Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
  • B05D1/08—Flame spraying
  • B05D1/10—Applying particulate materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
  • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
  • B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
  • B05B7/1481—Spray pistols or apparatus for discharging particulate material
  • B05B7/149—Spray pistols or apparatus for discharging particulate material with separate inlets for a particulate material and a liquid to be sprayed
  • B05B7/1495—Spray pistols or apparatus for discharging particulate material with separate inlets for a particulate material and a liquid to be sprayed and with separate outlets for the particulate material and the liquid
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/34—Applying different liquids or other fluent materials simultaneously

Definitions

• the invention relates to a method for applying a filler-containing plastic layer to a surface, in particular a shaped surface.
• the invention relates in particular to a method for applying a heavy layer on a shaped surface, for producing a sound-insulating multi-layer wall cladding, as is used, for example, in vehicle interior claddings.
• Sound-insulating multi-wall cladding which is contour-adapted to the vehicle interior, has been known for a long time.
• DE-OS 20 06 741 describes, for example, a multi-layer, sound-absorbing component that consists of a deformed carpet and a correspondingly deformed heavy layer, which are connected to one another by a conventional method, for example gluing, and that on a layer of dynamically soft material on the Body of the vehicle is floating. It is also described that the carpet surface only has to be coated locally, preferably in the area of the bulkhead, the wheel arches and in the storage area of the feet in front of the front seats. However, this lining is still relatively heavy.
• DE-PS 11 86 648 describes a sound-absorbing and vibration-damping material for cladding sheets of machines, which consists of a layer of a soft, elastic, sound-absorbing foam and a vibration-damping layer of synthetic resin connected to the layer. This layer can be mixed with a mineral filler to form a heavy layer.
• the vibration-damping material in the form of a mixture of binder and filler is sprayed directly onto the elastic foam layer or an intermediate layer of fabric or applied in some other way.
• DE 28 00 914 describes sound-absorbing multi-layer wall cladding for the walls of vehicles or machines, which consists of a heavy layer assigned to the wall to be clad, which is formed by binders containing more than 40% by weight of fillers and is arranged on a flexible intermediate layer.
• Various conventional processes are described for the production of these multilayer wall claddings, which have in common that a heavy insulation layer is produced from a mixture of plasticized binder, filler and optionally further additives with the aid of an extruder or calender. This either solidifies directly in the desired form brought or they are first allowed to harden and then brought into the desired shape by a suitable process such as deep drawing or vacuum forming.
• a disadvantage of the conventional injection molding process is that the heavy layers have a relatively high weight and that the devices used to produce these layers wear out quickly and in particular the mixing heads have to be replaced frequently.
• the object of the invention is to provide an improved method with which a plastic layer containing solids can be applied in a desired manner to a particularly shaped surface, and a suitable device for carrying out the method.
• the invention is based on the knowledge that there is a substantial saving in weight if the heavy layer is designed in such a way that it has the required thickness and / or density in accordance with the local structural and acoustic conditions.
• the heavy layer can be formed with a smaller thickness and / or density, for example, at those points in the vehicle where only low sound insulation is required.
• areas with high sound transmission can be increasingly isolated and insulated.
• the invention thus enables better sound insulation, since each area of the cladding can be designed in the best possible way in accordance with the acoustic specifications. B. can be determined based on measurements.
• the invention now provides an improved method with which layers of this type, in particular with locally different densities and / or thicknesses, can be produced in a simple manner.
• the controllable and changeable formation of the heavy layer is achieved according to the invention in that a filler-containing plastic layer is sprayed onto a particularly shaped surface, a free jet for spray application first being generated from a binder or binder mixture. Only then is the filler metered into the free jet of the binder or binder mixture that has not yet been polymerized.
• the filler is metered in via one or more, preferably individually controllable, solid nozzle (s) and can thus be precisely controlled and regulated as desired.
• the addition of the filler can be variably adjusted by the method according to the invention even during the spraying process.
• the filler is preferably a free-flowing, high-density solid and should be added in an amount of 10 to 90% by weight, preferably 50 to 80% by weight, based on the final mixture.
• Binders suitable for the production of mass-spring systems in the usual mixing ratios can be used as binders in the process according to the invention. It is preferable to use components that meet the current requirements for recyclability and that can be recycled as easily as possible at the end of the product life cycle. Binders preferred according to the invention are binders based on polyurethane, in particular those which can be produced on the basis of a polyol-isocyanate mixture. However, other suitable binders can also be used.
• the local density and thickness of the sprayed-on layer can also be variably controlled during the process by regulating or controlling the filler supply.
• the invention further provides a device according to claim 10. It was found that the erosion, ie the wear of the device, in particular of the mixing head, is significantly reduced by the method according to the invention. This also reduces the drift in the mixing quality, which has a major impact on ensuring a constant product quality.
