EP3433088A1 - Corps structuré et procédé de fabrication dudit corps - Google Patents

Corps structuré et procédé de fabrication dudit corps

Info

Publication number
EP3433088A1
EP3433088A1 EP17713282.6A EP17713282A EP3433088A1 EP 3433088 A1 EP3433088 A1 EP 3433088A1 EP 17713282 A EP17713282 A EP 17713282A EP 3433088 A1 EP3433088 A1 EP 3433088A1
Authority
EP
European Patent Office
Prior art keywords
structural body
layers
layer
hollow microspheres
density
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Withdrawn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
EP17713282.6A
Other languages
German (de)
English (en)
Inventor
Frank Maué
Matthias Kleinhans
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.)
IPCO Germany GmbH
Original Assignee
Sandvik Materials Technology Deutschland 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 Sandvik Materials Technology Deutschland GmbH filed Critical Sandvik Materials Technology Deutschland GmbH
Publication of EP3433088A1 publication Critical patent/EP3433088A1/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Withdrawn legal-status Critical Current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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/06—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/24—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/14—Layered products comprising a layer of synthetic resin next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B27/304—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
    • 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
    • B32B3/00—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
    • 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
    • B32B3/06—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 for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • 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
    • B32B5/02—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/14—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 a layer differing constitutionally or physically in different parts, e.g. denser near its faces
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    • 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
    • B32B5/14—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 a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B32B5/145—Variation across the thickness of the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B5/16—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 formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—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 formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
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    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29K2105/0076—Microcapsules
    • 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
    • B29K2105/041—Microporous
    • 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
    • B29K2105/25—Solid
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B33Y10/00—Processes of additive manufacturing

