EP4139123A1 - Reinforced roof panel for mobile homes and refrigerated lorries - Google Patents

Reinforced roof panel for mobile homes and refrigerated lorries

Info

Publication number
EP4139123A1
EP4139123A1 EP21717481.2A EP21717481A EP4139123A1 EP 4139123 A1 EP4139123 A1 EP 4139123A1 EP 21717481 A EP21717481 A EP 21717481A EP 4139123 A1 EP4139123 A1 EP 4139123A1
Authority
EP
European Patent Office
Prior art keywords
flat
composite material
fiber
reinforced plastic
flat composite
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.)
Pending
Application number
EP21717481.2A
Other languages
German (de)
French (fr)
Inventor
Frank Eichhorn
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.)
Sika Technology AG
Original Assignee
Sika Technology AG
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 Sika Technology AG filed Critical Sika Technology AG
Publication of EP4139123A1 publication Critical patent/EP4139123A1/en
Pending legal-status Critical Current

Links

Classifications

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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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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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    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/10—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
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    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
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    • B62D33/00—Superstructures for load-carrying vehicles
    • B62D33/04—Enclosed load compartments ; Frameworks for movable panels, tarpaulins or side curtains
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    • B60R13/08—Insulating elements, e.g. for sound insulation

Definitions

  • the present invention relates to a flat composite material with a base made of a flat porous rigid material and one or more elongated elements of a fiber-reinforced plastic material for stiffening the base material.
  • the thickness of the elongated elements made of the fiber-reinforced plastic material is less than that of the flat, porous rigid material.
  • the present invention further relates to sandwich panels containing such a composite material and methods for producing such composite materials and sandwich panels, as well as the use of elongated elements made of fiber-reinforced plastic material for reinforcing corresponding sandwich panels.
  • Sandwich panels or panels for installation in roof or side wall applications for e.g. caravans or refrigerated superstructures of trucks or vans are normally not significantly stiffened.
  • Such sandwich panels usually have a core made of an insulating material (e.g. a polyurethane foam), which is surrounded on both sides by a respective cover layer.
  • cover layers can be made from materials such as glass fiber reinforced polyester-based plastics, but also from metals such as aluminum, whereby polymer-based materials are used in vehicle applications because of their lower weight, easier repairability and better corrosion resistance (e.g. against road salt ) are preferred.
  • steel reinforcements are built into the plates, which are embedded in the plates.
  • these steel reinforcements consist of pipes that are also filled with rigid foam in order to avoid cold bridges between the inside and outside of a vehicle.
  • Steel as a material has, in addition to unfavorable thermal conductivity properties, the disadvantage of a relatively high weight, which is disadvantageous in the context of constantly increasing requirements with regard to the fuel consumption of vehicles.
  • Wood was proposed as a further possibility for stiffening and insulation, e.g. in the form of rods or panels that can be integrated into the panel construction.
  • WO 2017/087623 A1 discloses a production method for a rigid polymer composite material which comprises the coating of a film or textile layer with fibers or minerals and optionally with a binder and subsequent compression under heat.
  • DE 36 38 797 A1 discloses an air and impact sound insulation board made of foam plastic for floating screeds or floating floors made of wood, with specially arranged cavities being present in the board.
  • the disclosed panels and have a low stiffness required for impact sound insulation in construction and also have good insulation and fire properties.
  • stiffening means for corresponding sandwich panels which have a reduced weight compared to metal-based reinforcements, can be processed easily and can provide a comparable stiffening effect. Furthermore, the stiffening agent should, if possible, not form any thermal bridges.
  • the present invention addresses this need.
  • the present invention relates to a flat composite material which has a flat, porous rigid material as a base and one or more elongated elements of a fiber-reinforced plastic material.
  • the elongated element made of fiber-reinforced plastic material has a thickness which is less than that of the laminar porous rigid material.
  • “Flat” in the context of the present invention means that the dimensions of the material in at least one spatial direction (eg length or width) are significantly larger (ie by a factor of at least 5) than in the third spatial direction (eg thickness) one of the dimensions of the larger spatial directions by at least ten times, in particular at least fifty times and more preferably at least a hundred times larger than the dimension of the third (smaller) spatial direction.
  • the "flat" composite material can therefore, for example, in the form of a plate in which the dimensions of the material in two spatial directions (e.g. length and width) are significantly larger than in the third spatial direction, or in the form of an elongated carrier in which the dimensions of the material are significantly larger in only one spatial direction than in the third spatial direction.
  • porous denotes the fact that the material has pores which are filled with a gas, preferably air.
  • the (dry) density or the density of the porous material is usually less than 950 kg / m 3 , preferably less than 800 kg / m 3 and more preferably less than 700 kg / m 3.
  • a sensible lower limit, for example to ensure favorable strength, can be a density of at least 100 kg / m 3 , and in particular at least 200 kg / m 3 and more preferably at least 300 kg / m 3 are given.
  • the material is "rigid", ie inelastic, so that a plate with a thickness of 1 cm and a length and width of 20 cm cm can be bent.
  • the flat, porous rigid material provides the essential volume fraction of the flat composite material, ie in particular a volume fraction of at least 80% by volume, preferably at least 90% by volume and more preferably at least 95% by volume. %.
  • an “elongated element” denotes a material whose expansion in one spatial direction is significantly (i.e. preferably at least 5 times) greater than its own
  • the expansion in the two smaller spatial directions is at least a factor of 2 and preferably at least differentiated by a factor of 3, so that, for example, the elongated element is at least twice or at least three times as wide as it is thick.
  • This shape achieves, on the one hand, a maximum effect in terms of stiffening and, on the other hand, a minimal material weight.
  • Suitable shapes of elongate elements are, for example, strips or lamellae or a cylindrical or hollow-cylindrical shape. A strip shape is particularly preferred in the context of the invention.
  • the "hollow cylinder" can also be filled with another material, for example wood.
  • the polymer matrix is mostly based on epoxy, vinyl ester or a thermoplastic polyester resin, but can also be made of another polymer material.
  • the composite material can contain glass fibers or carbon fibers (also referred to as carbon fibers), but also fibers made of aramid or basalt, whereby glass and carbon fibers are preferred and carbon fibers are particularly preferred.
  • Carbon fiber reinforced plastics are also known as CFRP or CFRP.
  • the fibers and in particular the carbon fibers can be present as individual fibers, fiber bundles, or as woven carbon fiber materials.
  • the fiber-reinforced plastic material itself can either be stiff and thus directly impart a stiffening effect, but it can also be flexible, e.g. rollable on rollers, in which case the stiffening effect is achieved through a firm connection to another material, such as the flat, rigid one in particular Material that can be conveyed.
  • a particularly suitable carbon fiber reinforced plastic material for use in the present invention has a fiber volume content of more than 50% and preferably in the range from 55 to 80%.
  • Such a carbon fiber-reinforced plastic material is sold, for example, by Sika under the trade names Sika ® Carbodur ® S or Sika ® Carbodur ® M.
  • the elongated element (s) is / are made of fiber-reinforced plastic material by means of an adhesive with which flat porous rigid material connected, which forms the basis of the flat composite material.
  • Suitable adhesives are in particular polyurethane adhesives, especially two-component polyurethane adhesives, epoxy adhesives, especially toughened epoxy adhesives, adhesives based on silane-terminated polymers (STP), especially 2K-STP adhesives, and also STP-epoxy hybrid adhesives.
