EP2470351A1 - Fibre-reinforced polyurethane moulded part comprising three-dimensional raised structures - Google Patents
Fibre-reinforced polyurethane moulded part comprising three-dimensional raised structuresInfo
- Publication number
- EP2470351A1 EP2470351A1 EP10751805A EP10751805A EP2470351A1 EP 2470351 A1 EP2470351 A1 EP 2470351A1 EP 10751805 A EP10751805 A EP 10751805A EP 10751805 A EP10751805 A EP 10751805A EP 2470351 A1 EP2470351 A1 EP 2470351A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- polyurethane
- fiber
- long
- short fibers
- 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- Withdrawn
Links
Classifications
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
-
- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/14—Glass
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
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- 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.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
-
- 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.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
Definitions
- the present invention is a fiber-reinforced polyurethane molding having structures such as ribs, ridges or domes, wherein these structures are fiber-reinforced.
- the fiber reinforcement of different polymers is widespread.
- the combination of a fiber and a polymer matrix results in a material which has the low density of the polymer but at the same time has a high specific rigidity and strength. This makes such composites particularly interesting for lightweight applications. It is mainly made of flat structures, in which the fibers can be evenly distributed.
- fibers in polymer structures are known, for example, from US-A-3,824,201.
- Mats, nonwovens, long fibers or continuous fibers are wetted by polyester-polyurethane compounds described there and then cut before they cure.
- glass fibers In addition to the use of natural fibers, the use of glass fibers has become established for reinforcing polymer moldings. For mechanical applications, the glass fibers are usually present as roving, nonwoven or as tissue. Glass fibers have high strength and rigidity.
- the high strength of the glass fiber is based on the size influence.
- the elongation at break of a single fiber can be up to 5%.
- the tensile and compressive strength of the glass fiber ensures a special stiffening of the plastic while maintaining a certain flexibility.
- the modulus of elasticity of glass fibers differs only slightly from that of a compact volume of glass material.
- the glass fiber has an amorphous structure, the molecular orientation is random.
- the glass fiber has isotropic mechanical properties. Glass fibers behave ideally linear elastic until breakage. They have only a very small material damping on ng.
- the stiffness of a component made of glass fiber reinforced plastic results from the modulus of elasticity, direction and volume fraction of the glass fibers and to a small extent from the properties of the matrix material, since usually a much softer plastic is used.
- Fiberglass-reinforced plastics are of great importance today, for example in the aerospace or automotive industries, including automobiles, transport machines, construction machines, mobile homes, agricultural machines, trucks, semi-trailers, but also housing parts for stationary machines or non-self-propelled machines and truck boxes.
- composite structures with long fibers are used to build predominantly load-bearing structures.
- long fibers made of glass or natural fibers are currently being used to stiffen thermoplastic components (eg cladding).
- long glass fibers in a polymeric mixture they do not arrange themselves regularly; they are rather randomly distributed.
- Long glass fibers in a random arrangement in the polymeric structure are known, for example, from US-A-4,791,019.
- methods are also known by which the glass fibers are aligned in a particular direction. This is described for example in CN 101 314 931 A.
- JP 59086636 A describes a glass fiber reinforced resin composition, wherein the glass fibers have different lengths.
- long and short fibers are used to reinforce polyurethane compounds.
- the short fibers are 0.635 cm (1/4 inch) or less in length; the long fibers are 0.635 cm (1/4 inch) long or larger.
- the PUR and long and short fibers are mixed in a fixed mass ratio. The total fiber content in a rib is therefore always lower than in the area, if the long fibers do not penetrate into the rib.
- DE 101 20 912 A1 describes a composite component made of polyurethane and its use in exterior body parts.
- the corresponding composite components are composed of two layers, one layer full-surface short fiber reinforced polyurethane with a paintable surface contains.
- the second layer contains long fiber reinforced polyurethane.
- the use of short fibers leads to a smooth, so paintable, surface.
- this layer has other particular mechanical properties than the long fiber reinforced layer.
- a method for producing a foaming member is known.
- a foaming part consists for example of fiber-reinforced polyurethanes.
- carrier materials are temporarily incorporated into the structure. However, these do not connect to the plastic, so that the corresponding carrier material can be removed after curing.
- the obtained foam part then has a structure on the surface.
- the preparation of such materials usually takes place in such a way that the long fibers used for the reinforcement, preferably compressed air, are guided laterally into the spray jet of a polyurethane reactive mixture via a funnel-shaped applicator rigidly connected to the polyurethane (PUR) spray mixing head.
- PUR polyurethane
- Also available on the market are devices in which the polyurethane mixture is produced around a central tube. In the tube long fibers are transported by air flow. At the end of the tube, the "liquid tube" of freshly mixed polyurethane components wets the fiber / air flow
- the starting material is usually rovings, that is, bundles of endless, untwisted, stretched fibers.
- the long fibers are wetted substantially on all sides with polyurethane reactive mixture.
- Such PU-wetted fibers do not have a uniform structure. Rather, there are air pockets between the irregularly arranged long fibers.
- the PU-wetted long fibers are correspondingly introduced into an open mold. The loosely accumulated fibers are forced into the final position by closing the tool under pressure with possibly elevated temperature. Even air pockets are pressed out in this process.
- corresponding components For stiffening corresponding components often contain ribs, webs, domes or similar three-dimensional raised structures. These are needed, for example, for later attachment, for glands and inserts. Such structures are obtained by grooves and / or conical recesses in the upper tool, the punch. Frequently, the gap width or the diameter / cross section of these recesses is so small that long fibers with the intumescent PU can not penetrate into the cavities. Only those long fibers can foam into the cavities, which lie in their orientation to match the cavities. However, most of the long fibers are tilted, so that mainly PUR, but no or very few fibers penetrate. So it can not ensure that later ribs, webs and / or domes are fiber-reinforced.
- the protruding structures also have a lower bending modulus.
- the dome, ribs and / or webs are not sufficiently reinforced accordingly. Thus, only lower loads can be held over them as force introduction points, as would be possible with a completely fiber-reinforced polyurethane molded part. Also possibly introduced screws do not grasp here so well.
- a simple model will be described to estimate the likelihood that a fiber (such as glass fiber) applied to a tool half in a spray process may penetrate into a slender component structure, such as a rib.
- the single fiber is considered slim and rigid (fiber length>>
- the fibers initially settle in the tool level before being transported with the ascending matrix material into areas oriented perpendicular to the tool plane (for example ribs) (2-dimensional view)
- a fiber can penetrate into a rib if and only if the in
- Rib width projected fiber length is less than twice the
- the probability of an event (here: the application of a fiber in a certain angle range 0 ⁇ FaS er ⁇ gre nz) is defined as:
- the number of possible cases m corresponds to the number of applied fibers n.
- Favorable cases are all those fiber orientations lying between 0 ° and cxgrenz, ie
- Figure 2 shows the probability of fiber penetration into a rib (P R ) as a function of fiber length for four different rib thicknesses.
- Fig. 1 illustrates the relationship between fiber orientation, length and rib width.
- the assumption is that a fiber that is at most twice as long as the rib width can always enter the rib (regardless of the fiber angle).
- the idea is that the fiber only touches one edge of the rib and can then be "tucked" into the rib just when the point of contact of the fiber and the rib edge is the fiber center, and longer fibers can only enter the rib when their angle ⁇ FaSe r is less than a critical angle ⁇ gre nz, otherwise the fiber rests against both edges of the rib, and if the fiber rests on only one edge of the rib and the center of the fiber is outside the rib, it will slip away assuming that this fiber can not enter the rib, the assumptions made here will lead to a higher likelihood of fiber entry into the rib, since in reality the fibers will certainly interfere with each other in their mobility.
- the object of the present invention is therefore to provide a fiber-reinforced polyurethane molding, which raised Having three-dimensional structures, wherein the molded body itself and these structures are reinforced with fibers.
- the object is achieved by a long-fiber-reinforced polyurethane molded body, with three-dimensional raised structures, in particular ribs, webs and / or domes, which is characterized in that it also contains short fibers in addition to the long fibers, wherein the weight ratio between short Fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in a volume of ribs, webs and / or domes is greater than the weight ratio of short fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in areas outside the raised structures.
- Hemp fibers areal, flax application.
- glass fibers are used.
- These long fibers preferably come from a roving and are cut in a corresponding existing cutting tool, so that the fibers in the molded part, for example, a length of 1 to 30 cm, preferably from 2.5 to 10 cm.
- the three-dimensional raised structures ie ribs, webs and / or domes, contain short-fiber-reinforced polyurethane.
- the term "short fibers" also includes platelet-shaped fillers, for example phyllosilicates, in particular mica.