• the invention relates to a device for spray application of a solid-containing plastic layer to a surface with a mixing head, which has a first device for generating a free jet of the binder mixture and at least a second device for metered supply of a filler, characterized in that the second device for metered supply of the Filler is arranged so that the filler is metered into the free jet emerging from the mixing head to the binder mixture.
• the device can provide a plurality of second devices for metering the filler, which are arranged rotationally symmetrically with respect to the first device.
• the device preferably has three second devices which are arranged at an angular distance of approximately 120 ° around the first device.
• the second devices preferably consist of solids nozzles which can be controlled individually or in a coupled manner. According to a preferred embodiment, they also consist of a particularly wear-resistant material, for example ceramic material.
• the invention further relates to plastic layers which are produced by the method according to the invention or by means of the device according to the invention. These can have partially or locally different densities and / or thicknesses.
• Another embodiment relates to single- or multi-layer two-component polyurethane systems, sound-absorbing or sound-absorbing components and heavy layers for sound-insulating mass-spring systems with one or more layers, which are produced by the process according to the invention.
• Figure 1 is a schematic representation for explaining a device according to the invention for applying a plastic layer on a particularly shaped surface.
• FIG. 2 shows a schematic illustration to explain the filler feed using the example of an embodiment with three symmetrically arranged filler nozzles
• FIG. 3 shows a schematic illustration to explain the filler distribution on the surface to be sprayed with an arrangement of the solid nozzles as shown in FIG. 2.
• plastic layers containing filler are sprayed onto a particularly shaped surface.
• the method is particularly suitable for the production of heavy layers for sound-absorbing or -damping components which act according to the known mass-spring system.
• the method according to the invention forms heavy layers by spray application directly on the foam or spring layer or, if appropriate, a further intermediate layer.
• the foam or spring layer consists of an open or closed cell foam, an impregnated fiber made of organic, natural or synthetic fibers, or also inorganic, natural or synthetic fibers.
• the filler-containing plastic layer can be applied to surfaces of any shape using the spray process.
• a free jet is first generated with the aid of a mixing head with nozzles from a binder or a binder mixture.
• the nozzle diameter should be 0.15 mm, preferably 0.5-3 mm.
• Thermoplastics e.g. Polyvinyl acetate, polyvinyl propionate, polyacrylic acid ester, polymethacrylic acid ester, polystyrene, polyethylene as homo- or copolymers or mixtures thereof, two-component synthetic resins, e.g. Polyurethane, epoxy resin, polyester and the like, bitumen, pitch, wax, tree or root resins, natural and artificial rubber, rubber regenerate or mixtures thereof can be used.
• Preferred binders are two-component synthetic resins, in particular binders based on polyurethane.
• Polyol-isocyanate mixtures with a pressure range of 20-250 bar, preferably 60-150 bar, and a temperature range of the polyol of 10-150 ° C., preferably 20-100 ° C., and of the isocyanate are found to be particularly favorable for sound engineering applications from 10-100 ° C, preferably 20-60 ° C.
• the mixing ratio of polyol / isocyanate is 100/5 to 100/90, preferably 100/8 to 100/80.
• a filler is metered outside the mixing head 1 into the binder mixture, which has not yet polymerized out, in approximately one area.
• the filler is supplied using a conventional filler conveyor, which can convey a free-flowing filler in a thick stream.
• the filler is preferably a free-flowing, high density solid.
• the density of fillers suitable according to the invention is in the range above 2 g / cm 3 , preferably above 4.5 g / cm 3.
• the amount of filler or solid added depends in particular on the binder used and the desired density of the layer to be applied.
• the mixing ratio of binder to filler can be easily for the person skilled in the art, for. B. determine by experiment, the spray distance, ie the distance between the mixing head and the surface to be coated, should be 20-500mm, preferably 100-250mm, in order to ensure uniform mixing in the spray jet 8.
• the filler should preferably be added in an amount of 10 to 90% by weight, preferably 50 to 80% by weight, based on the final mixture.
• the filler can consist of one or more particulate materials which have at least one, preferably several of the following properties: a specific weight of more than 2 g / cm 3 , are finely ground, a bulk density of more than 600 g / 1 and one Have grain size (particle diameter) between 10 and 500mm, preferably between 50 and 250mm.
• the used according to the invention Fillers should be easy to pour.
• Preferred fillers are granular, flaky or powdery particles, for example made of barium sulfate (BaSO 4 ).
• the filler is metered in from one or more directions via one or more solid nozzles 5, in particular up to 16, preferably 2 to 6 solid nozzles, which are arranged symmetrically on the mixing head 1.
• the filler is particularly preferably supplied via 3 solid nozzles, which are arranged at an angular distance of approximately 120 °. This achieves an optimal mixing and connection of binder and filler in the spray jet, so that even in the finished product a uniform distribution of the filler and thus a uniform density distribution is achieved.
• the diameter of the solid nozzles 5 should be 0.1-10 mm, preferably 1-5 mm.
• the metering in of the filler can be variably controlled by the method according to the invention, in particular also during the spraying process.
• the filler content in the spray jet 8 can be freely selected and, depending on the requirements of the surface areas to be coated, continuously adjusted and changed.
• the density of the sprayed-on layer can be determined by controlling the filler content in the spray jet 8.