  • STP silane-terminated polymers
  • An adhesive based on polyurethane, and in particular a 2K polyurethane adhesive, can be specified here as a preferred, suitable type of adhesive.
  • 2K polyurethane adhesives which are particularly suitable for the present invention are disclosed, for example, in WO 2020/016003 A1 and WO 2019/002538 A1.
  • a 2K epoxy adhesive particularly suitable for the present invention is disclosed, for example, in WO 2020/016372 A1.
  • Adhesives particularly suitable in this context preferably have one or more properties selected from a tensile shear strength in the range from 5 to 30 N / mm 2 , preferably 10 to 20 N / mm 2 , a tensile strength in the range from 5 to 30 N / mm 2 , preferably 10 to 20 N / mm 2 , an elongation at break in the range from 60 to 200% and in particular 80 to 150% and a modulus of elasticity in the range 200 to 600 N / mm 2 and in particular 250 to 500 N / mm 2 .
  • adhesive such as is available under the trade name SikaForce ® -840 Sika. Such adhesives are advantageous because they ensure good adhesion between the fiber-reinforced plastic material and the flat, porous rigid material, while tensions between the two materials, which can occur, for example, in an injection molding process, are avoided.
  • the flat composite material can be produced by placing one or more elongated elements made of fiber-reinforced plastic material in a cavity, into which a material is then introduced by injection molding that a rigid foam forms around the fiber-reinforced plastic material. The injected material or injection molding material is then hardened to form a rigid foam. In this case, the rigid foam material is bonded to the fiber-reinforced plastic material as a result of the hardening process.
  • one or more elongated elements made of fiber-reinforced plastic material are introduced into the flat, porous rigid material, e.g. by first inserting a corresponding bore into the porous rigid material, into which the elongated element can be inserted.
  • the use of only a flexible, fiber-reinforced plastic material is less suitable for such an application, since the required connection with the flat, porous, rigid material can only be achieved with difficulty.
  • the flat, porous rigid material can be any material that is used today to provide porous base materials for sandwich element panels or non-metallic stiffening supports for such panels.
  • the flat, porous rigid material particularly preferably comprises or is based on a plastic foam, in particular on a polyurethane, polyvinyl chloride or polyethylene foam, or on wood.
  • the flat, porous, rigid material very particularly preferably consists of one or more of these materials.
  • the elongated elements and in particular the strips of the fiber-reinforced and preferably of the carbon-fiber-reinforced plastic material, which are included in the flat composite material expediently have a width in the range from about 20 to 100 mm, preferably from about 15 to 70 mm and even more preferably from about 30 to 50 mm.
  • the elongated elements or strips of the fiber-reinforced plastic material have a thickness in the range of 0.8 to 3 mm and more preferably 1 to 1.5 mm.
  • the spatial and, in particular, two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is generally less than that of the flat composite material. If the sheet-like composite material is a two-dimensional composite material such as a plate, it is preferred if the two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is in the range from 1 to 50%, preferably 2 to 30% and more preferably 5 to 15% of the two-dimensional expansion of the flat composite material lies.
  • the two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is in the range of 20 to 90%, preferably 40 to 85% and even more preferably 50 up to 80% of the two-dimensional expansion of the flat composite material.
  • the flat composite material according to the invention can expediently be further developed with one or more cover layers which are arranged on the top and / or underside of the flat composite material.
  • This cover layer or layers are preferably compact, i.e. non-porous.
  • a fiber-reinforced plastic, e.g. based on polyesters, or a metal, such as aluminum in particular, can be specified as a particularly suitable material for such cover layers.
  • the flat composite material is modified with one or more cover layers, it is also possible that the elongated element (s) made of fiber-reinforced plastic material is / are connected to the cover layer, the connection being expediently realized with a corresponding adhesive can. If the elongated element made of fiber-reinforced plastic material is attached to the flat, porous rigid material on its upper or lower side, it can be useful if elongated elements and, in particular, strips of the material are attached to both the upper and lower sides of the material. With such a design, the flat composite material is stiffened against forces that act on the flat composite material from the top and bottom.
  • the flat composite material is only stiffened against the action of forces that act on the composite material from one side, such as rainwater accumulations on a roof. Accordingly, in one embodiment, elongated elements of the fiber-reinforced plastic material can only be attached to one side of the flat composite material, preferably to its underside.
  • elongated elements are fastened in one direction on the flat porous rigid material, or that elongated elements intersect, for example at an angle of about 60 ° or about 90 ° or, for example, are attached to the material in a checkerboard shape, in order to achieve stiffening not only in one, but in several spatial directions.
  • the sheet-like composite material is the carrier with a length that is great compared to the thickness and width (which is preferably greater than 8 times, more preferably greater than 15 times and even more preferably greater than 25 times , the longer the thickness and width).
  • a range of 15 to 60 mm and in particular 20 to 45 mm can be specified here as suitable dimensions for the thickness and width.
  • the length of the carrier is preferably at least 500 mm and more preferably at least 1000 mm.
  • the length of the beam is not limited, but for most applications a maximum length of 3000 mm is sufficient.
  • a preferred carrier contains two elongated elements which are arranged spaced apart from one another in the carrier, ie for example on the top and Bottom or in the carrier with a distance to one side that is greater than the distance to the other side.
  • the present invention relates to a sandwich panel which has an inner core layer and an upper and a lower cover layer which form the respective outer sides of the sandwich panel, the core layer containing one or more elements of the flat composite material described above.
  • the composite material can, for example, be in the form of a plate which forms the inner core layer, or the composite material can be in the form of one or more supports which are arranged between the cover layers and do not completely fill the inner core layer.
  • a sandwich panel preferred in the context of this invention contains one or more carriers in the core layer which are formed from the flat composite material according to the invention.
  • the space of the core layer that is not filled by the composite material is preferably filled with an insulating material such as glass wool or a polymer foam.
  • an insulating material such as glass wool or a polymer foam.
  • the sandwich panel is a roof or a side wall of the vehicle, preferably a caravan, mobile home or refrigerated trailer.
  • Another aspect of the present invention relates to a method for producing a flat composite material or a sandwich panel, each as described above, the method comprising a step of bringing a flat porous rigid material into contact with one or more elongated elements of a fiber-reinforced Plastic material, wherein the or the elongate (s) element (s) have a thickness which is less than that of the sheet-like porous rigid material comprises.
  • Bringing into contact or contacting can, as described above, in particular by placing the elongated elements of the fiber-reinforced and preferably the carbon-fiber-reinforced plastic material in front of it and injecting a material that hardens to form a hard foam, by attaching the elongated elements of the fiber-reinforced plastic material to a rigid foam or other flat porous rigid material, in particular with the help of an adhesive, by introducing material that hardens to a fiber-reinforced plastic material in recesses in a flat porous rigid material, or by introducing an elongated element made of cured fiber-reinforced plastic material in recesses of a flat porous rigid material.
  • Yet another aspect of the present invention finally relates to the use of elongated elements made of fiber-reinforced plastic material for reinforcing a sandwich panel with a core made of a flat, porous rigid material and upper and lower cover layers which form the respective outer sides of the sandwich panel.
  • these two carrier Carbodur ® orbits are of a width of 20 mm so inserted that the trains are positioned at an end on the surface of the carrier (sh. Fig. 1).