- the short fibers may be, for example, ground glass fibers, basalt fibers or carbon fibers. But it can also wollastonite, for example, are available under the brand name used Tremin ® or a similar mineral.
- the fibrous, needle-like crystals of Tremin ® are inventively preferred.
- the size of the short fibers / platelet fillers is defined by their length / diameter.
- the length of short fibers / diameter of platelet-shaped fillers is: between 1 ⁇ m to 800 ⁇ m, preferably 4 ⁇ m to 600 ⁇ m, particularly preferably 100 ⁇ m to 500 ⁇ m
- the mixture of polyurethane reactive mixture and long fibers is introduced into an open mold, as shown in FIG. Subsequently, polyurethane is applied locally to the corresponding points of the raised structures together with short fibers.
- the polyurethane reactive mixture containing short fibers is applied in particular at the locations where the cavities for the ribs, webs and / or domes are located in the die and flows after closing the tool unhindered in these cavities.
- the polyurethane reactive mixture containing the short fibers can be introduced into the cavities and then the polyurethane reactive mixture containing long fibers can be applied in a planar manner.
- the short fibers thus have a length that is short enough so that they can flow freely into the cavities for the ribs, webs and / or domes. They therefore flow with the optionally foaming PUR into the cavities, while long fibers tilt and can not or hardly penetrate into the cavities with the PUR.
- FIG. 4 describes a corresponding method without the use of short fibers or platelet-shaped fillers, in which the raised areas remain unfilled.
- a polyurethane molded body according to the invention also has an additional outer skin, which adjoins the side which has no three-dimensional structures.
- an outer skin consists in particular of a thermoformed film which in particular comprises acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene-acrylate (ASA), polycarbonate (PC), thermoplastic polyurethane, polypropylene (PP), polyethylene (PE) and / or polyvinyl chloride (PVC).
- these may also comprise so-called in-mold coating coatings or gel coat coatings.
- In-mold coating is a process by which the coating of a plastic molded part is already carried out in the mold.
- a highly reactive 2-component paint is brought into the mold by means of suitable painting technology.
- the long-fiber-reinforced polyurethane layer is applied to the open mold.
- the short fiber-reinforced polyurethane component is applied locally and the tool is closed here.
- the present invention is achieved by a method for producing a fiber-reinforced polyurethane molding.
- a process comprises wetting long glass fibers with a polyurethane reactive mixture, introducing this mixture into the open mold, topping with short fiber reinforced PUR, and closing the mold.
- a method is particularly preferred in which the gas stream containing solids or the gas streams containing solids are not metered into the already dispersed spray jet of the reaction mixture, but are introduced into the mixing chamber of the mixing head in the still liquid, non-dispersed jet.
- a "liquid jet of a PUR reaction mixture” is understood according to the invention as meaning a fluid jet of a PUR material, in particular in the region of a mixing chamber for mixing the reaction components in liquid form, which is not yet in the form of fine reaction mixture droplets dispersed in a gas stream , ie in particular in a liquid viscous phase.
- the prior art processes essentially use a gas stream or nozzle to atomize a PUR reaction mixture and meter a solid-containing gas stream into such an atomized PUR spray.
- a gas stream or nozzle For each spray, as in this case, the distance between adjacent spray particles orthogonal to the main spray direction of a jet increases with increasing distance to the spray nozzle.
- the likelihood of the solid particles colliding with polyurethane droplets or already wetted filler particles and becoming wetted rapidly decreases rapidly.
- the conditions change when, according to the method according to the invention, the mixing of fillers and polyurethane takes place in a mixing chamber.
- the device is characterized in that solids are passed through a conveying gas stream into a mixing chamber and there encounter a liquid jet of a PUR reaction mixture.
- the gas streams with solids are allowed to meet in the mixing chamber by entering two or more points in the mixing chamber.
- adjacent spray jets can enclose large angles with each other and stand perpendicular to a circular peripheral line of the cylindrical mixing chamber. They then collide in the imaginary central axis of the mixing chamber. But they can also be introduced tangentially and form a vortex, which describes a circle which is orthogonal to the main flow direction in the mixing chamber.
- the particles can not dodge each other or move away from each other because they are prevented by the walls of the mixing chamber. Therefore, in the process according to the invention, solids are forcibly wetted with the PUR reaction mixture inside the mixing chamber without loss and become part of a homogeneous gas / solid / PUR material mixture.
- the air swirls are generated by air from tangential air nozzles.
- the circular surfaces enclosed by them form a right angle with the axis of the main flow direction in the mixing chamber.
- one and the same PUR can be used to use or increase the content of the short fibers;
- Common methods provide the short fibers in the polyol formulation so that the concentration is fixed throughout the production process.
- the upper part of the mold has cavities into which the foaming PUR reactive mixture can then penetrate.
- the short-fiber-reinforced reactive mixture penetrates here.
- a polyurethane molded body produced by such an inventive method not only has a high stability in the actual body.
- foaming the short fiber-reinforced polyurethane component in the cavities of the upper tool and the later dome ribs and / or webs are fiber-reinforced. As a result, a higher stability of these structures is achieved.
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- Mechanical Engineering (AREA)
- Composite Materials (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Polymers & Plastics (AREA)
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- Architecture (AREA)
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- Textile Engineering (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
The invention relates to a fibre-reinforced polyurethane moulded part which has structures such as ribs, struts or domes, said structures being likewise fibre-reinforced.
Description
FASERVERSTÄRKTES POLYURETHAN- FORMTEIL MIT DREIDIMENSIONALEN ERHOBENEN FIBER-REINFORCED POLYURETHANE FORMAT WITH THREE-DIMENSIONAL LEVERAGE
STRUKTUREN STRUCTURES
Gegenstand der vorliegenden Erfindung ist ein mit faserverstärktes Polyurethan-Formteil, welches Strukturen, wie beispielsweise Rippen, Stege oder Dome aufweist, wobei auch diese Strukturen faserverstärkt sind. The present invention is a fiber-reinforced polyurethane molding having structures such as ribs, ridges or domes, wherein these structures are fiber-reinforced.
Die Faserverstärkung von unterschiedlichen Polymeren ist weit verbreitet. Die Kombination aus einer Faser und einer Polymeren Matrix führt zu einem Werkstoff, der die geringe Dichte des Polymers aufweist, gleichzeitig jedoch eine hohe spezifische Steifigkeit und Festigkeit besitzt. Dies macht solche Verbundwerkstoffe insbesondere für Leichtbauanwendungen interessant. Es werden hieraus vor allem flächige Strukturen hergestellt, in den sich die Fasern gleichmäßig verteilen können. The fiber reinforcement of different polymers is widespread. The combination of a fiber and a polymer matrix results in a material which has the low density of the polymer but at the same time has a high specific rigidity and strength. This makes such composites particularly interesting for lightweight applications. It is mainly made of flat structures, in which the fibers can be evenly distributed.
Die Verwendung von Fasern in Polymeren Strukturen ist beispielsweise aus US-A-3, 824,201 bekannt. Matten, Vliese, lange Fasern oder Endlosfasern werden durch dort beschriebene Polyester-Polyurethanverbindungen benetzt und anschließend geschnitten, bevor diese aushärten. The use of fibers in polymer structures is known, for example, from US-A-3,824,201. Mats, nonwovens, long fibers or continuous fibers are wetted by polyester-polyurethane compounds described there and then cut before they cure.
Zur Verstärkung von Polymeren Formteilen hat sich neben der Verwendung von Naturfasern die Verwendung von Glasfasern etabliert. Für mechanische Anwendungen liegen die Glasfasern meistens als Roving, Vliesstoff oder als Gewebe vor. Glasfasern besitzen eine hohe Festigkeit und Steifigkeit. In addition to the use of natural fibers, the use of glass fibers has become established for reinforcing polymer moldings. For mechanical applications, the glass fibers are usually present as roving, nonwoven or as tissue. Glass fibers have high strength and rigidity.
Die hohe Festigkeit der Glasfaser beruht auf dem Größeneinfluss. Die Bruchdehnung einer einzelnen Faser kann bis zu 5% betragen. Die Zug- und Druckfestigkeit der Glasfaser sorgt für eine besondere Aussteifung des Kunststoffes bei gleichzeitiger Erhaltung einer gewissen Flexibilität.
