RU2017126250A - Армирование пенопластов из соединенных друг с другом сегментов волокнами - Google Patents

Армирование пенопластов из соединенных друг с другом сегментов волокнами Download PDF

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Publication number
RU2017126250A
RU2017126250A RU2017126250A RU2017126250A RU2017126250A RU 2017126250 A RU2017126250 A RU 2017126250A RU 2017126250 A RU2017126250 A RU 2017126250A RU 2017126250 A RU2017126250 A RU 2017126250A RU 2017126250 A RU2017126250 A RU 2017126250A
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RU
Russia
Prior art keywords
foam
fiber
molded product
fibers
layer
Prior art date
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RU2017126250A
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English (en)
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RU2705089C2 (ru
RU2017126250A3 (ru
Inventor
Хольгер РУКДЭШЕЛЬ
Рене АРБТЕР
Роберт ШТАЙН
Даниела ЛОНГО-ШЕДЕЛЬ
Тим ДИЛЬМАНН
Бангару Дхармапури Срирамулу САМПАТ
Петер Гутманн
Александре ТЕРРЕНОЙРЕ
Маркус ХАРТЕНШТАЙН
Андреас КИРГИС
Алессио МОРИНО
Грегор Даун
Марк Клауде МАРТИН
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Басф Се
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Publication of RU2017126250A publication Critical patent/RU2017126250A/ru
Publication of RU2017126250A3 publication Critical patent/RU2017126250A3/ru
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Publication of RU2705089C2 publication Critical patent/RU2705089C2/ru

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    • 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
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/35—Component parts; Details or accessories
    • B29C44/352—Means for giving the foam different characteristics in different directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C44/505—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying extruding the compound through a flat die
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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Claims (71)

1. Формованное изделие из пенопласта, причем пенопласт включает по меньшей мере два соединенные друг с другом пенопластовые сегмента, отличающееся тем, что волоконный участок (FB2) по меньшей мере одного волокна (F) находится внутри формованного изделия и окружен пенопластом, в то время как волоконный участок (FB1) волокна (F) выступает наружу с первой стороны формованного изделия, а вололконный участок (FB3) волокна (F) выступает наружу со второй стороны формованного изделия, причем волокна (F) частично введены в пенопласт методом, который включает следующие стадии a)-f):
a) при необходимости нанесение по меньшей мере одного слоя (S2) по меньшей мере на одну сторону пенопласта,
b) выполнение отверстия для волокна (F) в пенопласте и при необходимости в слое (S2), причем отверстие проходит от первой стороны пенопласта до его второй стороны и при необходимости через слой (S2),
c) предоставление по меньшей мере одного волокна (F) на второй стороне пенопласта,
d) пропускание иглы через отверстие от первой стороны пенопласта до его второй стороны и при необходимости через слой (S2),
e) прикрепление по меньшей мере одного волокна (F) к игле на второй стороне пенопласта, и
f) возвращение иглы вместе с волокном (F) через отверстие, выполняемое таким образом, чтобы волокно (F) вместе с волоконным участоком (FB2) находилось внутри формованного изделия и был окружен пенопластом, волоконный участок (FB1) волокна (F) выступал наружу с первой стороны формованного изделия или при необходимости из слоя (S2) и волоконный участок (FB3) волокна (F) выступал наружу со второй стороны формованного изделия.