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Abstract

The invention relates to a flat composite material with a base made of a flat, porous, rigid material and one or more elongated elements of a fibre-reinforced plastic material for reinforcing the base material, wherein the thickness of the elongated element is less than that of the flat, porous, rigid material. The invention also relates to sandwich panels, containing a composite material of this type, and a method for producing sandwich panels and composite materials of this type, as well as the use of elongated elements made of fibre-reinforced plastic material for reinforcing corresponding sandwich panels.

Description

VERSTEIFTES DACHPANEL FÜR WOHNMOBILE UND KÜHL-LKW Technisches Gebiet REINFORCED ROOF PANEL FOR CAMPER VANS AND REFRIGERATED TRUCKS Technical area
Die vorliegende Erfindung betrifft ein flächiges Verbundmaterial mit einer Basis aus einem flächigen porösen starren Material und einem oder mehreren länglichen Elementen eines faserverstärkten Kunststoffmaterials zur Versteifung des Basismaterials. Die Dicke der länglichen Elemente aus dem faserverstärkten Kunststoffmaterials ist geringer als die des flächigen porösen starren Materials. Die vorliegende Erfindung betrifft weiterhin Sandwichplatten, die eine solches Verbundmaterial enthalten und Verfahren zur Herstellung solcher Verbundmaterialien und Sandwichplatten, sowie die Verwendung von länglichen Elementen aus faserverstärktem Kunststoffmaterial zur Verstärkung von entsprechenden Sandwichplatten. The present invention relates to a flat composite material with a base made of a flat porous rigid material and one or more elongated elements of a fiber-reinforced plastic material for stiffening the base material. The thickness of the elongated elements made of the fiber-reinforced plastic material is less than that of the flat, porous rigid material. The present invention further relates to sandwich panels containing such a composite material and methods for producing such composite materials and sandwich panels, as well as the use of elongated elements made of fiber-reinforced plastic material for reinforcing corresponding sandwich panels.
Stand der Technik State of the art
Sandwichplatten oder -paneele für einen Einbau in Dach- oder Seitenwandanwendungen für z.B. Wohnwagen oder Kühlaufbauten von Lastwägen oder Transportern werden normalerweise nicht wesentlich versteift. Entsprechende Sandwichplatten weisen in der Regel einen Kern aus einem Dämmmaterial (z.B. einem Polyurethanschaum) auf, der beidseitig von einer jeweiligen Deckschicht eingefasst wird. Solche Deckschichten können z.B. aus Materialien wie Glasfaser-verstärkten Kunststoffen auf Polyester-Basis, aber auch aus Metallen, wie Aluminium, hergestellt werden, wobei Polymer-basierte Materialen bei Fahrzeuganwendungen wegen ihres geringeren Gewichts, einer leichteren Reparaturfähigkeit und einer besseren Korrosionsbeständigkeit (z.B. gegenüber Streusalz) bevorzugt sind. Sandwich panels or panels for installation in roof or side wall applications for e.g. caravans or refrigerated superstructures of trucks or vans are normally not significantly stiffened. Such sandwich panels usually have a core made of an insulating material (e.g. a polyurethane foam), which is surrounded on both sides by a respective cover layer. Such cover layers can be made from materials such as glass fiber reinforced polyester-based plastics, but also from metals such as aluminum, whereby polymer-based materials are used in vehicle applications because of their lower weight, easier repairability and better corrosion resistance (e.g. against road salt ) are preferred.
Bei Dach- oder Seitenwänden, die vollständig aus Kunstoffen gebildet sind, stellt sich, insbesondere aufgrund der relativ großen Dimensionen der Paneele und der Gesamtkonstruktion, die Schwierigkeit einer ausreichenden Versteifung, die oft nur durch die Steifigkeit der für die Herstellung der Sandwichplatten verwendeten Materialien bestimmt wird. Diese kann in Extremfällen, wie sie z.B. bei Unfällen auftreten, nicht ausreichend sein, so dass die Konstruktion unter hoher Belastung zerbricht, was die Fahrzeugpassagiere oder andere Verkehrsteilnehmer gefährden kann. Dieses Problem betrifft insbesondere Bereiche, in denen die Platten nicht durchgehend sind, weil sie z.B. Löcher für Fenster aufweisen. In the case of roof or side walls that are made entirely of plastics, the difficulty of adequate stiffening arises, in particular due to the relatively large dimensions of the panels and the overall construction, which is often only determined by the stiffness of the materials used for the production of the sandwich panels . In extreme cases, such as those that occur in accidents, this may not be sufficient, so that the construction is subject to high loads breaks, which can endanger vehicle passengers or other road users. This problem particularly affects areas in which the panels are not continuous because they have holes for windows, for example.
Zur Verbesserung der Steifigkeit der Gesamtkonstruktion werden daher u.a. Stahlverstärker in den Platten verbaut, die in die Platten eingelassen werden. Z.T. bestehen diese Stahlverstärker aus Rohren, die ebenfalls mit Hartschaum gefüllt sind, um so Kältebrücken zwischen der Innen-und Außenseite eines Fahrzeugs zu vermeiden. Stahl als Werkstoff weist allerdings, neben ungünstigen Wärmeleiteigenschaften, den Nachteil eines verhältnismäßig hohen Gewichts auf, was im Kontext stetig steigenden Anforderungen hinsichtlich des Kraftstoffverbrauchs von Fahrzeugen nachteilig ist. In order to improve the rigidity of the overall structure, steel reinforcements, among other things, are built into the plates, which are embedded in the plates. In some cases, these steel reinforcements consist of pipes that are also filled with rigid foam in order to avoid cold bridges between the inside and outside of a vehicle. Steel as a material, however, has, in addition to unfavorable thermal conductivity properties, the disadvantage of a relatively high weight, which is disadvantageous in the context of constantly increasing requirements with regard to the fuel consumption of vehicles.
Selbst wenn die aus Sicherheitsgründen geforderte Steifigkeit durch die Materialien der Platten, aus der z.B. die Dachkonstruktion hergestellt wird, bereitgestellt werden kann, kann es bei aus Sandwichplatten hergestellten Dachkonstruktionen zur Ausbildung von Wasserseen auf dem Dach kommen, weil sich die Paneele durchbiegen. Durch versteifende Stahlrohre kann dieses Problem nur teilweise behoben werden, da sich solche Stahlrohre unter Last ebenfalls teilweise durchbiegen und der Einsatz einer hohen Anzahl von Stahlrohen, mit dem dieser Effekt vermieden werden könnte, aus Gewichtsgründen nicht möglich ist. Even if the stiffness required for safety reasons can be provided by the materials of the panels from which the roof structure is made, for example, roof structures made from sandwich panels can lead to the formation of water pools on the roof because the panels bend. This problem can only be partially remedied by stiffening steel pipes, since such steel pipes also bend partially under load and the use of a large number of steel pipes, with which this effect could be avoided, is not possible for weight reasons.
Als weitere Möglichkeit zur Versteifung und Isolation wurde Holz vorgeschlagen, das, z.B. in Form von Stäben oder Platten, die in die Plattenkonstruktion integriert werden können. Wood was proposed as a further possibility for stiffening and insulation, e.g. in the form of rods or panels that can be integrated into the panel construction.
WO 2017/087623 Al offenbart ein Herstellverfahren für einen steifen Polymerkompositwerkstoff, welcher die Beschichtung einer Film- oder Textilschicht mit Fasern oder Mineralien und gegebenenfalls mit einem Bindemittel und eine anschliessende Verpressung unter Hitze umfasst.WO 2017/087623 A1 discloses a production method for a rigid polymer composite material which comprises the coating of a film or textile layer with fibers or minerals and optionally with a binder and subsequent compression under heat.
Auf das so hergestellte Versteifungselement wird noch ein Polymer extrudiert. Dieses Verfahren ist relativ komplex und benötigt mehrere aufwändige Arbeitsschritte zur Durchführung. US 2013/122244 Al offenbart Panels für Flugzeuginnenräume und deren Herstellung, wobei diese Panels einen Verstärkungskern, der beispielsweise aus Schäumen oder Polymerstäben bestehen kann, aufweisen. Diese Panels werden vorwiegend für akustische und thermische Dämmung in Flugzeugen eingesetzt. Another polymer is extruded onto the stiffening element produced in this way. This process is relatively complex and requires several complex work steps to carry out. US 2013/122244 A1 discloses panels for aircraft interiors and their production, these panels having a reinforcing core which can consist of foams or polymer rods, for example. These panels are mainly used for acoustic and thermal insulation in aircraft.