Der Elastizitätsmodul von Glasfasern unterscheidet sich nur wenig von dem eines kompakten Werkstoffvolumens aus Glas. Die Glasfaser weist eine amorphe Struktur auf, die molekulare Orientierung ist zufällig. Die Glasfaser hat isotrope mechanische Eigenschaften. Glasfasern verhalten sich bis zum Bruch ideal linear elastisch. Sie weisen nur eine sehr geringe Werkstoff dämpf u ng auf. Die Steifigkeit eines Bauteils aus glasfaserverstärktem Kunststoff ergibt sich aus Elastizitätsmodul, Richtung und Volumenanteil der Glasfasern sowie zu einem geringen Anteil aus den Eigenschaften des Matrixmaterials, da meist ein deutlich weicherer Kunststoff verwendet wird. The high strength of the glass fiber is based on the size influence. The elongation at break of a single fiber can be up to 5%. The tensile and compressive strength of the glass fiber ensures a special stiffening of the plastic while maintaining a certain flexibility. The modulus of elasticity of glass fibers differs only slightly from that of a compact volume of glass material. The glass fiber has an amorphous structure, the molecular orientation is random. The glass fiber has isotropic mechanical properties. Glass fibers behave ideally linear elastic until breakage. They have only a very small material damping on ng. The stiffness of a component made of glass fiber reinforced plastic results from the modulus of elasticity, direction and volume fraction of the glass fibers and to a small extent from the properties of the matrix material, since usually a much softer plastic is used.
Eine große Bedeutung haben Glasfaser-verstärkte Kunststoffe heutzutage beispielsweise in der Luft- und Raumfahrt oder beim Autobau, einschließlich Automobilen, Transportmaschinen, Baumaschinen, Wohnmobilen, Landwirtschaftsmaschinen, Lastwagen, Aufliegern aber auch Gehäuseteilen für stehende Maschinen oder nicht selbstfahrende Maschinen sowie Truckboxen. In der Luft- und Raumfahrt werden aus Verbundwerkstoffen mit langen Fasern überwiegend tragende Strukturen gebaut. In der Automobilindustrie werden zur Zeit lange Fasern aus Glas oder Naturfasern auch zur Versteifung von thermoplastischen Bauteilen (z. B. Verkleidungen) genutzt. Fiberglass-reinforced plastics are of great importance today, for example in the aerospace or automotive industries, including automobiles, transport machines, construction machines, mobile homes, agricultural machines, trucks, semi-trailers, but also housing parts for stationary machines or non-self-propelled machines and truck boxes. In aviation and aerospace, composite structures with long fibers are used to build predominantly load-bearing structures. In the automotive industry, long fibers made of glass or natural fibers are currently being used to stiffen thermoplastic components (eg cladding).
Mischt man lange Glasfasern in ein polymeres Gemisch, so ordnen diese sich nicht regelmäßig an; sie sind vielmehr zufällig verteilt. Lange Glasfasern in zufälliger Anordnung in der polymeren Struktur sind beispielsweise aus US-A- 4,791,019 bekannt. Es sind jedoch auch Verfahren bekannt, durch welche die Glasfasern in eine bestimmte Richtung ausgerichtet werden. Dies wird beispielsweise in CN 101 314 931 A beschrieben. If one mixes long glass fibers in a polymeric mixture, they do not arrange themselves regularly; they are rather randomly distributed. Long glass fibers in a random arrangement in the polymeric structure are known, for example, from US-A-4,791,019. However, methods are also known by which the glass fibers are aligned in a particular direction. This is described for example in CN 101 314 931 A.
Weiterhin sind Verfahren bekannt, in welchen ein flächiges Element mit einer faserverstärkten Polyurethanschicht überzogen wird. Durch diese Beschichtung wird die Stabilität des eigentlichen Produktes erhöht. Ein solches Verfahren ist
beispielsweise in WO 2007/075535 A2 und DE 10 2006 046 130 Al beschrieben. Furthermore, methods are known in which a sheet-like element is coated with a fiber-reinforced polyurethane layer. This coating increases the stability of the actual product. One such method is For example, in WO 2007/075535 A2 and DE 10 2006 046 130 Al described.
Aus DE 196 149 56 Al und DE 10 2006 022 846 Al sind faserverstärkte Formteile bekannt. Hier werden neben Glasfasern auch Matten zur Verstärkung der polymeren Struktur eingesetzt. Solche Matten, Gewebe oder Gewirke können ebenfalls aus Glasfaser bestehen. DE 196 149 56 A1 and DE 10 2006 022 846 A1 disclose fiber-reinforced molded parts. In addition to glass fibers, mats are used here to reinforce the polymeric structure. Such mats, woven or knitted fabric may also be made of glass fiber.
Bei der Herstellung eines faserverstärkten Polyurethan-Formteils im RIM (Reaction Injection Molding)-Verfahren wird üblicherweise ein Gemisch aus Polyurethan und den Fasern in den unteren Teil eines geöffneten Werkzeuges von einem Roboter flächig verteilt. Durch das Schließen der Form mit dem oberen Teil, dem Stempel, wird das Gemisch in die gewünschte Form gedrückt. Durch den Druck entweichen auch Luftblasen, welche in dem Gemisch eingeschlossen sind. Die Form des erhaltenen Produktes ist durch die Form des Werkzeuges vorgegeben. An der Oberfläche des Endproduktes sind auch nach dem Pressen Strukturen erkennbar, welche durch die Glasfasern hervorgerufen werden. Um eine einheitlichere Oberfläche zu erreichen ist es möglich, unterschiedlich lange Glasfasern zu verwenden. So beschreibt JP 59086636 A eine glasfaserverstärkte Harzzusammensetzung, wobei die Glasfasern unterschiedliche längen aufweisen. Auch in WO 00/40650 werden lange und kurze Fasern zur Verstärkung von Polyurethan-Verbindungen verwendet. Die kurzen Fasern weisen eine Länge von 0,635 cm (1/4 inch) oder weniger auf; die langen Fasern sind 0,635 cm (1/4 inch) lang oder größer. Hier werden das PUR sowie lange und kurze Fasern in einem festen Massenverhältnis vermischt. Der Gesamtfaseranteil in einer Rippe liegt deshalb immer niedriger als in der Fläche, wenn die langen Fasern nicht in die Rippe eindringen. In the production of a fiber-reinforced polyurethane molding in the RIM (Reaction Injection Molding) process, usually a mixture of polyurethane and the fibers in the lower part of an open tool is distributed by a robot surface. By closing the mold with the upper part, the punch, the mixture is pressed into the desired shape. The pressure also releases air bubbles trapped in the mixture. The shape of the product obtained is determined by the shape of the tool. On the surface of the end product structures are visible even after pressing, which are caused by the glass fibers. In order to achieve a more uniform surface, it is possible to use different lengths of glass fibers. Thus, JP 59086636 A describes a glass fiber reinforced resin composition, wherein the glass fibers have different lengths. Also in WO 00/40650 long and short fibers are used to reinforce polyurethane compounds. The short fibers are 0.635 cm (1/4 inch) or less in length; the long fibers are 0.635 cm (1/4 inch) long or larger. Here, the PUR and long and short fibers are mixed in a fixed mass ratio. The total fiber content in a rib is therefore always lower than in the area, if the long fibers do not penetrate into the rib.
In DE 101 20 912 Al wird ein Verbundbauteil aus Polyurethan und dessen Verwendung in Karosserieaußenteilen beschrieben. Die entsprechenden Verbundbauteile sind aufgebaut aus zwei Schichten, wobei eine Schicht
vollflächig kurzfaserverstärktes Polyurethan mit einer lackierfähigen Oberfläche enthält. Die zweite Schicht enthält langfaserverstärktes Polyurethan. Die Verwendung von kurzen Fasern führt zu einer glatten, also lackierfähigen, Oberfläche. Diese Schicht weist jedoch andere insbesondere mechanische Eigenschaften auf, als die Langfaser-verstärkte Schicht. DE 101 20 912 A1 describes a composite component made of polyurethane and its use in exterior body parts. The corresponding composite components are composed of two layers, one layer full-surface short fiber reinforced polyurethane with a paintable surface contains. The second layer contains long fiber reinforced polyurethane. The use of short fibers leads to a smooth, so paintable, surface. However, this layer has other particular mechanical properties than the long fiber reinforced layer.
Aus der DE 10 2005 034 916 Al ist ein Verfahren zum Herstellen eines Schäumteils bekannt. Ein solches Schäumteil besteht beispielsweise aus faserverstärkten Polyurethanen. Hier sind Trägermaterialien in die Struktur temporär eingebracht. Diese verbinden sich jedoch nicht mit dem Kunststoff, so dass das entsprechende Trägermaterial nach dem Aushärten abgezogen werden kann. Das erhaltene Schäumteil weist dann eine Struktur an der Oberfläche auf. From DE 10 2005 034 916 Al a method for producing a foaming member is known. Such a foaming part consists for example of fiber-reinforced polyurethanes. Here carrier materials are temporarily incorporated into the structure. However, these do not connect to the plastic, so that the corresponding carrier material can be removed after curing. The obtained foam part then has a structure on the surface.
