EP3365148A2 - Fabrication de structures complexes creuses en mousse ou en sandwich au moyen d'un noyau de moule - Google Patents

Fabrication de structures complexes creuses en mousse ou en sandwich au moyen d'un noyau de moule

Info

Publication number
EP3365148A2
EP3365148A2 EP16784464.6A EP16784464A EP3365148A2 EP 3365148 A2 EP3365148 A2 EP 3365148A2 EP 16784464 A EP16784464 A EP 16784464A EP 3365148 A2 EP3365148 A2 EP 3365148A2
Authority
EP
European Patent Office
Prior art keywords
tool
core
particles
foam
filling
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16784464.6A
Other languages
German (de)
English (en)
Inventor
Arnim Kraatz
Denis HOLLEYN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Evonik Operations GmbH
Original Assignee
Evonik Roehm GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Evonik Roehm GmbH filed Critical Evonik Roehm GmbH
Publication of EP3365148A2 publication Critical patent/EP3365148A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
    • B29C33/485—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling cores or mandrels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1252—Removing portions of the preformed parts after the moulding step
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1266—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being completely encapsulated, e.g. for packaging purposes or as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3821—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process composed of particles enclosed in a bag
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/54—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles made of powdered or granular material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1233—Joining preformed parts by the expanding material the preformed parts being supported during expanding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1271—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed parts being partially covered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/129—Enhancing adhesion to the preformed part using an interlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3415—Heating or cooling
    • B29C44/3426—Heating by introducing steam in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
    • B29K2079/08—PI, i.e. polyimides or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/048—Expandable particles, beads or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2671/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone, or derivatives thereof, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0063—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/44—Furniture or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/52—Sports equipment ; Games; Articles for amusement; Toys
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to a process for the preparation of complex, foam-molded
  • Hard foam materials in particular poly (meth) acrylimide (P (M) I), preferably from
  • Polymethacrylimide (PMI) cores which can be used for example in the automotive or aircraft industry.
  • the method is characterized by the fact that by using a particulate core during foaming, an additional weight saving compared to foam materials or sandwich materials of the prior art can be realized.
  • Sandwich components in many cases provide the best balance between weight and mechanical properties. For very large volume components, such as e.g. in complex three-dimensional structures with large thickness, or depending on the present
  • Kernamterial is not completely needed in the final application. In these cases, it primarily serves as a production aid, which unnecessarily adds additional weight in the final component.
  • wax cores are used today in small quantities.
  • fiber composite materials are applied to wax cores, consolidated in various infusion procedures and finally removed from the wax core.
  • the processing methods are limited to low temperatures and low pressures and removal of the wax core has proven to be a very complex process step. This results in only very long cycle times during processing. Thus, only very small quantities can be realized.
  • foams with a cavity such a method is not suitable.
  • a melting within a foam core is excluded due to the diffusion into the pores alone.
  • the wax core would have to be removed over a large-area recess, which in turn would lead to a reduced stability of the foam core.
  • DE 3 630 930 describes another process for foaming the abovementioned copolymer plates of methacrylic acid and methacrylonitrile.
  • the polymer plates with the help of a
  • Microwave field foamed which is why this is referred to below as the microwave method.
  • the plate to be foamed, or at least its surface must first be heated to or above the softening point of the material. Since the foaming of the material softened by the external heating naturally also starts under these conditions, the foaming process can not be controlled solely by the influence of a microwave field, but must also be controlled by an accompanying heating from the outside. Thus, a microwave field is added to the normal single-stage hot air process to accelerate the foaming. However, the microwave method has proved to be too complicated and therefore not relevant to practice and is still not used.
  • foams based on methacrylic acid and acrylonitrile are also known with similar properties. These are described, for example, in CN 100420702C. However, these foams are also produced by means of plates.
  • it was an object of the present invention by means of this method can be processed easily and at high throughput speed hard foam, in particular P (M) I particles in an in-mold-foaming process to molded foam cores or sandwich materials, these compared to the state
