Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • 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
  • B32B5/18—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 features of a layer of foamed material
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
  • B32B17/067—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of fibres or filaments
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  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
  • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
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  • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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  • B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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  • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • 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
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  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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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
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
• • 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
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
• • 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
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
  • Y10T428/249987—With nonvoid component of specified composition
  • Y10T428/249991—Synthetic resin or natural rubbers

Definitions

• the present invention describes a composite material comprising a spacer located between two layers of fibers.
• Composites are materials of two or more interconnected materials.
• properties of the material obtained are material and possibly also geometric properties of the individual components of importance. This makes it possible to combine properties of different components with each other, whereby the composite materials find wide applications.
• the properties required for the final product can be adjusted as needed by choosing different starting materials for the components.
• Composite materials can be produced in several ways.
• One possibility is the sandwich construction. This design is often used for semi-finished products where several layers of different properties are embedded in a material.
• the sandwich construction designates a form of lightweight construction, in which the components consist of usually kraftaufmden cover layers, which are held by a relatively soft, usually lightweight, core material (spacer) at a distance. Corresponding parts are very rigid with low weight.
• the core material may consist of honeycombs of different materials, for example paper, cardboard, plastics or metals, balsa wood, corrugated iron or foams. It transmits occurring shear forces and supports the cover layers.
• Applications for sandwich composite composites include, for example, pleasure boats, aircraft parts (fuselage, wing shells), railway wagons, vehicle and automotive parts, surfboards, and rotor blades for wind turbines.
• Honeycomb core sandwich panels made of fiberglass prepregs are also used as walls for galleys and lavatories in modern aircraft.
• prefabricated sandwich panels consisting of a reinforced concrete support shell, a thermal insulation and a facing cladding made of clinker or concrete.
• composite panels with metallic cover layers and an intermediate thermal insulation are referred to as a sandwich panel or sandwich panel.
• the sandwich construction is also used in automotive engineering. With low weight, high stability can be achieved.
• the first and second solid-state sandwich components are known, for example, from DE 10 057 365 A1.
• the sandwich construction is also used in solar technology.
• a solar module which comprises a sandwich element as a back cover.
• a sandwich element made of a metal foil as a spacer between two waterproof films is also known from US 2003/0178056 AI.
• this structure is also used for the back cover of a solar element.
• a similar structure of metal foil and sealing polymer layers for solar elements is also known from DE 10231401 AI.
• Honeycomb structures or corrugated sheets are frequently used as spacers in a sandwich element. These spacers usually have an outer layer on both sides. This outer layer is often made of plastic films. The connection of these films with the spacer is usually carried out at high temperature and pressure. The structure of the spacer often pushes through the film, so that the surface of the sandwich element is no longer smooth. The structure of the spacer then shows up in the final product.
• honeycomb structures that can absorb air is also known in the subject matter of the art, but has the disadvantage that the honeycomb structure is characterized by the pressing process on the functional or decorative layer or even destroys it.
• Object of the present invention is therefore to provide a composite material which can be obtained in sandwich construction and avoids the disadvantages of the prior art.
• a corresponding composite material should also have a large area a smooth surface (Class-A surface), in which the structure of the spacer is not visible.
• the surface should be very smooth and free of dents, air pockets or similar defects.
• the surface of the sandwich element should be so even that functional elements, such as solar panels, can be attached to it, without this already be damaged by the sandwich element, or the pushing through spacer.
• a rigid foam core with a defined off-centeredness during the pressing process can absorb trapped air and it does not interfere with the composite.
• this hard foam core has a sufficiently high pressure module or a sufficiently high compressive strength, so that does not collapse during compression of the hard foam core.
• the fibrous layers, between which the hard-core is located are well tied to the core. Due to the selected stiffness of the hard foam core, the structure according to the invention also has sufficient mechanical rigidity.
• the object underlying the invention is achieved by a composite material consisting of a spacer (1), which is located between two fiber-filled polyurethane layers (2), ie, the spacer includes hard foam.
• open-cell foam cores based on polyurethane are suitable.
• nen as a distance holder also, for example, open-celled (reticulated) PVC, PE, PP, PET, PS or EPS foams or open-cell metal or ceramic foams.
• the structure according to the invention can be used, for example, for the production of exterior components for motor vehicles (roof modules) if the functional layer is a plastic or a decorative material. It is possible to manufacture solar modules if the functional layer is a film solar laminate.