DE 36 38 797 Al offenbart eine Luft- und Trittschalldämmplatte aus Schaumkunststoff für schwimmende Estriche oder schwimmende Fussböden aus Holz, wobei speziell angeordnete Hohlräume in der Platte vorliegen. Die offenbarten Platten und weisen eine für die Trittschalldämmung im Bau erforderliche niedrige Steifigkeit auf und weiterhin gute Isolations- und Brandeigenschaften. DE 36 38 797 A1 discloses an air and impact sound insulation board made of foam plastic for floating screeds or floating floors made of wood, with specially arranged cavities being present in the board. The disclosed panels and have a low stiffness required for impact sound insulation in construction and also have good insulation and fire properties.
Nach dem Vorstehenden besteht ein Bedarf für Versteifungsmittel für entsprechende Sandwichplatten, die ein im Vergleich zu metallbasierten Verstärkern vermindertes Gewicht aufweisen, sich leicht verarbeiten lassen und eine vergleichbare Versteifungswirkung bereitstellen können. Weiterhin sollte das Versteifungsmittel möglichst keine Wärmebrücken bilden. According to the above, there is a need for stiffening means for corresponding sandwich panels which have a reduced weight compared to metal-based reinforcements, can be processed easily and can provide a comparable stiffening effect. Furthermore, the stiffening agent should, if possible, not form any thermal bridges.
Die vorliegende Erfindung befasst sich mit diesem Bedarf. The present invention addresses this need.
Beschreibung der Erfindung Description of the invention
In einem ersten Aspekt betrifft die vorliegende Erfindung ein flächiges Verbundmaterial, das ein flächiges poröses starres Material als Basis und ein oder mehrere längliche Elemente eines faserverstärkten Kunststoffmaterials aufweist. Das längliche Element aus faserverstärktem Kunststoffmaterial hat dabei eine Dicke, die geringer ist als die des laminaren porösen starren Materials. In a first aspect, the present invention relates to a flat composite material which has a flat, porous rigid material as a base and one or more elongated elements of a fiber-reinforced plastic material. The elongated element made of fiber-reinforced plastic material has a thickness which is less than that of the laminar porous rigid material.
„Flächig" bedeutet im Kontext der vorliegenden Erfindung, dass die Dimensionen des Materials in mindestens einer Raumrichtung (z.B. Länge oder Breite) deutlich größer (d.h. um einen Faktor von mindestens 5) sind als in die dritte Raumrichtung (z.B. Dicke). Vorzugsweise ist mindestens eine der Dimensionen der größeren Raumrichtungen um mindestens das zehnfache, insbesondere mindestens das fünfzigfache und weiter bevorzugt mindestens das Hundertfache größer als die Dimension der dritten (kleineren) Raumrichtung. Das „flächige" Verbundmaterial kann demzufolge z.B. in Form einer Platte, bei der die Dimensionen des Materials in zwei Raumrichtungen (z.B. Länge und Breite) deutlich größer sind als in die dritte Raumrichtung, oder in Form eines länglichen Trägers, bei dem die Dimensionen des Material in nur eine Raumrichtung deutlich größer sind als in die dritte Raumrichtung, vorliegen. Im Fall eines Trägers können die Dimensionen in die beiden Raumrichtungen mit geringerer Ausdehnung unterschiedlich oder gleich sein. "Flat" in the context of the present invention means that the dimensions of the material in at least one spatial direction (eg length or width) are significantly larger (ie by a factor of at least 5) than in the third spatial direction (eg thickness) one of the dimensions of the larger spatial directions by at least ten times, in particular at least fifty times and more preferably at least a hundred times larger than the dimension of the third (smaller) spatial direction. The "flat" composite material can therefore, for example, in the form of a plate in which the dimensions of the material in two spatial directions (e.g. length and width) are significantly larger than in the third spatial direction, or in the form of an elongated carrier in which the dimensions of the material are significantly larger in only one spatial direction than in the third spatial direction.
Die Angabe „porös" bezeichnet den Umstand, dass das Material Poren aufweist, die mit einem Gas, vorzugsweise Luft gefüllt sind. Die (Trocken) Dichte bzw. das Raumgewicht des porösen Materials liegt in der Regel bei weniger als 950 kg/m3, bevorzugt weniger als 800 kg/m3 und weiter bevorzugt weniger als 700 kg/m3. Als sinnvolle Untergrenze, z.B. zur Gewährleitung einer günstigen Festigkeit, kann eine Dichte von mindestens 100 kg/m3, und insbesondere mindestens 200 kg/m3 und weiter bevorzugt mindestens 300 kg/m3 angegeben werden. The term "porous" denotes the fact that the material has pores which are filled with a gas, preferably air. The (dry) density or the density of the porous material is usually less than 950 kg / m 3 , preferably less than 800 kg / m 3 and more preferably less than 700 kg / m 3. A sensible lower limit, for example to ensure favorable strength, can be a density of at least 100 kg / m 3 , and in particular at least 200 kg / m 3 and more preferably at least 300 kg / m 3 are given.
Das Material ist „starr", d.h. unelastisch, so dass eine Platte mit einer Dicke von 1 cm und einer Länge und Breite von 20 cm um beim Einwirken einer Kraft von 5 bis 20 N um nicht mehr als 2 cm und vorzugsweise nicht mehr als 1 cm durchgebogen werden kann. The material is "rigid", ie inelastic, so that a plate with a thickness of 1 cm and a length and width of 20 cm cm can be bent.
Die Angabe „als Basis" ist so aufzufassen, dass das flächige poröse starre Material den wesentlichen Volumenanteil des flächigen Verbundmaterial bereitstellt, d.h. insbesondere einen Volumenanteil von mindestens 80 Vol.-%, bevorzugt mindestens 90 Vol.-% und weiterbevorzugt mindestens 95 Vol.-%. The statement "as a basis" is to be interpreted in such a way that the flat, porous rigid material provides the essential volume fraction of the flat composite material, ie in particular a volume fraction of at least 80% by volume, preferably at least 90% by volume and more preferably at least 95% by volume. %.
Ein „längliches Element" bezeichnet im Rahmen der hier beschriebenen Erfindung ein Material, dessen Ausdehnung in einer Raumrichtung deutlich (d.h. vorzugweise mindestens 5 mal) größer ist als seineIn the context of the invention described here, an "elongated element" denotes a material whose expansion in one spatial direction is significantly (i.e. preferably at least 5 times) greater than its own
Ausdehnung in die anderen beiden Raumrichtungen. Bevorzugt ist dabei weiterhin, dass sich die Ausdehnung in den beiden kleineren Raumrichtungen um mindestens den Faktor 2 und bevorzugt mindestens den Faktor 3 unterschiedet, so dass z.B. das längliche Element mindestens zweimal bzw. mindestens dreimal so breit wie dick ist. Durch diese Form wird einerseits eine maximale Wirkung in Bezug auf die Versteifung und andererseits ein minimales Materialgewicht realisiert. Geeignete Formen von länglichen Elementen sind z.B. Streifen oder Lamellen oder eine zylindrische oder hohl-zylindrische Form. Eine Streifenform ist im Rahmen der Erfindung besonders bevorzugt. Bei einer hohlzylindrischen Form kann der „Hohlzylinder" auch mit einem anderen Material, z.B. Holz, gefüllt sein. Expansion in the other two spatial directions. It is also preferred that the expansion in the two smaller spatial directions is at least a factor of 2 and preferably at least differentiated by a factor of 3, so that, for example, the elongated element is at least twice or at least three times as wide as it is thick. This shape achieves, on the one hand, a maximum effect in terms of stiffening and, on the other hand, a minimal material weight. Suitable shapes of elongate elements are, for example, strips or lamellae or a cylindrical or hollow-cylindrical shape. A strip shape is particularly preferred in the context of the invention. In the case of a hollow cylindrical shape, the "hollow cylinder" can also be filled with another material, for example wood.