2. Формованное изделие по п. 1, отличающееся тем, что:
i) по меньшей мере два соединенные друг с другом пенопластовые сегмента соединены посредством склеивания и/или сваривания, причем предпочтительно все соединенные друг с другом пенопластовые сегменты формованного изделия соединены посредством термического сваривания и/или склеивания, и/или
ii) отдельные пенопластовые сегменты обладают длиной (направлением по оси X), составляющей по меньшей мере 2 мм, предпочтительно от 20 до 8000 мм, более предпочтительно от 100 до 4000 мм, шириной (направлением по оси Y), составляющей по меньшей мере 2 мм, предпочтительно от 5 до 4000 мм, более предпочтительно от 25 до 2500 мм, и толщиной (направлением по оси Z), составляющей по меньшей мере 2 мм, предпочтительно по меньшей мере 5 мм, особенно предпочтительно по меньшей мере 25 мм, наиболее предпочтительно от 30 до 80 мм, и/или
iii) отдельные пенопластовые сегменты обладают формой плит,
iv) отдельные пенопластовые сегменты характеризуются отношением длины (направления по оси X) к толщине (направлению по оси Z), составляющим по меньшей мере 5, предпочтительно по меньшей мере 10, более предпочтительно по меньшей мере 20, наиболее предпочтительно от 20 до 500, и/или
v) отдельные пенопластовые сегменты характеризуются отношением ширины (направления по оси Y) к толщине (направлению по оси Z), составляющим по меньшей мере 3, предпочтительно по меньшей мере 5, более предпочтительно по меньшей мере 10, наиболее предпочтительно от 10 до 250, и/или
vi) по меньшей мере одно волокно (F) проходит по меньшей мере через одну соединительную поверхность между двумя соединенными друг с другом пенопластовыми сегментами, причем предпочтительно по меньшей мере 20% всех волокон (F), особенно предпочтительно по меньшей мере 50% всех волокон (F) проходят по меньшей мере через одну соединительную поверхность между двумя соединенными друг с другом пенопластовыми сегментами пенопласта, и/или
vii) по меньшей мере одно волокно (F) частично или полностью проходит по меньшей мере через одну соединительную поверхность между двумя соединенными друг с другом пенопластовыми сегментами под углом δ, составляющим ≥20°, предпочтительно ≥35°, в частности, от 40° до 90°, и/или
viii) по меньшей мере одна соединительная поверхность, предпочтительно все соединительные поверхности между по меньшей мере двумя соединенными друг с другом пенопластовыми сегментами обладают толщиной, составляющей по меньшей мере 2 мкм, предпочтительно по меньшей мере 5 мкм, более предпочтительно от 20 до 2000 мкм, наиболее предпочтительно от 50 до 800 мкм,
и/или
ix) толщина по меньшей мере одной соединительной поверхности, предпочтительно всех соединительных поверхностей между по меньшей мере двумя соединенными друг с другом пенопластовыми сегментами превышает сумму средних значений толщины стенок ячеек, содержащихся в соединенных друг с другом пенопластовых сегментах, причем указанная толщина предпочтительно от 2 до 1000 раз, особенно предпочтительно от 5 до 500 раз превышает указанную сумму.
3. Формованное изделие по п. 1, отличающееся тем, что пенопластовые сегменты пенопласта состоят, например, из пенопласта, получаемого из вспененных частиц, экструзионного пенопласта, реакционноспособного пенопласта и/или пенопласта, получаемого периодическим методом, предпочтительно из экструзионного пенопласта, прежде всего из экструзионного пенопласта, получаемого методом, который включает следующие стадии:
I) предоставление полимерного расплава в экструдере,
II) введение по меньшей мере одного вспенивающего средства в предоставленный на стадии I) полимерный расплав с образованием вспениваемого полимерного расплава,
III) экструзию предоставленного на стадии II) вспениваемого полимерного расплава из экструдера по меньшей мере через одно отверстие экструзионной головки в зону пониженного давления, причем вспениваемый полимерный расплав расширяется с образованием вспененного пеноматериала,
IV) калибровку вспененного на стадии III) пеноматериала, для чего его пропускают через формующий инструмент, получая экструзионный пенопласт,
V) при необходимости выполняемую механическую обработку полученного на стадии IV) экструзионного пенопласта,
причем
i) предоставленной на стадии I) полимерный расплав при необходимости содержит по меньшей мере одну добавку, и/или
ii) на стадии II) к полимерному расплаву и/или между стадиями II) и III) к вспениваемому полимерному расплаву при необходимости добавляют по меньшей мере одну добавку, и/или
iii) на стадии III) и/или на стадии IV) на вспененный пеноматериал при необходимости наносят по меньшей мере одну добавку,
и/или
iv) на стадии IV) и/или непосредственно после стадии IV) на экструзионный пенопласт при необходимости наносят по меньшей мере один слой (S2).
4. Формованное изделие по п. 1, отличающееся тем, что пенопластовые сегменты содержат ячейки, причем:
i) по меньшей мере 50%, предпочтительно по меньшей мере 80%, более предпочтительно по меньшей мере 90% ячеек по меньшей мере двух пенопластовых сегментов, предпочтительно всех пенопластовых сегментов, являются анизотропными, и/или
ii) отношение наибольшего размера (в направлении «а») к наименьшему размеру (в направлении «с») по меньшей мере 50%, предпочтительно по меньшей мере 80%, более предпочтительно по меньшей мере 90% ячеек по меньшей мере двух пенопластовых сегментов, предпочтительно всех пенопластовых сегментов, равно или превышает 1,05 и предпочтительно находится в диапазоне от 1,1 до 10, особенно предпочтительно от 1,2 до 5,
и/или
iii) направление наибольшего размера (направление «а») по меньшей мере 50%, предпочтительно по меньшей мере 80%, более предпочтительно по меньшей мере 90% ячеек по меньшей мере двух пенопластовых сегментов, предпочтительно всех пенопластовых сегментов, ориентировано относительно направления толщины (d) формованного изделия под углом γ, составляющим ≤45°, предпочтительно ≤30°, более предпочтительно ≤5°.
