SE1451355A1 - Process for producing a sheet-shaped semi-finished capability to form, by heat treatment, a polymeric foam composite material - Google Patents
Process for producing a sheet-shaped semi-finished capability to form, by heat treatment, a polymeric foam composite material Download PDFInfo
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- SE1451355A1 SE1451355A1 SE1451355A SE1451355A SE1451355A1 SE 1451355 A1 SE1451355 A1 SE 1451355A1 SE 1451355 A SE1451355 A SE 1451355A SE 1451355 A SE1451355 A SE 1451355A SE 1451355 A1 SE1451355 A1 SE 1451355A1
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- drying
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- sheet
- radiation
- drying chamber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- Reinforced Plastic Materials (AREA)
Abstract
Uppfinningen avser ett förfarande för framställning av ett arkformigt halvfabrikat kapabelt att genom värmebehandling bilda ett polymert skumkompositmaterial, varvid: - ett ban- eller arkformigt fibröst material impregneras med en blandning innefattande termoplastiska partiklar och ett bindemedel i form av ett härdbart harts eller en oorganisk silikatförening, - ett flertal ark av det impregnerade fibrösa materialet staplas ovanpå varandra i en torkkammare hos en torkanordning, varvid mellanliggande luftspalter anordnas mellan arken, och - arken torkas i torkkammaren för bildande av nämnda halvfabrikat.The invention relates to a process for producing a sheet-shaped semi-finished product capable of heat-forming a polymeric foam composite material, wherein: a web or sheet-shaped fibrous material is impregnated with a mixture comprising thermoplastic particles and a binder in the form of a curable resin or an inorganic silicate compound, a plurality of sheets of the impregnated fibrous material are stacked on top of each other in a drying chamber of a drying device, intermediate air gaps being arranged between the sheets, and - the sheets are dried in the drying chamber to form said semi-finished product.
Description
20 25 30 35 material av ovan angiven typ för omvandling därav till halvfabrikat med önskad lösningsmedelshalt. Materials of the above type for conversion thereof into semi-finished products with the desired solvent content.
Enligt uppfinningen uppnås nämnda syfte med hjälp av ett förfarande uppvisande de i patentkravet 1 angivna särdragen.According to the invention, said object is achieved by means of a method having the features stated in claim 1.
Enligt uppfinningen sker torkningen av det impregnerade fibrösa materialet i en torkkammare där ett flertal ark av det aktuella materialet är staplade ovanpå varandra, varvid mellanliggande luftspalter är anordnade mellan arken. Härigenom blir det möjligt att åstadkomma en rationell och kostnadseffektiv torkning av det impregnerade fibrösa materialet för omvandling av detta till ett halvfabrikat med lämplig lösningsmedelshalt.According to the invention, the impregnated fibrous material is dried in a drying chamber where a plurality of sheets of the material in question are stacked on top of each other, intermediate air gaps being arranged between the sheets. This makes it possible to achieve a rational and cost-effective drying of the impregnated fibrous material for conversion thereof into a semi-finished product with a suitable solvent content.
DETALJERAD BESKRIVNING AV FÖREDRAGNA UTFÖRINGS- FORMER Enligt uppfinningen impregneras ett ban- eller arkformigt fibröst material med en blandning innefattande oexpanderade och/eller expanderade termoplastiska partiklar, så kallade mikrosfärer, och ett lösningsmedelsbaserat bindemedel i form av ett härdbart harts eller en oorganisk silikatförening.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS According to the invention, a web-shaped or sheet-shaped fibrous material is impregnated with a mixture comprising unexpanded and / or expanded thermoplastic particles, so-called microspheres, and a solvent-based binder in the form of a curable silica or a curable organ.
Det ban- eller arkformiga fibrösa materialet kan vara vävt eller ovävt och innefatta organiska eller oorganiska fibrer, såsom ex- empelvis glasfibrer, mineralfibrer, basaltfibrer, cellulosafibrer, kolfibrer, aramidfibrer, naturfibrer, kevlarfibrer eller polyesterfibrer. Det ban- eller arkformiga fibrösa materialet har lämpligen, betraktat i sin utgångsform, en vikt av 20-6000 g/m2, företrädesvis 30-3000 g/m2. Halvfabrikatet innehåller lämpligen 10-70 vikts-%, företrädesvis 15-60 vikts-%, fibrer.The web or sheet fibrous material may be woven or nonwoven and comprise organic or inorganic fibers, such as, for example, glass fibers, mineral fibers, basalt fibers, cellulosic fibers, carbon fibers, aramid fibers, natural fibers, kevlar fibers or polyester fibers. The web or sheet fibrous material suitably, considered in its initial form, has a weight of 20-6000 g / m 2, preferably 30-3000 g / m 2. The semi-finished product suitably contains 10-70% by weight, preferably 15-60% by weight, of fibers.