Die Herstellung solcher faserverstärkter Polyurethane erfolgt häufig im Sprühverfahren. Ein Verfahren beschreibt beispielsweise DE 10 2005 048 874 Al. The production of such fiber-reinforced polyurethanes is often carried out by spraying. A method describes, for example, DE 10 2005 048 874 A1.
Die Herstellung solcher Materialien erfolgt in aller Regel so, dass die für die Verstärkung verwendeten langen Fasern vorzugsweise Druckluft unterstützt über eine trichterförmige mit dem Polyurethan (PUR)-Sprühmischkopf festverbundenes Auftragsorgan seitlich in den Sprühstrahl eines Polyurethan- Reaktivgemisches geleitet werden. Auch sind Vorrichtungen auf dem Markt erhältlich, bei denen das Polyurethangemisch um ein mittleres Rohr herum erzeugt wird. Im Rohr werden lange Fasern per Luftstrom transportiert. Am Ende des Rohres benetzt der „flüssige Schlauch" aus frisch vermischten Polyurethankomponenten den Faser/Luftstrom. Im Falle von Materialien, die mit langen Fasern verstärkt werden , verwendet man als Ausgangsmaterial meist sogenannte Rovings, das heißt Bündel von endlosen, unverdrehten, gestreckten Fasern, die zunächst ein ebenfalls am PUR-Sprühmischkopf befestigtes Schneidwerk passieren, bevor die geschnittenen Fasern mit dem Polyurethan benetzt werden.
Bei Sprühverfahren dieser Art wird eine möglichst gleichmäßige Verteilung des Faser-PUR-Reaktionsgemisches, meist über mehrere Schichten hinweg, angestrebt. Bei Anwendungen mit hohem Reproduzierbarkeitsanspruch werden die Sprühmischköpfe samt Schütte daher durch Roboter geführt. The preparation of such materials usually takes place in such a way that the long fibers used for the reinforcement, preferably compressed air, are guided laterally into the spray jet of a polyurethane reactive mixture via a funnel-shaped applicator rigidly connected to the polyurethane (PUR) spray mixing head. Also available on the market are devices in which the polyurethane mixture is produced around a central tube. In the tube long fibers are transported by air flow. At the end of the tube, the "liquid tube" of freshly mixed polyurethane components wets the fiber / air flow In the case of materials reinforced with long fibers, the starting material is usually rovings, that is, bundles of endless, untwisted, stretched fibers. which first pass through a cutting unit also attached to the PUR spray mixing head before the cut fibers are wetted with the polyurethane. In spray processes of this type, the most uniform possible distribution of the fiber PUR reaction mixture, usually over several layers, sought. In applications with a high reproducibility claim, the spray mixing heads and the chute are therefore guided by robots.
Ideal ist, dass die langen Fasern im Wesentlichen allseitig mit Polyurethan- Reaktivgemisch benetzt werden. Solche mit PUR-benetzten Fasern weisen keine einheitliche Struktur auf. Vielmehr befinden sich Lufteinschlüsse zwischen den unregelmäßig angeordneten langen Fasern. Zur Herstellung eines Formteils werden die PUR-benetzten langen Fasern entsprechend in eine geöffnete Form eingetragen. Die locker gehäuften Fasern werden durch das Schließen des Werkzeugs unter Druck bei gegebenenfalls erhöhter Temperatur in die endgültige Lage gezwungen. Auch Lufteinschlüsse werden bei diesem Verfahren herausgepresst. Durch ein solches Verfahren ist es möglich unterschiedliche Bauteile, beispielsweise Instrumententafelträger, Türinnenverkleidung, Sitzrückenverkleidung, Hutablagen, horizontale und vertikale Außenverkleidungsteile wie z.B. Motorhauben, Dachmodule, Seitenverkleidungsteile herzustellen. It is ideal that the long fibers are wetted substantially on all sides with polyurethane reactive mixture. Such PU-wetted fibers do not have a uniform structure. Rather, there are air pockets between the irregularly arranged long fibers. To produce a molded part, the PU-wetted long fibers are correspondingly introduced into an open mold. The loosely accumulated fibers are forced into the final position by closing the tool under pressure with possibly elevated temperature. Even air pockets are pressed out in this process. By such a method, it is possible different components, such as instrument panel, door trim, seat back trim, hat racks, horizontal and vertical outer trim parts such. Engine hoods, roof modules, side paneling parts manufacture.
Zur Versteifung enthalten entsprechende Bauteile häufig Rippen, Stege, Dome oder ähnliche dreidimensionale erhobene Strukturen. Diese werden beispielsweise zur späteren Befestigung, für Verschraubungen und Inserts benötigt. Solche Strukturen werden durch Nuten und/oder kegelförmige Aussparungen im Oberwerkzeug, dem Stempel, erhalten. Häufig ist die Spaltbreite oder der Durchmesser/Querschnitt dieser Aussparungen so gering, dass lange Fasern mit dem aufschäumenden PUR nicht in die Kavitäten eindringen können. Es können lediglich solche langen Fasern in die Kavitäten mit einschäumen, welche in ihrer Orientierung passend zu den Kavitäten liegen. Der Großteil der langen Fasern verkantet jedoch, so dass vor allem PUR, jedoch keine oder nur sehr wenige Fasern eindringen. Es kann also nicht
sichergestellt werden, dass spätere Rippen, Stege und/oder Dome faserverstärkt sind. For stiffening corresponding components often contain ribs, webs, domes or similar three-dimensional raised structures. These are needed, for example, for later attachment, for glands and inserts. Such structures are obtained by grooves and / or conical recesses in the upper tool, the punch. Frequently, the gap width or the diameter / cross section of these recesses is so small that long fibers with the intumescent PU can not penetrate into the cavities. Only those long fibers can foam into the cavities, which lie in their orientation to match the cavities. However, most of the long fibers are tilted, so that mainly PUR, but no or very few fibers penetrate. So it can not ensure that later ribs, webs and / or domes are fiber-reinforced.
Daraus folgt, dass solche Strukturen, welche keinen oder einen geringeren Anteil an Fasern aufweisen, unterschiedliche Eigenschaften wie der eigentliche Formkörper aufweisen. So ist der thermische Längenausdehnungs-Koeffizient größer, wenn weniger Fasern vorhanden sind. Diese Unterschiede im Längenausdehnungs-Koeffizienten führen dann zu einer Verbiegung des eigentlichen Formkörpers bei thermischer Belastung. It follows that such structures, which have no or a smaller proportion of fibers, have different properties as the actual shaped body. Thus, the coefficient of thermal expansion is greater when there are fewer fibers. These differences in the linear expansion coefficient then lead to a bending of the actual molded body under thermal stress.
Die herausstehenden Strukturen besitzen außerdem einen geringeren Biege-E- Modul. Die Dome, Rippen und/oder Stege sind entsprechend nicht ausreichend verstärkt. Somit können über sie als Krafteinleitungspunkte nur geringere Lasten gehalten werden, wie dies bei einem vollständig faserverstärkten Polyurethan-Formteil möglich wäre. Auch eventuell eingebrachte Schrauben fassen hier nicht so gut. The protruding structures also have a lower bending modulus. The dome, ribs and / or webs are not sufficiently reinforced accordingly. Thus, only lower loads can be held over them as force introduction points, as would be possible with a completely fiber-reinforced polyurethane molded part. Also possibly introduced screws do not grasp here so well.
Im Folgenden wird ein einfaches Modell beschrieben, um abzuschätzen, mit welcher Wahrscheinlichkeit eine in einem Sprühprozess auf eine Werkzeughälfte aufgebrachte Faser (beispielsweise Glasfaser) in eine schlanke Bauteilstruktur wie beispielsweise eine Rippe eindringen kann. In the following, a simple model will be described to estimate the likelihood that a fiber (such as glass fiber) applied to a tool half in a spray process may penetrate into a slender component structure, such as a rib.
Dazu werden folgende Annahmen getroffen: The following assumptions are made for this:
Die einzelne Faser wird als schlank und starr angesehen (Faserlänge > > The single fiber is considered slim and rigid (fiber length>>
Faserdicke) Fiber thickness)
Die Fasern legen sich zunächst in der Werkzeugebene ab, bevor sie mit dem aufsteigenden Matrixmaterial in senkrecht zur Werkzeugebene orientierte Bereiche (beispielsweise Rippen) transportiert werden (2- dimensionale Betrachtung) The fibers initially settle in the tool level before being transported with the ascending matrix material into areas oriented perpendicular to the tool plane (for example ribs) (2-dimensional view)
Als Kriterium, ob eine Faser in eine Rippe eindringen kann, wird ausschließlich die Faserorientierung und die Faserlänge herangezogen. As a criterion of whether a fiber can penetrate into a rib, only the fiber orientation and the fiber length is used.