• such an open-cell rigid foam has a bulk density of 30 to 150 kg / m 3 , preferably from 40 to 120 kg / m 3 , particularly preferably from 50 to 100 kg / m 3 (measured according to DIN EN ISO 845).
• These rigid foams have an off-set of> 10%, preferably> 12%, more preferably> 15% (measured according to DIN EN ISO 4590-86), a compressive strength> 0.2 MPa, preferably> 0.3 MPa, more preferably> 0.4 MPa (measured in the compression test according to DIN EN ISO 826) and a pressure modulus> 6 MPa, particularly preferably> 10 MPa (measured in the compression test according to DIN EN ISO 826).
• a composite material according to the invention furthermore also includes, in particular, a functional and / or decorative layer (3).
• the advantage of the present invention over composites described in the prior art is that if it is used as a back cover in solar laminates, as a roof module, or other components, air trapped in the manufacturing process may escape through the open-faced shell, or so forth can be included.
• the sandwich element (4) is usually introduced initially and applied over any adhesive layer (s) to a decorative and / or functional layer (3).
• this decorative and / or functional layer (3) there is air between this and the underlying sandwich element (4).
• a pressure is now optionally applied under elevated temperature, if necessary, a vacuum can also be applied.
• the air can now escape over the edges.
• large-area materials however, this is not possible. The air therefore remains trapped between the sandwich element (4) and the functional and / or decorative layer (3).
• the spacer (1) is designed such that the air can be taken up or released through the open cells of the rigid foam. More often, air bubbles between sandwich element (4) and functional and / or decorative layer (3) are avoided.
• a spacer (1) is located between two fiber layers (2).
• These fiber layers (2) are usually fiber materials, which are impregnated with a resin, in particular a polyurethane resin.
• the polyurethane resin used can be obtained by reacting a) at least one polyisocyanate, b) at least one polyol component having an average OH number of 300 to 700 and containing at least one short-chain and one long-chain polyol, the starting polyols having a functionality of 2 to 6, c) water, d) activators , e) stabilizers, f) optionally auxiliaries, separating agents and / or additives.
• long-chain polyols are preferably suitable polyols having at least two to a maximum of six isocyanate-reactive hydrogen atoms; Polyester polyols and polyether polyols which have OH numbers of from 5 to 100, preferably from 20 to 70, particularly preferably from 28 to 56, are preferably used.
• Preferred short-chain polyols are those which have OH numbers of 150 to 2000, preferably 250 to 1500, particularly preferably 300 to 1100.
• Water is used in amounts of from 0 to 3.0, preferably from 0 to 2.0, parts by weight per 100 parts by weight of polyol formulation (components b) to f)).
• Suitable foam stabilizers are preferably polyether siloxanes, preferably water-soluble components.
• the stabilizers are usually used in amounts of from 0.01 to 5 parts by weight, based on 100 parts by weight of the polyol formulation (components b) to f)).
• the reaction mixture for the preparation of the polyurethane resin can optionally be added to auxiliaries, release agents and additives, for example surface-active additives, such as. Emulsifiers, flame retardants, nucleating agents, antioxidants, lubricants and mold release agents, dyes, dispersants, blowing agents and pigments.
• surface-active additives such as. Emulsifiers, flame retardants, nucleating agents, antioxidants, lubricants and mold release agents, dyes, dispersants, blowing agents and pigments.
• the components are reacted in amounts such that the equivalence ratio of the NCO groups of the polyisocyanates a) to the sum of the isocyanate-reactive hydrogens of components b) and c) and optionally d), e) and f) 0.8: 1 to 1.4: 1, preferably 0.9: 1 to 1.3: 1.
• Thermoplastic materials such as PE, PP, PA or other thermoplastic materials known from the prior art can furthermore be used as resins for the fiber layers.
• Thermosetting molding materials such as epoxy resins, unsaturated polyester resins, Venylesterharze, phenol-formaldehyde resins, Deallyphtalatharze, methacrylate resins or mamino resins such as melamine resins or urea resins can be used as a resin for the fiber layer.
• fiber material for the fiber layers glass fiber mats, glass fiber mats, Glasmaschinewirrlagen, glass fiber fabric, cut or ground glass or mineral fibers, natural fiber mats and knitted fabrics, cut natural fibers, as well as fiber mats, nonwovens and knitted fabric based on polymer, carbon or Aramid fibers and their mixture can be used.
• a fiber layer (2) gives the spacer made of open-cell rigid foam (1) the rigidity which is then required in the final product.
• a layer (2) according to the invention is also permeable to air.