Definitions

  • the invention relates to a thermoplastic material-containing structural body and a method for its preparation.
  • integral foams or structural foams have a high density outer skin or outer layer and an inner layer with decreasing density towards the core.
  • integral polyurethane foam can be produced directly by placing a foamable reaction mixture in a closed mold, the outside of which is cooled. As a result, during the foaming of the mixture on the cold inner surface of the mold, a zone is formed in which the foaming process, despite the foaming agent contained, is prevented and a solid skin of higher density forms, which contains no foam cells.
  • a variety of such methods are described, e.g. in Becker / Braun, Kunststoffhandbuch Bd. 7 Polyurethane, Hanser Verlag 1993.
  • thermoplastics e.g. thermoplastics
  • DE 102013 103 255 A1 DE 102013 103 255 A1 called. It describes how voids formation can be avoided by geometrically optimizing a standard technical process known per se for the production of PVC foam sheets in relation to the substance discharge.
  • the object of the invention is to provide a structural body, which does not have a part of the aforementioned disadvantages, as well as the finding of a method for its preparation.
  • the object is achieved by a structural body with the features of claim 1 and by a method for its preparation with the features of claim 15.
  • the invention thus relates to a structural body which is made at least from a powdery starting material under the action of heat and / or pressure and has a plurality of layers, wherein
  • the starting material consists predominantly of thermoplastic base material, and wherein the density of at least two layers of the structural body is different and,
  • At least one lower density layer contains hollow microspheres and at least one higher density layer does not contain hollow microspheres.
  • the hollow microspheres partially pass through the boundary layer to and / or the region near the border in the adjacent layer, preferably the number of hollow microspheres is lower in these regions than in the layer of lower density itself; advantageous is the entire border area so.
  • the hollow microspheres are arranged regularly or / and irregularly distributed in the relevant layer or layers of lower density.
  • the inventive method for producing a structural body having at least the features of claim 1 comprises at least the following, successively following steps, namely:
  • the powdered thermoplastic material of at least one of the scattered layers contains hollow microspheres; Solidifying the pulverulent layers together with bonding of adjacent layers by heating the materials with simultaneous increase in volume and / or partial changes in the surface of the territorially limited hollow microspheres,
  • the surface of the hollow microspheres may be relatively smooth in their initial state, which is positive for mixing of the starting materials. While then in further manufacturing process, especially in the heating and / or in the pressing of the materials, this initially smooth surface is rough or even protrude from the surface surface parts prickly away.
  • High density layers of a structural body / sheet are free of blowing agents to allow further thermal treatment of the fabricated structural body, e.g. is an intermediate product, without forming a foam-like structure in these layers of higher density, which could result in uncontrolled deformations;
  • an alternating sequence of layers with a foamy texture and non-foamy texture in one Structural body is easy to produce and without merging and bonding of individual layers prefabricated in separate processes;
  • All layers are based on a base formulation, that is to say based on a base material which contains thermoplastics of a polymer type or a polymer group;
  • the layers do not have a sharply defined interface like the structure bodies according to the prior art, but rather a boundary region to the respectively adjacent layer, with constituents / particles of both layers penetrating or mixing in this boundary region to such an extent that a so-called toothing effect is formed;
  • a so-called wavy boundary region is produced by the invention, which has a positive effect on increasing the shear strength.
  • a base e.g. successively applying a plurality of layers of powdery raw material of one kind or different types, all of which predominantly contain thermoplastic material, at least the powdered starting material for at least one of the layers, which will later have a lower density before the lower belt of a double belt press or the die of a press the application of which are mixed with hollow microspheres.
  • the penetration depth of particles of the material still to be scattered into the already scattered material is influenced by targeted scattering, to form a bonding layer in the border region of adjacent layers.
  • targeted scattering to form a bonding layer in the border region of adjacent layers.
  • the kinetic energy of the scattered particles in particular the kinetic energy of the hollow microspheres achieved.
  • the drop height of the material to be scattered wherein the drop height can also optionally be varied over the width of the structural body to be produced.
  • a sequence of powdered starting materials is sprinkled on the preferred lower belt of a double belt press.
  • a double belt press is known for example from the document DE 102014 110493 A1 or DE 102010033578 A1. These materials basically all consist of the same basic formulation, with the difference that those material layers which will form layers of low density contain an additional material which is thermally influenced extensible.
  • This additional material consists e.g. thermoplastic hollow microspheres filled with an expandable gas.
  • thermoplastic hollow microspheres expand from an initial diameter of about 12 m up to 150 ⁇ .
  • the wall thickness of the balls drops from about 2 ⁇ to about ⁇ , ⁇ from.
  • the expansion temperature can be varied between 80 and 230 ° C by the nature of the enclosed gas.
  • the expanded hollow microspheres are very elastic and are hardly destroyed by pressure.
  • this material is compatible with the majority of technically interesting thermoplastic polymers.
  • hollow microspheres of other types namely those that can change their outer body shape under the influence of heat and / or pressure, so then temporarily or permanently have an elastic outer surface.