Es wird somit die Eindringwahrscheinlichkeit von denjenigen Fasern abgeschätzt, die sich unmittelbar „unterhalb" einer entsprechenden
Bauteilstruktur wie einer Rippe befinden. Eine gegenseitige Behinderung der Fasern wird zur Vereinfachung ausgeschlossen. Thus, the probability of penetration of those fibers is estimated which are immediately "below" a corresponding one Component structure like a rib located. Mutual obstruction of the fibers is excluded for simplicity.
Eine Faser kann genau dann in eine Rippe eindringen, wenn die in A fiber can penetrate into a rib if and only if the in
Rippenbreite projizierte Faserlänge kleiner ist als zwei mal dieRib width projected fiber length is less than twice the
Rippenbreite (siehe Fig. 1) Rib width (see Fig. 1)
Bei der Verteilung der Faserorientierungen (Faserwinkel) wird davon ausgegangen, dass alle Orientierungen gleich wahrscheinlich sind, es also keine Vorzugsrichtung der Faserorientierung gibt In the distribution of the fiber orientations (fiber angle) it is assumed that all orientations are equally probable, ie there is no preferred direction of the fiber orientation
Die Wahrscheinlichkeit eines Ereignisses (hier: das Aufbringen einer Faser in einem bestimmten Winkelbereich 0 < αFaSer < αgrenz) ist definiert zu : The probability of an event (here: the application of a fiber in a certain angle range 0 <α FaS er <α gre nz) is defined as:
P = -S- m P = -S- m
mit With
P = Wahrscheinlichkeit (Wert zwischen 0 und 1) P = probability (value between 0 and 1)
g = Zahl der günstigen Fälle g = number of favorable cases
m = Zahl der möglichen Fälle m = number of possible cases
Die Zahl der möglichen Fälle m entspricht der Anzahl aller aufgebrachten Fasern n. Günstige Fälle sind alle diejenigen Faserorientierungen, die zwischen 0° und cxgrenz liegen, also The number of possible cases m corresponds to the number of applied fibers n. Favorable cases are all those fiber orientations lying between 0 ° and cxgrenz, ie
360° 360 °
Somit ergibt sich als Wahrscheinlichkeit für das Eintreten einer Faserorientierung innerhalb des oben genannten Winkelbereichs Thus, there is a probability of the occurrence of fiber orientation within the above-mentioned angle range
p _ α grenz p _ α border
360° 360 °
Bei einer kompletten 360° Drehung einer Faser kommt ein günstiger Winkelbereich zum Eindringen in die Rippe jedoch nicht nur einmal, sonder gleich viermal vor. Dies sind die Winkelbereiche (0 < αFaSer < oLgrenz), (180°- αgrenz < αFaSer < 180°), ( 180° < αFaSer < 180°+ αgrenz) Und (360°- (Xgrenz < αFaSer
< 360°). Somit ergibt sich als Wahrscheinlichkeit für das Eindringen einer Faser in die Rippe (PR). With a complete 360 ° turn of a fiber, however, a favorable angle range for penetration into the rib does not occur only once, but four times. These are the angular ranges (0 <α FaSe r <oL limit ), (180 ° - αgrenz <α FaS er <180 °), (180 ° <α FaS er <180 ° + α gre nz) and (360 ° - ( Xgrenz <α FaS er <360 °). Thus, there is a likelihood of penetration of a fiber in the rib (P R).
.2- B, .2 B,
α arcsin( ) α arcsin ()
grenz Δ— limit Δ-
PR = H— PR = H
360° 360° 360 ° 360 °
für 2 B for 2 B
1 1
Für Verhältnisse von Rippenbreite zu Faserlänge größer als 0,5 wird PR per Definition zu 1 (siehe Annahmen), da dann die Faserorientierung keine Rolle mehr spielt. For ratios of rib width to fiber length greater than 0.5, P R by definition becomes 1 (see assumptions) because then fiber orientation no longer plays any role.
Fig. 2 zeigt die Wahrscheinlichkeit des Eindringens einer Faser in eine Rippe (PR) als Funktion der Faserlänge für vier unterschiedliche Rippendicken. Figure 2 shows the probability of fiber penetration into a rib (P R ) as a function of fiber length for four different rib thicknesses.
Fig. 1 verdeutlicht den Zusammenhang zwischen Faserorientierung, -länge und Rippenbreite. Annahme ist, dass eine Faser, die höchstens doppelt so lang ist wie die Rippenbreite, immer in die Rippe eintreten kann (unabhängig vom Faserwinkel). Die Vorstellung dabei ist, das die Faser nur einen Rand der Rippe berührt und gerade dann noch in die Rippe mit hineingezogen („hineingekippt") werden kann, wenn der Berührungspunkt von Faser und Rippenrand der Fasermittelpunkt ist. Längere Fasern können nur dann in die Rippe eintreten, wenn ihr Winkel αFaSer kleiner als ein Grenzwinkel αgrenz ist, da die Faser ansonsten an beiden Rändern der Rippe aufliegt. Liegt die Faser nur auf einem Rand der Rippe auf und ist der Mittelpunkt der Faser außerhalb der Rippe, wird davon ausgegangen, dass diese Faser nicht in die Rippe eintreten kann. Die hier getroffenen Annahmen werden zu einer höheren Eintrittswahrscheinlichkeit der Faser in die Rippe führen, da in der Realität sich die Fasern sicherlich untereinander in ihrer Beweglichkeit behindern werden. Fig. 1 illustrates the relationship between fiber orientation, length and rib width. The assumption is that a fiber that is at most twice as long as the rib width can always enter the rib (regardless of the fiber angle). The idea is that the fiber only touches one edge of the rib and can then be "tucked" into the rib just when the point of contact of the fiber and the rib edge is the fiber center, and longer fibers can only enter the rib when their angle α FaSe r is less than a critical angle α gre nz, otherwise the fiber rests against both edges of the rib, and if the fiber rests on only one edge of the rib and the center of the fiber is outside the rib, it will slip away assuming that this fiber can not enter the rib, the assumptions made here will lead to a higher likelihood of fiber entry into the rib, since in reality the fibers will certainly interfere with each other in their mobility.
Die Aufgabe der vorliegenden Erfindung besteht demnach in der Bereitstellung eines faserverstärkten Polyurethan-Formkörpers, welcher erhobene
dreidimensionale Strukturen aufweist, wobei der Formkörper selbst und auch diese Strukturen mit Fasern verstärkt sind. The object of the present invention is therefore to provide a fiber-reinforced polyurethane molding, which raised Having three-dimensional structures, wherein the molded body itself and these structures are reinforced with fibers.
In einer ersten Ausführungsform wird die Aufgabe gelöst durch einen Langfaser-verstärkten Polyurethan-Formkörper, mit dreidimensionalen erhobenen Strukturen, insbesondere Rippen, Stegen und/oder Domen, der dadurch gekennzeichnet ist, dass er neben den Langfasern weiterhin Kurzfasern enthält, wobei das Gewichtsverhältnis zwischen kurzen Fasern und/oder plättchenförmigen Füllstoffen zur faserfreien Polyurethanmatrix in einem Volumen aus Rippen, Stegen und/oder Domen größer ist, als das Gewichtsverhältnis an kurzen Fasern und/oder plättchenförmigen Füllstoffen zur faserfreien Polyurethanmatrix in flächigen Bereichen außerhalb der erhobenen Strukturen. In a first embodiment, the object is achieved by a long-fiber-reinforced polyurethane molded body, with three-dimensional raised structures, in particular ribs, webs and / or domes, which is characterized in that it also contains short fibers in addition to the long fibers, wherein the weight ratio between short Fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in a volume of ribs, webs and / or domes is greater than the weight ratio of short fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in areas outside the raised structures.
Als lange Fasern können natürliche oder synthetische Fasern verwendet werden. Neben Glasfasern und Basaltfasern As long fibers, natural or synthetic fibers can be used. In addition to glass fibers and basalt fibers
finden auch Kohlenstofffasern, Aramidfasern, Naturfasern, beispielsweisealso find carbon fibers, aramid fibers, natural fibers, for example
Hanffasern (Sisal, Flachs) Anwendung. Bevorzugt werden Glasfasern verwendet. Hemp fibers (sisal, flax) application. Preferably, glass fibers are used.
Diese langen Fasern stammen vorzugsweise von einem Roving und werden in einem entsprechend vorhandenen Schneidwerkzeug geschnitten, so dass die Fasern im Formteil beispielsweise eine Länge von 1 bis 30 cm, bevorzugt von 2,5 bis 10 cm aufweisen. These long fibers preferably come from a roving and are cut in a corresponding existing cutting tool, so that the fibers in the molded part, for example, a length of 1 to 30 cm, preferably from 2.5 to 10 cm.