Das faserverstärkte Kunststoffmaterial, das auch als FRP (= fiber reinforced plastic) bezeichnet wird, ist ein Kompositmaterial, das eine Polymermatrix aufweist, die mit Fasern verstärkt ist. Die Polymermatrix beruht dabei meist auf Epoxy-, Vinylester- oder einem thermoplastischen Polyesterharz, kann aber auch aus einem anderen Polymermaterial gebildet sein. Als Fasern kann das Kompositmaterial Glasfasern oder Kohlefasern (auch als Carbonfasern bezeichnet), aber auch Fasern aus Aramid oder Basalt enthalten, wobei Glas- und Kohlefasern bevorzugt und Kohlefasern besonders bevorzugt sind. Kohlefaser verstärkte Kunststoffe werden auch als CFK oder CFRP bezeichnet. Die Fasern und insbesondere die Kohlefasern können als einzelne Fasern, Faserbündel, oder auch als gewebte Kohlefaser Materialien vorliegen. Das faserverstärkte Kunststoffmaterial kann selbst entweder steif sein, und so direkt eine versteifende Wirkung vermitteln, es kann aber auch flexibel, z.B. auf Rollen aufrollbar sein, wobei in diesen Fall die versteifende Wirkung durch ein feste Anbindung an ein anderes Material, wie insbesondere das flächigen starre Material, vermittelt werden kann. The fiber-reinforced plastic material, which is also referred to as FRP (= fiber reinforced plastic), is a composite material that has a polymer matrix that is reinforced with fibers. The polymer matrix is mostly based on epoxy, vinyl ester or a thermoplastic polyester resin, but can also be made of another polymer material. As fibers, the composite material can contain glass fibers or carbon fibers (also referred to as carbon fibers), but also fibers made of aramid or basalt, whereby glass and carbon fibers are preferred and carbon fibers are particularly preferred. Carbon fiber reinforced plastics are also known as CFRP or CFRP. The fibers and in particular the carbon fibers can be present as individual fibers, fiber bundles, or as woven carbon fiber materials. The fiber-reinforced plastic material itself can either be stiff and thus directly impart a stiffening effect, but it can also be flexible, e.g. rollable on rollers, in which case the stiffening effect is achieved through a firm connection to another material, such as the flat, rigid one in particular Material that can be conveyed.
Ein besonders geeignetes kohlefaserverstärktes Kunststoffmaterial zur Verwendung in der vorliegenden Erfindung weist einen Faservolumengehalt von mehr als 50 % und bevorzugt im Bereich von 55 bis 80% auf. Ein derartiges kohlefaserverstärktes Kunststoffmaterial wird z.B. von Sika unter den Handelsbezeichnungen Sika® Carbodur® S oder Sika® Carbodur® M vertrieben. A particularly suitable carbon fiber reinforced plastic material for use in the present invention has a fiber volume content of more than 50% and preferably in the range from 55 to 80%. Such a carbon fiber-reinforced plastic material is sold, for example, by Sika under the trade names Sika ® Carbodur ® S or Sika ® Carbodur ® M.
In einer Ausführungsform ist/sind das/die längliche(n) Element(e) aus faserverstärktem Kunststoffmaterial mittels eines Klebstoffs, mit dem flächiges porösen starren Material verbunden, das die Basis des flächigen Verbundmaterials bildet. In one embodiment, the elongated element (s) is / are made of fiber-reinforced plastic material by means of an adhesive with which flat porous rigid material connected, which forms the basis of the flat composite material.
Geeignete Klebstoffe sind insbesondere Polyurethanklebstoffe, insbesondere zweikomponentige Polyurethanklebstoffe, Epoxyklebstoffe, insbesondere zähigkeitsmodifizierte (toughened) Epoxyklebstoffe, Klebstoffe auf Basis von Silan-terminierten Polymeren (STP), insbesondere 2K-STP Klebstoffe, sowie auch STP-Epoxy-Hybridklebstoffe. Als bevorzugter geeigneter Klebstofftyp kann hier ein Klebstoff auf der Basis von Polyurethan, und insbesondere ein 2K-Polyurethanklebstoff angegeben werden. Suitable adhesives are in particular polyurethane adhesives, especially two-component polyurethane adhesives, epoxy adhesives, especially toughened epoxy adhesives, adhesives based on silane-terminated polymers (STP), especially 2K-STP adhesives, and also STP-epoxy hybrid adhesives. An adhesive based on polyurethane, and in particular a 2K polyurethane adhesive, can be specified here as a preferred, suitable type of adhesive.
Für die vorliegende Erfindung besonders geeignete 2K- Polyurethaklebstoffe sind beispielsweise offenbart in WO 2020/016003 Al und WO 2019/002538 Al. Ein für die vorliegende Erfindung besonders geeigneter 2K-Epoxyklebstoff ist beispielsweise offenbart in WO 2020/016372 Al. 2K polyurethane adhesives which are particularly suitable for the present invention are disclosed, for example, in WO 2020/016003 A1 and WO 2019/002538 A1. A 2K epoxy adhesive particularly suitable for the present invention is disclosed, for example, in WO 2020/016372 A1.
In diesem Zusammenhang besonders geeignete Klebstoffe weisen bevorzugt eine oder mehrere Eigenschaften ausgewählt aus einer Zugscherfestigkeit im Bereich von 5 bis 30 N/mm2, bevorzugt 10 bis 20 N/mm2, eine Zugfestigkeit im Bereich von 5 bis 30 N/mm2, bevorzugt 10 bis 20 N/mm2, eine Reißdehnung im Bereich von 60 bis 200% und insbesondere 80 bis 150% und ein E-Modul im Bereich 200 bis 600 N/mm2 und insbesondere 250 bis 500 N/mm2 auf. Ein hier als ganz besonders geeignet zu nennender Klebstoff ist z.B. unter dem Handelsnamen SikaForce®-840 von Sika erhältlich. Derartige Klebstoffe sind vorteilhaft, weil sie eine gute Haftung zwischen dem faserverstärkten Kunststoffmaterial und dem flächiges porösen starren Material sicherstellen, während Spannungen zwischen beiden Materialen, die z.B. bei einem Spritzgussverfahren auftreten können, vermieden werden. Adhesives particularly suitable in this context preferably have one or more properties selected from a tensile shear strength in the range from 5 to 30 N / mm 2 , preferably 10 to 20 N / mm 2 , a tensile strength in the range from 5 to 30 N / mm 2 , preferably 10 to 20 N / mm 2 , an elongation at break in the range from 60 to 200% and in particular 80 to 150% and a modulus of elasticity in the range 200 to 600 N / mm 2 and in particular 250 to 500 N / mm 2 . Here to be particularly suitable to be mentioned adhesive such as is available under the trade name SikaForce ® -840 Sika. Such adhesives are advantageous because they ensure good adhesion between the fiber-reinforced plastic material and the flat, porous rigid material, while tensions between the two materials, which can occur, for example, in an injection molding process, are avoided.
In einer anderen Ausführungsform kann das flächige Verbundmaterial hergestellt werden, indem ein oder mehrere längliche Elemente aus faserverstärktem Kunststoffmaterial in einem Hohlraum vorgelegt werden, in den anschließend durch Spritzgießen ein Material eingebracht wird, dass einen Hartschaum um das faserverstärkte Kunststoffmaterial bildet. Anschließend wird dann das eingespritzte Material, bzw. Spritzgussmaterial zu einem Hartschaum gehärtet. In diesem Fall erfolgt die Anbindung des Hartschaummaterials an das faserverstärkte Kunststoffmaterial infolge des Aushärtens. In another embodiment, the flat composite material can be produced by placing one or more elongated elements made of fiber-reinforced plastic material in a cavity, into which a material is then introduced by injection molding that a rigid foam forms around the fiber-reinforced plastic material. The injected material or injection molding material is then hardened to form a rigid foam. In this case, the rigid foam material is bonded to the fiber-reinforced plastic material as a result of the hardening process.
In einer noch weiteren Ausführungsform werden ein oder mehrere längliche Elemente aus faserverstärktem Kunststoffmaterial in das flächige poröse starre Material eingebracht, z.B. in dem zunächst in das poröse starre Material eine entsprechende Bohrung eingeführt wird, in die das längliche Element eingeführt werden kann. Für eine derartige Anwendung ist die Verwendung ausschließlich eines flexiblen faserverstärkten Kunststoffmaterial weniger geeignet, da hier die erforderliche Verbindung mit dem flächigen porösen starren Material nur schwer realisiert werden kann. Es ist aber z.B. möglich, ein elastisches faserverstärkte Kunststoffmaterial zunächst mit einem steifen Material, z.B. einem Holzelement, zu verbinden, um so ein Versteifungselement zu bilden. In a still further embodiment, one or more elongated elements made of fiber-reinforced plastic material are introduced into the flat, porous rigid material, e.g. by first inserting a corresponding bore into the porous rigid material, into which the elongated element can be inserted. The use of only a flexible, fiber-reinforced plastic material is less suitable for such an application, since the required connection with the flat, porous, rigid material can only be achieved with difficulty. However, it is possible, for example, to first connect an elastic, fiber-reinforced plastic material with a rigid material, e.g. a wooden element, in order to form a stiffening element.