  • the technique should also have a significantly reduced weight.
  • poly (meth) acrylimide (P (M) I) polymethacrylimides, polyacrylimides or mixtures thereof are understood.
  • the term (meth) acrylic acid is understood to mean both methacrylic acid and acrylic acid and mixtures of these two.
  • foam cores Poly (meth) acrylimide (P (M) I) foam cores.
  • rigid foam core generically comprises foam bodies without cover layers, but in particular not necessarily
  • Hard foam core e. optional opening of the film at the accessible former contact area from process step b. and f. Removal of the particles from the hard foam core.
  • step b. inserted into the tool so that the filling core between 0.5 and 10, preferably 1 to 5 area percent of the inner wall of the tool touches.
  • the opening for example, can be hung simply.
  • process step e is omitted. and the removal of the particles in process step f. is easiest.
  • step b. In a second variant of the filling core in step b. inserted in such a way that the filling core after process step d. completely surrounded by the foam. This can be done by the filler core
  • Invention is the foam in step e. partially drilled or cut open. This is done to the particles in step f. then remove. The result is a foam body whose cavity can be almost completely surrounded by the foam. The size of the subsequent opening depends on the particle size and the flowability, as well as possibly the shape of the cavity and the desired removal time of the particles.
  • the filling core in method step b. inserted so that the filling core between 0.5 and 10, preferably 1 to 5 area percent of
  • Device closed This may be, for example, a plug or a clamp. This device is finally in step e. away.
  • the device can be used again after the removal of the particles and thereby fixed, for example by means of gluing or sewing.
  • Shaking, bumping or poking can be put back into a free-flowing state.
  • the particles are preferably chemically stable under prolonged loading under said foaming temperature and overpressure, undergo only a slight change in volume and do not melt or stick together.
  • Particularly suitable particles are sand, at the foaming temperature stable and solid polymer particles, e.g. made of PEEK, metal particles or glass beads.
  • Conceivable are other especially mineral fillers or temperature-stable seeds.
  • the film should likewise be an analogue temperature-stable film.
  • examples include PTFE, PEEK or PPSU film. It is also conceivable, e.g. to use silicone or metal coated or impregnated film. In the latter, it can be as
  • Carrier material also act on a tissue or paper, which has been coated or impregnated.
  • the filling core is preferably in a tightly packed and thus dimensionally stable form.
  • the filling can be done for example by means of compressed air or suction under vacuum.
  • pressure can additionally be applied to the outside, for example in a press.
  • a shaping of the filling core can also take place.
  • the shaping can also be carried out or supported by the underpressure and / or overpressure.
  • the film can either be closed to a closed bag or remain open at the filling point and introduced with this pointing upwards into the tool.
  • the filling core is open at one point and is at this open point in step b. hung in the tool.
  • step b inserted into the tool so that it touches the inner wall of the tool in at least two places.
  • the second position which does not point upwards within the movement, is forcibly closed.
  • Process step f. to blow the particles out of the cavity by means of compressed air.
  • the second or the second accessible on the surface of the hard foam core point must be opened.
  • all known processes for the production of particle foams can be integrated into the process according to the invention. As a particularly preferred, it has a method in which the actual foaming takes place while relaxing the tool interior, has been found. Such a method is for example for P (M) I in the international application
  • the matrix particles are produced in a process step cO. preheated and filled under pressure in the tool. Foaming then takes place at the foaming temperature by lowering the pressure.
  • the process steps c. and d. in this embodiment have the following individual steps: cO: heating of matrix particles to a normal pressure foaming temperature Ti, this taking place under a pressure pi at which a volume nominal of the P (M) I particles of not more than 10% by volume takes place in 10 minutes, c1: filling of the matrix particles into the cavity formed by filler core and tool inside, wherein the filling takes place at a pressure p2, which is preferably at most 10% less than pi, and
  • a particular advantage of this embodiment is that the foaming can be carried out within at most 2 min, and that the method steps a. to d. can be performed together within a short period of 5 to 45 minutes, wherein method step a. can be performed in parallel to the other process steps.
  • Another advantage is the even temperature distribution within the material at the moment of foaming. This leads to a particularly uniform distribution and size distribution of
  • the end product has no or only minimal density gradients compared with foams of the prior art.
  • the outer regions are generally more foamy than inner regions.
  • the temperature Ti is preferably between 150 and 250 ° C., more preferably between 180 and 220 ° C.
  • Pressure pi in process step cO. and pressure p2 in step c1. are preferably between 2 and 20 bar.