5. Формованное изделие по п. 1, отличающееся тем, что пенопластовые сегменты основаны по меньшей мере на одном полимере, выбранном из полистирола, сложного полиэфира, полифениленоксида, получаемого из фениленоксида сополимера, получаемого из стирола сополимера, полиарилэфирсульфона, полифениленсульфида, полиарилэфиркетона, полипропилена, полиэтилена, полиамида, полиамидимида, полиэфироимида, поликарбоната, полиакрилата, полимолочной кислоты, поливинилхлорида и их смеси,
предпочтительно на полимере, выбранном из полистирола, полифениленоксида, смеси полистирола с полифениленоксидом, полиэтилентерефталата, поликарбоната, полиэфирсульфона, полисульфона, полиэфироимида, получаемого из стирола сополимера и смеси получаемых из стирола сополимеров,
особенно предпочтительно на полимере, выбранном из полистирола, смеси полистирола с поли(2,6-диметилфенилен-оксидом), смеси, состоящей из сополимера стирола с малеиновым ангидридом и сополимера стирола с акрилонитрилом, и/или сополимера стирола с малеиновым ангидридом,
причем получаемый из стирола сополимер помимо мономерных звеньев стирола предпочтительно содержит звенья другого мономера, выбранного из α-метилстирола, галогенированных в ядро стиролов, алкилированных в ядро стиролов, акрилонитрилов, сложных эфиров акриловой кислоты, сложных эфиров метакриловой кислоты, N-виниловых соединений, малеинового ангидрида, бутадиена, дивинилбензола и бутандиолдиакрилата.
6. Формованное изделие по п. 1, отличающееся тем, что все пенопластовые сегменты пенопласта основаны на одинаковых полимерах.
7. Формованное изделие по одному из пп. 1-6, отличающееся тем, что:
i) волокно (F) является отдельным волокном или пучком волокон, предпочтительно пучком волокон, и/или
ii) волокно (F) является органическим, неорганическим, металлическим, керамическим волокном или их комбинацией, предпочтительно полимерным волокном, базальтовым волокно, стеклянным волокном, углеродным волокном или природным волокном, особенно предпочтительно полиарамидным волокном, стеклянным волокном, базальтовым волокном или углеродным волокном, причем полимерное волокно предпочтительно является волокном из сложного полиэфира, полиамида, полиарамида, полиэтилена, полиуретана, поливинилхлорида, полиимида и/или полиамидимида, а природным волокнам предпочтительно является волокно из сизаля, пеньки, льна, бамбука, кокоса и/или джута, и/или
iii) волокно (F) используют в виде пучка волокон, причем количество элементарных волокон в пучке составляет по меньшей мере 10, предпочтительно от 100 до 100000, особенно предпочтительно от 300 до 10000 (в случае стеклянных волокон) и от 1000 до 50000 (в случае углеродных волокон), в частности, предпочтительно от 500 до 5000 (в случае стеклянных волокон) и от 2000 до 20000 (в случае углеродных волокон), и/или
iv) длина участка (FB1) и участка (FB3) соответственно независимо друг от друга составляет от 1 до 45%, предпочтительно от 2 до 40%, особенно предпочтительно от 5 до 30% от общей длины волокна (F), тогда как длина участка (FB2) составляет от 10 до 98%, предпочтительно от 20 до 96%, особенно предпочтительно от 40 до 90% от общей длины волокна (F),
v) волокно (F) введено в пенопласт под углом α относительно направления толщины (d) формованного изделия, составляющим от 0 до 60°, предпочтительно от 0 до 50°, более предпочтительно от 0 до 15° или от 10 до 70°, в частности, от 30 до 60°, более предпочтительно от 30 до 50°, еще более предпочтительно от 30 до 45°, в частности, 45°, и/или
vi) в формованном изделии первая сторона формованного изделия, из которой выступает наружу участок (FB1) волокна (F), расположена напротив второй стороны формованного изделия, из которой выступает наружу участок (FB3) волокна (F),
и/или
vii) формованное изделие содержит множество волокон (F) предпочтительно в виде пучка волокон и/или включает более 10 волокон (F) или пучков волокон, предпочтительно более 1000 волокон (F) или пучков волокон, особенно предпочтительно от 4000 до 40000 волокон (F) или пучков волокон соответственно в расчете на квадратный метр.