Schließlich ist es möglich, ein nicht gehärtetes faserverstärktes Kunststoffmaterial in längliche Aussparungen eines flächigen porösen starren Materials einzuspritzen und dort auszuhärten. Finally, it is possible to inject a non-hardened fiber-reinforced plastic material into elongated recesses of a flat, porous rigid material and to harden it there.
Das flächige poröse starre Material kann jedwedes Material sein, das heute zur Bereitstellung von porösen Basismaterialien von Sandwichelementplatten oder nicht metallischen Versteifungsträgern solcher Platten verwendet wird. Besonders bevorzugt umfasst oder basiert das flächige poröse starre Material auf einen Kunststoffschaum, insbesondere auf einem Polyurethan-, Polyvinylchlorid- oder Polyethylenschaum, oder auf Holz. Ganz besonders bevorzugt besteht das flächige poröse starre Material aus einem oder mehreren dieser Materialien. The flat, porous rigid material can be any material that is used today to provide porous base materials for sandwich element panels or non-metallic stiffening supports for such panels. The flat, porous rigid material particularly preferably comprises or is based on a plastic foam, in particular on a polyurethane, polyvinyl chloride or polyethylene foam, or on wood. The flat, porous, rigid material very particularly preferably consists of one or more of these materials.
Die länglichen Elemente und insbesondere die Streifen des faserverstärkten und bevorzugt des kohlefaserverstärkten Kunststoffmaterials, die in das flächiges Verbundmaterial einbezogen werden, weisen zweckmäßig eine Breite im Bereich von etwa 20 bis 100 mm, vorzugsweise von etwa 15 bis 70 mm und noch weiter bevorzugt von etwa 30 bis 50 mm auf. Alternativ, der zusätzlich dazu weisen die länglichen Elemente oder Streifen des faserverstärkten Kunststoffmaterials eine Dicke im Bereich von 0,8 bis 3 mm und weiter bevorzugt 1 bis 1,5 mm auf. The elongated elements and in particular the strips of the fiber-reinforced and preferably of the carbon-fiber-reinforced plastic material, which are included in the flat composite material, expediently have a width in the range from about 20 to 100 mm, preferably from about 15 to 70 mm and even more preferably from about 30 to 50 mm. Alternatively, in addition to this, the elongated elements or strips of the fiber-reinforced plastic material have a thickness in the range of 0.8 to 3 mm and more preferably 1 to 1.5 mm.
Die räumliche und insbesondere zweidimensionale Ausdehnung der länglichen Elemente des faserverstärkten Kunststoffmaterials ist regelmäßig geringer als die des flächigen Verbundmaterials. Wenn es sich bei dem flächigen Verbundmaterial um ein zweidimensionales Verbundmaterial wie eine Platte handelt ist es bevorzugt, wenn die zweidimensionale Ausdehnung der länglichen Elemente des faserverstärkten Kunststoffmaterials im Bereich von 1 bis 50%, vorzugsweise 2 bis 30% und weiter bevorzugt 5 bis 15% der zweidimensionalen Ausdehnung des flächigen Verbundmaterials liegt. Wenn das flächige Verbundmaterial in nur einer Dimension deutlich größer ist als in den anderen beiden Dimensionen, ist es bevorzugt, wenn die zweidimensionale Ausdehnung der länglichen Elemente des faserverstärkten Kunststoffmaterials im Bereich von 20 bis 90%, bevorzugt 40 bis 85% und noch weiter bevorzugt 50 bis 80% der zweidimensionalen Ausdehnung des flächigen Verbundmaterials liegt. The spatial and, in particular, two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is generally less than that of the flat composite material. If the sheet-like composite material is a two-dimensional composite material such as a plate, it is preferred if the two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is in the range from 1 to 50%, preferably 2 to 30% and more preferably 5 to 15% of the two-dimensional expansion of the flat composite material lies. If the flat composite material is significantly larger in only one dimension than in the other two dimensions, it is preferred if the two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is in the range of 20 to 90%, preferably 40 to 85% and even more preferably 50 up to 80% of the two-dimensional expansion of the flat composite material.
Das erfindungsgemäße flächige Verbundmaterial kann zweckmäßig mit einer oder mehreren Deckschichten weitergebildet werden, die auf der Ober- und/oder Unterseite des flächigen Verbundmaterials angeordnet sind. Diese Deckschicht oder die Deckschichten sind vorzugsweise kompakt, d.h. nicht porös. Als besonders geeignetes Material für solche Deckschichten kann ein Faser-verstärkter Kunststoff, z.B. auf der Basis von Polyestern, oder ein Metall, wie insbesondere Aluminium, angegeben werden. The flat composite material according to the invention can expediently be further developed with one or more cover layers which are arranged on the top and / or underside of the flat composite material. This cover layer or layers are preferably compact, i.e. non-porous. A fiber-reinforced plastic, e.g. based on polyesters, or a metal, such as aluminum in particular, can be specified as a particularly suitable material for such cover layers.
Ist das flächige Verbundmaterial mit einer oder mehreren Deckschichten modifiziert, so ist es auch möglich, dass das/die längliche(n) Element(e) aus faserverstärktem Kunststoffmaterial mit der Deckschicht verbunden ist/sind, wobei die Verbindung zweckmäßig mit einem entsprechen Klebstoff realisiert werden kann. Ist das längliche Element aus faserverstärktem Kunststoffmaterial auf dessen Ober- oder Unterseite an dem flächigen porösen starren Material angebracht, so kann es zweckmäßig sein, wenn längliche Elemente und insbesondere Streifen des Materials sowohl auf der Ober- als auch auf der Unterseite des Materials angebracht sind. Bei einer solchen Ausbildung ist das flächige Verbundmaterial gegen Kräfte, die von der Ober- und Unterseite auf das flächige Verbundmaterial wirken, versteift. Abhängig vom Verwendungszweck kann es aber auch ausreichend sein, wenn das flächige Verbundmaterial nur gegen die Einwirkung von Kräften versteift ist, die von einer Seite auf das Verbundmaterial wirken, wie z.B. bei Regenwasseransammlungen auf einem Dach. Demnach können in einer Ausführungsform längliche Elemente des faserverstärkten Kunststoffmaterials nur auf einer Seite des flächigen Verbundmaterials, vorzugsweise auf dessen Unterseite befestigt sein. If the flat composite material is modified with one or more cover layers, it is also possible that the elongated element (s) made of fiber-reinforced plastic material is / are connected to the cover layer, the connection being expediently realized with a corresponding adhesive can. If the elongated element made of fiber-reinforced plastic material is attached to the flat, porous rigid material on its upper or lower side, it can be useful if elongated elements and, in particular, strips of the material are attached to both the upper and lower sides of the material. With such a design, the flat composite material is stiffened against forces that act on the flat composite material from the top and bottom. Depending on the intended use, however, it can also be sufficient if the flat composite material is only stiffened against the action of forces that act on the composite material from one side, such as rainwater accumulations on a roof. Accordingly, in one embodiment, elongated elements of the fiber-reinforced plastic material can only be attached to one side of the flat composite material, preferably to its underside.
Darüber hinaus ist es möglich, dass mehrere längliche Elemente in einer Richtung auf dem flächigen porösen starren Material befestigt sind, oder dass sich längliche Elemente kreuzen, z.B. in einem Winkel von etwa 60° oder etwa 90° oder beispielsweise Schachbrettförmig auf dem Material angebracht sind, um eine Versteifung nicht nur in eine, sondern in mehrere Raumrichtungen zu erzielen. In addition, it is possible that several elongated elements are fastened in one direction on the flat porous rigid material, or that elongated elements intersect, for example at an angle of about 60 ° or about 90 ° or, for example, are attached to the material in a checkerboard shape, in order to achieve stiffening not only in one, but in several spatial directions.