  • Temperature T2 is preferably set to a value between 150 and 250 ° C, particularly preferably between 180 and 220 ° C.
  • the pressure p3 is preferably between 0, 1 and 2.0 bar, more preferably between atmospheric pressure and 1, 5 bar.
  • the preheating of the particles takes place in the
  • step d. also foamed.
  • the pressure P2 is flexibly selectable and it can e.g. be filled at atmospheric pressure.
  • Preferred over this variant is an embodiment of the method according to the invention, in the method step cO. before method step c1. is carried out.
  • the particles in process step cO. to store in a reservoir at temperature Ti and the pressure pi and thus preheat.
  • the particles are then batchwise in process step c1. filled in the tool, wherein after the batchwise filling in each case the connection between the reservoir and the tool is closed before the relaxation in step d1. he follows.
  • the matrix particles prior to addition in step c1. in the reservoir at a temperature less than 50 ° C below the
  • Foaming temperature is, and stored at a pressure which is at least 1 bar above normal pressure, and are filled batchwise in step c1 in the tool, wherein after the batchwise filling in each case the connection between the reservoir and the tool is closed.
  • step c1. into the cavity within the tool to suck and / or blow.
  • the pressure P2 in method step c1. results from the pressure in the particle template, such as e.g. a reservoir, the blank pressure of the tool and the pressure changes resulting from suction or blowing devices.
  • the configuration of the parameters for method step c1. According to the invention, care should be taken that all these parameters are set so that P2 is at most 10% below pi or even above pi. This will be too fast
  • step c1 advantageous to fill the tool to a level between 50 and 100%, preferably between 75 and 98% with particles.
  • 100% level in this context means that the tool is filled up to the top edge with the particles.
  • between the particles remain free spaces whose size depends on the particle size and particle shape. Theoretically, these clearances can also make up a level of 100% up to 50% of the interior of the tool.
  • process step c These free spaces are finally closed by the foaming, so that a homogeneous hard foam core is formed.
  • the interior of the tool can be equipped with so-called inserts. These are when filling the granules in step c.
  • inserts may be, for example, articles with an internal thread.
  • the rigid foam cores can be screwed later.
  • Analog can also bolts, hooks, pipes or the like can be installed. It is also possible to integrate electrochips or cables already in the production of the hard foam core in this.
  • step c there are various preferred embodiments of matrix particles used.
  • the matrix particles are a ground material made of a rigid foam, in particular P (M) 1 plate polymer, which is obtained as a cast polymer. These plates can be comminuted, for example in a mill to suitable particles. Milled matrix particles are preferably used in this variant with a particle size between 1, 0 and 4.0 mm.
  • these matrix particles are prefoamed before they are melted in process step c. be filled in the tool. It is important to ensure that the pre-foaming is not complete, but only up to a Schu ment degree between 10 and 90%, preferably between 20 and 80% is performed. The final foaming then takes place in process step d.
  • Pre-expanded matrix particles are preferably used in this variant with a particle size between 1, 0 and 25.0 mm.
  • the prefoamed matrix particles preferably have a density between 40 and 400 kg / m 3 , preferably between 50 and 300 kg / m 3 , more preferably between 60 and 220 kg / m 3 and especially preferably between 80 and 220 kg / m 3 .
  • a particularly suitable process for prefoaming P (M) I is described, for example, in German Patent Application No. 102013225132.7.
  • the matrix particles are hard foam, preferably P (M) 1 suspension polymers.
  • P (M) 1 suspension polymers are preferably used with a particle size between 0, 1 and 1, 5 mm, more preferably between 0.1 and 1, 0 mm.
  • the preparation of P (M) l suspension polymers can be read, for example, in the international application with the file reference PCT / EP2014 / 050658.
  • Suspension polymers in process step c. used. With regard to the degree of foaming, the same applies as described above for the prefoamed matrix particles of a millbase.
  • the prefoamed matrix particles preferably have a density between 40 and 400 kg / m 3 , preferably between 50 and 300 kg / m 3 , more preferably between 60 and 220 kg / m 3 and especially preferably between 80 and 220 kg / m 3 .
  • Such prefoamed suspension polymers are preferably used with a particle size between 0, 1 and 2.0 mm, more preferably between 0.2 and 1.5 mm.
  • Hot air, a hot gas or steam, preferably a hot inert gas or air are conducted into the interior of the tool. This introduction has a temperature between 90 and 300 ° C, preferably between 150 and 250 ° C.
  • moldings or foam materials with a significantly more homogeneous pore structure and without defects and at the same time in more complex forms can be produced by means of a process based on flash-foaming. Furthermore, it is possible with this method to produce these complex shapes quickly, in short cycle times and with particularly good quality.
  • the method according to the invention has shortened heating and cooling cycles compared to prior art methods.
  • the present method has the great advantage over the prior art that it is so gentle that the surface of the matrix particles is not damaged.
