FR2903337A1 - Producing a motor vehicle component containing fragments of agglomerated flexible foam, comprises mixing the foam, prepolymer resin and catalyst in an aqueous solution in a mixing unit to produce the mixture - Google Patents

Abstract

The process of producing a motor vehicle component containing fragments of agglomerated flexible foam, comprises mixing the foam, prepolymer resin and catalyst for 60 seconds in an aqueous solution in a mixing unit to produce the mixture, manually disposing and distributing the mixture in an open mold, closing the mold, and manually demolding the obtained component. The catalyst is acted on the resin at 50[deg]C and ambient pressure to carry out polymerization of the prepolymer and to obtain polymeric binder, where the prepolymer is useful is produce polyurethane binder. The process of producing a motor vehicle component containing fragments of agglomerated flexible foam, comprises mixing the foam, prepolymer resin and catalyst for 60 seconds in an aqueous solution in a mixing unit to produce the mixture, manually disposing and distributing the mixture in an open mold, closing the mold, and manually demolding the obtained component. The catalyst is acted on the resin at 50[deg]C and ambient pressure to carry out polymerization of the prepolymer and to obtain polymeric binder, where the prepolymer is useful is produce polyurethane binder. The mixture is produced using a propeller laid out at the bottom of the mixing unit, where the propeller rotates at a speed of 1000 tours/minute. An independent claim is included for a component.

Description

The invention relates to a method for producing a component, in particular

  motor vehicle, based agglomerated soft foam flakes, and a component made by such a method.

  It is known to produce a component based on agglomerated soft foam flakes, in particular derived from recycling, for example a soundproofing component, by a process comprising the following steps: • mixing in a large mixing unit the necessary quantity producing a plurality of components of a mixture of soft foam flakes and polyurethane-based prepolymer resin, arranging said mixture in a storage unit, arranging the quantity of said mixture necessary for the production of a component in a mold, generally closed, • injecting into said mold water vapor, especially at a temperature of about 110 [deg.] C., so as to carry out the polymerization of said prepolymer and to obtain an expanded polymeric binder, • demold the component obtained • drying in an oven, especially at a temperature between 100 and 130 C. Such a process requires equipment ts complex and bulky, large amounts of energy and a large surface receiving equipment. The invention aims to overcome these disadvantages. For this purpose, and according to a first aspect, the invention provides a method of producing a component, especially a motor vehicle, based on agglomerated soft foam flakes, said process comprising the following steps: in a mixing unit the amount necessary to produce the component of a mixture of soft foam flakes, prepolymer resin, and catalyst in aqueous solution, so as to achieve said mixture in a time less than the start time 5 of reacting said resin with said catalyst, • disposing said mixture in an open mold and distributing it in said mold, • closing said mold and allowing said catalyst to act on said resin at moderate temperature and ambient pressure, so as to carry out the polymerization of said prepolymer and to obtain a polymeric binder, • demold the component obtained. In this way, the mixture is prepared just before production of the component, and in the amount necessary for its manufacture. As a result, the use of a storage unit is dispensed with and the mixing unit is very small in size. In addition, the presence of catalyst makes it possible to avoid the injection of water vapor into the mold. The molds are simplified. Moreover, it is no longer necessary to perform a drying of the components after molding. Finally, we save energy related to steam production and drying. It should be noted that the polymerization being carried out in the absence of water, apart from the residual one serving as solvent for the catalyst, the binder has a compact form, ie not expanded. According to a second aspect, the invention proposes a component produced by such a method, the binder being in compact form.

  A method of producing a component, especially a motor vehicle component, based on agglomerated flexible foam flakes, said method comprising the following steps: • mixing vigorously in a small mixing unit the quantity necessary for producing the component of a mixture of soft foam flakes, prepolymer resin, and catalyst in aqueous solution, so as to make said mixture in a time less than the starting time of the reaction of said resin with said catalyst, Disposing said mixture in an open mold and distributing it in said mold, closing said mold and allowing said catalyst to act on said resin at moderate temperature and ambient pressure, for example for a period of about 4 to 10 minutes, so that performing the polymerization of said prepolymer and obtaining a polymeric binder, • demolding the component obtained.

In one embodiment, the prepolymer is selected to produce a polyurethane binder. The moderate temperature can be of the order of 50 C, the molds can be maintained at this temperature by circulating water in their body. According to one embodiment, the mixing time is between 30 and 120 seconds, and in particular less than 60 seconds and less than the start time of the reaction of the resin with the catalyst.

According to one embodiment, the mixing is carried out by a propeller disposed at the bottom of the mixing unit, said propeller rotating at a speed of between 800 and 1600 revolutions / minute, for example at a speed of approximately 1000 revolutions / minute. which makes it possible to ensure the mixing in the aforementioned time, with surface impregnation of the flakes with the prepolymer and the catalyst.

According to one embodiment, the distribution of the mixture in the mold is performed manually, the operator performing this distribution taking into account possible thickness fluctuations of the component.

In one embodiment, the foam flakes are derived from recycling. A component made by such a process has the particularity that the binder is in compact form, ie unexpanded.

Claims (8)

  A method of producing a component based on agglomerated soft foam flakes, said method comprising the following steps: mixing in a mixing unit the quantity necessary for producing the component of a mixture of flexible foam flakes, of prepolymer resin, and of catalyst in aqueous solution, so as to carry out said mixture in a time less than the starting time of the reaction of said resin with said catalyst, • arranging said mixture in an open mold and distributing it in said mold, • closing said mold and let said catalyst act on said resin at moderate temperature and ambient pressure, so as to carry out the polymerization of said prepolymer and to obtain a polymeric binder, • demolding the component obtained.   2. The method of claim 1, wherein the prepolymer is selected to produce a polyurethane binder.   3. Method according to claim 1 or 2, the moderate temperature being of the order of 50 C.   4. Process according to any one of claims 1 to 3, the mixing time being between 30 and 120 seconds, and in particular less than 60 seconds.   5. Method according to any one of claims 1 to 4, the mixture being formed by a propeller disposed at the bottom of the mixing unit, said propeller 30 rotating at a speed between 800 and 1600 revolutions / minute, in particular at a speed of about 1000 rpm. 2903337 6   6. Method according to any one of claims 1 to 5, the distribution of the mixture in the mold being performed manually.   7. Process according to any one of claims 1 to 6, the foam flakes being derived from recycling.   8. Component produced by a process according to any one of claims 1 to 7, the binder being in compact form.