8. Панель, включающая по меньшей мере одно формованное изделие по одному из пп. 1-7 и по меньшей мере один слой (S1).
9. Панель по п. 8, отличающаяся тем, что слой (S1) содержит по меньшей мере одну смолу, предпочтительно реакционноспособную термореактивную или термопластичную смолу, более предпочтительно смолу на основе эпоксидов, акрилатов, полиуретанов, полиамидов, сложных полиэфиров, ненасыщенных сложных полиэфиров, сложных виниловых эфиров или их смесей, причем смолой прежде всего является отверждающаяся амином эпоксидная смола, латентно отверждающаяся эпоксидная смола, отверждающаяся ангидридом эпоксидная смола или полиуретан на основе изоцианатов и полиолов.
10. Панель по п. 8, отличающаяся тем, что слой (S1) дополнительно содержит по меньшей мере один волокнистый материал, причем:
i) волокнистый материал содержит волокна в виде одной или нескольких прокладок из штапельных волокон, нетканых материалов, однонаправленных тканей, трикотажных материалов и/или тканей, предпочтительно в виде однонаправленных тканей или тканей, особенно предпочтительно в виде однонаправленных тканей или тканей, масса которых, отнесенная к единице площади, составляет от 150 до 2500 г/м2,
и/или
ii) волокнистый материал содержит органические, неорганические, металлические или керамические волокна, предпочтительно полимерные волокна, базальтовые волокна, стеклянные волокна, углеродные волокна или природные волокна, особенно предпочтительно стеклянные волокна или углеродные волокна.
11. Панель по п. 8, отличающаяся тем, что она включает два слоя (S1), каждый из которых нанесен на ту сторону формованного изделия, которая находится в формованном изделии напротив соответствующей другой стороны.
12. Панель по одному из пп. 8-11, отличающаяся тем, что:
i) участок (FB1) волокна (F) частично или полностью, предпочтительно полностью контактирует с первым слоем (S1),
ii) участок (FB3) волокна (F) частично или полностью, предпочтительно полностью контактирует со вторым слоем (S1)
и/или
iii) панель между по меньшей мере одной стороной формованного изделия и по меньшей мере одним слоем (S1) содержит по меньшей мере один слой (S2), который предпочтительно является слоем из плоских волокнистых материалов или полимерных пленок, особенно предпочтительно слоем из стеклянных волокон или углеродных волокон в виде нетканых материалов, однонаправленных тканей или тканей.
13. Способ изготовления формованного изделия по одному из пп. 1-7, отличающийся тем, что частичное введение по меньшей мере одного волокна (F) в пенопласт осуществляют на следующих стадиях a)-f):
а) при необходимости нанесение по меньшей мере одного слоя (S2) по меньшей мере на одну сторону пенопласта,
b) выполнение отверстия для волокна (F) в пенопласте и при необходимости в слое (S2), причем отверстие проходит от первой стороны пенопласта до его второй стороны и при необходимости через слой (S2),
c) предоставление по меньшей мере одного волокна (F) на второй стороне пенопласта,
d) пропускание иглы через отверстие от первой стороны пенопласта до его второй стороны и при необходимости через слой (S2),
e) прикрепление по меньшей мере одного волокна (F) к игле на второй стороне пенопласта, и
f) возвращение иглы вместе с волокном (F) через отверстие, выполняемое таким образом, чтобы волокно (F) с волоконным участком (FB2) находилось внутри формованного изделия и было окружено пенопластом, волоконный участок (FB1) волокна (F) выступал наружу с первой стороны формованного изделия или при необходимости из слоя (S2) и волоконный участок (FB3) волокна (F) выступал наружу со второй стороны формованного изделия,
причем стадии b) и d) особенно предпочтительно реализуют одновременно.
14. Способ изготовления панели по одному из пп. 8-12, отличающийся тем, что на формованном изделии по одному из п.п. 1-7 создают, наносят и отверждают по меньшей мере один слой (S1) в виде реакционноспособной вязкой смолы предпочтительно методом жидкостной пропитки, особенно предпочтительно методом жидкостной пропитки с поддерживающим воздействием давления или разрежения, особенно предпочтительно методом вакуумной инфузии или инжекционным методом с поддерживающим воздействием давления, наиболее предпочтительно методом вакуумной инфузии.
15. Применение формованного изделия по одному из пп. 1-7 или панели по одному из пп. 8-12 для лопастей, в ветроэнергетических установках, в транспортной отрасли, в строительной отрасли, автомобилестроении, судостроении, в строительстве железнодорожного подвижного состава, в контейнеростроении, для медико-санитарных устройств и/или в авиации и космонавтике.
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