• the filler is expediently fed into the spray jet by means of compressed air or another pressure fluid which preferably does not react with the materials involved. Furthermore, in the method according to the invention, use is made of the negative pressure gradient in the direction toward or into the free jet 3.
• the binder which emerges from the mixing head 1 in the form of the free jet 3, entrains the added filler in the streamline as it emerges from the filler nozzle 5, as a result of which a homogeneous spray jet 8 is produced.
• the method according to the invention is promoted by the corrugation and atomization of the filler in the free jet 3.
• the filler is absorbed into the free jet 3 by the internal turbulence of the liquid by the jet and mixed uniformly therein.
• the method contributes to the fact that the spray device used is subject to less wear and tear, since the abrasive particulate filler does not get into the mixing head 1 or into pipes connected to it. On the one hand, this extends the lifespan of the equipment, which saves considerable costs, and on the other hand, the product quality is maintained over a longer period. In contrast, in conventional processes, a drift in the mixing quality was observed after a certain operating time, which is probably due to erosion of the mixing head.
• the method can also be modified or supplemented in a manner known to those skilled in the art.
• auxiliaries or additives known in the prior art can be added to the binder mixture.
• the invention provides a device for spray application of a solid-containing plastic layer to a particularly shaped surface, with which the above-mentioned method can be carried out.
• the device which is described with reference to FIG. 1, consists of a mixing head 1, which has a first device 2 for generating a free jet 3 of the binder or the binder mixture and at least a second device 4 for metered supply of a filler.
• the first device 2 preferably has a nozzle 5 for feeding or ejecting the binder mixture.
• the metering and control of the filler supply via a feed line 6 can take place in a conventional manner by means of compressed air, which is imposed via a further feed line 7 and entrains the added filler into the free jet 3.
• the addition of the filler is further supported by the negative pressure gradient described above.
• the second device 4 for the metered supply of the filler 5 is arranged according to the invention such that the filler is metered into the free jet 3 emerging from the mixing head 1 to the binder mixture.
• the device preferably has at least two, more preferably three, second devices 4 for metered supply of the filler. These should be arranged rotationally symmetrically with respect to the first device 2.
• FIG. 2 A particularly preferred embodiment is shown in FIG. 2, with three second devices 4 being arranged at an angular distance of approximately 120 ° around the first device 2. With this arrangement, the best possible filler distribution in the spray jet 8 can be achieved.
• the filler distribution in the spray circuit that can theoretically be achieved with this preferred device is shown in FIG. 3.
• the second devices 4 should be arranged such that the filler is supplied as directly as possible only a short distance after the free jet 3 emerges from the first device 2 into the free jet 3. With increasing distance, the scatter of the spray jet 8 increases. This leads to poorer mixing and less precise application accuracy of the filler-containing plastic mixture formed in the spray jet 8.
• the second devices 4 preferably have solids nozzles 5 which can be controlled individually or in a coupled manner.
• the independent controllability is particularly advantageous in applications in which the spray angle is not perpendicular to the application surface.
• the spray jet 8 frequently strikes the surface at an acute or obtuse angle. Due to the high density difference between the binder or binder mixture and filler, partial separation of the spray jet 8 would easily occur and thus an uneven distribution of the filler in the product.
• the individual solid material nozzles 5 can be controlled individually, so that the filler supply can be set and regulated independently via the respective nozzles 5. This ensures even application even under extreme spray angles.
• the devices 4 can be made entirely or at least in the area of the filler nozzles 5 from a resistant material, for example from a ceramic material.
• the invention relates to the products produced using the method according to the invention or the device according to the invention.
• the method is suitable for the production of numerous plastic layers, in particular those which have partially different densities and / or thicknesses.
• the method is particularly suitable for producing two-component polyurethane systems with one or more layers, sound-absorbing or sound-absorbing components with one or more layers and heavy layers for sound-insulating mass-spring systems as are used in the automotive industry for sound insulation.
• the products produced according to the invention are characterized by a particularly uniform filler distribution in the respective areas, which can be of different thicknesses and / or densities.

Landscapes

• Application Of Or Painting With Fluid Materials (AREA)
• Laminated Bodies (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
• Coating Of Shaped Articles Made Of Macromolecular Substances (AREA)
• Nozzles (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=7709286

Family Applications (1)

Country Status (8)

Families Citing this family (28)

Family Cites Families (5)

• 2001
  • 2001-12-14 DE DE10161600A patent/DE10161600A1/de not_active Withdrawn
• 2002
  • 2002-12-13 JP JP2003553024A patent/JP2005512775A/ja active Pending
  • 2002-12-13 DK DK02804897T patent/DK1458494T3/da active
  • 2002-12-13 AT AT02804897T patent/ATE400370T1/de active
  • 2002-12-13 US US10/498,469 patent/US20050202181A1/en not_active Abandoned
  • 2002-12-13 WO PCT/EP2002/014240 patent/WO2003052157A2/fr active IP Right Grant
  • 2002-12-13 EP EP02804897A patent/EP1458494B1/fr not_active Expired - Lifetime
  • 2002-12-13 ES ES02804897T patent/ES2309239T3/es not_active Expired - Lifetime
  • 2002-12-13 DE DE50212490T patent/DE50212490D1/de not_active Expired - Lifetime

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events