Det harts som kan ingå i impregneringsblandningen kan exempelvis utgöras av ett så kallat formaldehydbaserat harts med karbamid, fenol, resorcinol eller melamin eller med en blandning av några av dessa ämnen. Dock kan även andra typer av härdbara hartser användas, såsom polykondenserade hartser, till 10 15 20 25 30 35 exempel polyimid, polyadderade hartser, till exempel polyuretan, och radikalpolymeriserade hartser, till exempel polyester. Även akrylhartser kan användas.The resin which may be included in the impregnation mixture may, for example, consist of a so-called formaldehyde-based resin with urea, phenol, resorcinol or melamine or with a mixture of some of these substances. However, other types of curable resins can also be used, such as polycondensed resins, for example polyimide, polyadded resins, for example polyurethane, and radically polymerized resins, for example polyester. Acrylic resins can also be used.
Den oorganiska silikatföreningen som kan ingå i impregneringsblandningen är lämpligen en förening som vid uppvärmning avger en beståndsdel som fungerar kylande.The inorganic silicate compound which may be included in the impregnation mixture is suitably a compound which, on heating, releases a component which has a cooling effect.
Silikatföreningen kan exempelvis utgöras av vattenglas, vilket innehåller bundet vatten som vid uppvärmning frigörs så att därigenom ett bidrag till brandskyddsfunktionen uppstår.The silicate compound can, for example, consist of water glass, which contains bound water which, when heated, is released so that a contribution to the fire protection function thereby arises.
De termoplastiska partiklar som används vid framställning av det uppfinningsenliga halvfabrikatet har skal som kan vara bildade av polymerer eller sampolymerer, såsom exempelvis sampolymerer av vinylklorid och vinylidenklorid, sampolymerer av vinylklorid och akrylnitril, sampolymerer av vinylidenklorid och akrylnitril, sampolymerer av styren och akrylnitril, sampolymerer av metylmetakrylat innehållande upp till ca 20 vikts-% styren, sampolymerer av metylmetakrylat innehållande upp till ca 50 vikts-% kombinerade monomerer av etylmetakrylat, eller sampolymerer av metylmetakrylat innehållande upp till ca 70 vikts-% ortoklorstyren. Partikelstorleken för de oexpanderade sfärerna och därmed för de expanderade sfärerna kan varieras inom vida gränser och väljs med ledning av de egenskaper som önskas hos den färdiga produkten. Partikelstorleken hos de oexpanderade termoplastiska partiklarna kan exempelvis vara 1 um till 1 mm, företrädesvis 2 um till 0,5 mm och särskilt föredraget 5 pm till 50 pm. Vid expansionen ökar de termoplastiska partiklarnas diameter med en faktor av cirka 1-10.The thermoplastic particles used in the preparation of the semi-finished product according to the invention have shells which may be formed of polymers or copolymers, such as, for example, copolymers of vinyl chloride and vinylidene chloride, copolymers of vinyl chloride and acrylonitrile, copolymers of vinylidene chloride and acrylonitrile, copolymer of acrylonitrile, copolymer of acrylonitrile methyl methacrylate containing up to about 20% by weight of styrene, copolymers of methyl methacrylate containing up to about 50% by weight of combined monomers of ethyl methacrylate, or copolymers of methyl methacrylate containing up to about 70% by weight of orthochlorine styrene. The particle size of the unexpanded spheres and thus of the expanded spheres can be varied within wide limits and is selected on the basis of the desired properties of the finished product. The particle size of the unexpanded thermoplastic particles may be, for example, 1 μm to 1 mm, preferably 2 μm to 0.5 mm, and particularly preferably 5 μm to 50 μm. During expansion, the diameter of the thermoplastic particles increases by a factor of about 1-10.
De oexpanderade termoplastiska partiklarna innehåller flyktiga, flytande jäsmedel som förångas vid värmetillförseln. Dessa jäsmedel kan utgöras av freoner, kolväten, såsom n-pentan, i-pentan, neopentan, butan, i-butan eller andra jäsmedel som konventionellt används i termoplastiska partiklar av här angivet slag. 5-30 vikts-% av den termoplastiska partikeln kan lämpligen utgöras av jäsmedel. 10 15 20 25 30 35 Blandningen av bindemedel och termoplastiska partiklar kan om så önskas eller erfordras försättas med olika tillsatser, såsom stabilisatorer, kopplare, fyllmedel, brandhämmande tillsatser och/eller pigment. I blandningen av bindemedel och termoplastiska partiklar kan även införas partiklar eller kulor av organiskt eller oorganiskt material, till exempel glas.The unexpanded thermoplastic particles contain volatile, liquid blowing agents that evaporate on heat application. These blowing agents may be freons, hydrocarbons such as n-pentane, i-pentane, neopentane, butane, i-butane or other blowing agents conventionally used in thermoplastic particles of the type indicated herein. 5-30% by weight of the thermoplastic particle may suitably be blowing agent. The mixture of binders and thermoplastic particles can, if desired or required, be supplemented with various additives, such as stabilizers, couplers, fillers, flame retardant additives and / or pigments. Particles or spheres of organic or inorganic material, for example glass, can also be introduced into the mixture of binders and thermoplastic particles.