• An inventive sandwich element (4) is therefore suitable, for example, for the production of solar elements.
• a solar laminate is used as the functional layer (3).
• Such a solar laminate has, in use, a transparent layer facing a light source and an adhesive layer having at least one solar element.
• the transparent layer may consist of the following materials: glass, polycarbonate, polyester, polymethyl methacrylate, polyvinyl chloride, fluorine-containing polymers, epoxies, thermoplastic polyurethanes or any combination of these materials. Furthermore, it is also possible to use transparent polyurethanes based on aliphatic isocyanates. As Isocyante HDI (hexamethylene diisocyanate), IPDI (isophorone diisocyanate) and / or H 12-MDI (saturated Methylendiphenyldiisocyanat) are used. Polyol component used are polyethers and / or polyester polyols and chain extenders, preferably aliphatic systems are used.
• the transparent layer may be designed as a plate, film or composite film.
• a transparent protective layer can preferably also be applied to the transparent layer, for example in the form of a lacquer or a plasma layer. By such a measure, the transparent layer could be set softer, whereby voltages in the module can be further reduced. Protection against external influences would take over the additional protective layer.
• the adhesive layer preferably has the following properties: high transparency in the range from 350 nm to 1150 nm, good adhesion to silicon and to the material of the transparent layer and to the sandwich element.
• the adhesive layer may consist of one or more adhesive films which are laminated onto the transparent layer and / or the sandwich element.
• the adhesive layer is soft to compensate for the stresses caused by the different thermal expansion coefficients of the transparent layer, solar cells and sandwich element.
• the adhesive layer is preferably made of a thermoplastic polyurethane, which may optionally be colored.
• the adhesive layer can also consist, for example, of ethylene-vinyl acetate, polyethylene, polyvinyl butyral or silicone rubber.
• a sandwich element according to the invention may also have a decorative layer (3).
• a corresponding composite material is then suitable, for example, for the production of components in the automotive industry.
• a composite material according to the invention for example, a roof module can be produced with a Class A surface.
• thermoplastic films for example conventional films based on acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene-acrylate (ASA), polycarbonate (PC), thermoplastic polyurethane, polypropylene, polyethylene, and / or polyvinyl chloride (PVC).
• ABS acrylonitrile-butadiene-styrene
• PMMA polymethyl methacrylate
• ASA acrylonitrile-styrene-acrylate
• PC polycarbonate
• thermoplastic polyurethane polypropylene
• polyethylene polyethylene
• PVC polyvinyl chloride
• coated or lacquered films can also be used.
• Subratlage own turn films based on acrylonitrile-butadiene-styrene (ABS), polymethylmethacrylate (PMMA), acrylonitrile-styrene-acrylic ester (ASA), polycarbonate (PC), thermoplastic polyurethane, polypropylene, polyethylene, and / or polyvinyl chloride (PVC ).
• ABS acrylonitrile-butadiene-styrene
• PMMA polymethylmethacrylate
• ASA acrylonitrile-styrene-acrylic ester
• PC polycarbonate
• thermoplastic polyurethane polypropylene
• polyethylene polyethylene
• PVC polyvinyl chloride
• a decorative layer (3) are also all conventional metal foils into consideration, preferably using an aluminum foil or a steel foil, in particular a so-called aluminum coil coating.
• Such decorative layers (3) are commercially available and their preparation is well known.
• the aforementioned films generally have a thickness of 0.2 to 5 mm, preferably from 0.5 to 1.5 mm.
• a decorative layer (3) for example, coextruded films with a spacer layer of polycarbonate or ABS (acrylonitrile-butadiene-styrene) and a surface layer of PMMA (polymethyl methacrylate) are used.
• a spacer layer of polycarbonate or ABS acrylonitrile-butadiene-styrene
• PMMA polymethyl methacrylate
• monofilms of ABS preferably have a modulus of elasticity above 800 MPa, preferably from 1000 MPa to 100000 MPa, so that their inherent rigidity ensures a basic stability.
• a composite material according to the invention has a plastic frame in another embodiment.
• a plastic frame protects the spacer (1) from moisture, air or other environmental influences which can penetrate through the sides which are not covered with the fiber-filled polyurethane layers (2). Ingress of moisture can severely impair the quality of the entire sandwich element (4). A homogeneous surface and, associated therewith, a good visual impression or good adhesion of the functional and / or decorative layer (3) is then no longer guaranteed. By a frame according to the invention such influences are prevented.
