EP2203291A1 - Structure sandwich et son procédé de fabrication - Google Patents

Structure sandwich et son procédé de fabrication

Info

Publication number
EP2203291A1
EP2203291A1 EP08843269A EP08843269A EP2203291A1 EP 2203291 A1 EP2203291 A1 EP 2203291A1 EP 08843269 A EP08843269 A EP 08843269A EP 08843269 A EP08843269 A EP 08843269A EP 2203291 A1 EP2203291 A1 EP 2203291A1
Authority
EP
European Patent Office
Prior art keywords
core
layer
cover layer
sandwich structure
core layer
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.)
Withdrawn
Application number
EP08843269A
Other languages
German (de)
English (en)
Inventor
Ulrike Hoesch-Vial
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.)
Polymerpark Technologies GmbH and Co KG
POLYMERPARK Tech GmbH and Co KG
Original Assignee
Polymerpark Technologies GmbH and Co KG
POLYMERPARK Tech GmbH and Co KG
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 Polymerpark Technologies GmbH and Co KG, POLYMERPARK Tech GmbH and Co KG filed Critical Polymerpark Technologies GmbH and Co KG
Publication of EP2203291A1 publication Critical patent/EP2203291A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/06—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C2045/14532—Joining articles or parts of a single article injecting between two sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • 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
    • B32B2607/00—Walls, panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]