Erfindungsgemäß enthalten die dreidimensionalen erhobenen Strukturen, also Rippen, Stege und/oder Dome, kurzfaserverstärktes Polyurethan. Erfindungsgemäß umfasst der Begriff der „kurzen Fasern" auch
plättchenförmige Füllstoffe, beispielsweise Schichtsilikate, insbesondere Glimmer. Als kurze Fasern finden natürliche oder synthetische Fasern Verwendung. Die kurzen Fasern können beispielsweise gemahlene Glasfasern, Basaltfasern oder Carbonfasern sein. Es kann aber auch Wollastonit, beispielsweise erhältlich unter der Marke Tremin® oder ein ähnliches Mineral verwendet werden. Die faserig, nadeligen Kristalle von Tremin® sind erfindungsgemäß bevorzugt. According to the invention, the three-dimensional raised structures, ie ribs, webs and / or domes, contain short-fiber-reinforced polyurethane. According to the invention, the term "short fibers" also includes platelet-shaped fillers, for example phyllosilicates, in particular mica. As short fibers, natural or synthetic fibers are used. The short fibers may be, for example, ground glass fibers, basalt fibers or carbon fibers. But it can also wollastonite, for example, are available under the brand name used Tremin ® or a similar mineral. The fibrous, needle-like crystals of Tremin ® are inventively preferred.
Die Größe der kurzen Fasern/plättchenförmigen Füllstoffe wird durch deren Länge/Durchmesser definiert. Insbesondere beträgt die Länge kurzer Fasern / Durchmesser plättchenförmiger Füllstoffe: zwischen 1 μm bis 800 μm, bevorzugt 4 μm bis 600 μm, besonders bevorzugt 100 μm bis 500 μm The size of the short fibers / platelet fillers is defined by their length / diameter. In particular, the length of short fibers / diameter of platelet-shaped fillers is: between 1 μm to 800 μm, preferably 4 μm to 600 μm, particularly preferably 100 μm to 500 μm
Erfindungsgemäß wird das Gemisch aus Polyurethanreaktivgemisch und langen Fasern in ein geöffnetes Werkzeug eingebracht, wie in Fig. 3 dargestellt. Anschließend wird lokal an die entsprechenden Stellen der erhobenen Strukturen Polyurethan zusammen mit kurzen Fasern aufgebracht. Das Polyurethanreaktivgemisch, welches kurze Fasern enthält, wird insbesondere an den Stellen aufgebracht, an denen sich die Kavitäten für die Rippen, Stege und/oder Dome im Stempel befinden und strömt nach Schließen des Werkzeuges ungehindert in diese Kavitäten. According to the invention, the mixture of polyurethane reactive mixture and long fibers is introduced into an open mold, as shown in FIG. Subsequently, polyurethane is applied locally to the corresponding points of the raised structures together with short fibers. The polyurethane reactive mixture containing short fibers is applied in particular at the locations where the cavities for the ribs, webs and / or domes are located in the die and flows after closing the tool unhindered in these cavities.
Wenn sich die Kavitäten für Rippen, Stege und/oder Dome im unteren Teil des Werkzeuges befinden, kann das die kurzen Fasern enthaltende Polyurethanreaktivgemisch in den Kavitäten vorgelegt werden und anschließend das Polyurethanreaktivgemisch, das lange Fasern enthält flächig aufgebracht werden. If the cavities for ribs, webs and / or domes are in the lower part of the tool, the polyurethane reactive mixture containing the short fibers can be introduced into the cavities and then the polyurethane reactive mixture containing long fibers can be applied in a planar manner.
Die kurzen Fasern besitzen demnach eine Länge, die kurz genug ist, dass sie in die Kavitäten für die Rippen, Stege und/oder Dome ungehindert einströmen können. Sie strömen demnach mit dem gegebenenfalls aufschäumenden PUR
in die Kavitäten ein, während lange Fasern sich verkanten und nicht oder kaum mit dem PUR in die Kavitäten eindringen können. The short fibers thus have a length that is short enough so that they can flow freely into the cavities for the ribs, webs and / or domes. They therefore flow with the optionally foaming PUR into the cavities, while long fibers tilt and can not or hardly penetrate into the cavities with the PUR.
In der Fig. 4 wird ein entsprechendes Verfahren ohne Einsatz von kurzen Fasern oder plättchenförmigen Füllstoffen beschrieben, bei dem die erhobenen Bereiche ungefüllt bleiben. FIG. 4 describes a corresponding method without the use of short fibers or platelet-shaped fillers, in which the raised areas remain unfilled.
Bevorzugt weist ein erfindungsgemäßer Polyurethan-Formkörper noch eine zusätzliche Außenhaut auf, welche an die Seite anschließt, die keine dreidimensionalen Strukturen aufweist. Eine solche Außenhaut besteht insbesondere aus einer tiefgezogenen Folie, welche insbesondere aus Acrylnitril-Butadien-Styrol (ABS), Polymethylmethacrylat (PMMA), Acrylnitril- Styrol-Acrylester (ASA), Polycarbonat (PC), thermoplastische Polyurethan, Polypropylen (PP), Polyethylen (PE) und/oder Polyvinylchlorid (PVC) besteht. Preferably, a polyurethane molded body according to the invention also has an additional outer skin, which adjoins the side which has no three-dimensional structures. Such an outer skin consists in particular of a thermoformed film which in particular comprises acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene-acrylate (ASA), polycarbonate (PC), thermoplastic polyurethane, polypropylene (PP), polyethylene (PE) and / or polyvinyl chloride (PVC).
Alternativ zu den vorgenannten Außenhäuten können diese auch so genannte In-Mould-Coating-Beschichtungen oder Gel-Coat-Beschichtungen umfassen. Das In-Mould-Coating ist ein Verfahren, mit dem die Lackierung eines Kunststoffformteils bereits im Werkzeug durchgeführt wird. Dazu wird ein hoch reaktiver 2-Komponenten-Lack mittels geeigneter Lackiertechnik in die Form gebracht. Danach wird in die offene Form erfindungsgemäß die mit Langfasern-verstärkte Polyurethanschicht aufgebracht. Anschließend wird auch hier die Kurzfaser-verstärkte Polyurethan-Komponente lokal aufgebracht und das Werkzeug geschlossen. As an alternative to the aforementioned outer skins, these may also comprise so-called in-mold coating coatings or gel coat coatings. In-mold coating is a process by which the coating of a plastic molded part is already carried out in the mold. For this purpose, a highly reactive 2-component paint is brought into the mold by means of suitable painting technology. Thereafter, according to the invention, the long-fiber-reinforced polyurethane layer is applied to the open mold. Subsequently, the short fiber-reinforced polyurethane component is applied locally and the tool is closed here.
In einer weiteren Ausführungsform wird die vorliegende Erfindung durch ein Verfahren zur Herstellung eines faserverstärkten Polyurethan-Formkörpers gelöst. Ein solches Verfahren umfasst das Benetzen von Langglasfasern mit einem Polyurethan-Reaktivgemisch, das Einbringen dieser Mischung in die geöffnete Form, das lokale Aufbringen mit Kurzfaser- verstärktem PUR und das Schließen der Form.
Hierzu ist besonders ein Verfahren bevorzugt, bei dem der Feststoff enthaltende Gasstrom bzw. die Feststoff enthaltenden Gasströme nicht in den bereits dispergierten Sprϋhstrahl des Reaktionsgemisches dosiert,, sondern innerhalb der Mischkammer des Mischkopfes in den noch flüssigen nicht dispergierten Strahl eingetragen werden. In a further embodiment, the present invention is achieved by a method for producing a fiber-reinforced polyurethane molding. Such a process comprises wetting long glass fibers with a polyurethane reactive mixture, introducing this mixture into the open mold, topping with short fiber reinforced PUR, and closing the mold. For this purpose, a method is particularly preferred in which the gas stream containing solids or the gas streams containing solids are not metered into the already dispersed spray jet of the reaction mixture, but are introduced into the mixing chamber of the mixing head in the still liquid, non-dispersed jet.
Unter einem „flüssigen Strahl eines PUR- Reaktionsgemisches" wird erfindungsgemäß ein solcher Fluid-Strahl eines PUR-Materials, insbesondere im Bereich einer Mischkammer zur Vermischung der Reaktionskomponenten in flüssiger Form, verstanden, welcher noch nicht in Form feiner, in einem Gasstrom dispergierter Reaktionsgemischtröpfchen vorliegt, d. h. insbesondere in einer flüssigen viskosen Phase. A "liquid jet of a PUR reaction mixture" is understood according to the invention as meaning a fluid jet of a PUR material, in particular in the region of a mixing chamber for mixing the reaction components in liquid form, which is not yet in the form of fine reaction mixture droplets dispersed in a gas stream , ie in particular in a liquid viscous phase.