• An inventive plastic frame preferably also consists of fiber-reinforced, in particular glass fiber reinforced polyurethane.
• a polyurethane is obtainable, for example, by reacting organic di- and / or polyisocyanates with at least one polyether polyol.
• Suitable isocyanate components are aliphatic, cycloaliphatic, araliphatic, arymathic and heterocyclic polyisocyanates, as described, for example, by W. Siefken in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136.
• Polyether polyols used are preferably polyols having a functionality of 2 to 8, in particular 2 to 4, a hydroxyl number of 20 to 1000 mg KOH / g, preferably 25 to 500 mg KOH / g, and 10 to 100% primary hydroxyl groups.
• the polyols generally have a molecular weight of 400 to 10,000 g / mol, preferably from 600 to 6000 g / mol.
• Polyether polyols are particularly preferred because of their higher hydrolytic stability.
• a mixture of at least two polyether polyols is used here, the first polyether polyol having an OH number of from 20 to 50, preferably from 25 to 40, and the second polyether polyol having an OH number of from 100 to 350, preferably 180 to 300, wherein generally the weight ratio of the first to the second polyether polyol is 99: 1 to 80: 20.
• a polyurea plastic from which the inventive frame is formed optionally contains other different polyether polyols, polymer polyols, and optionally chain extenders.
• amine catalysts metal catalysts and optionally further additives is possible.
• Suitable additives are surface-active additives, such as emulsifiers, foam stabilizers, stabilizers, lubricants and mold release agents, dyes, dispersants and / or pigments, as known from the prior art.
• the object underlying the present invention is achieved by a method for producing a composite material according to the invention.
• a method for producing a composite material according to the invention is characterized in that one i) a sandwich element (4) of at least one spacer of an open-cell hard foam, and at least one fiber-filled polyurethane layer (2) located on each side of this spacer (1),
• this layer structure is optionally compressed under the influence of temperature and / or optionally under the application of a vacuum.
• a further method according to the invention for the production of a composite material is therefore characterized in that i) a functional and / or decorative layer (3) is provided,
• this layer structure is optionally compressed under the influence of temperature and / or optionally under the application of a vacuum.
• the object underlying the present invention is achieved by the use of a composite material according to the invention as a solar module, roof module, body part, structural part in vehicle, ship or aircraft construction, cladding element or decorative element.
• a composite material according to the invention as a solar module, roof module, body part, structural part in vehicle, ship or aircraft construction, cladding element or decorative element.
• the sandwich element (4) consists of a spacer (1), which is embedded between two fiber-filled polyurethane layers (2).
• Sandwich element (4) which consists of spacers (1) and
• Polyurethane layers (2) can now optionally with the help of a
• Adhesive layer with a functional and / or decorative layer (3) are connected.
• a 125 ⁇ m thick polycarbonate film (type Makrofol® DE 1-4 from Bayer MaterialScience AG, Leverkusen) was used as the front layer.
• the hot-melt adhesive layer used was two 480 ⁇ m thick TPU films (type Vistasolar® from Etimex, Rottenacker).
• the individual components in the order polycarbonate film, TPU film, 4 silicon solar cells and TPU film were combined into a laminate and evacuated in a vacuum laminator (NPC, Tokyo, Japan) at 150 ° C for 6 minutes and then 7 minutes at 1 bar pressure to a foil solar laminate pressed.
• the sandwich element used was a Baypreg® sandwich.
• a Baynat rigid polyurethane foam board System Baynat 81IF60B / Desmodur VP.PU 0758 of Bayer MaterialScience AG (10 mm thickness, bulk density 66 kg / m 3 (measured according to DIN EN ISO 845), off-set 15.1% ( measured according to DIN EN ISO 4590-86), compressive modulus of elasticity (measured according to DIN EN ISO 826) of 11.58 MPa and a compressive strength of 0.43 MPa (measured according to DIN EN ISO 826) on both sides with a random fiber mat of the type 300 g / m 2 (from Vetrotex, Herzogenrath) was then applied to this structure and 300 g / m 2 of a reactive polyurethane system were subsequently sprayed on both sides with a high-pressure processing machine Bavarian MaterialScience AG, Leverkusen consisting of a polyol (Baypreg® VP, PU 01IF13) and an
• the structure made of rigid foam board and the tangled with polyurethane random fiber mats was transferred to a pressing tool in which was on the bottom of the previously inserted foil-solar laminate.
• the mold was heated to 130 ° C and the assembly was pressed 90 seconds to a 10 mm thick sandwich solar module.

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