Definitions

  • the present invention relates to a sandwich structure and a method for producing a sandwich structure.
  • Sandwich or multilayer constructions are widely used in a wide variety of applications because they generally have high strength and rigidity despite being light in weight. For example, they are used for load-bearing assemblies in lightweight construction.
  • sandwich structures consist of relatively stiff cover layers, which are glued to a relatively lightweight core material. When a sandwich element is bent, the cover layers absorb the tensile and compressive forces while the core transmits the shear forces.
  • plastic materials have a very low density and thus a low weight.
  • plastic products are known based on thermoset materials and these are combined with reinforcing polyester, polyurethane or epoxy glass fiber topcoats.
  • thermoset sandwich structures are available in a wide variety of designs and qualities, they are often difficult or impossible to recycle because of their character. In addition, the toughness of these materials is very low.
  • thermoplastic materials are superior to thermoset materials in terms of toughness and recyclability.
  • thermoplastic materials usually require very high investment costs for an industrial production, so that then large quantities have to be produced in order to be able to offer the sandwich structures at competitive prices.
  • the known line systems also show little or no process flexibility.
  • mechanically bearing cover layers are thermally or chemically connected to the lightweight core material.
  • an existing finished core material is brought together with an existing finished cover layer. This process creates a two-stage or multi-stage process that is expensive. Such a complicated process is described by way of example in EP 0 794 859.
  • a method for producing a sandwich structure comprising the steps of: a) inserting a first cover layer into an injection mold, b) inserting a second cover layer into the injection mold, c) closing the injection mold, d) injecting a core material into the mold closed injection mold between the first and the second cover layer by means of injection molding, e) curing of the core material, so that between the two cover layers, a core layer is formed, and f) opening the injection mold and demolding the sandwich structure.
  • injection molds have at least two tool parts.
  • the first cover layer is inserted into the first tool part, while the second cover layer is inserted into the second tool part. If necessary, measures are taken to keep the cover layer in the injection mold.
  • the injection mold is then closed and the core material injected under pressure and generally at elevated temperature into the injection mold. After the material has hardened forming a core layer between the two cover layers, the injection mold can be opened and the resulting sandwich structure can be removed from the mold.
  • first and second cover layers are selected from the same material. They preferably have substantially the same thickness, so that a symmetrical sandwich structure is formed.
  • the first and / or the second cover layer may be made of a polymer material, for.
  • a thermoset or thermoplastic material preferably thermoplastic material is used here.
  • thermoplastic material has better toughness and is generally easier to recycle.
  • Exemplary materials which are suitable for the cover layer are polypropylene (PP), polyethylene (PE), copolymers of PE and PP, polyamides, for example PA6 or PA66, copolymers of PA6, PA66 and / or PA 12.
  • thermoplastic Polyesters such as, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), acrylonitrile-butadiene-styrene copolymer (ABS) or polyester-acrylate (SAN) can be used.
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • ABS acrylonitrile-butadiene-styrene copolymer
  • SAN polyester-acrylate
  • thermoplastic elastomers such as e.g. thermoplastic polyurethane (TPU), PP with ethylene-propylene-diene rubber (EPDM) or thermoplastic elastomers based on polyamide, polypropylene or polyethylene.
  • TPU thermoplastic polyurethane
  • EPDM ethylene-propylene-diene rubber
  • thermoplastic elastomers based on polyamide, polypropylene or polyethylene thermoplastic elastomers
  • elastomers may be useful for some applications, since they are particularly impact resistant. Examples are elastomers based on polyamide or polyester.
  • a metallic layer is selected as the cover layer.
  • the cover layer is fiber reinforced, i. the first and / or the second cover layer consists of a fiber-plastic composite.
  • Such fiber-plastic composites preferably consist of about 60% by weight of fibers, which are introduced in about 40% by weight of a matrix material, namely the polymer materials mentioned.
  • single or multi-layer unidirectionally reinforced or fabric reinforced long fiber composites can be used. Scratches have proved to be particularly advantageous as reinforcing material in the cover layer.
  • the fibers may be glass, carbon, ara- mide, basalt or natural fibers, such as e.g. Be jute, hemp or kenaf.
  • fibers of thermoplastic material such as e.g. PP, PE, copolymers of PE and PP, various polyamides, e.g. PA6 or PA66, copolymers of PA6 and PA66, PA12 or the like, or thermoplastic polyesters, e.g. PET or PBT can be used.
  • the core layer is preferably made of a polymer material.
  • the core layer may consist of any polymer material, but for the reasons already mentioned, a thermoplastic material is preferred.
  • the core layer consists of a foam.
  • a foam is understood as meaning a polymer material whose structure is formed by pores.
  • the core layer forms an integral foam, i. it has a substantially closed outer skin and a porous core.
  • thermoplastics e.g. Polyphenylene sulfide (PPS), polyether ether ketone (PEEK) or polysulfone (PSU) in the core and / or the top layer proven.
  • PPS Polyphenylene sulfide
  • PEEK polyether ether ketone
  • PSU polysulfone
  • the mechanical properties of the core layer can be improved if the polymer material additionally contains fillers and / or reinforcing materials. These may preferably be CaCO 3, talc, TiC> 2 , short fibers, discontinuous long fiber of glass or carbon or natural fibers.
  • the core layer and cover layers are selected such that the core layer is compatible with the first and / or the second cover layer.
  • Compatible materials are understood as meaning all materials which fuse together under pressure and / or with an increase in temperature or can be connected to one another as a result of a chemical reaction.
  • cover and core layers of the same base material i. to select the same polymer material, which may differ in the cover and / or core layer introduced fibers or fillers.
  • an adhesion promoter filler is applied to the first and / or second cover layer.
  • An adhesive film is understood to mean a film that is compatible with the two layers between which it is inserted.
  • a primer film may consist of two co-extruded layers, one layer being compatible with the top layer while the other layer is compatible with the core layer.
  • bioplastic if necessary, plus reinforcements and / or fillers exist.
  • PLA polylactic acid
  • the base material consists of starch, starch blends, polyhydroxybutyrate (PHB) or cellulose acetates.
  • PHA polylactic acid
  • PHB polyhydroxybutyrate
  • biodegradable fibers and / or fillers are also used in this case.
  • the first and / or the second cover layer differs from the core layer in a chemical and / or physical property.
  • the cover layer may have a much higher ductility or density than the core layer, giving the sandwich structure overall greater impact resistance.
  • the method described also works when the first and / or the second cover layer is inserted into the injection mold without preheating. Therefore, in a preferred embodiment, the preheating is dispensed with, further simplifying the manufacturing process.
  • step d) consists of the steps: d1) injecting the core material into the closed injection mold between the first and the second cover layer by means of injection molding under pressure and d2) increasing the volume of the cavity of the injection mold and
  • an integral foam can be produced in a simple manner, wherein first the core material is injected under high pressure.
  • the injection mold is designed such that the volume of the cavity can be changed. After the material intended for the core layer has been injected, the volume of the cavity is increased. This has the consequence that the core regions of the core layer have pores.
  • the core layer is thus produced with a compacted edge region, so that the density of the core layer in the compacted edge region is greater than in the center of the core layer.
  • the proportion of pores in the compacted edge region is less than 2%, preferably less than 1% and particularly preferably less than 0.5%.
  • the density of the compacted edge region is at least 90% of the density of the polymer material used for the core layer.
  • the object mentioned at the outset is achieved by a sandwich structure consisting of a core layer and two on opposite sides of the core layer arranged outer layers, wherein the core layer in turn consists of a central core region and two arranged on opposite sides of the core region edge regions, wherein the edge regions have a higher density than the core region.
  • the density in the edge regions is at least 50%, preferably at least 100% and particularly preferably at least 300% greater than the density of the core region.
  • the first and second cover layers are preferably made of the same material and more preferably have substantially the same thickness.
  • At least one cover layer and / or the core layer consists of a polymer material, preferably of a thermoplastic material and particularly preferably of a fiber-plastic composite.
  • the sandwich structure has a thickness of at least 4mm.
  • the core layer preferably has a thickness of at least 3 mm.
  • the cover layer in a preferred embodiment has a thickness between 0.3 and 2 mm.
  • the core layer has a thickness of preferably between 8 and 30 mm, wherein the compacted edge region preferably has a thickness between 0.3 and 1.5 mm.
  • Figure 1 is a schematic representation of an embodiment of the invention
  • Figure 2 is a schematic plot of the density versus the distance to the surface of the sandwich structure.
  • FIG. 1 schematically shows the sandwich structure 1 according to the invention.
  • This consists of a core layer 2 and two cover layers 3, which are arranged on both sides of the core layer 2.
  • the core layer 2 in turn, consists of a core region 4 and compacted edge regions 5.
  • the density of the sandwich structure is not homogeneous.
  • the course can be seen schematically in FIG.
  • FIG. is a line graph showing the density as a function of the distance to the surface (each in arbitrary units).
  • the density on the surface of the sandwich structure is shown on the left in FIG. 2 and the density in the core region of the core layer on the right.
  • the sandwich structure 1 has the greatest density in the region of its cover layers 3 and, at the transition to the compacted edge region 5 of the core layer, initially drops sharply. Within the compacted edge region, the density falls only slightly in the direction of the structure interior. In the transition from the compacted edge region 5 into the core region of the core layer, the density drops again sharply and approaches a substantially constant low density in the center of the sandwich structure 1.
  • the density in the compacted edge region 5 of the core layer 2 is much higher than the density in the core region 4. In other words, the density changes twice abruptly from the outside to the inside.
  • the method according to the invention it is possible to provide a sandwich structure which has very good mechanical properties.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une structure sandwich qui soit de fabrication simple et qui présente des propriétés physiques et/ou chimiques particulières. Pour y parvenir, l'invention propose un procédé de fabrication de cette structure sandwich qui comprend les étapes suivantes : a) mise en place d'une première couche de recouvrement (3) dans un moule d'injection ; b) mise en place d'une deuxième couche de recouvrement (3) dans le moule d'injection ; c) fermeture du moule ; d) injection, par moulage par injection, d'un matériau d'âme dans le moule fermé entre la première et la deuxième couches de recouvrement (3) ; e) durcissement du matériau d'âme, de sorte qu'une couche d'âme (2) est formée entre les deux couches de recouvrement (3) ; et f) ouverture du moule et démoulage de la structure sandwich (3).
EP08843269A 2007-10-24 2008-10-09 Structure sandwich et son procédé de fabrication Withdrawn EP2203291A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007051132A DE102007051132A1 (de) 2007-10-24 2007-10-24 Sandwichstruktur sowie Verfahren zur Herstellung hierfür
PCT/EP2008/063566 WO2009053253A1 (fr) 2007-10-24 2008-10-09 Structure sandwich et son procédé de fabrication