In einer besonders bevorzugten Ausführungsform liegt das flächige Verbundmaterial als Träger mit einer im Vergleich zu Dicke und Breite großen Länge (die bevorzugt größer ist als das 8-fache, weiter bevorzugt größer als das 15-fache und noch weiter bevorzugt größer als das 25- fache, des jeweils längeren der Dicke und Breite) vor. Als geeignete Dimensionen für die Dicke und Breite können hier ein Bereich von 15 bis 60 mm und insbesondere 20 bis 45 mm angegeben werden. Die Länge des Trägers beträgt bevorzugt mindestens 500 mm und weiter bevorzugt mindestens 1000 mm. Die Länge des Trägers ist nicht relevant begrenzt, für die meisten Anwendungen ist jedoch eine Länge von höchstens 3000 mm ausreichend. In a particularly preferred embodiment, the sheet-like composite material is the carrier with a length that is great compared to the thickness and width (which is preferably greater than 8 times, more preferably greater than 15 times and even more preferably greater than 25 times , the longer the thickness and width). A range of 15 to 60 mm and in particular 20 to 45 mm can be specified here as suitable dimensions for the thickness and width. The length of the carrier is preferably at least 500 mm and more preferably at least 1000 mm. The length of the beam is not limited, but for most applications a maximum length of 3000 mm is sufficient.
Ein bevorzugter Träger enthält zwei längliche Elemente die voneinander beanstandet im Träger angeordnet sind, d.h. z.B. auf der Ober- und Unterseite oder im Träger mit einem Abstand zur einen Seite, der größer ist als der Abstand zur jeweils anderen Seite. A preferred carrier contains two elongated elements which are arranged spaced apart from one another in the carrier, ie for example on the top and Bottom or in the carrier with a distance to one side that is greater than the distance to the other side.
In einem weiteren Aspekt betrifft die vorliegende Erfindung eine Sandwichplatte, die eine innere Kernschicht, und eine obere und eine untere Deckschicht, die die jeweiligen Außenseiten der Sandwichplatte bilden, auf, wobei die Kernschicht ein oder mehrere Elemente des vorstehend beschriebenen flächigen Verbundmaterials enthält. Das Verbundmaterial kann z.B. als Platte vorliegen, die die innere Kernschicht bildet, oder das Verbundmaterial kann als ein oder mehrere Träger vorliegen, die zwischen den Deckschichten angeordnet sind, und die innere Kernschicht nicht vollständig ausfüllen. In a further aspect, the present invention relates to a sandwich panel which has an inner core layer and an upper and a lower cover layer which form the respective outer sides of the sandwich panel, the core layer containing one or more elements of the flat composite material described above. The composite material can, for example, be in the form of a plate which forms the inner core layer, or the composite material can be in the form of one or more supports which are arranged between the cover layers and do not completely fill the inner core layer.
Bezüglich für derartige Sandwichplatten geeigneter Materialien, und Dimensionen oder Anordnungen der einzelnen Elemente der Sandwichplatte kann auf die vorausgehenden Ausführungen im Zusammenhang mit dem erfindungsgemäßen flächigen Verbundmaterial verwiesen werden. With regard to materials suitable for such sandwich panels, and dimensions or arrangements of the individual elements of the sandwich panel, reference can be made to the preceding statements in connection with the flat composite material according to the invention.
Eine im Kontext dieser Erfindung bevorzugtes Sandwichplatte enthält einen oder mehrere Träger in der Kernschicht, die aus dem erfindungsgemäßen flächigen Verbundmaterial gebildet sind. Bevorzugt ist der nicht vom Verbundmaterial ausgefüllte Raum der Kernschicht mit einem ein Dämmmaterial, wie Glaswolle oder einen Polymerschaum, gefüllt. Weiterhin ist es bevorzugt, wenn die länglichen Elemente in derartigen Sandwichplatten parallel zu den Deckschichten angeordnet sind, wobei sich „parallel" hier auf die Oberfläche der länglichen Elemente mit der größten Ausdehnung bezieht. A sandwich panel preferred in the context of this invention contains one or more carriers in the core layer which are formed from the flat composite material according to the invention. The space of the core layer that is not filled by the composite material is preferably filled with an insulating material such as glass wool or a polymer foam. Furthermore, it is preferred if the elongate elements in such sandwich panels are arranged parallel to the cover layers, "parallel" here referring to the surface of the elongate elements with the greatest extent.
Ganz besonders bevorzugt ist es, wenn die Sandwichplatte ein Dach oder eine Seitenwand des Fahrzeugs, vorzugsweise eines Wohnwagens, Wohnmobils oder Kühlanhänger, ist. Ein weiterer Aspekt der vorliegenden Erfindung betrifft ein Verfahren zur Herstellung eines flächigen Verbundmaterials oder einer Sandwichplatte, jeweils wie vorstehend beschrieben, wobei das Verfahren einen Schritt des in Kontakt-bringens oder Kontaktierens eines flächigen porösen starren Materials mit einem oder mehreren länglichen Elementen eines faserverstärkten Kunststoffmaterials, wobei der oder die längliche(n) Element(e) eine Dicke aufweisen, die geringer ist als die des flächigen porösen starren Materials, umfasst. Das in Kontakt-bringen oder Kontaktieren kann, wie vorstehend geschildert, insbesondere durch Vorlegen der länglichen Elemente des faserverstärkten und bevorzugt des kohlefaserverstärkten Kunststoffmaterials und Einspritzen eines zu einem Hartschaum aushärtenden Materials, durch Anbringen der länglichen Elemente des faserverstärkten Kunststoffmaterials auf einem Hartschaum oder anderen flächigen porösen starren Material, insbesondere mit Hilfe eines Klebstoffs, durch Einbringen von Material, das zu einem faserverstärkten Kunststoffmaterial aushärtet, in Aussparungen in ein flächiges poröses starres Material, oder durch Einbringen eines länglichen Elements aus ausgehärtetem faserverstärkten Kunststoffmaterial in Aussparungen eines flächigen porösen starren Materials realisiert werden. It is very particularly preferred if the sandwich panel is a roof or a side wall of the vehicle, preferably a caravan, mobile home or refrigerated trailer. Another aspect of the present invention relates to a method for producing a flat composite material or a sandwich panel, each as described above, the method comprising a step of bringing a flat porous rigid material into contact with one or more elongated elements of a fiber-reinforced Plastic material, wherein the or the elongate (s) element (s) have a thickness which is less than that of the sheet-like porous rigid material comprises. Bringing into contact or contacting can, as described above, in particular by placing the elongated elements of the fiber-reinforced and preferably the carbon-fiber-reinforced plastic material in front of it and injecting a material that hardens to form a hard foam, by attaching the elongated elements of the fiber-reinforced plastic material to a rigid foam or other flat porous rigid material, in particular with the help of an adhesive, by introducing material that hardens to a fiber-reinforced plastic material in recesses in a flat porous rigid material, or by introducing an elongated element made of cured fiber-reinforced plastic material in recesses of a flat porous rigid material.
Ein noch weiterer Aspekt der vorliegenden Erfindung betrifft schließlich die Verwendung von länglichen Elementen aus faserverstärktem Kunststoffmaterial zur Verstärkung einer Sandwichplatte mit einem Kern aus einem flächigen porösen starren Material und oberen und unteren Deckschichten, die die jeweiligen Außenseiten der Sandwichplatte bilden. Yet another aspect of the present invention finally relates to the use of elongated elements made of fiber-reinforced plastic material for reinforcing a sandwich panel with a core made of a flat, porous rigid material and upper and lower cover layers which form the respective outer sides of the sandwich panel.
Im Folgenden wird die Erfindung durch Beispiele näher illustriert, die jedoch nicht als in irgendeiner Form beschränkend für den Schutzumfang der Anmeldung aufgefasst werden sollten. The invention is illustrated in more detail below by means of examples, which, however, should not be construed as restricting the scope of protection of the application in any form.
Beispiel: Example:
Ein Polyurethanträger mit den Dimensionen Dicke = 29 mm x Breite = 40 mm x Länge = 1865 mm wurde hergestellt. In diesen Träger sind zwei Carbodur®-Bahnen mit einer Breite von 20 mm so eingelassen, dass die Bahnen an einem Ende an der Oberfläche des Trägers positioniert sind (sh. Fig. 1). A polyurethane carrier with the dimensions thickness = 29 mm x width = 40 mm x length = 1865 mm was produced. In these two carrier Carbodur ® orbits are of a width of 20 mm so inserted that the trains are positioned at an end on the surface of the carrier (sh. Fig. 1).