  • This can e.g. Be hollow microspheres made of glass whose spherical surface is relatively thin, but still so thick that a deformation of their spherical surface does not lead to cracking in selbiger or breakage.
  • the hollow microspheres consist of a thermosetting material, of an inorganic material or else of rubber or a rubber-like substance.
  • the use of a mixture of hollow microspheres of different types / types is also expedient.
  • the inventive method it is advantageous for the inventive method to keep the grain size of the scattered materials of the base formulation in the order of the ball sizes of the hollow microspheres used to obtain a good mixing and segregation on impact with the scattered powder or powder mixture on the already scattered layer prevent. Therefore, it is an essential part of the invention to use powder for the layers to be scattered, the average particle sizes as possible by 250 ⁇ ", preferably below 250 ⁇ .
  • Such powders can be readily generated, inter alia, when using PVC as a thermoplastic with the addition of the customary additives in the known heating / cooling mixer method; For example, with a method for producing a thermoplastic powder according to the patent application DE 102015000262.7 of the applicant.
  • inventive method is not limited to PVC formulations in principle, but also with other thermoplastic polymers feasible.
  • the addition of hollow microspheres to the base formulation does not cause a significant change in the rheological behavior of the melting process, i. It is necessary that the powder particles, regardless of the added hollow microspheres have identical melting behavior, so that an undisturbed composite material can arise.
  • the thickness of the connecting boundary layer is at least 5%, preferably 10% and at most 30% of the thickness of the adjacent thicker layer.
  • Figure 1 shows a vertical section through a structural body having a plurality of layers of different density
  • Figure 1a is a graph of density D over the thickness of
  • FIG. 1 shows the detail A of Figure 1
  • FIG. 3 shows a first layer of the invention
  • FIG. 4 shows a second layer of the invention
  • FIG. 5 shows a modified first layer of the
  • FIG. 6 shows a modified second layer of the
  • Figure 7 is a vertical section through a first
  • Figure 8 is a vertical section through a second
  • Figure 9 is a vertical section through a third
  • FIG. 1 shows a cross section through a structural body K according to the invention, which here is a sheet-like structural body 15. At the left and right edges of this figure, the structural body 15 is provided with a break line to indicate that the body is still moving. A coordinate system with X and Y axes has been placed in the center of the structural body 15. The small circles 9 and 10 represent expanded hollow microspheres in the finished produced structural body 15 (ie after heating and pressing and cooling).
  • the transition regions T1, T2, T3, T4, T5 and T6 expanded hollow microspheres present; the number of which is substantially lower in these areas than in the adjacent layers 2, 4 and 6.
  • the layers 1, 3, 5 and 7 each have a higher density and the layers 2, 4 and 6 a lower density.
  • the layers 2, 4 and 6 are thus lighter and softer than the other four layers.
  • a carrier material 8 in the form of a fabric is arranged for stability.
  • the waveform can be continuous as well as discontinuous, wherein a wavy line can have continuous as well as discontinuous part line sections.
  • one of the wavy lines of a transition region has a continuous wave and the second wavy lines of this transition region have a discontinuous wave.
  • FIG. 2 shows the section "A" of FIG. 1 and FIG. 2 a shows the enlarged view of FIG. 2.
  • the upper layer 7 has essentially no hollow microspheres, but in its section of the boundary layer T6 hollow microspheres 10 have migrated / diffused, which when sprinkling a powdery material of the first kind, that is, a thermoplastic base material 20 for the formation of the seventh layer 7, have migrated to the already applied sixth layer 6 of a powdery hollow microspheres 9 mixed base material 20 from the collection of hollow microspheres 9 and in the following after the scattering further manufacturing process / Procedure were set there, for the purpose of an improved so-called interlocking of the layers with each other.
  • a powdery material of the first kind that is, a thermoplastic base material 20 for the formation of the seventh layer 7
  • a powdery hollow microspheres 9 mixed base material 20 from the collection of hollow microspheres 9 and in the following after the scattering further manufacturing process / Procedure were set there, for the purpose of an improved so-called interlocking
  • the layer 7 is compared to the layer 6 significantly denser and thus harder or firmer.
  • FIG. 3 shows a first layer 1 with higher density, which is also present in the structural body 15 according to FIG.
  • This first layer 1 consists of a first type material, a thermoplastic base material 20, e.g. a material according to the base formulation shown in the table above.
  • FIG. 4 shows a second layer 2 with low density.
  • This second layer 2 consists of a material of the first type, that is to say again of a thermoplastic base material 20 and admixed hollow microspheres 9.
  • FIG. 5 shows a modified first layer 1a with a higher density.
  • This modified first layer 1a is made of a second type material consisting of a thermoplastic base material 20 and additives 21.
  • FIG. 6 shows a modified second layer 2a of low density.
  • This modified second layer 2a consists of a second type material, which consists of a thermoplastic base material 20 and additives 21, and admixed hollow microspheres 9.
  • the swelling of the expandable or deformable particles in this boundary layer that is to say in particular the hollow microspheres, at least partially, preferably predominantly to completely, encloses the surrounding non-inflated particles during the melting process and / or pressing and thus leads to a vertical penetration of both materials in one certain vertical range.
  • the puffing of the particles in the context of the invention is the expansion process and / or the deformation process of the hollow microspheres.
  • an increase in volume of the hollow microspheres which is also called frothing in professional circles, and / or at least partial deformation of the spherical surface through which regions of the spherical surface partial elevations and / or depressions, e.g. concave and / or convex portions receives, which is also conducive to the gearing.