Publications (1)

Publication Number Publication Date
EP2203291A1 true EP2203291A1 (fr) 2010-07-07

Family

ID=40210737

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08843269A Withdrawn EP2203291A1 (fr) 2007-10-24 2008-10-09 Structure sandwich et son procédé de fabrication

Country Status (6)

Country Link
US (1) US20100233452A1 (fr)
EP (1) EP2203291A1 (fr)
JP (1) JP2011500384A (fr)
CA (1) CA2704143A1 (fr)
DE (1) DE102007051132A1 (fr)
WO (1) WO2009053253A1 (fr)

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WO2014083200A1 (fr) * 2012-11-30 2014-06-05 Innventia Ab Matériau en sandwich
DE102012024167A1 (de) 2012-12-10 2014-06-12 Florian Tuczek Lösbare Verbindung von ineinandergreifenden Platten einer facettierten Anordnung mit verschiedener Verwendung
DE102013114770A1 (de) * 2013-12-23 2015-06-25 Rühl Puromer GmbH Verfahren zur in situ Herstellung von mit Verstärkungsfasern verstärkten Sandwichbauteilen
DE102015219798A1 (de) * 2015-10-13 2017-04-13 Tesa Se Verfahren zum Verbinden zweier Bauteile unterschiedlicher Materialien
DE102015015010A1 (de) * 2015-11-19 2017-05-24 Daimler Ag Hutablage für einen Personenkraftwagen sowie Verfahren zum Herstellen einer solchen Hutablage
DE102017130341B4 (de) 2017-12-18 2022-10-13 Brandenburgische Technische Universität Cottbus-Senftenberg Verfahren und system zur herstellung von sandwichbauteilen mit faserverstärkten decklagen sowie sandwichbauteil
US20230112317A1 (en) * 2021-10-11 2023-04-13 Maxell, Ltd. Resin sheet and resin molding

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Also Published As

Publication number Publication date
DE102007051132A1 (de) 2009-04-30
US20100233452A1 (en) 2010-09-16
CA2704143A1 (fr) 2009-04-30
JP2011500384A (ja) 2011-01-06
WO2009053253A1 (fr) 2009-04-30

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