  • the inner sides of the tool shells before step b. or c. with a material, which is a later
  • Cover layer forms, preferably interpreted with prepregs or organic sheets. It is also possible, for example, to bring decorative films or metals.
  • the films, metals, prepregs or organ sheets may optionally be coated with an adhesive or a primer. When foaming in process step d. The resulting foam then combines with the coated or
  • the hard foam core in process step d. taken in the form of a composite material with cover layers.
  • forming a later topcoat means preferably that it is an organo sheet or prepreg which cures in parallel under the foaming conditions.
  • the filler core If the filler core is completely closed, it must be opened at one or more points accessible on the outside of the material.
  • the removal of the particles in process step f. In the simplest case, this is done by simply pouring it out, whereby the particles can usually be reused afterwards. Under certain circumstances, it is in method step f. necessary, removal e.g. by shaking, blowing, poking or hitting.
  • the foil is pulled out of the hard foam core. Should not be possible or desired, it can also remain within the cavity without significant weight contribution.
  • Adhesion promoters are used. As an alternative to application in a later method step, these adhesion promoters may also be applied to the surface of the matrix particles even before the prefoaming according to the invention.
  • polyamides or poly (meth) acrylates have proven to be suitable as adhesion promoters.
  • Matrix material of the cover layer known in the art, can be used.
  • the method according to the invention has the great advantage that it can be carried out very quickly and thus in combination with follow-up processes with very short cycle times.
  • the inventive method can be very well integrated in a series production.
  • the process parameters to be selected depend on the design of the system used in the individual case and its design, as well as the materials used. They can easily be determined by a few preliminary tests for the expert.
  • the intermediate product after process step d., Containing the filler core, and / or initially to further refining steps, such as e.g. a bonding,
  • the material used according to the invention is preferably P (M) I, in particular PMI.
  • P (M) I foams are characterized by a special strength.
  • the P (M) I foams are normally produced in a two-stage process: a) production of a cast polymer and b) optional partial foaming of this cast polymer. According to the prior art, these are then cut or sawn into the desired shape. An alternative which is even less technically established is the executed in-mold foaming for which the method according to the invention can be used.
  • P (M) I first monomer mixtures, which (meth) acrylic acid and
  • (Meth) acrylonitrile preferably in a molar ratio of between 2: 3 and 3: 2, contained as main components.
  • other comonomers may be used, such as e.g. Esters of acrylic or methacrylic acid, styrene, maleic acid or itaconic acid or their anhydrides or
  • the copolymerization mixture further contains blowing agents which either decompose or vaporize at temperatures of about 150 to 250 ° C to form a gaseous phase.
  • blowing agents which either decompose or vaporize at temperatures of about 150 to 250 ° C to form a gaseous phase.
  • the polymerization takes place below this temperature, so that the cast polymer contains a latent blowing agent.
  • the polymerization suitably takes place in block form between two glass plates.
  • the production of such PMI semi-finished products is in principle known to the person skilled in the art and can
  • the P (M) I particles are a suspension polymer which, as such, can be introduced directly into the process.
  • the preparation of such suspension polymers can be described, for example, in DE 18 17 156 or in WO
  • Hard foams such as PP, PET, PE, PVC or hard PU foams can be used. An adaptation of the process to these foams takes place via the respectively specifically required process parameters during foaming and are easy to deduce for the skilled person.
  • Foam core associated cavity This point preferably makes up between 1 and 10 area percent of the surface.
  • this point can then be closed with a cover material by means of gluing, sewing, pinning or bolting.
  • a cover material by means of gluing, sewing, pinning or bolting.
  • Organ sheet placed and cured. Furthermore, these are optional with the previously
  • foam bodies or foam cores have between the inner surface of the foam and the cavity a film, a cured prepreg or organo sheet or nothing at all.
  • P (M) I rigid foam cores in sandwich materials or in order
  • the hard foam core may preferably have a complex shape.
  • Foam body according to the invention is at least 95% of one of the
  • Hard foam material existing preferably a thickness of at least 100 ⁇ having skin is enclosed. This means that these new foam foam cores or bodies are not open
  • These novel rigid foam cores preferably have a density of between 20 and 180 kg / m 3 .
  • This density specification refers to a hollow foam body including cavity, whose opening is closed real or fictitious.
  • foamed foams produced according to the invention can be further processed, for example, into foam core composite materials.
  • Foam core composite or sandwich materials may be used in particular in the
  • rigid foam cores according to the invention are suitable in principle for any type of lightweight construction.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