  • the penetration quality of this range is defined by the grain size distribution of the scattered materials as well as by the kinetics of the foaming process or the space demanding deformation process.
  • the temperature control in the melting process and in the foaming process is important for a good toothing.
  • the choice of the so-called puffing material must be such that the expansion process does not start until the melting process has largely started, so that by the expansion process no still solid material can be displaced from the boundary layer.
  • the expansion processes of the hollow microspheres should only begin above 150 ° C.
  • three layers of pulverulent materials in the sense of the aforementioned example formulations are applied sequentially to a running lower belt of a double belt press so that a foamable layer and then another nonfoamable layer follow a non-foamable layer, two of the aforementioned boundary layers are produced.
  • a subsequent thermal treatment with a corresponding temperature control with respect to the preferred melting process and the subsequent foaming produces a three-layer sheet that meets the requirements set.
  • the sheet has two outer layers of higher density without foaming materials and a lower density core with Foam structure, so a foam-like structure, see Figures 9 and 9a, it is a third structural body 13 is prepared.
  • the density ratios as well as the mechanical and physico-chemical properties can be varied very easily via the variations of the base formulations to changing requirements on the end product; this is indicated schematically in FIG. 9a by the modified first layer 1a.
  • the modified first layer 1a is made of a second type material consisting of a thermoplastic base material 20 and additives 21.
  • the powdery material of the second kind may be present as a mixture of the two constituents 20 and 21, or the two constituents 20 and 21 have already been bound together in the production of the body for the production of the powdery material of the second kind and are therefore present in each powder particle.
  • the inventive method for producing a structural body is superior to the known techniques for the production of bodies of integral foams in terms of economy and possible variations.
  • the structural body K e.g. a first structural body 11 shown in a sectional view in FIG. 7 at the bottom, a first layer 1 with higher density and above this layer 1 a second layer 2 with low density.
  • a second structural body 12 shown in a sectional view in FIG. 8 has a lower lower layer 2 at the bottom Density and above this layer 2, a first layer 1 with higher density.
  • a third structural body 13 shown in a sectional view in FIGS. 9 and 9a has at the bottom a first layer 1 with higher density and above this layer 1 a second layer 2 with low density and above the second layer 2 a modified first layer 1a with higher density or a first layer 1 of higher density.
  • the transition region / boundary layer between the two upper layers is marked here by TZ in order to distinguish it from the structural body 15 according to FIG.
  • This boundary layer TZ likewise has, like the lower boundary layer T1, partially arranged hollow microspheres 10 whose positive effect has already been explained above.
  • a fourth structural body 14, shown in a sectional view in FIG. 10, has at the bottom a second layer 2 with low density and above this layer 2 a first layer 1 with higher density and above the first layer 1 a modified second layer 2a with low density or a second one Layer 2 with low density.
  • the transition region / boundary layer between the layer 1 and the layer 2 has partially arranged hollow microspheres 10, similar to the boundary layer T1 of the structural body 15 according to FIG.
  • the boundary layer between the layer 1 and the layer 2a is marked here by the reference numeral TX.
  • This boundary layer TX also has partially arranged hollow microspheres 10.
  • Such a reinforcement can be made according to the invention by sprinkling on a lower, non-foamable layer, followed by a foamable layer, a central non-foamable layer, which in turn is covered by a foamable layer followed by a non-foamable layer.
  • the result is a symmetrically constructed five-layer structure with a core of high density and outsides of high density.
  • sequence of such layers is not limited to the example mentioned.
  • the central layer by a carrier material 8, preferably a prefabricated sheet, such. replace or strengthen textile substrates, glass fleece, scrims or continuous fibers or plastic films, which are introduced between the corresponding scattering processes.
  • the carrier or the film may also be made of a non-thermoplastic material.
  • a sheet or a structural body can be made, which carries layers of low density on one or both outer sides and having a core of high density.
  • Such products are e.g. applied when building panels are laid on uneven ground and a horizontal balance must be created. Unevenness of the substrate then presses into the relatively soft outside of the laid plate and help to a uniform surface contact.
  • reinforcing fibers including continuous fibers
  • these fibers are melted into the polymer matrix.
  • This procedure has the advantage that it is also possible to use fibers which, because of their dimensions, can not already be incorporated into the base scattering materials during the preceding mixing process because they disturb the homogeneity of the scattering materials and thus the scattering processes.
  • Structural bodies / fabrics produced in this way are capable of achieving density reductions of up to 100%, based on products without foam structures, with comparable mechanical properties. It is readily possible with the method according to the invention to vary the number of layers their properties and their sequence.
  • the layers of different density, viewed in the X direction, can change several times.
  • Microbubbles arranged statistically distributed.
  • Thermoplastics of a polymer type or a polymer group are Thermoplastics of a polymer type or a polymer group.
  • Base material for the base formulation, is PVC.
  • first layer higher density, first type material
  • second type material 1 first layer (higher density, second type material)
  • thermoplastic base material 20 thermoplastic base material
  • Tx, Tz boundary layers transition regions between adjacent layers, preferably wave-shaped