Efter impregneringen staplas ett flertal ark av det impregnerade fibrösa materialet ovanpå varandra i en tillslutbar torkkammare hos en torkanordning, varvid mellanliggande luftspalter anordnas mellan arken. Torkkammaren tillsluts därefter och arken torkas i torkkammaren för bildande av nämnda halvfabrikat. Vid torkningen reduceras lösningsmedelshalten i det impregnerade fibrösa materialet till en för halvfabrikatet önskad nivå.After the impregnation, a plurality of sheets of the impregnated fibrous material are stacked on top of each other in a closable drying chamber of a drying device, intermediate air gaps being arranged between the sheets. The drying chamber is then closed and the sheets are dried in the drying chamber to form said semi-finished product. During drying, the solvent content of the impregnated fibrous material is reduced to a level desired for the semi-finished product.
Torkningsförhållandena, dvs torkningstemperaturen och torkningstiden, väljs så att det ej sker någon sluthärdning av bindemedlet under torkningen I det fall då det impregnerade fibrösa materialet är banformigt klipps detta upp i ark av lämplig storlek innan materialet underkastas torkning i torkkammaren.The drying conditions, ie the drying temperature and the drying time, are chosen so that there is no final curing of the binder during drying. In the case where the impregnated fibrous material is web-shaped, it is cut into sheets of suitable size before the material is subjected to drying in the drying chamber.
Torkanordningen kan vara en varmluftstork, exempelvis utformad som en konventionell virkestork, varvid torkningen sker med hjälp av varmluft som bringas att cirkulera i torkkammaren med hjälp av en i torkanordningen ingående fläkt. Torkanordningen kan alternativt vara en strålningstork, varvid torkningen sker med hjälp av långvågig IR-strålning, mellanvågig IR-strålning, kortvågig IR-strålning eller mikrovågsstrålning. Även en vakuumtork kan användas som torkanordning.The drying device can be a hot air dryer, for example designed as a conventional wood dryer, the drying taking place by means of hot air which is caused to circulate in the drying chamber by means of a fan included in the drying device. The drying device can alternatively be a radiation dryer, the drying taking place by means of long-wave IR radiation, medium-wave IR radiation, short-wave IR radiation or microwave radiation. A vacuum dryer can also be used as a drying device.
Arken kan med fördel placeras på var sitt stödgaller i torkkammaren för att vila på dessa stödgaller under torkningen.The sheets can advantageously be placed on separate support grilles in the drying chamber to rest on these support grilles during drying.
De oexpanderade termoplastiska partiklar som eventuellt ingår i impregneringsblandningen kan bringas att expandera under torkningen eller bringas att kvarstå i oexpanderad form i det 10 15 20 25 genom torkningen bildade halvfabrikatet. Halvfabrikatet kan även innehålla en blandning av expanderade och oexpanderade termoplastiska partiklar.The unexpanded thermoplastic particles which may be included in the impregnation mixture may be expanded during drying or may be left in unexpanded form in the semi-finished product formed by drying. The semi-finished product may also contain a mixture of expanded and unexpanded thermoplastic particles.
Det uppfinningsenliga halvfabrikatet kan exempelvis framställas på något av de sätt som beskrivs i EP 0 041 054 A2, SE 505 843 C2, SE 508 051 C2, SE 513 860 C2 och SE 529 803 C2, vars innehåll införlivas häri genom hänvisning.The semi-finished product according to the invention can be prepared, for example, in any of the ways described in EP 0 041 054 A2, SE 505 843 C2, SE 508 051 C2, SE 513 860 C2 and SE 529 803 C2, the contents of which are incorporated herein by reference.
För att sedan åstadkomma en skiva av polymert skumkompositmaterial placeras halvfabrikatet i erforderligt antal lager tillsammans med eventuellt ytterligare förekommande materiallager i en pressanordning i form av en varmpress eller liknande och kombinationen utsätts där för värme och tryck så att sluthärdning av bindemedlet sker och eventuell återstående expansion av de termoplastiska partiklarna äger rum. Därvid sker också en sammanbindning av skumkompositmaterialet till övriga eventuellt förekommande materiallager.In order to then produce a sheet of polymeric foam composite material, the semi-finished product is placed in the required number of layers together with any additional material layers in a press device in the form of a hot press or the like and the combination is subjected to heat and pressure so that final curing of the binder the thermoplastic particles take place. In this case, the foam composite material is also bonded to any other material layers that may occur.
Uppfinningen är givetvis inte på något sätt begränsad till de ovan beskrivna utföringsformerna, utan en mängd möjligheter till modifikationer därav torde vara uppenbara för en fackman på området, utan att denne för den skull avviker från uppfinningens grundtanke sådan denna definieras i bifogade patentkrav.The invention is of course not in any way limited to the embodiments described above, but a number of possibilities for modifications thereof should be obvious to a person skilled in the art, without this deviating from the basic idea of the invention as defined in the appended claims.
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SE1451355A SE1451355A1 (en) | 2014-11-13 | 2014-11-13 | Process for producing a sheet-shaped semi-finished capability to form, by heat treatment, a polymeric foam composite material |
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