La présente invention concerne un procédé de fabrication de matériaux complexes en mousse dure, expansés dans un moule, en particulier de noyaux de poly(méth)acrylimide (P(M)I), de préférence de polyméthacrylimide (PMI), qui peuvent être utilisés par exemple dans la construction automobile ou aéronautique. Le procédé se caractérise en ce que l'utilisation d'un noyau particulaire pendant l'expansion peut permettre une économie de poids supplémentaire par rapport aux matériaux en mousse ou matériaux en sandwich de l'état de la technique.
EP16784464.6A 2015-10-22 2016-10-17 Fabrication de structures complexes creuses en mousse ou en sandwich au moyen d'un noyau de moule Withdrawn EP3365148A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP15191005.6A EP3159129A1 (fr) 2015-10-22 2015-10-22 Fabrication de structures complexes creuses en sandwich ou en mousse a l'aide d'un noyau de moule
PCT/EP2016/074825 WO2017067867A2 (fr) 2015-10-22 2016-10-17 Fabrication de structures complexes creuses en mousse ou en sandwich au moyen d'un noyau de moule

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EP3365148A2 true EP3365148A2 (fr) 2018-08-29

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EP15191005.6A Withdrawn EP3159129A1 (fr) 2015-10-22 2015-10-22 Fabrication de structures complexes creuses en sandwich ou en mousse a l'aide d'un noyau de moule
EP16784464.6A Withdrawn EP3365148A2 (fr) 2015-10-22 2016-10-17 Fabrication de structures complexes creuses en mousse ou en sandwich au moyen d'un noyau de moule

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EP15191005.6A Withdrawn EP3159129A1 (fr) 2015-10-22 2015-10-22 Fabrication de structures complexes creuses en sandwich ou en mousse a l'aide d'un noyau de moule

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US (1) US10919198B2 (fr)
EP (2) EP3159129A1 (fr)
CN (1) CN108136624A (fr)
HK (1) HK1256005A1 (fr)
WO (1) WO2017067867A2 (fr)

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Publication number Priority date Publication date Assignee Title
MX2020001993A (es) 2017-08-24 2020-09-25 Evonik Operations Gmbh Espumas de particulas de pei para aplicaciones en interiores de aviacion.
WO2020109072A1 (fr) 2018-11-26 2020-06-04 Mubea Carbo Tech Gmbh Procédé de production de matériaux de poly(méth)acrylimide

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Also Published As

Publication number Publication date
US10919198B2 (en) 2021-02-16
CN108136624A (zh) 2018-06-08
WO2017067867A3 (fr) 2017-06-15
US20180311869A1 (en) 2018-11-01
HK1256005A1 (zh) 2019-09-13
WO2017067867A2 (fr) 2017-04-27
EP3159129A1 (fr) 2017-04-26

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