a three-dimensional lattice structure, embedded in the filler are. The solid can be solidified by solidifying liquid viscous phases (e.g. silicate melts, Metals or thermoplastics) or reaction of the liquid viscous phases (two-component materials such as synthetic resins, thermal solidification of ceramic materials) after shaping arise. The useful factor of this process is either the resulting internal structure (lightweight materials with high mechanical strength, weight savings for components) or the inclusion of the individual packing in a stable casing (controlled release of ingredients in the surrounding system in the event of dissolution or destruction of the lattice framework phase, e.g. B. medical Active ingredients, fertilizers, toxic substances).

To produce the networked internal structure, a pressure / conveyor system for the envelope phase and two pressure / conveyor systems are required for the filling phases, the two conveyor systems for the Filling phases also with joint advance of the filling phases and in the nozzle head Funding regulations can be implemented (see also Example 1, Example 2). Form and distribution of the  Delivery channels can be adapted to the desired structure, for special tasks too the number of material phases used are increased or the envelope phase from different Phases are built up (for example, to introduce electrically conductive connections).

example 1

In the most general case with a homogeneous stand or shell phase and two filling phases, each of which is fed from its own conveying channel with its own variable conveying speed into a nozzle system, production takes place as described below. The three different material phases (here called 1, 2 a, 2 b) are in the liquid state and under pressure in their own storage containers 11, 12 a, 12 b and are each with their own pressure / inflow regulator 31 , 32 a, 32 b Pipe connections to the nozzle head 4 can be supplied.

In the most general case shown here, a scaffolding phase (here called phase 1 ) and two filling phases (here called phase 2 a and 2 b) are each provided in their own storage containers under their own pressure (see FIG. 1), each via a pipe system Pressure and inflow controllers are connected to the nozzle head (see Fig. 2).

In the figure of the nozzle head (Fig. 2) perpendicular hatched conveyor illustrated cells 6 are commonly connected to phase 2 a (filling phase), the horizontally hatched between together with Phase 2 b (filling phase), and located within the conveying channel wall 7 latticed gaps shown dotted the conveyor cells are connected to phase 1 (scaffolding phase).

The inflow to the nozzle head is regulated by the inflow regulators in such a way that the total delivery volume of all three inflows is always the same and at the same time an amount that at least completely fulfills the delivery channel 5 is delivered.

Appropriate viscosity adjustment is carried out in the delivery channel by expulsion against gravity and / or input into closed molds a sufficient counter pressure is set so that the Training of the cellular structure takes place.

The inflow amounts of phases 2 a and 2 b are continuously varied during the production process so that the total amount remains the same.

In FIGS. 3 to 11 more sections through the final product during a Zuflußsteuerzyklusses. Here Z2a represents the inflow of a Phase 2 and Z2b b of the inflow stage. 2

A small cell area is shown enlarged, the position of the conveyor cells by lines indicated.

FIGS. 3 to 5 show, starting from the same flow rates of the phases 2 a and 2 b, cuts with increasing amount of phase 2 a and until none sinking promotion of Phase 2 b, Figs. 5 to 9 sections with increasing proportion from phase 2 b and with the exception of no promotion of phase 2 a, FIGS. 9 to 11 sections with an increasing proportion of phase 2 a up to the same delivery rate of phase 2 a and phase 2 b.

The result is a three-dimensionally crosslinked system from the skeleton phase, in the packing of phases 2 a and 2 b are embedded (see Fig. 12).

Example 2

A shell or scaffolding phase and two filling phases are required to set up the structured product. The two filling phases must belong to two pressure / conveyor systems. The two pressure / conveying systems can also be realized by jointly promoting the filling phases with a regulated pressure system for the two conveying systems of the filling phases, with a nozzle head structure described below. The packing phase (here called phase 2 from) is conveyed at a constant flow rate into a chamber of the two-chamber nozzle head, which is closed by a base plate 9 provided with openings. By means of a slide plate 8 , which has alternating passages and is continuously moved back and forth, the passages in the base plate are alternately reduced to closed or enlarged until fully opened. Each breakthrough in the base plate 9 opens into a feed cell 10 for phase 2 in the second chamber of the nozzle head, which is followed by the feed channel. The scaffolding phase 1 is fed into the spaces between the conveyor cells. The total flow rate of the scaffolding phase and the filling phases remains the same, the reciprocating slide plate 8 alternately opens passages for adjacent delivery cells (see FIG. 13). A sufficient back pressure is produced in the delivery channel, so that a complete filling of the delivery channel and the formation of the cellular structure is ensured. Here, too, a three-dimensionally networked system emerges from the scaffolding phase, into which packing elements from phase 2 are embedded (see Fig. 14).

Claims (7)

1. Process for the production of composite materials from single bodies stored in a framework phase from filling phases by means of a feed and nozzle system and changing, in total same supply of different liquid or gaseous phases, at least which the framework build-up phase solidifies after forming, so that a honeycomb-like three-dimensionally cross-linked, structure similar to the structure of plant tissue arises. 2. The method according to claim 1, characterized in that the main phase or framework phase Solid and the filling or secondary phases are gases, so that a closed-pore honeycomb Body with gas pockets is created. 3. The method according to claim 2, characterized in that the closed-pore elastic honeycomb-like body is perforated in a further operation, so that a compressible body, which automatically returns to its original shape when pressure is released occupies. 4. The method according to claim 1, wherein the main phase or framework phase is a low-gas liquefied Solid and the filling or secondary phases are foamed solids, for example by Pressure released, dissolved gases or foamed by chemical reaction. 5. The method according to claim 1, wherein the main phase and secondary phase are low-gas liquefied substances, so that a system of small discrete bodies is created within the whole body, the all-round are surrounded by a sheathing through the scaffolding phase. 6. The method according to claim 1, characterized in that the main phase or framework phase Solid and the filling or secondary phases are gases or liquids, so that a closed-pore honeycomb-like body with gas or liquid inclusions, which is between translucent Panes onto which conductive tracks for electrical current have been applied are introduced, so that the individual honeycomb cells can be individually controlled by applied currents, for example for the application with data display devices. 7. The method according to claim 1, characterized in that the main phase or framework phase insulating solid and the filling or secondary phases are electrically conductive solids, whereby by consecutive supply of main phase with only one secondary phase, then simultaneous supply of the main phase and both secondary phases (the amount of both to enlarge the surface Secondary phases should oscillate, but both should always be fed simultaneously to one continuous conductive connection) and supply of main phase with only the second Side phase and subsequent attachment of contacts at the two ends of the emerging Body mutually insulated electrically conductive body with a large surface to Example of use as a capacitor.