Die Verfahren des Standes der Technik verwenden im Wesentlichen einen Gasstrom oder eine entsprechende Düse zur Zerstäubung eines PUR- Reaktionsgemisches und dosieren in einen solchen zerstäubten PUR- Sprühstrahl einen Feststoff-enthaltenden Gasstrom. Für jeden Sprühstrahl gilt wie auch in diesem Fall, das der Abstand zwischen benachbarten Sprühpartikeln orthogonal zur Hauptsprührichtung eines Sprühstrahls mit zunehmender Entfernung zur Sprühdüse wächst. Zwangsläufig verringert sich rasch die Wahrscheinlichkeit, das Feststoffpartikel mit Polyurethantröpfchen oder bereits benetzten Füllstoffpartikeln kollidieren und so benetzt werden. Die Verhältnisse ändern sich, wenn gemäß dem erfindungsgemäßen Verfahren die Vermischung von Füllstoffen und Polyurethan in einer Mischkammer erfolgt. The prior art processes essentially use a gas stream or nozzle to atomize a PUR reaction mixture and meter a solid-containing gas stream into such an atomized PUR spray. For each spray, as in this case, the distance between adjacent spray particles orthogonal to the main spray direction of a jet increases with increasing distance to the spray nozzle. Inevitably, the likelihood of the solid particles colliding with polyurethane droplets or already wetted filler particles and becoming wetted rapidly decreases rapidly. The conditions change when, according to the method according to the invention, the mixing of fillers and polyurethane takes place in a mixing chamber.
Die Vorrichtung ist dadurch gekennzeichnet, dass Feststoffe durch einen Fördergasstrom in eine Mischkammer geleitet werden und dort auf einen flüssigen Strahl eines PUR-Reaktionsgemisches treffen. Die Gasströme mit Feststoffen lässt man in der Mischkammer aufeinandertreffen, indem sie über zwei oder mehr Punkte in die Mischkammer eintreten. Hierbei können benachbarte Sprühstrahlen große Winkel miteinander einschließen und senkrecht auf einer kreisförmigen Umfanglinie der zylindrischen Mischkammer stehen. Sie kollidieren dann in der gedachten Mittelachse der Mischkammer.
Sie können aber auch tangential eingeleitet werden und einen Wirbel bilden, der einen Kreis beschreibt, der orthogonal zur Hauptströmungsrichtung in der Mischkammer steht. Bei dem erfindungsgemäßen Verfahren können die Partikel einander nicht ausweichen oder sich voneinander entfernen, weil sie durch die Wände der Mischkammer daran gehindert werden. Deshalb werden in dem erfindungsgemäßen Verfahren Feststoffe verlustfrei mit dem PUR- Reaktionsgemisch im Inneren der Mischkammer zwangsbenetzt und Teil eines homogenen Gas/Feststoff/PUR-Material-Gemisches. The device is characterized in that solids are passed through a conveying gas stream into a mixing chamber and there encounter a liquid jet of a PUR reaction mixture. The gas streams with solids are allowed to meet in the mixing chamber by entering two or more points in the mixing chamber. Here, adjacent spray jets can enclose large angles with each other and stand perpendicular to a circular peripheral line of the cylindrical mixing chamber. They then collide in the imaginary central axis of the mixing chamber. But they can also be introduced tangentially and form a vortex, which describes a circle which is orthogonal to the main flow direction in the mixing chamber. In the method according to the invention, the particles can not dodge each other or move away from each other because they are prevented by the walls of the mixing chamber. Therefore, in the process according to the invention, solids are forcibly wetted with the PUR reaction mixture inside the mixing chamber without loss and become part of a homogeneous gas / solid / PUR material mixture.
Es ist bevorzugt, die Vermischungsqualität des resultierenden Gas/Feststoff/PUR-Material-Gemisches in der Mischkammer durch zusätzliche Luftwirbel nochmals zu steigern. Die Luftwirbel werden durch Luft aus tangentialen Luftdüsen erzeugt. Die von ihnen eingeschlossenen Kreisflächen bilden mit der Achse der Hauptströmungsrichtung in der Mischkammer einen rechten Winkel. It is preferred to further increase the mixing quality of the resulting gas / solid / PUR material mixture in the mixing chamber by additional air swirls. The air swirls are generated by air from tangential air nozzles. The circular surfaces enclosed by them form a right angle with the axis of the main flow direction in the mixing chamber.
Erfindungsgemäß kann man ein und dasselbe PUR nutzen, um die kurzen Fasern einzusetzen bzw. im Gehalt zu erhöhen; übliche Methoden legen die kurzen Fasern in der Polyolformulierung vor, so dass die Konzentration über den Produktionsprozess hinweg unveränderlich ist. According to the invention, one and the same PUR can be used to use or increase the content of the short fibers; Common methods provide the short fibers in the polyol formulation so that the concentration is fixed throughout the production process.
Das Oberteil der Form weist Kavitäten auf, in welche das ausschäumende PUR- Reaktivgemisch dann eindringen kann. Insbesondere dringt hier das Kurzfaser-verstärkte Reaktivgemisch ein. The upper part of the mold has cavities into which the foaming PUR reactive mixture can then penetrate. In particular, the short-fiber-reinforced reactive mixture penetrates here.
Ein durch ein solches erfindungsgemäßes Verfahren hergestellter Polyurethan- Formkörper weist nicht nur eine hohe Stabilität im eigentlichen Körper auf. Durch das Einschäumen der Kurzfaser-verstärkten Polyurethan-Komponente in die Kavitäten des Oberwerkzeugs werden auch die späteren Dome, Rippen und/oder Stege faserverstärkt. Hierdurch wird ein höhere Stabilität dieser Strukturen erreicht.
Bezuqszeichenliste: A polyurethane molded body produced by such an inventive method not only has a high stability in the actual body. By foaming the short fiber-reinforced polyurethane component in the cavities of the upper tool and the later dome, ribs and / or webs are fiber-reinforced. As a result, a higher stability of these structures is achieved. LIST OF REFERENCES:
1 frisch vermischtes Polyurethan 1 freshly mixed polyurethane
2 lange Fasern 2 long fibers
3 obere Halbform 3 upper half form
4 Aussparung für Rippe 4 recess for rib
5 untere Halbform 5 lower half form
6 frisch vermischtes Polyurethan mit kurzen Fasern 6 freshly mixed polyurethane with short fibers
7 Bauteil mit flächig verpressten langen Glasfasern 7 Component with flat pressed long glass fibers
8 Rippe eines Bauteil gefüllt mit unverstärktem Polyurethan 8 rib of a component filled with unreinforced polyurethane
9 Rippe eines Bauteil gefüllt mit Polyurethan verstärkt mit kurzen Fasern
9 rib of a component filled with polyurethane reinforced with short fibers
Claims
1. Langfaser-verstärkter Polyurethan-Formkörper, mit dreidimensionalen erhobenen Strukturen, insbesondere Rippen, Stegen und/oder Domen, dadurch gekennzeichnet, dass er neben den Langfasern weiterhin Kurzfasern enthält, wobei das Gewichtsverhältnis zwischen kurzen Fasern und/oder plättchenförmigen Füllstoffen zur faserfreien Polyurethanmatrix in einem Volumen aus Rippen, Stegen und/oder Domen größer ist, als das Gewichtsverhältnis an kurzen Fasern und/oder plättchenförmigen Füllstoffen zur faserfreien Polyurethanmatrix in flächigen Bereichen außerhalb der erhobenen Strukturen. 1. Long-fiber-reinforced polyurethane molded body, with three-dimensional raised structures, in particular ribs, webs and / or domes, characterized in that it further contains short fibers in addition to the long fibers, wherein the weight ratio between short fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in a volume of ribs, webs and / or domes is greater than the weight ratio of short fibers and / or platelet-shaped fillers to the fiber-free polyurethane matrix in flat areas outside the raised structures.
2. Polyurethan-Formkörper gemäß Anspruch 1, dadurch gekennzeichnet, dass die Langfasem Glasfasern umfassen. 2. Polyurethane shaped body according to claim 1, characterized in that the long fibers comprise glass fibers.
3. Polyurethan-Formkörper gemäß Anspruch 1, dadurch gekennzeichnet, dass die Langfasern ein Länge von 1 bis 30 cm, insbesondere von 2,5 bis 10 cm aufweisen. 3. Polyurethane shaped body according to claim 1, characterized in that the long fibers have a length of 1 to 30 cm, in particular from 2.5 to 10 cm.