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  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
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  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

La présente invention concerne un corps structuré et un procédé de fabrication dudit corps. Ledit corps structuré est fabriqué au moins à partir d'un matériau de départ pulvérulent soumis à l'action de la chaleur et/ou de la pression, et comprend plusieurs couches. Le matériau de départ est constitué principalement d'une matière de base thermoplastique, la densité d'au moins deux couches du corps structuré est différente, et au moins une couche de densité plus faible contient des microbilles creuses.
EP17713282.6A 2016-03-23 2017-03-23 Corps structuré et procédé de fabrication dudit corps Withdrawn EP3433088A1 (fr)

Applications Claiming Priority (2)

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DE102016204775.2A DE102016204775A1 (de) 2016-03-23 2016-03-23 Strukturkörper und Verfahren zu seiner Herstellung
PCT/EP2017/057001 WO2017162827A1 (fr) 2016-03-23 2017-03-23 Corps structuré et procédé de fabrication dudit corps

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US11142623B2 (en) 2016-02-09 2021-10-12 Bauer Hockey Llc Athletic gear or other devices comprising post-molded expandable components
US10569521B2 (en) * 2016-04-05 2020-02-25 Thermwood Corporation Methods of securing an initial layer during additive manufacturing of thermoplastic material
WO2018017330A1 (fr) * 2016-07-22 2018-01-25 Brook Kennedy Fabrication additive tridimensionnelle (3d) ondulée
US11634261B2 (en) 2019-12-11 2023-04-25 Pregis Innovative Packaging Llc Deflatable inflatable web
DE102020201543A1 (de) * 2020-02-07 2021-08-12 Adidas Ag Verfahren zur Herstellung eines Schaumstoffbauteils
GB2592616B (en) * 2020-03-03 2023-07-19 Bockatech Ltd Method of forming an article
CN111283170B (zh) * 2020-03-28 2021-11-09 哈尔滨工程大学 具有网格增强结构的金属空心球复合材料的制备方法
US20220002019A1 (en) * 2020-07-01 2022-01-06 Pregis Innovative Packaging Llc Bagger with padding expansion
BR112023001700A2 (pt) * 2020-07-31 2023-05-02 Pregis Innovative Packaging Llc Método para fazer uma parede de expansão, método para fabricar uma rede de parede de expansão, dispositivo para produzir uma rede de parede de expansão, conjunto de parede de expansão e parede de expansão
WO2024036414A1 (fr) * 2022-08-19 2024-02-22 Inca Renewable Technologies Inc. Composites multicouches, et procédés et systèmes pour leur préparation

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US20170274588A1 (en) 2017-09-28
KR20190009283A (ko) 2019-01-28
DE102016204775A1 (de) 2017-09-28
WO2017162827A1 (fr) 2017-09-28

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