Claims

Ansprüche Expectations
1. Flächiges Verbundmaterial, umfassend ein flächiges poröses starres Material als Basis und ein oder mehrere längliche Elemente eines faserverstärkten Kunststoffmaterials mit einer Dicke, die geringer ist als die des laminaren porösen starren Materials. 1. A sheet-like composite material comprising a sheet-like porous rigid material as a base and one or more elongated elements of a fiber-reinforced plastic material with a thickness which is less than that of the laminar porous rigid material.
2. Flächiges Verbundmaterial nach Anspruch 1, wobei das faserverstärkte Kunststoffmaterial Glas- oder Kohlefasern enthält, und bevorzugt als kohlefaserverstärktes Kunststoffmaterial vorliegt. 2. Flat composite material according to claim 1, wherein the fiber-reinforced plastic material contains glass or carbon fibers, and is preferably present as a carbon fiber-reinforced plastic material.
3. Flächiges Verbundmaterial nach Anspruch 1 oder 2, wobei das oder die längliche(n) Element(e) aus faserverstärktem Kunststoffmaterial mittels eines Klebstoffs, vorzugsweise auf der Basis von Polyurethan, und insbesondere mittels eines 2K- Polyurethanklebstoffs, mit dem flächigen porösen starren Material verbunden ist/sind. 3. Flat composite material according to claim 1 or 2, wherein the elongated element (s) made of fiber-reinforced plastic material by means of an adhesive, preferably based on polyurethane, and in particular by means of a 2K polyurethane adhesive, with the flat porous rigid material is / are connected.
4. Flächiges Verbundmaterial nach Anspruch 1 oder 2, erhältlich durch Spritzgießen eines Materials, das einen Flartschaum um das oder die länglichen Elemente aus faserverstärktem Kunststoffmaterial bildet, und anschließendes Flärten des Spritzgussmaterials zu einem Flartschaum. 4. Flat composite material according to claim 1 or 2, obtainable by injection molding a material which forms a flare foam around the elongated element or elements made of fiber-reinforced plastic material, and then flaring the injection molding material to form a flare foam.
5. Flächiges Verbundmaterial nach Anspruch 1 oder 2, wobei das oder die länglichen Elemente aus faserverstärktem Kunststoffmaterial in das flächige poröse starre Material eingeführt wird/werden. 5. Flat composite material according to claim 1 or 2, wherein the elongated element or elements made of fiber-reinforced plastic material is / are introduced into the flat porous rigid material.
6. Flächiges Verbundmaterial nach einem der vorangehenden Ansprüche, wobei das flächige poröse starre Material auf einem Polyurethan-, Polyvinylchlorid- oder Polyethylenschaum basiert.6. Flat composite material according to one of the preceding claims, wherein the flat porous rigid material is based on a polyurethane, polyvinyl chloride or polyethylene foam.
7. Flächiges Verbundmaterial nach einem der Ansprüche 1 bis 3 oder 5, wobei das flächige poröse starre Material Holz ist. 7. Flat composite material according to one of claims 1 to 3 or 5, wherein the flat porous rigid material is wood.
8. Flächiges Verbundmaterial nach einem der vorangehenden Ansprüche, ferner umfassend eine oder mehrere Deckschichten, die auf der Ober- und/oder Unterseite des flächigen porösen starren Materials angeordnet sind, wobei die Deckschicht(en) vorzugsweise kompakt sind. 8. Flat composite material according to one of the preceding claims, further comprising one or more cover layers, which are arranged on the top and / or bottom of the flat porous rigid material, wherein the cover layer (s) are preferably compact.
9. Flächiges Verbundmaterial nach Anspruch 8, wobei die Deckschicht(en) aus einem Faser-verstärkten Kunststoff hergestellt ist/sind. 9. Flat composite material according to claim 8, wherein the cover layer (s) is / are made of a fiber-reinforced plastic.
10. Flächiges Verbundmaterial nach Anspruch 8 oder 9, wobei das oder die längliche(n) Elemente aus faserverstärktem Kunststoffmaterial, vorzugsweise mittels eines Klebstoffs, mit der Deckschicht verbunden ist/sind. 10. Flat composite material according to claim 8 or 9, wherein the elongated element (s) made of fiber-reinforced plastic material is / are connected to the cover layer, preferably by means of an adhesive.
11. Flächiges Verbundmaterial nach einem der vorangehenden Ansprüche, wobei die länglichen Elemente des faserverstärkten Kunststoffmaterials eine Breite im Bereich von etwa 20 bis 100 mm, vorzugsweise von etwa 30 bis 50 mm und/oder eine Dicke im Bereich von 0,8 bis 3 mm und vorzugsweise 1 bis 1,5 mm aufweisen. 11. Flat composite material according to one of the preceding claims, wherein the elongate elements of the fiber-reinforced plastic material have a width in the range from about 20 to 100 mm, preferably from about 30 to 50 mm and / or a thickness in the range from 0.8 to 3 mm and preferably 1 to 1.5 mm.
12. Flächiges Verbundmaterial nach einem der vorangehenden Ansprüche, wobei die zweidimensionale Ausdehnung der länglichen Elemente des faserverstärkten Kunststoffmaterials im Bereich von 1 bis 50%, vorzugsweise 2 bis 30% und weiter bevorzugt 5 bis 15% der zweidimensionalen Ausdehnung des flächigen Verbundmaterials liegt, wenn diese als zweidimensionales Verbundmaterial vorliegt, und im Bereich von 20 bis 90%, vorzugsweise 40 bis 85% und weiter bevorzugt 50 bis 80% der zweidimensionalen Ausdehnung des flächigen Verbundmaterials liegt, wenn nur eine Dimension des flächigen Verbundmaterials deutlich größer ist als die beiden anderen Dimensionen. 12. Flat composite material according to one of the preceding claims, wherein the two-dimensional expansion of the elongated elements of the fiber-reinforced plastic material is in the range of 1 to 50%, preferably 2 to 30% and more preferably 5 to 15% of the two-dimensional expansion of the flat composite material, if this is present as a two-dimensional composite material, and is in the range of 20 to 90%, preferably 40 to 85% and more preferably 50 to 80% of the two-dimensional extent of the flat composite material if only one dimension of the flat composite material is significantly larger than the other two dimensions.
13. Sandwichplatte, umfassend eine innere Kernschicht und eine obere und eine untere Deckschicht, wobei die Kernschicht ein oder mehrere flächige Verbandmaterialien gemäß mindestens einem der Ansprüche 1 bis 12 enthält. 13. Sandwich panel, comprising an inner core layer and an upper and a lower cover layer, wherein the core layer contains one or more flat dressing materials according to at least one of claims 1 to 12.
14. Sandwichplatte nach Anspruch 13, wobei die Kernschicht einen oder mehrere Träger enthält, die aus dem erfindungsgemäßen flächigen Verbundmaterial gebildet sind, und wobei bevorzugt ein von dem oder den Trägern nicht ausgefüllter Bereich der Kernschicht mit einem Dämmmaterial gefüllt ist. 14. Sandwich panel according to claim 13, wherein the core layer contains one or more carriers which are formed from the flat composite material according to the invention, and wherein preferably a region of the core layer not filled by the carrier or carriers is filled with an insulating material.
15. Sandwichplatte nach Anspruch 13 oder 14, wobei die15. Sandwich panel according to claim 13 or 14, wherein the
Sandwichplatte ein Dach oder eine Seitenwand des Fahrzeugs, vorzugsweise eines Wohnwagens, Wohnmobils oder Kühlanhänger, ist. Sandwich panel is a roof or a side wall of the vehicle, preferably a caravan, mobile home or refrigerated trailer.
16. Verfahren zur Herstellung eines flächigen Verbundmaterials nach einem der Ansprüche 1 bis 12 oder einer Sandwichplatte gemäß einem der Ansprüche 13 bis 15, umfassend einen Schritt des in Kontakt-bringens oder Kontaktierens eines flächigen porösen starren Materials mit einem oder mehreren länglichen Elemente eines faserverstärkten Kunststoffmaterials, wobei der oder die16. A method for producing a flat composite material according to one of claims 1 to 12 or a sandwich panel according to one of claims 13 to 15, comprising a step of bringing into contact or contacting a flat porous rigid material with one or more elongated elements of a fiber-reinforced plastic material , where the
Streifen eine Dicke aufweisen, die geringer ist als die des flächigen porösen starren Materials. Strips have a thickness which is less than that of the sheet-like porous rigid material.
17. Verwendung von länglichen Elementen aus faserverstärktem17. Use of elongated elements made of fiber-reinforced
Kunststoffmaterial zur Verstärkung einer Sandwichplatte mit einem Kern aus einem flächigen porösen starren Material und oberen und unteren Deckschichten, die die jeweiligen Außenseiten der Sandwichplatte bilden. Plastic material for reinforcing a sandwich panel with a core made of a flat, porous rigid material and upper and lower cover layers which form the respective outer sides of the sandwich panel.
EP21717481.2A 2020-04-22 2021-04-15 Reinforced roof panel for mobile homes and refrigerated lorries Pending EP4139123A1 (en)

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PCT/EP2021/059824 WO2021213894A1 (en) 2020-04-22 2021-04-15 Reinforced roof panel for mobile homes and refrigerated lorries

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FR3128934A1 (en) * 2021-11-05 2023-05-12 Lecapitaine Industrie Body assembly comprising at least one composite wall and utility vehicle comprising such a body assembly

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DE3638797A1 (en) 1985-11-19 1987-05-21 Marquet & Cie Noel Acoustic insulation comprising arrays of expanded polyolefin tubes
US9005730B2 (en) 2011-11-14 2015-04-14 The Boeing Company Aircraft interior panels and methods of panel fabrication
US9981411B2 (en) 2015-11-17 2018-05-29 Marhaygue, Llc Structural composition and method
PL3645594T3 (en) 2017-06-30 2022-07-18 Sika Technology Ag Two-component polyurethane composition with adjustable pot life
EP3597684A1 (en) 2018-07-17 2020-01-22 Sika Technology Ag Structural polyurethane adhesive with good adhesion after short-term heating
US11643580B2 (en) 2018-07-18 2023-05-09 Sika Technology Ag Method for strengthening of metal structures using toughened 2C-epoxy adhesives

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