4. Polyurethan-Formkörper gemäß Anspruch 1, dadurch gekennzeichnet, dass kurze Fasern eine Länge/Durchmesser von 1 bis 800 μm, insbesondere von 4 bis 600 μm aufweisen. 4. polyurethane molding according to claim 1, characterized in that short fibers have a length / diameter of 1 to 800 .mu.m, in particular from 4 to 600 microns.
5. Polyurethan-Formkörper gemäß Anspruch 4, dadurch gekennzeichnet, dass die Kurzfasern gemahlene Glasfasern umfassen. 5. Polyurethane shaped body according to claim 4, characterized in that the short fibers comprise ground glass fibers.
6. Polyurethan-Formkörper gemäß Anspruch 5, dadurch gekennzeichnet, dass die Kurzfasern Wollastonitfasern umfassen. 6. Polyurethane molded article according to claim 5, characterized in that the short fibers comprise wollastonite fibers.
7. Polyurethan-Formkörper gemäß einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Langfaser-verstärkte Seite weiterhin eine Außenhaut aufweist. 7. polyurethane molding according to one of claims 1 to 6, characterized in that the long fiber-reinforced side further comprises an outer skin.
8. Polyurethan-Formkörper gemäß Anspruch 7, dadurch gekennzeichnet, dass die Außenhaut eine tiefgezogene Folie, insbesondere aus Acrylnitril- Butadien-Styrol (ABS), Polymethylmethacrylat (PMMA), Acrylnitril-Styrol- Acrylester (ASA), Polycarbonat (PC), thermoplastischem Polyurethan, Polypropylen (PP), Polyethylen (PE) und/oder Polyvinylchlorid (PVC) aufweist. 8. Polyurethane molded body according to claim 7, characterized in that the outer skin of a deep-drawn film, in particular of acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene acrylic ester (ASA), polycarbonate (PC), thermoplastic Polyurethane, polypropylene (PP), polyethylene (PE) and / or polyvinyl chloride (PVC).
9. Polyurethan-Formkörper gemäß Anspruch 7, dadurch gekennzeichnet, dass die Außenhaut eine Zweischichtfolie umfasst. 9. polyurethane molding according to claim 7, characterized in that the outer skin comprises a two-layer film.
10. Polyurethan-Formkörper gemäß Anspruch 7, dadurch gekennzeichnet, dass die Außenhaut eine Metallfolie, insbesondere eine Aluminiumfolie oder eine Stahlfolie umfasst. 10. Polyurethane shaped body according to claim 7, characterized in that the outer skin comprises a metal foil, in particular an aluminum foil or a steel foil.
11. Polyurethan-Formkörper gemäß Anspruch 7, dadurch gekennzeichnet, dass die Außenhaut eine In-Mould-Coating und/oder Gel-Coat-Beschichtung umfasst. 11. Polyurethane shaped body according to claim 7, characterized in that the outer skin comprises an in-mold coating and / or gel coat coating.
12. Verfahren zur Herstellung eines Polyurethan-Formkörpers gemäß einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass 12. A process for producing a polyurethane molding according to any one of claims 1 to 11, characterized in that
(a) Langfasern mit einem PUR-Reaktivgemisch benetzt werden, diese in ein geöffnetes Werkzeug eingebracht werden, (a) long fibers are wetted with a PUR reactive mixture, these are introduced into an open mold,
(b) lokal verteilt mit kurzen Fasern verstärktes PUR-Reaktivgemisch aufgebracht und (B) locally distributed with short fibers reinforced PUR reactive mixture applied and
(c) anschließend die Form mit dem Oberteil geschlossen wird. (c) then the mold is closed with the upper part.
13. Verfahren gemäß Anspruch 12, dadurch gekennzeichnet, dass die Schritte (a) und (b) vertauscht werden. 13. The method according to claim 12, characterized in that the steps (a) and (b) are reversed.
14. Verfahren nach Anspruch 12 oder 13, wobei man i) einen kurze Fasern enthaltenden Gasstrom in einen flüssigen Strahl eines Polyurethanreaktivgemisches einbringt, wobei der die kurze Fasern enthaltende Polyurethanstrahl versprüht wird, ii) gegebenenfalls in diesen Sprühstrahl einen Langfasern enthaltenden Gasstrom einbringt, iii) den die kurze Fasern und gegebenenfalls die Langfasern enthaltenden PUR-Sprühstrahl in eine offene Form oder auf einen Substratträger sprüht, iv) gegebenenfalls die Menge an die kurze Fasern unter (i) erhöht, wenn kein die Langfasern enthaltender Gasstrom gleichzeitig eingebracht wird. 14. The method of claim 12 or 13, wherein i) introduces a gas stream containing short fibers in a liquid stream of a polyurethane reactive mixture, wherein the polyurethane fibers containing the short fibers is sprayed, ii) optionally introduces a gas stream containing long fibers in this spray, iii) spraying the short fibers and optionally the long fibers containing PUR spray into an open mold or onto a substrate carrier, iv) optionally increasing the amount of the short fibers below (i), if no gas stream containing the long fibers is introduced simultaneously.
15. Verfahren nach einem der Ansprüche 12 bis 14, dadurch gekennzeichnet, dass man ein Oberteil oder ein Unterteil des Werkzeugs mit Kavitäten für Rippen, Stege und/oder Dome einsetzt. 15. The method according to any one of claims 12 to 14, characterized in that one uses an upper part or a lower part of the tool with cavities for ribs, webs and / or domes.
16. Verfahren nach einem der Ansprüche 12 bis 15, dadurch gekennzeichnet, dass in das geöffnete Werkzeug zunächst eine Außenhaut eingelegt wird, anschließend die PUR benetzten Langfasern eingebracht werden, hierauf zusätzlich lokal verteilt Kurzfaser-verstärktes PUR- Reaktivgemisch aufgebracht und anschließend die Form mit dem Oberteil geschlossen wird. 16. The method according to any one of claims 12 to 15, characterized in that in the open tool first an outer skin is inserted, then the PUR wetted long fibers are introduced, then additionally applied locally distributed short-fiber reinforced PUR reactive mixture and then the mold with the Upper part is closed.
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CN1990961A (en) * | 2005-12-28 | 2007-07-04 | 曾建祥 | Composite material moulded well covers |
DE102006022846A1 (en) | 2006-03-10 | 2007-09-13 | Fritzmeier Composite Gmbh & Co. Kg | Composite component comprises an outer shell and a matrix containing fibers and a foamable compression molding compound, where the concentration of the molding compound is placed in a layer constraining the outer shell |
US20080057286A1 (en) * | 2006-08-30 | 2008-03-06 | Polk Dale E | Method of forming a molded plastic article having at least one molded extension |
DE102006046130A1 (en) | 2006-09-28 | 2008-04-03 | Kraussmaffei Technologies Gmbh | Producing a coated large-area part comprises varying the amount and/or composition of polyurethane material deposited on the part in lines or sections |
CN101314931A (en) | 2007-05-28 | 2008-12-03 | 中国船舶重工集团公司第七二五研究所 | Novel synthesis wooden sleeper |
-
2010
- 2010-08-17 US US13/391,961 patent/US20120148803A1/en not_active Abandoned
- 2010-08-17 RU RU2012111120/05A patent/RU2012111120A/en unknown
- 2010-08-17 BR BR112012004110A patent/BR112012004110A2/en not_active Application Discontinuation
- 2010-08-17 CN CN2010800380119A patent/CN102574335A/en active Pending
- 2010-08-17 JP JP2012525908A patent/JP2013503211A/en active Pending
- 2010-08-17 EP EP10751805A patent/EP2470351A1/en not_active Withdrawn
- 2010-08-17 KR KR1020127004859A patent/KR20120089840A/en not_active Application Discontinuation
- 2010-08-17 WO PCT/EP2010/005047 patent/WO2011023322A1/en active Application Filing
- 2010-08-17 MX MX2012002237A patent/MX2012002237A/en not_active Application Discontinuation
- 2010-08-17 CA CA2769884A patent/CA2769884A1/en not_active Abandoned
Non-Patent Citations (1)
Title |
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See references of WO2011023322A1 * |
Also Published As
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BR112012004110A2 (en) | 2016-03-15 |
RU2012111120A (en) | 2013-10-10 |
KR20120089840A (en) | 2012-08-14 |
JP2013503211A (en) | 2013-01-31 |
MX2012002237A (en) | 2012-03-07 |
CA2769884A1 (en) | 2011-03-03 |
CN102574335A (en) | 2012-07-11 |
US20120148803A1 (en) | 2012-06-14 |
WO2011023322A1 (en) | 2011-03-03 |
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